Boiler Feed Pump Vol-1 PDF

BHARAT HEAVY ELECTRICALS LIMITED
RAMACHANDRAPURAM::HYDERABAD-502032
OPERATING AND MAIN'TENANCE INSTRUCTIONS

OF
PUMPS
VOLUME-1
BOILER FEED BOOSTER PUMP, .
;..· BOILER FEED PUMP &
CONDENSATE EXTRACTION PUMP
OP JINDAL STPP PH-III, RAIGARH - 4x600. MW
JINDAL POWER LIMITED

LIST OF CONTENTS
VOLUME -1
PART~ 1 SAFETY STANDARDS
PART~ 2 SYSTEM INFORMATION
PART -3 PRESERVATION & STORAGE

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... PART-4 EQUIPMENT DETAILS
A. BOILER FEED BOOSTER PUMP

B. BOILER FEED PUMP
C. CONDENSATE EXTRACTION PUMP
PART-5 SUB-DELIVERY ITEMS
A. CONNECTING COUPLINGS, BFP SET

B. SUCTION STRAINERS, BP & BFP
C. BFP RECIRCULATION CONTROL VALVE
D. CONNECTING COUPLING, CEP
) E. SUCTION STRAINER, CEP
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PART-6 DRAWINGS I DOCUMENTS
A. BOILER FEED BOOSTER PUMP

B. BOILER FEED PUMP
C. CONDENSATE EXTRACTION PUMP
VOLUME- 2
------------------------~------------------------~-------------------,-
HYDRAULIC COUPLING FOR BFP

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PART -1
SAFETY STANDARDS
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SAFETY STANDARDS
Persons responsible for the equipment covered in this manual must ensure that
it is property and safely installed and maintained, and operated at the specified
conditions. Only appropriately qualified staff, applying acceptable standards of
engineering practice and the recommendations contained in this manual, must
be employed in these activities.
Any similar instructions for the overall plant in which the equipment is to be
incorporated, which have an influence on the equipment application, must be
strictly followed.
Statutory and local requirements concerning work practices, safety and/or health
precautions must be observed.
When appropriate, warnings, cautions and notes are included in the manual,
and are defined as follows :-
WARNING : A WARNING CALLS ATTENTION TO INSTRUCTIONS WHICH

MUST BE FOLLOWED TO AVOID DANGER TO PERSONNEL.
CAUTION : A caution calls attention to instructions which must be

followed to avoid damaging the equipment or its surroundings.
NOTE : A note gives supplementary information where considered necessary.
OPERATING ·CONDITIONS
If the equipment application or operating conditions differ from those for which
equipment was supplied, the equipment and the operating recommendations
contained in this manual may be inappropriate. In such circumstances
verification of the suitability of the equipment and of the operating and
maintenance manual must be obtained in writing from BHEL ltd.
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PART- 2
SYSTEM INFORMATION
PART- 2
SYSTEM INFORMATION
LIST OF CONTENTS
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CHAPTER TITLE
1 General System Description
2 Equipment Schedule
3 List of Sub-vendors for Bought-out Items
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PART- 2
SYSTEM INFORMATION
1.0 GENERAL SYSTEM DESCRIPTION
1 .1 Chandrapur Thermal Power Station Expansion, Unit-8&9, of Maharashtra State
/
Power Generation Co.Ltd. consists of Two generating units of 500 MW capacity
each along with their auxiliaries. This manual contains the description, operation
and maintenance instructions for Boiler Feed Booster Pumps, Boiler Feed Pumps
and Condensate Extraction Pumps.
1.2 There are three Boiler Feed Pumps ( 2 Turbine Driven and 1 Motor Driven) each of
50% capacity, which take suction from the deaerator and discharge the feed water
to series of HP heaters, economizer and finally to Boiler Drum.
1.3 The Condensate Extraction Pumps (3 x 50%) capacity take suction from the
'
respective hot wells and discharge to dea~rator through gland steam condenser
and LP Heaters.
"-~- 2.0 EQUIPMENT SCHEDULE:

Following equipments are covered in Volume-1 and Volume-2.
1. Boiler Feed Booster Pump, type : FA 1B75
2. Boiler Feed Pump, type : FK4E36
3. Condensate Extraction Pump, type : EN6J40/500
4. Recirculation Control Valve for BFP
5. Hydraulic Coupling of MDBFP, type : R18KGS
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3.0 SUB VENDOR LIST FOR BOUGHT-OUT ITEMS
3.1 Mechanical Seals : (a) M/s.Burgmann India Pvt. Ltd

A.K. Industrial Estate
Madina Manzil Compound
S.V.Road, Goregaon (W)
BOMBAY- 400 062
Tel : 022-28741534, 1820, 1905
Fax : 022-28748820
(b) M/s.Fiowserve Sanmar Limited

147, Karapakkam Village
CHENNAI - 600 096
Tel : 044-2450 4140
Fax : 044-2450 2124
(c) M/s.Eagle Seals&Systems India Ltd

212/2, Sholapur-Poona Road
Hadapsar
PUNE- 411 028
Tel : 020-2650 81 00
Fax : 020-2699 3921
3.2 Journal Bearings : (a) M/s. Waukesha Bearings

Argyle House, Joel Street
Northwood Hills, Middlesex.
Middlesex, United Kingdom, HA 6 1 LN
(b) M/s.Michell Bearings

Scotswood Road
' ' New Castle Upton Type
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'\,,
N E 1 5 6LL, U.K.
(c) M/s.Michell Bearings India Pvt Ltd.

80, Attibele lndl Area, Hosur Road,
Bangalore - 562 107
Tel : 080-2782 0202, 0303
Fax : 080-2782 0302
(d) M/s.Colherne Ltd.

Lodge Street, Newton Hyde
Cheshire, SK 14 4LE
United Kingdom
Tel : 061-366 6603 !
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Fax : 061-367 8239 i
3.3 Thrust Bearings : (a) M/s.Michell Bearings

\._, Scotswood Road
New Castle Upton Type
N E 1 5 6LL, -U.K.
(b) M/s.Michell Bearings India Pvt Ltd.
8D, Attibele lndl Area, Hosur Road,
Bangalore - 562 107
Tel : 080-2782 0202, 0303
Fax : 080-2782 0302
(c) M/s. Kingsbury Inc.

10385, Drummond Road
Philadelphia., Pennsylvania, 19154 USA
1/A: M/s.Arcum Engineering Pvt Ltd
B-201, Matrusri Apartments
Hyderguda, Hyderabad-500 029
Tel : 040-23211765
Fax: 040-23296197
3.4 Hydraulic Coupling (a) M/s. Voith Turbo GMBH & Co.
P.B.No.1555
D-7180, Crailsheim
GERMANY
1/A: M/s.Voith India Pvt. Ltd.

P.O. Industrial Estate
Nacharam,
HYDERABAD-500 076
Tel : 040-2717 3561, 3592
Fax : 040-2727 1141
3.5. BFP RC Valve (a) M/s. Dresser Produits lndustriels, France

I.A. : M/s. Dresser Valves India Pvt Ltd.
No.12, 2nd Floor, D-Biock, Doshi Gardens
174, Arcot Road, Vadapalani
Chennai - 600 026
Tel : 040-52134056, 24802393
Fax : 040-52134057
(b) M/s. Control Components Inc.,

22591, Avenida Empresa
Rancho Margarita
California 92688 U.S.A
IJ\. :-Mts-:-euntrol-eompunent.s-lndia
Flat no. 5-B,
377-A, Prince Anwar Shah Road
Kolkata -700 068
Tel : 033-24833583
Fax : 033~~48~~05~
3.6 Suction Strainers (a) M/s. Gujarat Otofilt
BP : Simplex Basket type Plot no. 3712, Phase-IV
BFP : Conical type GIDC Estate, P.B.No. 67
CEP : Simplex Basket type B/H New Nirma, Vatva
Ahmedabad - 382 445
Tel : 079-25841164, 25842719
Fax : 079-25842719
(b) M/s. Otoklin Global Business

Plot no.1, Shah Industrial Estate
Veera Desai Road
Andheri West
Mumbai - 400 053
·-·-
Tel : 022-26732135, 226732123
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e-mail: otoklin@vsnl.com
(c) M/s. Multitex Filteration Engineers (P) Ltd.

217, Hans Bhavan
Bahadurshah Zafar Marg
New Delhi - 110 002
Tel : 011-23311275, 23316779
Fax: 011-2372 2221
3.7 Connecting couplings (a) M/s. Euroflex Transmissions India Pvt. Ltd
Plot No.99, CIE Phase-11
Gandhinagar, Balanagar
HYDERABAD - 500 037
Tel : 040-23079775, 23076970
Fax: 040-23079523, 27847149
(b) M/s. Bibby Transmissions Limited.

Cannon Way, Mill Street West
Dewsbury, Yorkshire, WF 13 1 EH, UK
IIA : M/s. Rathi Transpower Pvt. Ltd.

Rathi Chambers, 7-Deccan College Road
PUNE- 411 006
Tel : 020-26696820, 26694826
Fax : 020-26695655
(c)
M/s. Unique Transmissions (India) Pvt. Ltd.
Mercantile Building, •
- - - - - - - - - - - - - - - - - - - - - 1 o7r~Cal5azar Street'_ _ _ _ _ _ _ __
3rd Floor (Rear Block)
KOLKATA -700 001
Tel : 033-2220 0366, 2248 0231
Fax: 033-2230 6593
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3.8 Local Gauge Board Assy_ with
Pre & Temg Instruments
(a) M/s. Nagarjuna Fabricators
Plot No. 44-B, Phase-1
IDA, Jeedimetla
Hyderabad - 500 855
Tel : 040-23096515
Fax : 040-23413977
(b) M/s. Procon Instrumentation Pvt. Ltd.
1H, Sakthi Towers
766, Anna Salai
Chennai - 600 002
Tel : 044-28524942
Fax : 044-28522348
(c) M/s. Panam Controls

(--
\ 12-11-1299/3, Raghavendra nagar
I,
Warasiguda
Secunderabad - 500 061
Tel : 040-27077546
Fax : 040-27070365
(d) M/s. Instrumentation Limited

KOTA - 324 005
Tel : 0744-426309, 423381-85
Fax: 0744-426309
3.9 Local Instrument Rack (a) M/s. Instrumentation Limited
for Transmitters, BFP&CEP KOTA - 324 005
Tel : 0744-426309, 423381-85
Fax: 0744-426309
3.10 Reverse Rotation Monitoring (a) M/s.Bently Nevada Corporation

Sy_stem of TD &MD BFPs P.O.Box No.1 57
1617, Water Street
Minden, Nevada, USA 89423
Through:
M/s.Bently Nevada (Sales&Services) Ltd
AIFACS Building, 1-Rafi Marg
NEW DELHI - 110 001
Tel : 011-23355899, extn. 505
Fax : 011-23737608
(b) M/s. Shinkawa Electric Co. Ltd, Japan
Through:
M/s.Forbes Marshall I
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A-34/35, MIDC Estate, H-Biock L_
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Pimpri, Pune- 411 018
Tel : 020-27442020, extn. 355 I
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Fax: 020-27442040 I
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PART- 3
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PRESERVATION & STORAGE
LIST OF CONTENTS
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STD. NO. TITLE
HY0490563 TRP Application on Ferrous components of different

products
HY0490564 Code of practice for storage of different products and

their components
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HY0490563
PLANT STANDARD REV. NO: 04
HYDERABAD
PAGE 1 OF 12
TRP APPLICATION ON FERROUS COMPONENTS OF DIFFERENT PRODUCTS
1. SCOPE:
1.1 The standard covers the selection and applications of Temporary Rust Preventives (TRP)
for different products & their components during production, before despatch and at site.
1.2 This standard supersedes the old company standard and other Product Standards/
documents made on the subject.
2. GENERAL:
The effectiveness ofTRP depends on the following aspects:
2.1 Selection of proper TRP.
2.2 Proper preparation of the surface to be protected. Refer plant standard HY 067 41 66.
2.3 Application of TRP - Under normal atmospheric conditions, corrosion of machined

surfaces starts as soon as they are accessible to moisture, air etc. Hence it is necessary to
apply rust preventive immediately after the machining of surfaces.
2.4 TRP - Reference on manufacturing & erection instructions/drgs. wherever necessary by

Engg.
3. SELECTION OF TRPs:
The list of rationalized TRPs, is given in Annexure - I. This covers various types, method
of application, durability of protection, equivalent brands etc.
4. SURFACE PREPARATION: (For details refer plant std HY0674166)
Before application of TRPs, it is necessary to ensure that the surfaces are free from rust,
dust, dirt, grease, oil etc. The effectiveness of TRP depends on the cleanliness of the
surface.
Revisions: Cl. Nos. 1.2, 2.2 modified. Issued:

Cl. No. 2.4 added. Cl. Nos. 4.1 to 4.4 deleted. STANDARDS ENGINEERING DEPARTMENT
Annexures I, II, & III modified.
Rev.No. 04 Amd. No. Reaffirmed: Prepared: Approved: Date:
------------1-------- --~~-----------1~----------1------!
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Dt.FEB. 98 Dt. Year: STDS.ENGG. SR.MANAGER MAY, '83

STDS. ENGG.
HY0490563
Rev. No.04
PLANT STANDARD
HYDERABAD
PAGE 2 OF 12
1 - - - - - - - - - - - " - - - - -- - - - - - - - - - - - - - - - - - - - - - _ _ _ _ ______l _ _ _ _ _ _
5. TRP APPLICATION:
5.1 The application ofTRPs is classified in Annexure II keeping in view the finish and the
extent of protection required.
5.2 The details of components against each category of application arc given product wise in
the Annexure III.
6. PRECAUTIONS FOR APPLICATION:
6.1 The TRP shall be stirred well in the original container so as to make a homogenous
mixture of its constituents.
6.2 The container, brush, cloth to be used for application of TRP shall be clean. The
container and the brush shall be washed with white spirit, for the next operation.
6.3 Preservative shall be applied in closed premises not later than 3-5 hours after cleaning
and degreasing. Application shall not be done in humid atmosphere and during sharp
changes in temperature, which may cause sweating.
6.4 Care shall be taken to see that the preservative coating is uniform and without overflow
or gaps, bald spots, and flows in. Each subsequent layer shall be coated after the
preceding one dries up completely.
6.5 The quality of preservative layer shall be checked by visual inspection for uniform coat.
Any defect observed shall be immediately rectilicd.
7. DURABILITY OF PRESERVATION:
The durability of preservation varies from 6 months to I year depending on the category
of TRP application refer Annexure-!. After this period, it is necessary to inspect the
preserved parts and if necessary carry out re-p reservation after cleaning and making the
surfaces free from corrosion, if any.
8. DETAILS OF REPRESERVA TION TECHNIQUES:
8. I The earlier coating shall be removed by using white spirit.
8.2 Rust if any shall be removed with fine emery paper. Care shall be taken to see that
precision machined surfaces like Journal surfaces shall not be damaged during this
operation.
8.3 Surfaces prepared for re-preservation shall not be touched by hand.
8.4 The duration of re-preservation shall be as per the durability of protection specified in
Annexure I. After drying, re-preservation shall be carried out in accordance with clause
h
HY0490563
PLANT STANDARD
REV.N0.04
HYDERABAD
PAGE 3 OF 12
9. DEPRESERVATION BEFORE ASSEMBLY I ERECTION:
9.1 Depreservation of the various parts shall be done during Assembly/erection period as and
when necessary.
9.2 Depreservation of parts consists of removal of TRP coatings from all the machined
surfaces with white spirit.
9.3 Degreasing or cleaning of any forged components like rotors, blades, shafts etc., shall not
be done with Chlorinated Solvents like Carbon Tetrachloride.
Preservative Instruction to Site:
1. This standard on preservation of different products and components shall be followed.
2. As soon as the components are received at site, they should be examined for rupture of
TRP film, VCI paper and development of rust, if any. Patch work wherever necessary
should be done with the TRP system.
3. The components should be stored in such a way that TRP film does not get damaged.
4. The surface of TRP coated components shall be examined for damage and corrosion
spots regularly.
5. Represervation shall be followed as per the Tag attached to the component.
6. Inspect coated and wrapped surfaces. If coating or wrapping appears to have been
removed during shipping clean and re-wrap or coat as applicable.
. ' 7. Inspect shafts for adequate preservative and add a heavy film of valvoline TECTYL
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894 or Equivalent as necessary.
8. Rotate the Rotors a few revolutions every month and ensure that the bearings are
packed with grease.
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HY0490563
PLANT STANDARD
Rev. No.04
PAGE 4 OF 12
- - - - --- --
HYDERABAD
RECOMMENDED TYPES OF TRPs

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(Clause- 3) ANNEXURE-I
-- --
Type orTRP Description or Method of Durability or Equivalent
TRP/SPEC. No. Application Protection Brands
Rust Preventive Dipping, 6 months liE 1710
liard Film liard Film Black Spraying, (Bhopal)
Solvent AA55154 Brushing
deposited Rust Preventive Dipping, I year liE 1706
Hard Film Ycllow Spraying, (Bhopal)
AA55155 Brushing --- ----
Rust preventive 6 months HE 1709

solution, clear (TRP) (Bhopal)
Soft Film AA55152 -Do- --- ----
deposited Rust solution, Steam 3 months HE 1712

washable (TRP) (Bhopal)
AA55151 ---
Grease Temporary Corrosion Smearing 6 months IOC Multi-
Preservative Grease Brushing Purpose Grease
IS:958 No.2
Oil Rust inhibitive oil Dipping, 3 weeks HE 1711
(TRP) AA55153 Rinsing, (Bhopal)
Temporary corrosion Spraying, 6 months ESSO: RUST
Preventive Fluid BAN 394
IS: 1153
Powder/ Volatile Corrosive Sprinklin 3 months
Tablet inhibitor (VCI)
powder/tab let
IS:5730
Paper VCI paper IS:6263 Wrapping 3 months
Gas Nitrogen Blanketing Filling 3 months
Crystal Silica-jel Inserting 3 months
rum PLANT STANDARD
HYDERABAD
TRP APPLICATION CATEGORIES

HY0490563
REV.N0.04
PAGE 5 OF 12
(Clause- 5) ANNEXURE-II
TRP Application Details Guide Lines for Selection

Appli-
cation
Category
Apply 1 Coat of Rust Preventive Hard Film Longer duration of protection before
yellow (HE 1706) I AA55155 and 1 Coat of despatch to site. Suitable for
ci Rust Preventive Hard Film Black precision machined surfaces with
~
t- >
.
- c (AA55154)/HE1710. Wrap the surfaces with simple profiles, eg. Rotor Journal
~ g
., ----· - 0E
...l A Volatile Corrosive inhibitive (VCI) paper Surfaces
"'<t;..c"
...l"' with its active side facing the surfaces. Fix
u.:=: the ends with adhesive tape. Wrap the
- 0
-··./
~-
t-
u "'~ surfaces with rubber sheet and then with
~ "'
...lc
~ ·- aluminium foil of thickness 0.05 to 0.1 mm.
><~
_>-; Fix the adhesive tape.
~-<-
+=§:l" Apply 1 Coat of Rust Preventive Hard Film Longer duration of protection before
= c ~ t- " yellow (HE 1706) /AA55155 and 1 Coat of despatch to site. Suitable for
;g ;2 -~
8;2-8 B Rust Preventive Hard Film Black precision machined surfaces like
Uco1d (AA55154)/ HE1710. parting plane suraces, covers,
-o'o"'
; t' § couplings, base plates, machined
~"' c
.c: g.·- cross around pipes etc .
e.o~>
·-
:..
~.!:
0.'::
"' f:! " Apply 2 Coats of Anti Rust solution, steam Steam Turbine components of
c.c~:.o
Q ·- c
u -·-
:::: ~
c washable (TRP) (AA55151) I HE1712 complicated profiles where steam
s;::::;-;::::>
"' 0 washing facility is available eg.
" "
"'C.::
0 "' Steam Turbine rotor components.
-
"'""
:,c-,
§ "~ D
Apply 2 Coats of Rust Preventive solution,
Clear (TRP) (AA55152) I HE1709
Steam Turbine components of
complicated profiles where there is
.. .. §~ no facility for steam washing .
- 0
~ c
Etii Apply 2 Coats ofTRP fluid (IS:1153) Steam Turbine components of
<8 ;:I
.S E
.,_ E complicated profiles. The TRP is
.::::
t- with brown Pigment.
Apply 1 Coat of Rust inhibitive oil (TRP) Machined components during the
F (AA55153) I HE1711 process, Storage on shop floor over
1 month upto 3 months.
Apply Temporary Corrosion Preventive Suitable for Fasteners, chains, Gear
G Grease IS:958 liberally and wrap in Wheels etc.
polythene sheet/bag and tie it with a thread
H Wrap with 2 layers of VCI paper IS:6263 Suitable for commutator of
and one layer ofPolythene Sheet. Armature, Bushings.
Sprinkle VCI powder/tablets IS:5730 inside Inside oil pipes.
I pipe. Close the ends by plastic caps and
adhesive tape .
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HY0490563
Rev. No.04
PLANT STANDARD
HYDERABAD
PAGE 6 OF 12
f----------------- - -- - -- - - - - - - - - - - - - - - - - - - - - - ' - - - - - - - - - l
ANNEXURE- II
. - - - - - - - , - - - - - - - - - - - - - ----------------------,---,-:---,-----,----,--,-----,-------,
TRP Application Details (iuide Lines for Selection
Appli-
cation
Category
Draining after Hydro Test drying with hot Suitable for the water chamber and
J air, evacuation ofthe vessel and Nitrogen the shell side of Heat Exchanger
blanketing.
------r,----~~,---,----,---,----,-------,-------+------~------,------~
Keep silica-jel bag inside suction and Suitable for all exposed tapped
discharge branches. close all opening close holes and flanged openings on the
K all tapped holes with red plastic caps pumps and Tubings.
(l-IY7242375 for G threads, HY7242579 for
NPT threads). Close all flanged openings
with suitable metal covers (HY7790963).
HY0490563
PLANT STANDARD
REV.N0.04
HYDERABAD
PAGE 7 OF 12
PRODUCT COMPONENTS- TRP CATEGORIES

(CLAUSE -5.2)
ANNEXURE -III
DETAILS OF COMPONENTS TRP APPLICATION

CATEGORY
STEAM TURBINE AND COMPRESSORS
HP,LP and other rotors.
Rotor Journals, Thrust Collars A
Base plate machined. B

Crossed around pipes, machined B
Bearing pedestals with assembled parts and bearing housings
Outer machined surfaces B
HP turbine outer casings
Outer machined B
HP, LP and other rotors.
Rotor coupling flange faces, coupling bolt holes B
Welded low pressure Turbine components
Longitudinal Grider and front
Outer machined
LP upper part outer machined surface B
LP inner outer casings outer machined surface B
LP Inner, inner casings outer machined surface B
Fasteners ofThreaded portions
Unthreaded portions (M64 and above) B
HP Exhaust Elbow outer machined surface B
Shaft lifting and clearance measuring device, machined surface B
Assembly fixtures for HP Turbine, machined surface B
Turning over device for HP Turbine, machined surface B
Transportation device for HP Turbine, machined surface B
Oil tank
Outer machined surface B
Injector Nb. 300
Main steam and re-heat strainer body
Outer B
Cast exhaust hood
HY0490563
1----------·--
Rev. No.04
PLANT STANDARD
HYDERABAD
PAGE 8 OF 12
1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ---- - - - - - - - - - - ' - - - - - - -
ANNEXURE -III
, - - - - - - - - - - - - - - - - - - -- . ------~-------- --·
r---------------------------+-_:C::.:A..:.T_::_:::EC..:::G..::O:_:R_:_:Y ___ _
Cross around pipes, inner
Valves-casings and covers
Inner un-mach ined surface c
Bearing pedestals with assembled parts and bearing housings
Outer un-machincd surface c
I IP and outer turbine outer casing-
Inner c
HP and IP inner casing and diaphram-carricr and guide blade carrier-
Outer c
Inner c
liP, LP and other rotors.
A II surfaces except journals, Thrust collars
Flange cases and coupling bolt holes c
STEAM TURBINE AND COMPRESSORS
Welded low pressure Turbine components-

Logitudinal Girder and front valves
Inner c
LP upper part,
Inner c
LP Inner, outer casings c
Inner including blades c
Outer un-machined c
LP Inner, inner casings
Inner including blades c
Outer un-machined c
Cover for shaft sealing casing
Inner c
Steam inlet and extraction connections
Inner and outer c
HP Exhaust elbow
Inner c
Handling Barring Gear and hydraulic Gear oil tank
Inner c
Injector Nb.300
Inner c
Main steam and re-heat strainer body
Inner c
ilJI PLANT STANDARD
HYDERABAD
HY0490563
REV.N0.04
PAGE 9 OF 12
ANNEXURE -III

CATEGORY
Blanking arrangement for strainer body c
Oil strainer c
Main steam and reheat strainer handling device, machined c
Oil throttle valve, inner c
Oil stripper journal c
Cast exhaust hood
I
Inner c
' Compressor Rotor D/E
' ci
Ul . Bearings, Oil seals, couplings, spare blades, gland ring G
E-< i:
::E "'Q
~
Lifting beams and clamps machined G
~ E
...l 0
Cl) "
Valves - casings and covers
<.S
...l "
U"'- Inner machined G
~ 0
t:<:~
E-< ~ Spindles G
u ~
u:~E Fasteners of Threaded portions
...l
Ul "
·= Unthreaded portions G
>-<.S
-;~.: Emergency Governor G
~~~ Piping of governing and LP bypass central rack and supply
e
=
cu E-<
-= ·-
~
=<~
0
.:=
~ >
unit for valves, inner
Suspension arrangement for ESU and interceptor valve
G
-== ..._""t:">
Urr:~"'
0 Machined surfaces and springs G
~
0:: t:: "'
g_.s Tools and tackles for governing equipment, machined G
fn e 1::
·c ~~
~.s ~ Oil pipeline outside the governing equipment I
c. ·-
Q -~]
··, r
,,_,.
(~ ~ -~ Other pipings I
I
§.?.:
'-' ~
0 "
~
"'C, ELECTRICAL MACHINES A
.~ ~
£--g Rotor Journals, Slip rings, Journals of Armature
"'0 "'
"
"'o..o"
·~ g
Stator End Flanges, machined flanges, Machined surfaces of
E 1n Foundation Frames, Base plates. B
<S E
.5 " Machined components, Base plates, Machined surfaces of
"
""~
~
Oil cooler, Air cooler, Accessories B
E-<
Rotor coupling face, threaded holes of exposed surfaces,
bearing shells. Fasteners, internal/external threaded surfaces G
Commutator of Armature, Bushings H
- -
HY0490563
Rev. No.04
PAGE 10 OF 12
PLANT STANDARD
----- ---
HYDERABAD
-- - --
Ci5il
ANNEXURE -III
-- -- ----
CATEGORY
SWITCHGEAR
I lydraulic pistons A
Operating mechanisms after testing and before shipment I II,1)
Base frame, Machined Flange surfaces and mechanism housing,
Terminal butting surfaces. -- --
------------ - ------
D/E -
Machined Ferrous components like shafts, pins, gears
Springs, links and levers, castings, machined surfaces of F
fabricated housings, catches, latches, rollers protective pipe
flanges.
Chains and bearings, pull rod (threaded portion), Base frame G
Tapped holes, external/internal threaded surf~1ccs, f~1stcncrs.
HEAT EXCHANGERS DIE
inside condenser shells, inside deaerator shells, machined
surfaces of flanges and drilled tube sheets/ support plates
Inside of Rectangular and very large condensers.
Machined surfaces of condenser, tube sheets. G
Inside water chamber and shell side of feed water heaters J
OIL FIELD EQUIPMENT
Rig instrumentation
Valves and disconnectors dampers for gauges, indicating G
instruments.
Mud Agitators
Machined surfaces of mud system G
Hoisting and rotating equipment
Rotary, Swivel, travelling block, Hydra Hooks G
Mud system
Centrifugal pump, external surfaces of mud agitators
Mud pump external surfaces, loose parts of mud pump.
Mud pump internal surfaces with oil contact. G
Centrifugal pump, mud pump internal surfaces with L

liquid contact. (Except Oil)
It'!
' HY 0490563
PLANT STANDARD REV.N0.04
HYDERABAD
PAGE 11 OF 12
ANNEXURE- III

CATEGORY
BOWL MILLS
Machined surfaces DIE
Inside Gear case assembly F
Bearings, Drive couplings, fastener, external/internal threaded G
surfaces
PUMPS
Journal Bearings, bearing surfaces and exposed portion of shafts. A
Exposed machined surfaces of ferrous components like thrust
collar large fabricated frames, foundation frames, pump discharge B
ci
w .
E- i:
covers, tubular cooler, catridge, keyway blocks of pump casings,
-- E
::E "'c Head gears, Canisters, Foundation Rings, elements, CWP parts.
....l 0
Cll "
....l "
Ferrous components stored in assembly shop, freshly machined F
<>:£
U'-
-~ ~
0
surfaces with more than 1 to 3 months gap between one operation
E-
u ~
~
to another
wB
....l
w" ·= Spare parts, fasteners, external/internal threaded joints G
>-£
·--;~£:
....
=
.., E-
~"'
iiE
~
All exposed tapped holes and flanged openings on the pumps and
tubings
K
"0 ~ ·-
lC ;::
c..o:-l:l GAS TURBINES
0 :r: >
Uo:l" Journal & Thrust Bearings, Rotor journals & Thrust collars A
"0 ""'
0 >
;!:
= >. c
~ t "'
25.-= Ferrous components stored in assembly shop, freshly
-=.~s..v
-w
0>
machined surfaces with more than one month gap between F
,.,. QJ t)
-·~£ .§ operations
::> -~]
:..> ~ ·~
0
All exposed tapped holes and flanged openings on the pumps K
,_
r
c >
" ~ Exposed machined surfaces/parting planes of all ferrous fabricated B
0
-o e
"
-~:.a frames including base plates, couplings
-€-g
c "'
0 "'
c "
o..o Fasteners, External/Internal threaded joints G
·~ 0
c c
c t:l Oil pipes when stored for long periods or when despatched loose I
.s<2 s"'
~.:::
E- Torque converter- fill with lube oil, plug all openings
If storage and/or despatch period together exceeds 3 months
Fuel pump and flow dividers-fill with HSD, plug all openings, if
storage and/or despatch period together exceeds 3 months
rmn
~---------------,---------------------------------- -----~~========~
HY0490563
Rev. No.04
PLANT STANDARD
~---------------- HYDERABAD
PAGE 12 OF 12
----- --------- - ---------------------- ----- _ _ _ _ _ _ _____1_ _ _ _ _ _ _ _ _ _ _ _
ANNEXURE- A
LIST OF SUPPLIERS OF TRP
MIS. BIIEL, Bhopal Rust preventive oil
MIS. Ceturion coatings, Madras Rust preventive compound (proprietary)
MIS. Agromore Ltd., Bangalore - Rust preventive Agents

~ ~
MIS. Mascot chemical works, Bangalore - •'
::: §
/. :;
J
MIS. Chembond chemicals Pvt. Ltd., Bombay
MIS. Pradeep Metal Treatment Chemical Pvt. Ltd., Thane -
MIS. Surcndra Enterprises, Hyderabad -
MIS. Canning Mithra phomics Ltd., Bombay -
MIS. Grawer & Wei! (lnd) Ltd., Bombay - "
MIS. Metrit Industries, Bombay -
MIS. Electro chemicals, Calcutta -
MIS. CMF Systems, Sccunderabad -
MIS. Peddainton chemicals Industries (lnd), Bombay -
MIS. Protochem Industries, Bombay -
MIS. Suprabha protective, Products, Pune - Rust Poliq- N (Proprietary)
MIS. OKS, 5/9, Primorse Road,- 1) OKS- 240 Anti- seize compound
Bangalore- 560025 2) OKS- 1140 High Temperature Silicone grease
3) OKS- 410 Mos 2 High performance long life grease
4) OKS- 300 Mos 2 Mineral oil concentrate (Additive)
5) OKS- VCI : 368 N
6) OKS - VCI : 369 N
7) OKS -2140
8) OKS -2160
9) OKS -2201
MIS. Prosol Chemicals Pvt. Ltd. - I) Rustex -221

MIS. Futech chemicals (P), Secundeabad - I) Futech - AR (L T)
HY0490564
PLANT STANDARD REV. NO: 01
HYDERABAD
PAGE 1 OF 7
CODE OF PRACTICE FOR STORAGE OF DIFFERENT

PRODUCTS AND THEm COMPONENTS
1.0 SCOPE:
1.1 This standard covers the requirements of storage conditions applicable for different
products and their components (either manufactured, boughtout or subcontracted) at shop,
before despatch and at site. The relevant storage condition at site shall be indicated in the
despatch note.
1.2 Reference may be made to the following related standards:
1.2.1 HY 0490561 - Code of practice for storage of preservation of Materials in stores.
1.2.2 HY0674160 - Code of practice for painting of different products and their components.
1.2.3 HY0490563 - Code of practice for preservation of different products and their
components.
2.0 TYPES OF STORAGE CONDITIONS:
The storage conditions are classified as follows:
2.1 Storage condition 'P'
2.1.1 Denotes storage in a totally enclosed shed under controlled conditions.
2.1.2 The shed shall be free from any kind of corrosive gas like chlorine, ammonia or smoke,
chemicals and charged accumulators.
2.1.3 Stored items shall be covered with polythene sheets.
2.2 Storage condition 'Q'
2.2.1 Denotes storage in a totally enclosed shed.
2.2.2 The shed shall be ventilated dry, free from dust, any kind of gas or chemicals.
2.2.3 Items like Motors, Coils and all spare parts shall be covered with polythene sheet.
Revisions Issued:
STANDARDS ENGINEERING
DEPARTMENT
Rev.No. Rev. Date Revised: Prepared: Approved: Date:
~---l-=sR~.~N.UlN~=A~G=E=R~I---------I------
01 OCT. 93 AGM (E&CC) VNR STDS. ENGG. MAY, '83

HY0490564
Rev. No.Ol
PLANT STANDARD
··-·-···- .... ---------- HYDERABAD
PAGE 2 OF 7
2.3 Storage condition 'R'
2.3.1 Denotes storage in shed having roof but no side walls.
2.3.2 The floor shall be either of concrete or wood to take the load of the components/parts to
be stored. The shed shall provide protection to the components/parts stored against
ram.
2.4 Storage condition'S'
2.4.1 Denotes storage in open yard on elevated platform/wooden sleeper.
3.0 GUIDELINES FOR CONSTRUCTION OF STORAGE SHEDS
3.1 The shed may be constructed on Tubular Truses with Asbestos cement sheet roofing.
3.2 The sheds/yards shall be provided with path ways to facilitate movement of vehicles.
3.3 Sheds and storage areas shall be provided with good lighting to facilitate handling of
materials at night.
3.4 All equipment shall be stored on sleepers for easy handling.
3.5 Necessary lifting equipment shall be provided.
4.0 STORAGE CONDITIONS FOR DIFFERENT PRODUCTS/COMPONENTS:
The details of components to be stored under ditTerent storage conditions product wise
are indicated in Annexure I.
5.0 PRECAUTIONS DURING STORAGE
The following special precautions shall be taken during storage:
a) Instruments: Instruments shall be stored within the original packing boxes as far as
possible. Instruments shall be handled carefully. They shall not be stacked on over
the other. The cables shall not be twisted.
b) Pipes: All pipes upto &including 25mm 00 shall be stacked in suitable racks to
facilitate access and handling. Pipes above 25 mm 00 shall be stacked on wooden
sleepers to prevent ingress of dust & moisture. Pipe openings shall be closed with
suitable plugs/caps. Deformity during storage shall be avoided. Heat exchangers
tubes shall be stored within the original cases in which they are received.
C) Rotors: The rotors shall be stored in the original packing boxes. The turbine and
compressor rotors shall be rotated once in 3 months to avoid sag due to long storage.
i) It shall be rotated by 180 deg, after its receipt at site.

ii) It shall be rotated by 90 deg, after 3 months.
iii) It shall be rotated by 180 deg, after subsequent 3 months.
iv) It shall be rotated by 90 deg, after subsequency 3 months.
HY0490564
PLANT STANDARD
REV.NO.Ol
HYDERABAD
PAGE 3 OF 7
d) Casings
i) The parting planes of casings shall be kept on the top to the extent possible. If the
casinghas to be kept in inverted position due to unavoidable reasons, the parting planes
shall be kept on dry wooden beams. Rubber pads or grease or oilimmersed felt shall be
kept between the parting plane and contact surfaces to protect the surfaces.
e) Auxiliary Pumps
If the pump is kept idle for 6 months, the bearings of the pumps shall be cleaned and the
shaft shall be rotated after pouring oil into the lubricating chambers.
t) Electrical components:
The Handling, storage and preservation of Turbo-generators and auxiliaries shall be as per
product standards TG55500 and TG55501.
g) Operating Mechanism of switchgear
The heater shall be switched 'ON' in cold and humid conditions.
h) H 2 seal oil system components, air coolers and accessories, valves.
All openings shall be closed with suitable blinds/plugs/caps to prevent the entry of dirt,
foreign matter and moisture.
i) Rubber gaskets and other miscellaneous items.
All rubber gaskets shall be applied with a coat of french chalk. Care shall be taken to
prevent twisting, deformation and stress during storage. They shall be stacked separately to
prevent damage.
j) Foundation Frames
The frames shall be placed over the wooden sleepers at a number of points interposing 10
mm rubber sheets at the resting places. No other load shall be placed over the frames to
prevent permanent deformation.
k) The original steel blanking plates shall be fastened with hardware and sent along with the
equipment from the plant. They shall be retained during the entire storage period and
removed only at the time of erection.
6.0) NOTE
1) Refer Plant Standard Hy 0490562 for 'Preservation of Heat Exchangers before

shipment.
HY0490564
Rev. No.Ol
PLANT STANDARD
------ . - --~--- --~
HYDERABAD
PAGE 4 OF 7
Annexure I
,..,----,-,---=------=-----------,-----:-,-------=---------- --
Details of components/parts Type of Remarks
storage
· - · - - - - - - - - - - - - - - - - - - - - - - -------'-''------t------------
INDUSTRIAL TURBINE & COMPRESSORS Maximum Temparature 20"
Instruments like Electromagnetic protection, C. Temparature deviation in
vibration measuring equipment, Eccentricity p 24 hours shall not exceed
mesuring equipment. so C. llumidity less than 40%.
f----:::-----,------------:--c--· -- ~
Assembled Compressors & Turbines, Rotors,
Casings, Valves, Bearing Pedestals, Bearings,
Gears, Parting plane bolts, Servomotors
(Hydraulic actuators), Inspection shaft with its Q
rings & all precision mechanical equipment,
bolts heating equipment, Thermometers,
Pressure gauges, mano stats etc.
Oil Tanks, oil coolers, Turbine and Compressor

Covers, Injectors, Piping and safety membranes, R
bearing covers Fasteners, oil seals, Couplings
etc.
Pipes, Flanges, Channels, Sheets etc for s
construction purpose at site.
STEAM TURBINES
P Max Temp 20°C.
Instruments, Turbovisory equipment Temparature deviation in 24
hours shall not exceed S°C.
Humidity less than 40%
Rotors, l-IP & MP casings, 1-IPQC stop and
governing, valves LPQC inspection valves,
Bearing pedestals, Bearings, Non- return valves, Q
Parting plane Bolts, Servo- motors, jacking oil
pump with its rings, Inspection shaft, Middle LP
Body, Bolt heating equipment, Thermometers,
Pressure Gauges, manostats etc .. Front and rear
LP top and bottom parts.
..
~171
HY0490564
PLANT STANDARD
REV.NO.Ol
HYDERABAD
PAGE 5 OF 7

storage
Main oil Tank, Auxiliary Oil Tank, Oil coolers,
Turbine Cover, Injector, MP upper and Lower tube R
fittings, interconnecting piping and safety
membranes, piping outside the pedestal, Foundation
bolts etc.
ci .
~
~ >
GAS TURBINES
~ c
:::E ~
~ E
"'" l )0"
C Rotor, HP & LP journals and thrust Collars Base
·. / "'<;..c:
u~
" " plate. Q
02.:: Machined surface of:
u~ 1:!"'
~.':! Inlet casing
"'"
~
><ll
c ·- Compressor casing
->~
~<:~ Turbine casing
~~~
0,)~"
Bearing housing
~~d Assembly fixtures
g~.g
U.oid Fuel nozzle
-='a::: Tip assembly
;£§ Cap
-=....c.oB>
"c.._
c
.... a.':::: Transition piece
to.""
~..::: ~
ec;~ Lifting beams
u<:> ·-"·;:c
" 0
Bearing liners
E >
::J-;:: Fasteners, external & internal
"0 ·=""
'"C Threaded surfaces
"'-a
:..2"'0
~ " ELECTRICAL MACHINES
c0 "'
;::l
.9::
c " Instruments, Thermometers, Pressure Switches, Q
~ 0
'· "' ~
E c Flow Switches, Rubber and Neoprine, gaskets, 'V'
I ~ "'
:] E Belts, Stator, Rotor, Bearing pedestals, Bearings,
".=: tube oil console with motors, Non return valves, Air
15
coolers, co 2 equipment, shaft driven oil pump with
pulleys, precision components and machined parts.
Oil coolers, Fasteners, Lube oil Piping & Cooling

water piping, erection fixtures like Tackles, R
Mounting Blocks, Extension Beam and MS sheets,
outer covers Erection fixtures
Transport Frames, Stands, Plates, Foundation s
Frame.
'
i
HY0490564
---------- ----·-
Rev. No.Ol
PLANT STANDARD
HYDERABAD
PAGE 6 OF 7 -- _ _ _ _ ___jL___ _ _ _ _ _ _ _
f---------------------. --- ---- - - - - - - - --· -------------
r--- ---·-·- ·- -- -------,--------------

storage
1 - - - - - - - - - - - - - - - - - - -------------l-----'""----11----------
TURBO GENERATORS & !\UXILIAR!ES
P Temparature Range
Stator with transportation frame, Rotor, Exciter 35-45° C. Relative
stator & Gear Box 1\ssy, Exciter Armature, output humidity less than
leads, A VR Cubicle, Field Breaker Cubicle,!\ VR 40%, Dust free
Accessories, Gas and oil panels, Field Rheostat. atmosphere.
Rotor Temperature recorder, Gas and oil panel,
Relay control panels HGL components, Internal
covers, Rubber packings. _____ _ - -- - - - - - - - - - - -
-
End shields, Body of sealings, Bearings, Fan blades,

112 coolers Brush gear, stilling tank, seal oil unit,
vacuum unit, PMG, Air coolers, Exciter rear Bearing
and Assy, Thermometers. -------+-----+----------!
Foundation Frame, Foundation Bolts and Base
plates, Mounting Extension and intermediate piece, R
stand and yoke, Mounting Truck, Covers, Piping
Air proof door, supporting frame, slide valves
suspension device, Fasteners.
SWITCH GEAR
<)
Spare items like interrupter assy, fixed contact 1\ssy,
moving contact assy, Lam washer, interrupter Disc.
Poles of circuit Breaker, operating Mechanism, Base R
Frame, Structure details
BOWL MILLS Q
PUMPS Maximum
P Temperature
Axial shift indicator, Reverse Running inidcator, deviaton in 24 hours
vibraton Monitor instrument. shall not exceed 5°
C. Humidity less
than 40%
Flil
HY0490564
PLANT STANDARD
REV.NO.Ol
HYDERABAD
PAGE 7 OF 7

storage
Instruments, Pressure gauges, Pressure switches,
Temperature gauges, Temperature switches, RTDs,
Assembled pumps mounted on their individual
foundation frames, Drive Motors, Hydralic
couplings, connecting couplings with protective
gaurds, all types of valves along with actuvators, oil
ci
w
!-< ,; and water coolers, all spare parts except instruments, Q
- s::
~ g special tools for maintenance of pumps including
-
...l E
0
Cll
...l 0)
(.) pump assy & dismantling fixtures, local panel, .
( <(..S::
u.:=: column pipes, Discharge Elbows, Foundation ring
. (:2~
shafts, Condensate tank/canister, Local panel.
u!-< "'
~
W2:l
...l s:: Foundation Bolts, fabricated grillages, common for
w ·-
><ll Boiler feed pumps, Hydraulic coupling BFP Motor R
->~
~-<- and Booster pump.
~~~
~ !-< 0) HEAT EXCHANGERS
;g ~ ·§
g;-;;.g
u.J..>
CQ "'
Surface condensers and its parts like water Q
~~?;
; € § chambers, shells, springs, superstructure, Hotwell,
.... "0. ·-
.c s:: Instruments, steam jet Air ejector, and spare nozzles,
bJ:l e >
L.P. Heaters, Chemney steam Condenser,Gland
'~...!:
"' " ~
·- Q..":;:::
(.)
c..:; :.a steam Condenser, H.P Heaters, Deaerator and its

u =·;:
0 ·- s::
" 0
parts like storage tank, Header Assy, Vent
E >
:l"P
<.)
0 0)
(.) Condenser and its parts like instruments, safety
"'0 .::
"'""' valves, oil coolers, Air coolers, Hydralic coolers,

:a-o
-
§ ~
0)
Vacuum pumps, HE tubes
.9 ~
" 0)
- 0
I
'.' § ~
! ; t8 ::'I I
.5 E
'
.,_ I
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!-<
i
I
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i
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I
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)
) .
PART-4
EQUIPMENT DETAILS
II
--------------------~-
i
J
I
PART-4
EQUIPMENT DETAILS
LIST OF CONTENTS
SECTION TITLE
(A) Boiler Feed Booster Pump
(B) Boiler Feed Pump
(C) Condensate Extraction Pump
"!
I
- I
I
i
PART- 4
SECTION -A -::1
BOILER FEED .
BOOSTER PUMP
' ,.
- - - - - - - - - - - - - - - - - - - - - -
•
PART-4
EQUIPMENT DETAILS
SECTION- A
BOILER FEED BOOSTER PUMP
LIST OF CONTENTS
CHAPTER TITLE
1 oe·scription
2 Opening Instructions
3 Maintenance Instructions
4 Sub-Vendor's Drawings I Instructions

/
-------------------------------------------------------------------jL_
SECTION -A
CHAPTER-1
DESCRIPTION
LIST OF CONTENTS
1 Introduction
2 Technical Data
2.1 Motor Driven pump
2.2 Turbine driven pumps
2.3 Driver I Pump flexible coupling
3 Description
3.1 Pump casing
3.2 Rotating assembly
3.3 Journal and thrust bearings
3.4 Bearing housings
3.5 Mechanical Seals
3.6 Driver I pump coupling

CHAPTER-1
DESCRIPTION
1. INTRODUCTION :
Three Booster Stage Pumps are supplied to each 500 MW Unit. Each pump
consists of FA 1B75 type Booster Stage Pump, two are driven by turbine through
gear box and one is Motor Driven.
The FA 1B75 type Booster stage pump is a single stage, horizontal, axial split .\
!
casing type, having the suction and discharge branches on the casing bottom half,
thus allowing the pump internals to be removed without disturbing the suction and
discharge pipe work or the alignment between the pump and driving motor.
The pump shaft is sealed at the drive and non-drive end by mechanical seals
which are flushed by boiler feed water pumped round a closed circuit. The rotating
assembly is supported by plain white metal lined journal bearing sand axially
located by a double thrust bearing.
The bearings in the pump are lubricated by forced oil lubrication system.
2. TECHNICAL DATA:
2.1 Motor Driven Pump
2.1.1 Pump
/ Manufacturer BHEL
Type FA1B75
Direction of rotation Anti-Clockwise
(Viewed on non-drive end)
Liquid pumped Boiler feed water
2.2 Turbine Driven Pump
2.1.2 Pump
Type FA1B75
Direction of rotation Clockwise
(Viewed on non-drive end)
Liquid pumped Boiler feed water
Manufacturer Michell Bearing I Glacier

Type Double thrust
2.4 Mechanical seal
Manufacturer BURGMANN, Germany
2.5 Driver/Pump Flexible Coupling
Manufacturer Euroflex, India
3. DESCRIPTION :
3.1 Pump Casing :
The cast steel pump casing is of the double volute type, split on the horizontal
center line. The top and bottom half casing are located to each other by dowel pins
and secured by the studs and nuts, sealing at the axial split being effected by a
two-ply brown paper joint.
The bottom half pump casing has the suction and discharge branches and support
feet, cast integrally.
The pump casing is machined internally to accept the casing rings and stuffing
boxes are also formed at each end of the casing to accommodate the water
jackets and the mechanical seals, thus preventing leakage along the pump shaft.
The interface of the casing and base plate supports is near the shaft axis. Dowels
and a guide key are arranged to maintain longitudinal and transverse alignments
whilst accommodating thermal expansion.
A tapped air vent connection is provided on the top half casing. Connections are
also provided on the suction and discharge branches for pressure gauges and a
drain.
3.2 Rotating Assembly :
The rotating assembly consists of the shaft, impellers, nuts, keys, seal sleeves,
thrust collar, the rotating parts of the mechanical seals and pump half coupling.
The double entry impeller is keyed to the shaft and is located axially by an impeller
nut on each side of the impeller hub. The impeller is fitted with a wear ring on each
shroud, the rings being retained by grub screws.
The seal sleeves are keyed to the shaft and are located and secured by grub
screws. Leakage between the shaft and sleeve is prevented by an '0' ring fitted in a
groove machined in the bore of the sleeve. The thrust collar is keyed to the shaft
and is secured against a shoulder on the shaft by the thrust collar nut. The pump
half coupling is keyed to the tapered end of the shaft and is secured by a coupling
nut, locked by a lock screw.
3.3 Journal and Thrust Bearings :
The rotating assembly is supported at each end of the shaft by a white

metal lined journal bearing and the residual axial thrust is taken up by a tilting pad
double thrust bearing mounted at the non-drive end of the pump.
The journal bearing shells are of mild steel, white metal lined, thick wall type, and
are split on the horizontal plane through the shaft axis. Each bearing is prevented
from rotating by a dowel pin located in a recess in the top half bearing housing.
The thrust bearing is fitted at the non-drive end of the pump and has eight titling
pads in a split carrier ring on each slide of a thrust collar, which is keyed to the
pump shaft and secured by a nut and lock-washer. The carrier rings are held in
non-drive end bearing housing and are prevented from turning with the thrust
collar by dowels locating in slots in the top half of the housing. The thrust pads are
retained on the carrier rings by special pad stops screwed into the rings. Machined
spacers are fitted behind each carrier ring during manufacturer to effect the axial
running position of the rotating assembly. The thrust bearing is provided with for
resistance temperature detectors.
A split floating oil seal is fitted in a groove in the housing to maintain a level of
lubricating oil with in the housing, around the thrust bearing, when the pump is
stopped. The floating seal is prevented from turning by an anti-rotation pin fitted in
a slot in the bottom half of the housing. An orifice plug fitted at the thrust bearing
lubricating oil outlet ensures a flooded bearing housing when the pump is
stationary. The bearing are supplied with lubricating oil from the forced lubricating
oil system.
For further information on the bearings references should be made to be bearing

manufacturer's instructions at Chapter 4.
3.4 Bearing Housings :
The bearing housings are in the form of cylindrical castings, split horizontally,
secured to each bracket, by set screws and dowels located. Each housing is
provided with lubricating oil inlet and outlet connections, vent connections and
instrument entry points.
The top and the bottom halves of the drive end bearing housings are secured
together by studs and nuts, and the housing is closed at the drive end by a cover
plate. An oil retaining shield at each end of the housing prevents oil leakage from
the housing when the pump is running.
The top and the bottom halves of the non-drive end bearing housing are secured
together by studs and nuts and located by dowel pins. Leakage of lubricating oil
from the non-drive end bearing housing is prevented by an oil retaining,_s_h-'-'io'-el:-:-:d-:-'i--:n____ i
------------,tne-Tn-ooardsiae of1he housing and by a bearing housing end cover and joint ;-
secured to the out board side of the housing by hexagon head screws.
3.5 Mechanical seals :
The drive and non-drive end seal cooling jackets are fitted with mechanical seals mounted
on seal sleeves and located within seal cooling jackets.
The cooling jacket, which provides a heat soak barrier between the pump casing and the
mechanical seal, is continuously flushed with cooling water from an external source.
A pumping ring incorporated in the mechanical seal pumps a supply of boiler feed
water through a heat exchanger in a closed circuit, thus keeping the seal circuit
temperature at approximately 60°C.
For further information on the mechanical seals reference should be made to the
manufacturer's instructions at chapter 4.
3.6 Driver I pump coupling :
The drive from the driver to the pump shaft is transmitted through a spacer flexible
coupling.
SECTION -A
CHAPTER-2
OPERATING INSTRUCTIONS
\ LIST OF CONTENTS
1. Introduction
2. Fault finding
1',
l
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _!._
CHAPTER- 2
1. INTRODUCTION :
The type FA 1 875 booster stage pump is an integral part of the 50%
tandem Boiler pump set and must be operated as a pump set.
For operating instructions of the pump set, refer the operating instructions
for the pressure stage pumps.
2. FAULT FINDING :
Symptom Possible Cause Action
( 1) Pump fails (a) Driver fault. Check driver.

to starts.
(b) Power supply fault. Check supply.
(c) Seizure of pump set Disconnect couplings and

Locate seizure. Overhaul
as necessary.
(d) Deareator Level Check deareator.

Low- Low
(e) Pump set tripped. Investigate cause.

Rest trips.
(2) Pump (a) Driver fault Check driver.

performance
Low.
(b) Incorrect rotation. Check direction of driver.
(c) Pump suction line Check deaerator, suction

defective. strainer and suction
isolating valve, etc.
(d) Excessive wear of Check clearances and

pump internals. overhaul as necessary.
(3) Bearings (a) Defective in lubricating Check lubricating oil system.

overheating. oil system.
(b) Bearings worn or Examine bearings.

misaligned.
(c) Misalignment of pump. Check alignment.
(4) Mechanical (a) Insufficient cooling Check cooling water supply.

seals water.
:- 1:\, .. overheating
'
(b) Mechanical seal faulty. Check mechanical seal.
(5) Excessive (a) Misalignment of pump. Check alignment.

noise and/or
vibration
(b) Bearing misalignment. Examine bearing.
(c) Excessive clearance of Check clearances and

pump internals. overhaul as necessary.
(e) Rotating assembly out Check dynamic balance.

of balance.
,..
I.
I
SECTION -A
CHAPTER- 3
MAINTENANCE INSTRUCTIONS
LIST OF CONTENTS
1 Introduction
1.1 Periodic and preventive maintenance
1 .2 Routine checks
2 Maintenance Particulars
2.1 Estimated weights
2.2 Joints
2.3 Recommended lubricants
3. Maintenance procedures
3.1 Preparation for maintenance
3.2 Examine the drive and journal bearing
3.3 Examine the non-drive and journal and
thrust bearing
4. Overhaul
4.1 Preparation for overhaul
4.2 Dismantling the pump
4.3 Inspection and renewal
4.4 Assembling the pump
5 Parts Identification
CHAPTER-3
1. INTRODUCTION :
It is recommended that a system of routine inspection be established by

which the condition of the pump can be determined and recorded for comparison
with later inspections. Any defects should be repaired or the components renewed
at the earliest opportunity. Certain inspections can only be made when the pump is
shut down, but others can be made under operating conditions.
)
!
A high degree of cleanliness of each pump and of the surrounding areas
should be maintained, as this will assist in the early detection of minor leaks or
defects which, if unnoticed, could lead to more serious operational or maintenance
problems.
1.1 Periodic and preventive Maintenance
The pump performance should be used as the criterion for the need to
renew wearing parts. The pump may deteriorate due to excessive leakage past
the impeller I casing wear rings, or vibration may indicate that the wear rings or
bearings are worn.
Note : The recommended renewal clearances are 1.5 times the clearances shown
on the Sectional Arrangement Drawing HY-DG-188-139-0017. If the pump
performance has declined it may be necessary to renew the wearing parts
before the recommended clearances are reached.
1'
I
I 1.2 Routine Checks :
It is essential that the routine checks given in the operating instructions for
the pressure stage pump are carried out regularly. The checks concerned with the
mechanical condition of the pump are repeated here for the convenience of the
main~enance engineers. ;
1.2.1 Periodic Checks :
It is recommended that the following checks are carried out regular

intervals.
(1) Check that the suction and discharge pressure are normal.
(2) Check that the pump bearing lubricating oil pressures and temperatures
-----------are-normal. ------
(3) Check for leakage from the mechanical seals.
(4) Check all joints for leakage.
(5) Check for any undue noise or vibration.
(6) Carry out visual check on all keeps and fastenings, playing particular
attender to the holding-down bolts.
Note : Reference should also be made to the manufacturer's instructions in

Chapter-4.
2 MAINTENANCE PARTICULARS :
2.1 Estimated Weights (for lifting purposes)
Weight, Kg.
Pump assembly 2365

Top half pump casing 760
Pump shaft 74.5
Impeller 127
Water jacket 31
2.2 Joints:
Joints Between Material Section
Top half pump casing/ Brown paper Two ply

Bottom half pump casing
Pump casing I water jacket Klingersil 4200
Non-drive end bearing Brown paper Two ply
Housing I end cover
2.3 Recommended Lubricants
For the recommended grade of lubricating oil for the journal and thrust
bearings of the booster stage pumps, refer to the lubrication schedule included at
the end of this chapter. For the grade of lubricant supplied, refer to the
manufacturer's instructions for the turbine and the turbo coupling.
3. MAINTENANCE PROCEDURES :
WARNING: IT IS ESSENTIAL THAT THE PLANT SAFETY RULES AND

REGULATIONS ARE OBSERVED AT ALL TIMES DURING
MAINTENANCE PROCEDURES.
Note : The Booster stage pump is an integral part of the Boiler feed pump
set. The following instructions should, therefore, be read in
conjunction with those for the pressure stage pump and the
associated equipment.
3.1 Preparation for Maintenance :
Before commencing any maintenance procedures, the pump set must be

Isolated as follows :
(1) Isolate the driving motor I turbine. Refer to manufacturer's instructions.
(2) Isolate the electrical power supplies to all instruments.
3.2 Examining the Drive End (DE) Journal Bearing :
(1) Disconnect and remove any instruments which could interface with the
dismantling procedures.
(2) Remove the drive I pump drive coupling guard.
(3) Disconnect the drive I pump coupling.
COUPLING : The top half bearing housing is located on the bottom half
bearing housing by two dowel pins. Care must be taken to
avoid damage to the dowel on the holes in the bottom half
\) housing.
(4) Withdraw the dowel pins and remove the nuts from the studs securing the
top of bearing housing to the bottom half bearing housing.
(5) Lift away the top half bearing housing complete with the top half oil guards.
Remove the top half journal bearing from the shaft.
(7) Take the weight of the pump shaft and rotate the bottom halves of the journal
bearing and oil guards around the shaft and lift them away.
(8) Examine the journal bearing and shaft journal for signs of damage, scoring
or deterioration and examine the journal bearing and the oil guards for
wear. Reference should be made to the Sectional Arrangement Drawing
HY-DG-188-139-0017 for the clearances of the journal bearing.
Note : Lightly smear the shaft and journal bearing surface with oil before final
assembly.
(9) Rotate the bottom halves of the journal bearing and all rotating shields
around the shaft and into position in the bottom half bearing housing.
Release the weight of the pump shaft.
Note : It is recommended that, at this stage, the thrust bearing axial clearance is
checked and any necessary adjustments made before proceeding further.
Refer to section 3.3. in this chapter.
(1 0) Locate the top half journal bearing in position on the pump shaft.
(11) Lift the top half bearing housing complete with the top halves of the oil
guards onto the bottom half bearing housing.
(12)~-t-o-cate-th-e-top-half-b-earing-h-ousing-to--the-bottom--half-h-ousing-with-th·e,---'
dowel pins, then secure the top half housing in position with the studs and
I
nuts.
_I
(13) Reconnect the drive/pump coupling.
(14) Replace the instruments and the drive/pump drive coupling guard.
3.3. Examine the non-drive End (NDE) Journal and Thrust Bearing :
(1) Disconnect and remove any instrument which could interface with the
(3) Disconnect the drive I pump coupling.
(4) Remove the screws securing the bearing housing end cover to the top and
bottom half bearing housings. Remove the cover and discard the joint.
CAUTION: The top half bearing housing is located on the bottom half bearing
housing by two dowel pins. Care must be taken to avoid damage
to the dowels or the holes in the bottom housing.
top half bearing housing to the bottom half bearing housing.
(6) Lift the top half bearing housing complete with the top half oil guard away.
Remove the top half journal bearing form the shaft.
(7) Unclip the spring and remove the split floating oil seal from the bearing
housing.
Note : The thrust carrier ring split line is vertical to the bearing housing horizontal
surface.
(8) Remove each thrust carrier ring in turn, as a complete unit, as follows :
Rotate the complete carrier ring around the shaft until the half ring with the
stop pin can be removed, then rotate the other half ring around the shaft
until it can be lifted clear of the shaft. Repeat with the second carrier ring
on the other side of the thrust collar.
(9) Take the weight of the pump shaft (i.e, support the shaft) and rotate the
bottom halves of the journal bearing and the oil guard around the shaft and
out of the bottom half bearing housing. Lift the halves of the bearing and
guard away.
(1 0) Examine the journal bearing, shaft journal, thrust pads, thrust collar, split
oil and oil guard for damage or deterioration. Under normal operation
conditions it is not expected that any measurable wear will take place on
the thrust pads other than a dulling of the white metal surfaces. It is
(18) Secure the bearing housing end cover to the top half housing with the
screws.
(19) Install the drive/pump drive coupling spacer and element assemblies.
(20) Replace the instruments and the drive I pump drive coupling guard.
4. OVERHAUL:
The following instructions apply when the pump is due for a complete
overhaul and it is necessary to dismantle it to its components parts to examine
them for wear. The following procedures are intended as a guide and should be
read carefully by the engineer before commencing to dismantling the pump.
WARNING : IT IS ESSENTIAL THAT THE PLANT SAFETY RULES AND

REGULATIONS ARE OBSERVED AT ALL TIMES DURING
MAINTENANCE PROCEDURE.
4.1 Preparation for Overhaul
Before commencing overhaul procedures, the pump set must be isolated

as follows:
(1) Isolate the electrical power supplies to the pump set driving motor I turbine
and the lubricating oil system (refer to manufacturer's instructions).
CAUTION: The pump set pipe work and halves are not in pumps scope of
supply. Reference therefore, should be made to the system
instructions for the isolation of the pump set.
(3) Check that the pump set suction, discharge and leak-off isolating valves
are shut.
(4) Check that the cooling water has been isolated.
(5) Open the drain and vent connections and drain the pump casing.
WARNING: BEFORE PROCEEDING WITH OVERHAUL OF THE PUMP,

ENSURE THAT THERE IS NO PRESSURE WITH IN THE PUMP
CASING.
(6) Disconnect and remove any instrument which could interfere with the
(7) Disconnect and remove any small bore pipe work which could interfere with
the Dismantling procedures.
(8) Check that all lifting equipment and special tools are in good condition.
Note : All the shaft nuts have right hand threads.
4.2 Dismantling The Pump :
(2) Remove the drive I pump drive coupling spacer and element assemblies.
CAUTION: The top half bearing housing is located on the bottom half bearing
housing by two dowel pins. Care must be taken to avoid damage to
the dowels or the holes in the bottom half housing.
drive end top half bearing housing to the bottom half bearing housing.
(4) Lift away the top half bearing housing, complete with the top halves of the
oil guards. Remove the top half journal bearing form the shaft.
(5) Remove the screws securing the bearing housing end cover to the non-
drive end top and bottom half bearing housings. Remove· the cover and
discard the joint.
CAUTION : The top half bearing housing is located on the bottom half bearing
housing by two dowel pins. Care must be taken to avoid damage to
the dowels or the holes in the bottom half housing.
non-drive end·top half bearing housing to the bottom half bearing housing.
(7) Lift away the top half bearing housing, complete with the top half I oil guard.
Note The thrust carrier ring split line is vertical to the bearing housing
horizontal surface.
(8) Remove each thrust carrier ring in turn, as a complete unit, as follows :
Rotate the complete carrier ring around the shaft until the half ring with the
until it can be lifted clear of the shaft. Repeat with the second carrier ring on
the other side of the thrust collar.
(9) Slacken the securing socket head cap screws and rotate the mechanical
seal eccentric washers to locate in the seal sleeve groove. Lock the
washers in this positions.
(1 0) Remove the grub screws securing the seal sleeve to the shaft.
(11) Remove the socket head screws securing the seal plates to the water
jackets at the drive and non-drive end of the pump casing.
(12) Remove the socket head screws securing the water jackets to the pump
casing at the drive and non-drive end of the pump casing.
CAUSING : The top half pump casing is located on the bottom half casing by two
dowel pins. Care must be taken to avoid damage to the dowels or the
holes in the bottom half casing.
top half pump casing to the bottom half pump casing.
(14) Attach lifting equipment to the cast lugs on the top half pump casing.
(15) Use the jacking screws to break the pump casing joint, then lift the top half
casing clear of the bottom half casing to expose the rotating assembly.
Discard the pump casing joint.
(16) Attach lifting equipment to the rotating assembly and lift the assembly
complete with casing rings, water jackets and mechanical seals clear of the
bottom half pump casing.
(17) Transport the assembly to a suitable maintenance area and support the
assembly on wooden stands or trestles so that the impeller is clear of the
ground.
(18) Remove the bottom halves of the journal bearings and the oil guards from
the drive and non-drive end bottom half bearing housings.
(19) Slacken the coupling nut lock washer, unscrew and remove the coupling
nut.
(20) Withdraw the pump half coupling from the .shaft. Remove and retain the
coupling key.
(21) Slide the driven end mechanical seal cartridge off the shaft. Remove and
retain the sleeve key. For dismantling instructions for the mechanical seal,
refer to the manufacturer's instructions in Chapter-4.
(22) Withdraw the drive end water jackets from the shaft, then lift the casing
wear ring off the impeller.
(23) Unlock the thrust collar nut· lock-washer, then using the special spanner
supplied, unscrew and remove the nut. Remove and retain the lock-
washer.
(24) Withdraw the thrust collar from the shaft. Remove and retain the thrust
collar key.
(25) Remove and retain the split floating oil seal.
(26) Slide the non-drive end mechanical seal cartridge off the shaft. Remove and
retain the sleeve key. For dismantling instructions for the mechanical seal,
refer to the manufacturer's instructions in Chapter-4.
(27) Withdraw the non-drive end water jacket from the shaft, then lift the casing
wear ring off the impeller.
4.3 . Inspection and renewal :
The pump components should be cleaned thoroughly then inspected for any
signs of wear including scoring or wiping.
All diametrical clearances should be measured with internal and external

micrometers.
4.3.1 Clearances
Refer to the Sectional Arrangement Drawing for the details of the

clearances. It is recommended that when the pump internal clearances have
reached 1.5 times the figure quoted or are expected to do so before the next
overhaul, the component or components should be renewed. The main
consideration, however, is pump performance and motor power consumption.
4.3.1 (1) Examine the impeller and casing wear rings for signs of wear or damage.
Check the diametrical clearance between the impeller and casing wear
rings. Compare the readings obtained with those given. If necessary, renew
the wear rings.
(2) Renew the impeller wear rings as follows:
\ (a) Remove the grub screws securing the wear rings to the impeller.
(b) Machine the wear rings from the impeller eyes.
(c) Thoroughly clean the seating and shrink the spare wear rings onto
the Impeller shrouds.
(d) Secure the wear rings to the impeller shrouds with grub screws. Lock
the grub screws by light punching with a center punch at the thread
junctions.
A. Machine the outside diameter of the impeller wear rings to required
diameter to achieve diametrical clearance between the impeller and
casing wear rings as given on the Sectional Arrangement Drawings.
4.3.3 Impeller
-----------;=E~xa~m~in~e~th~e~imp_eJLer_foLsigns_oLwear-or-emsiGn,especially-around-the
blade tips.
4.3.4 Pump Shaft ends Sleeves
(1) Examine the pump shaft for signs of damage or bowing and check for
concentricity; it should be within 0.05 mm full indicator movement.
(2) Check that all threads are in good condition.
(3) Check that all keyways are free form burrs.
(4) Examine the seal sleeves for any signs of wear or damage.
4.3.5 Thrust collar and Floating oil seal
(1) Examine the thrust collar for any signs of wear or damage.
(2) Examine the floating oil seal for any wear or damage.
4.3.6 Studs, Nuts, Dowels and Keys
(1) The threads of all studs, screws and nuts must be clean, well formed and
free from burrs. If the threads are damaged in any way, the component
must be renewed.
(2) All keys must be good fit in their key ways and must also be flat, parallel
and free from burrs. Worn or damaged keys must be renewed.
(3) All dowels must be clean and free from damage or deterioration. Worn or
damaged dowels must be renewed.
4.3. 7 Joints and '0' Rings
All joints and '0' rings should be renewed on assembly. Apply soft soap to
all '0' rings prior to assembly.
4.3.8 Journal Bearings
Inspect the journal for signs of wear or damage and renew as necessary.
4.3.9 Thrust Bearing
Under normal operating conditions it is not expected that nay measurable

wear will take place on the thrust pads other than a dulling of the white surfaces. It
is recommended that when this dulling has spread to more than half the surface
area of the pads, they should be renewed. Refer to Manufacturer instructions in
Chapter 4.
4.3.1 0 Mechanical Seals
Information on dismantling and examining the mechanical seals is given in

the Manufacturer's instructions in Chapter- 4.
4.3.11 Fitting a Spare Impeller
The impeller should only be removed from the shaft if it is found necessary
to fit a spare impeller or shaft. To renew the impeller, carry out the following
instructions.
CAUTION : Before removing the impeller from the pump shaft it is important to
identify the correct rotating direction of impeller blades and also the
position of the impeller on the pump shaft for assembly purposes.
(1) Unlock the impeller nut lock-washers, then using the special spanner
provided, unscrew and remove the impeller nuts and lock-washers from
each end of the pump shaft.
(2) Withdraw the impeller from the pump shaft. Removed and retain the
impeller key.
(3) Check that the key fits correctly in the spare impeller or shaft key way.
(4) Fit the impeller on the shaft, ensuring the impeller key way is lined up
accurately with the key.
(5) Ensure that the impeller is fitted correctly for the direction of rotation and
also its original position on the shaft.
(5) Secure the impeller on the pump shaft with the impeller nuts and lock-
washers.
4.4 Assembling the Pump
To assist the assembly procedure, all fittings and threads should be

smeared with anti-scuffing paste.
(1) Support the pump shaft I impeller assembly on wooden trestles.
(2) Locate the casing wear rings on the impeller shrouds, then slide the water
jackets, with new joints fitted, on to each end of the shaft.
(3) Ensure that a new '0' ring is located in the internal groove of each seal
sleeve and the groove in the seal plate face.
(4) Insert the seal sleeve keys into their keyways and slide the mechanical seal
cartridges on to each end of the shaft, ensuring that the sleeve keys
engage in the keyways in the bores of the sleeves.
(5) Insert the coupling key into its keyway in the shaft and install the half
coupling, ensuring that the key engages in the keyway in the half coupling
bore.
(6_) _ _Screw_on_and-tighten-the-coupling--nut-and-sGrew-it-in-position-with-the-lock----:~,
screw.
.~· 1
I
-I
I!
(7) Insert the thrust collar key into its keyway in the shaft. Apply heat to the
thrust collar hub until the bore of the collar is expanded sufficiently to slide
the collar onto the shaft.
(8) Slide the thrust collar onto the shaft until butts against the shoulder,
ensuring that the key engages in the keyway in the thrust collar bore.
(9) Allow the collar to cool to ambient temperature, then secure it in position
with the thrust collar nut and lock-washer.
(1 0) Locate the bottom halves of the journal bearings and the oil guards into the
bottom halves of the drive and non-drive end bearing housings.
(11) Renew the top I bottom half pump casing joint.
Note : The joint should be cut in one piece to fit the outside edges of the top half
casing. The internal cutting of the joint should ensure that the joint fits all
bore contours accurately.
(12) Attach lifting equipment to the rotating assembly and lift into a position
above the bottom half pump casing.
Note : Lightly smear the shaft journal and bearing surfaces with lubricating oil.
(13) Carefully lower the assembly into he bottom half casing, at the same time
locating the casing wear rings in the bottom half casing grooves and
ensuring that the water jackets are correctly positioned, taking care not to
damage the joints.
(14) Fit a new paper joint onto the bearing housing and cover and secure it to
the non-drive and bottom half bearing with the screws.
(15) Check the axial running clearance of the thrust bearing as follows :-
(a) Install the inner halves of the thrust bearing carrier rings and spacers
in the bottom half housing and move the rotating assembly as far as
possible towards the drive end of the pump.
(b) Install the outer halves of the thrust bearing carrier rings and spacers
in the bottom half bearing housing.
(c) Check the axial clearance by moving the pump shaft so that the thrust
pads collar is hard against one set of thrust pads and use feeler
gauges between the opposite thrust bearing spacer and the bearing
housing. The total axial clearance should be 0.35 mm minimum and
any measurable variation should be investigated.
CAUTION : Do not insert feeler gauges between the thrust collar and the
thrust pads this may give an inaccurate reading and cause
damage to the white metal pad surface.
(16) Install the split floating oil seal on the pump shaft with the spring.
(17) Locate the top half journal bearings in position on each end of the pump
shaft.
(17) Lift the drive end top half bearing housing complete with the top halves of
the oil guards onto the bottom half bearing housing.
(18) Locate the top half bearing housing to the bottom half housing with the
dowel pins, then secure the top half housing in position with the studs and
nuts.
(19) Lift the non- drive end top half bearing housing complete with the top half oil
guard onto the bottom half bearing housing, ensuring that the carrier ring
stop pins are properly located.
(20) Locate the top half bearing housing to the bottom half bearing housing with
the dowel pins, then secure the top half housing in position with the studs
and nuts. ·
(21) Secure the bearing housing end cover to the top half housing with the
screws.
(22) Attach lifting equipment to the cast lugs on the top half pump casing and.
Ensuring that all joint faces are perfectly dean, lift it carefully on to the
bottom half casing.
Note : Before securing the top half casing in position, ensure that the rotating
assembly turns freely by hand.
(23) Locate the top half pump casing to the bottom half casing with the dowel
pins, then secure the top half casing in position with the studs and nuts.
Check the rotating assembly for freedom of rotation.
(24) Secure the water jackets to each end of the pump casing with the socket
head screws.
Note : The mechanical seal is a cartridge assembly and eccentric washers located
in the seal sleeve groove set the position of the seal.
(25)
Slide each seal cartridge into the seal cooling jackets, ensuring the sleeve
key locates in the seal sleeve keyway, until the seal plates about the
-----------eooling-jaeketsc-.--~---------------------
(26) Secure the seal plates to the water jackets with the socket head screws.
' - - - - - - - - - - - - - - - - ------------------ .~~~-~----~- ---------

(27) Secure the sleeves to the shaft with the grub screws.
CAUTION : It is important to remember to revolve the eccentric washers through

180° and lock with the socket head cap screws prior to starting the
pump. Refer to Chapter 4 for the manufacturer's instructions.
(28) Replace all small bore pipe work and instruments that were removed for
dismantling purposes.
(29) Check the coupling alignment (refer to lllus. No P2424) then install the
driver/pump drive coupling spacer and element assemblies. Replace the
coupling guard.
5. PARTS IDENTIFICATION
When ordering spare parts reference must be made to the pump serial or
job Number, Nomenclature, the Sectional Arrangement Drawing and item Number,
and the quantity of each component.
SECTION -A
CHAPTER-4
SUB- VENDOR'S DRAWINGS /INSTRUCTIONS
LIST OF CONTENTS
1. Mechanical Seals
2. Heat Exchangers for Mechanical Seal
3. Magnetic filters for Mechanical Seal
4. Thrust Bearing
SECTION-A
CHAPTER-4
1. MECHANICAL SEALS
(
\
OPERATING MANUAL
This document was drawn up observing the FC directives
Machinery (FN2922) and the German Directives VDI-4500
BURMANN MECHANICAL SEAL (M.S.)
09-11751 f2/1 OO-ex1
(Drive End)
These instructions are intended

for the assembly, operating and
control personnel and should be
kept at hand on site.
Ultimate user
Customer BHEL (India)
Pump company BHEL
Pump type & size FAIB75
PLEASE READ this manual carefully and OBSERVE the information contained as to
• Safety • Start up • Removal
• Storage • Maintenance • Repair
• Installation
If there are any unclear points please contact BURGMANN by all means.
/:
/
Table of Contents
• 1. PRODUCTION INFORMATION ......................................................................... . ..

.)
1.1 Manufacture and country of origin ...................................................................... . 3

1.2 Declaration .......................................................................................................... 3
1 .3 Type designation ................................................................................................. 3
1.4. Operating conditions ........................................................................................... . 3
1.5 Designated use ................................................................................................. . 3
~-··-
1.6 Drawings, diagram ............................................................................................. . 4

. 1.7 Description and function .................................................................................... . 4
1.8 Required space, connecting dimensions ........................................................... . 4
1.9 Power requirements ........................................................................................... . 4
1.10 Additional equipment ........................................................................................ . 5
1.11 Emissions ........................................................................................................... 5
1.12 Copyright ........................................................................................................... . 5
2. SAFETY NOTES ............................................................................................. .. 6
, 3. TRANSPORT, STORAGE, INSTALLATION ..................................................... .. 7

I 3.1 Recommendation for transport and storage ....................................................... .. 7
; 3.2 Preparation for assembly ................................................................................... . 10
I
1 3.3 Assembly I installation ...................................................................................... .. 10
I 3.4 Supply connections ........................................................................................... .. 11
I
i 4. OPERATION ..................................................................................................... . 12
i 4.1 Instructions for start up ..................................................................................... .. 12
i 4.2 Instructions for safe operation ........................................................................... .. 12
i 4.3 Instructions for worker's protection ................................................................... .. 12
! 4.4 Directives in case of failure ................................................................................ . 13
Is. SERVICING ...................................................................................................... .. 13
5.1 Maintenance ....................................................................................................... 13
5.2 Reconditioning (repair) ....................................................................................... . 13
5.3 Disassembly I removal ...................................................................................... .. 14
5.4 Spare parts ......................................................................................................... 14
! 5.5 Required details for enquiries and orders .......................................................... . 14
)5.6 After-sales service by BURGMANN .................................................................. .. 15
1. PRODUCT INFORMATION
1.1 Manufacturer and country of origin
FEODOR BURGMANN
Dichtungswerk GmbH & Co
D- 82502 Wolfratshausen
Federal Republic of Germany
1.2 Declaration
Within the meaning of the EC-directive >>MACHINERY<<
'"l A mechanical seal does not function independently it is intended to be

incorporated in to or assemble with machinery.
1.3 Type designation
09-H75F2/1 OO-ex1 (drive end)
For non drive end seal please refer to drg. 09-H75F2/1 OO-EX2
Materials according to drawing and/or to order.
1.4 Operating conditions
Pump type & size FA1B75

Medium to be sealed Boiler feed water
Temperature of medium 165°C
Stuffing box cooling by pump jacket cooling
Pressure to be sealed 25 bar
Supply at API 610 Plan 23 + filter
Shaft diameter at seal 82.53 I 80 (stepped)
Shaft speed (approx.) 1495 to 1644 rpm
Direction of rotation CCW, seen from the driven end
Mounting position horizontal
Axial movability of M.S. ± 2mm
1.5 Designated use
This mechanical seal is exclusively designed for the use in the specified machine.
A different utilization or a utilization going beyond the specification is considered
contrary to its designated use and excludes a liability by the manufacturer.
.. i ..
Operation under conditions lying outside those limits stated in paragraph >>
operating data << is considered contrary to its designated use.
Should the seal be operated under different conditions or at a different application

BURGMANN has to be asked for recognition as safe in advance.
1.6 Drawings, diagrams
Assembly drawing 09-H75F2/1 OO-EX1 (drive end)
The assembly drawing in the original scale and in its latest edition (latest revision)
only is decisive for the design and the use in connection with this manual.
In the following description all figures in parentheses, e.g. (2) define the respective
part item no. in the assembly drawing.
1. 7 Description and function
Single, balanced mechanical seal (M.S.) for boiler feed pumps.
Together with the housing parts (6.4A, 16A) supplied the seal forms a pre-mounted
unit (seal cartridge), assembled at works, ready to be installed without any
adjustment.
Assembly fixtures (9) are provide for holding the cartridge in one piece during
transport, storage, assembly and disassembly.
The seal face (1.1) is loaded by means of multiple springs (1.4). It is arranged
rotating on the shaft sleeve.
The seat (2) is mounted in a cover (4A) and arranged Stationary.
Due to the integrated dual pumping screw at Drive collar (1.5A), Labyrinth Ring
(16A) and pumping sleeve in cover (4A) the seal cartridge is un-directional.
Torque transmission from mechanical seal to the shaft by means of a key.
Axial fixing of the shaft sleeve (6) by means of set screw (12a)
1.8 Required space, connecting dimensions
The connecting dimensions of the mechanical seal were checked and approved by
the customer on the main drawing.
The available mounting space given by the machine was decisive for the design of
the housing parts of mechanical seal. The connecting dimensions are checked
before shipment with regard to the BURGMANN drawing.
1.9 Power requirements

The total power consumption of the mechanical seal under the considerable
influence of the turbulence losses of the rotating seal parts has been calculated for
the individual application. To ensure a safe operation the required quantity of
circulated liquid will be individually determined by the seal manufacturer by
modifying the pumping device in the mechanical seal.
The total calculated power consumption of one seal cartridge is approx. 17.4 KW.
The pump manufacturer has to take this additional load into consideration when
designing the drive.
1.10 Additional equipment
For a safe operation of the mechanical seal a circulation circuit is required, from the
seal through a heat exchanger (if necessary, also through an additional magnetic
separator or filter) back to the seal, as described in API 610, plan 23. When the
shaft rotates the liquid is circulated by a pumping device in the mechanical seal.
Jacket cooling of the stuffing box is provide in the pump and should be operated for
reasons of longer service life.
Safe operation can be expected when observing the following seal circuit
temperatures, measured at seal outlet :
• warning temperature : 55° ·C
• shut-off temperature : 65° C
• standstill temperature : 75° C
1.11 Emissions
) A mechanical seal is dynamic seal that cannot be free of leakage due to physical
and technical reasons. Seal design, manufacture tolerance, operating conditions,
running quality of the machine etc. Mainly define the leakage value. In fact,
compared to other sealing systems (e.g. packings) there is few leakage.
Small seal leakage is desirable and admissible, because of longer operating life of
mechanical seal. If however, leakage exceeds a value of 8 litres per hour, the seal
is damaged . It has to be replaced.
Hot medium or even steam may splash out if the seal fails. Personal injury may be
prevented by the user providing for splash protection and wearing safety goggles.
Care has to be taken by the user for proper disposal of the leakage.
Components which may get in contact with the leakage have to be erosion
1-------~resistant-or-have-te-be-adequately-pr:otected.---.----------~------
1.12 Copyright
The FEODOR BURGMANN Dichtungswerke GmbH & Co. (FRG) has the copyright
in this Manual Buyer, planner and user of the product are authorized for use in
connection with further documentation.
2. SAFETY NOTES
Any person at the user's shop being involved in assembly, disassembly, start up,
operation and maintenance of the BURGMANN Mechanical Seal must have read
and understood this instruction Manual and in particular the safety notes we
recommended the user to have this confirmed.
BURGMANN Mechanical seals are manufactured on high quality level and they
keep a high working reliability. Yet, if they are not operated within their intended
purpose or handled by untrained personnel they may cause risks.
The user is asked to check as part of his security program what effect a failure of
the mechanical seal might have on the environment and what additional safety
measures have to be taken to prevent personal injury.
Any operation mode that affects the operational safety of the mechanical seal is not
permitted.
The pump must be positioned in a way that no persons are endangered if product
splashes out in case of seal failure. Leakage of product has to be disposed
properly.
BURGMANN mechanical seals must be operated maintained or repaired by

authorized, trained and instructed personnel only.
Any work to be done on the mechanical seal is only permitted when the seal is
neither operating nor pressurized, ensure the equipment at room temperature.
The responsibilities for the respective jobs to be done have to be determined

clearly and observed in order to prevent unclear competencies form the point of
security.
Apart from the notes given in this manual the general regulations for worker's
protection and those for prevention of accidents have to be observed.
Unauthorized modifications or alterations are not permitted as they affect the

operational safety of the mechanical seal.
3. TRANSPORT, STORAGE, INSTALLATION
3.1 Recommendation for transport and storage
• PACKING AND SHIPMENT

If not specified differently in the order the BURGMANN standard packaging is used,
suited for dry transport by truck, train or plane. The signs and notes for handling on
the packaging have to be observed.
In addition seaworthy packing may become necessary.
• STORAGE AND PRESERVATION
• Range of validity
The following recommendations apply to all BURGMANN Mechanical Seals which

have been supplied and stored in their undamaged original packing as well as to
seals which have been installed in a component of a plant (e.g pump, compressor,
agitator, etc.) but have not yet been put into operation.
• General
BURGMANN mechanical seals for components of power plants are super finished
and tested machine elements whose handling during the erecting and start-up
period of a power plant as well as during the storage period (in particular of spare
parts) entails certain measures to keep the full efficiency of the seals.
Sliding materials and elastomers are subject to material-specific and time-based

alterations (distortion, aging) which might reduce the full efficiency of the seals.
Yet, such processes must not occur automatically.
The mechanical seal may be stored welded onto vapour-safe plastics sheets by
adding a drying agent e.g. "SILICAGEL".
Damages caused by improper storage may not be claimed on the BURGMANN

company with reference to their warranty.
• INSTALLED BURGMANN - M.S.
Components of power plants which are equipped with BURGMANN mechanical

seals are usually delivered in a completely mounted state. Often the parts were
tested at works beforehand.
• Start-up at the power plant
For the start up of BURGMANN mechanical seals as well as of possible

accessories extra instructions have to be observed which consider the respective
conditions.
1--~---__:__-New~producLplants~often~ha~e_erection~times_oLup_t_o_j_O_y~ears. In· such cases the

period between the production of the M.S. and its installation and start-up may
exceed the usual period of approximately 2-3 years.
BURGMANN recommend to disassemble such seals in time before the planned
start-up of the components of power plant and to sent the seals to the manufacturer
or the nearest BURGMANN service centre where they can be checked and
reconditioned, if necessary.
If this is not possible for primary reasons (distance, dispatch conditions, etc.) other
companies (never other seal manufacturers!) may be charged if they are suitably
equipped and have the know-how required. Yet, BURGMANN'S confirmation for
recognition as safe is absolutely necessary in particular with regard to claims under
warranty.
• Preservation in case of instaiiation
Check in case of a preservation of complete plants with mechanical seals installed
• The compatibility of the chosen preservation agent with the seal materials and
with elastomers.
• No impairment of the seal's axial movability by conglutination or by gumming.
We recommend to dry the seal parts after the preceding functional test and to
keep them dry when being installed. Values of < 50 % relative humidity are
considered as dry condition. If there are uncertainties as to the correct proceeding
please contact BURGMANN.
• STORAGE OF BURGMANN-M.S.
Premises
The mechanical seals have to be stored in dry, dust free, moderately ventilated and
tempered rooms. We recommend relative air humidity below 65 % temperature
between 15°C and 25°C.
Direct exposure of the mechanical seal to heat (sun, heating) as well as to axone,
present or produced by ultraviolet light (halogen of fluorescent lamps), must be
avoided because of the risk of embrittlement of elastomer materials.
Handling
Store the seals in their original packing lying on a flat surface.
Thus a protection from shocks and from damage of edges is provided.
For storage the mechanical seal is welded into vapour-safe plastic sheets by
adding the drying agent" SILICAGEL ". Thus the humidity inside the packaging is
stabilized.
The packaging should be periodically checked for damage.

'I
'
An easy control of the package contents is provide due to the transparent

polyethylene sheet as well as by the attached package list or the package label.
Check the mechanical seal :
• After a storage period of approximately 2-3 years.
• After a damage of the packing
• After a shock on the mechanical seal (e.g. by dropping the packed seal)
~ At the manufacturer's or at the nearest service centre.
If necessary, a different, evident component authority may be contacted. Yet,

BURGMANN must be informed about this fact, as BURGAMANN's confirmation for
recognition as a safe is absolutely necessary.
NOTE: An installation of the M.S. is possible if the prescribed checks cannot

be carried out for special reasons, yet, only if the seal parts have no
visible damages.
BURMANN must be informed about this kind of installation. Otherwise a warranty

as to leakage and/or operational reliability will be refused by BURGMANN.
A possibly increased leakage during start-up will decrease to a normal quantity
after the running in period of the sliding faces.
If this is not the case or if there are other malfunctions the mechanical seal has to
be shut down, removed and checked for reasons of safety.
If there is a malfunction which you cannot correct on your own, or if the cause of
malfunction is not clearly recognizable please immediately contact the nearest
BURGMANN agency, a BURGMANN service centre or the BURGMANN
I
j headquarters.
• Control of humidity inside the packaging
All water vapour-proof sheets inside the package are supplied with humidity
indicators which show the relative air humidity inside the packaging. On a scale the
colour changes from blue (=dry) to pink (=humid).
For check of the stored mechanical seals which should be carried out periodically
and should be recorded in-plant the following points have to be observed :
• Humidity is indicated with values > 50% rei. humidity :
=> Contact BURGMANN as a control of the seal and new packaging is necessary.
• Humidity is indicated with values < 50% rei. humidity, yet the storage period of
2-3 years is exceeded.
3.2 Preparation for assembly
Check the parts of the machine for :
~ Chamfered edges (sliding cones i.e. 30°/2 mm or in accordance with DIN

24960).
• radiused transmissions
e Mating fits and 0-iing surfaces: fine finished Rz i 0 f.Jm (=N?=CLA 63).
• Shaft surface in the area of the M.S.: fine finished Rmax. 5 f.Jm (=N6=CLA 32)
Check at the machine :
• Damage of connecting surfaces to the M.S.
• Mating dimensions, rectangularity and concentricity to the shaft axis.
• Direction of rotation must comply with the seal drawing, otherwise contact
BURGMANN immediately.
• Insert a parallel key into the groove provided.
• Lubricate the shaft slightly in the area of the seal.
~ Elastomers made of EP-rubber must never come into contact with

lubricants on the base of material oil (swelling, decomposition)
~ Lubricant for elastomers (a-rings etc.) recommended by BURGMANN.
~ TURMOPOLGREASE SH2 <<make Lubricant Consult (LUBCON)
3.3 Assembly I installation
The material seal is supplied as a cartridge unit, pre-mounted at works, and does
not require any adjustment during installation. This document provides the required
information for Installation and removal of the cartridge only.
For installation the assembly drawing 09-H75F2/1 OO-EX1 has to be on hand.

The mechanical seal has to be installed very carefully and under the cleanest
conditions.
Do never force during installation.

The order of assembly to install the mechanical seal into the pump depends on the
design of the pump and should advisably be determined by the pump
manufacturer.
Possible installation order :
• Check of o-rings (5 and 7) have been installed.
• Feed the complete seal cartridge onto the shaft.
~ The key in the shaft has to be engage into the keyway in the shaft sleeve (6).
~ Avoid bumping the seal cartridge against the shaft or shaft steps as the brittle
ceramic components break easily.
• Bolt the mechanical seal to the assembly flange in such a way that the
connections for supply and disposal are positioned in accordance with view
"X" in the drawing.
• Tighten the set screw (12a) uniformly & firmly.
• Remove the assembly fixtures (17) and keep them for a later removal of the
seal.
3.4 Supply connections
/ The supply connection is designated as a female threaded NPT connection.

\
.I
The connection for supply is marked on the mechanical seal.
• Remove the plastic protection cap from the supply connection after
installation.
Supply piping :
• Use pipes of stainless steel with a big cross-section.
• Install the pipes continuously rising, ~s short and convenient as possible for
the flow to ensure self-venting.
• Avoid air inclusions and provide for venting connections, if necessary.
~-----------=•:__~C~Ie~an the piping thoroughly. Fasten all pipe connections pressure-sealed.
4. OPERATION
4.1 Instructions for start up
Safety checks before start up
• Seal assembly fixtures disengaged
~ Torque transmission and axial fixing between mechanical seal and shaft duly
installed.
• Supply connections tightened pressure-sealed.
For a safe operation of the mechanical seal a circulation circuit is required. Design
in accordance with the scheme in the assembly drawing. Supply fluid flows from
stuffing box through a filter and a cooler back to stuffing box, similar to API 610,
Plan 23.
Forced circulation of the fluid when the shaft rotates by means of a uni-rotational
pumping device in the seal.
Jacket cooling of the stuffing box is provided in the pump and should be operated
for reasons of longer service life.
• Flood pump and seal cavity (stuffing box) with medium.
• Thoroughly vent seal cavity and circulation system.
• After a short startup period repeat the venting procedures several times with
the pump being at standstill.
o Now the seal is ready for operation.
4.2 Instructions for safe operation :
Safe operating can be expected when observing the following seal circuit
temperatures, measured at seal outlet:
• Warning temperature
• Shut-off temperature
• Standstill temperature
If the operation limit values and the instructions given in this manual are followed a
trouble-free operation of the mechanical seal can be expected.
4.3 Instructions for worker's protection :

Hot medium or even steam may splash out if the seal falls. Personally injury many
be prevented by the user providing for splash protection and wearing safety
goggles. Care has to be taken by the use for proper disposal of the leakage.
4.4 Directives in case of failure
Try to define the kind of failure and record it.
In case of failure due to high leakage the amount of leakage should be observed.
Changes of the operating conditions have to be recorded. In case of an
unacceptable temperature rise the mechanical seal must be shut down for reasons
of safety.
A damage of the mechanical seal is indicated by a continuous, flowing leakage.
BURGMANN agency, a BURGMANN service centre of the BURGMANN
headquarters.
During the warranty period the mechanical seal must only be disassembled or
removed the BURGMANN's approval or when a BURGMANN representative is
present.
5 SERVICING
5.1 Maintenance
A correctly operated mechanical seal is maintenance-free. Wear parts, however,

have to be replaced, if necessary.
An inspection of the mechanical seal should be carried out during a revision of the
complete plant. We recommend to have this inspection be performed by
authorized BURGMANN personnel.
If the mechanical seal is disassembled during a revision of the plant the sliding
faces should be refinished at the manufacturer and both 0-rings and springs
should be replaced.
5.2 Reconditioning (repair)
If repair is necessary, the complete seal cartridge should be sent to the

manufacturer, as this is the best way to find out which components can be
reconditioned or which parts must be replaced.
~--------·..__,R~e...-:co~n,_._.d..._it._..io~n~ing
of the mechanical seal by the user is not desirable for reasons of
operational safety. Repair should only be carried out by BURGMANN service
personnel or by trained personnel of the machine manufacturer in suitably
)
equipped clean rooms. Seal cartridges only should be replaced by the user if
possible.
5.3 Disassembly I removal
• Shut down the pump duly procedure, let it cool down an depressurize it.
• No product should contact the mechanical seal => drain the pump, if
necessary.
• Secure the pump against inadvertent start.
• Observe the safety notes (safety data sheets)
Mechanical seal cartridges should possibly not be disassembled or extremely

cleaned during or after removal so that the damages and their causes may be
correctly analysed by qualified personnel of the manufacturer of the user.
neither operating nor pressurized.
Follow the valid regulations for preventing accidents when disassembling

mechanical seals as well as handling hazardous substances if the seals have been
already in operation. In case of doubt the necessary information have to be
obtained before starting removal disassembly or repair.
• Remove the supply piping.
• Engage the assembly fixtures (9) into the groove in the shaft sleeve (6) and
fasten them.
• Loosen all the screw's (12a).
• Loosen all screw connections between seal cartridge and the respective
machine parts .
•
The disassembly (removal of the seal is carried out in the reverse sequence
as described for assembly (set up).
The order of disassembly to remove the mechanical seal out of the pump
depends on the design of the pump and has to be determined by the pump
manufacturer.
5.4 Spare parts
• Only BURGMANN original spare parts must be used. Otherwise
• Risks of a seal failure endangering persons and environment.

);> Risks of a seal failure, endangering persons and environment.
);> The BURGMANN guarantee for the mechanical seal lapses.
• For a quick exchange a complete spare seal should be on stock.
5.5 Required details for enquiries and orders
For enquiries and orders the following details are required.
• BURGMANN commission no.
• Drawing no. of mechanical seal: 09-H75F21100-EX1
• Part item no. Designation, material number of pieces ace. Of drawing.
5.6 After-sales service by BURGMANN
The range of service offered by BURGMANN not only includes advise during the
planning stages but also technical support after commissioning. This is supported
by a world-wide comprehensive network of subsidiaries, field engineers and
service centers.
In India please contact first:
Headquarter :
BURGMANN INDIA Pvt. Ltd.

Madina Manzila Compound
S.V.Road, Goregoan (West)
Bombay - 400 062
if 874 1534 I 1820 I 1905
Telefax 022-8 74 8810
Branch Offices : Baroda, Pune, Delhi, Calcutta, Madras, Hyderabad, Surat, Kota,
Chandigarh, Visakapatnam, Cochin.
Kuehlwosser ____..,.---4
cooling water
EAU DE REFRDIDISSEMENT
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heat exchanger
ECHANGEUR DE CHALEUR
Burgmonn supply
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magnetic filler
FIL TRE HAGNETIOUE
Burgmonn supply
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) COOLING JACAKET GARNITURE MECHANIOUE
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schema du circuit de balayage
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VINDHYACHAL SUPER THERMAL POWER PROJECT
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1 Mr. 241 oesichertl ______, BHEL DRG. No.: HY-DG-209-139-0060, REV. 01
IPorts de!}'eosed ond fixed j 1-----!NTPC DRG. No.: 2240-108-04HY-PVM-C-103, REV. 01
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~MPENTYP/PUMP TYPE. FA-18-75
REHZAHL/SPEED 1495(RPM)
IEDIUM/FLU\0 BOILER FEED WATER
- :EMPERATUR/TEMP 165 c·c)
RUCK/PRESSURE 15 (bar)
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Oichtungswerke GmbH B. (a.
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rsa 2169-mK 0-82502 Wolfrotshausen
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OPERATING MANUAL
This document was drawn up observing the FC directives
Machinery (FN2922) and the German Directives VDI-4500
BURMANN MECHANICAL SEAL (M.S.}
09-H751 F2/100-EX2
(Non-Drive End}
)
These instructions are intended

for the assembly, operating and
control personnel and should be
kept at hand on site.
Ultimate user
BHEL (India)
Customer
Pump company BHEL
PLEASE READ this manual carefully and OBSERVE the information contained as to
•start up •Removal
•Safety
•Maintenance •Repair
•storage
•Installation
If there are any unclear points please contact BURGMANN by all means.
Table of Contents
10 PRODUCTION INFORMATION .................. o. ...... ................... ...... .. .. .. .. .. . .. .. .... .. .. 3

101 Manufacture and country of origin ....................................................................... 3
1 02 Declaration 0000...... 0... 00........ 0.. 0.. 00........ 0.. 0. 0... 0.... 0.. 00.. 0...... 000............. 0.. 0.. 0..... 00.... 0. 00 3
103 Type designation ...... 0... 0.. 0.. 00.... 0........ o ......... 00....... 00.... 0.. 0........ 00........... 0....... 0. 0..... 3
1.4. Operating conditions 00. 0.. 0.............. o .. o 0......... o .. 0................. 00.......... 0.. 0.. 0.. o .. o .. 0.. 0. 0.. 0 3
105 Designated use ...... o . . . . . . . . . ooo . . . . . . . . o . . . . . . o . . . . . . o . . . . . . . . 0........ 0.000 o o o o o o . . . . . . . . . . . . oo . . . · o · · o • • o · o 0 3
106 Drawings, diagram .. 00000.. o .. 0.. 0.. 0........... 000...... 00.... 0............. 0. 00........................ 00....
o 4
107 Description and function ..................................................................................... 4
108 Required space, connecting dimensions ..... ................ ... ..... ...... .. .. .. .. ...... .. .... .. ... 4
109 Power requirements 0.......... 0.. 0......... o .. 0.... 0...... 0..... 0.. o ...... 0.... 00.... 00..... 0.......... 0.. 0.... 4
1010 Additional equipment .................................................................................... ..... 5
1.11 Emissions ............. 0000.................................. 0.... 0............... 0........ 0.......... 0.. 00... 0..... 0 5
1012 Copyright ........................... 0........................ 0.......... o .................. 0................. 0....... 5
20 SAFETY NOTES ............................................... 0......................... 0..................... 6
3. TRANSPORT, STORAGE, INSTALLATION....................................................... 7
301 Recommendation for transport and storage......................................................... 7

3.2 Preparation for assembly ................ .............. ... .. .. .. .. ..................... ...... ... ......... .... 10
303 Assembly I installation ...... ... ......... ............. ...... ...... .. .. ......... ... .. .. ......................... 10
304 Supply connections ............. 0................... o .... o .......... o .......................................... 0 11
40 OPERATION 0................... 0.. 0.... 0........................................................................ 0 12
4.1 Instructions for start up ........ ...................................... ............... .......................... 12
402 Instructions for safe operation ................ ............. ......................... ........... ............ 12
403 Instructions for worker's protection 00 o • • • o o · · · o · o · · . . oo . . . . . o . . . . . ooo o o o • o · · · o o • o · · · o o o o o o o o o o o · o o · o o 00 0 12
4.4 Directives in case of failure ....................................... ................... ....................... 13
5. SERVICING ........................... 0........................ 0.......................................... 0........ 13
501 Maintenance .............................. 0...................................................... 0.. ..... .. .. ... .. . 13
502 Reconditioning (repair) ................................. o . . . . . . o.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
503 Disassembly I removal ...... 00. 00.. 000..... 0. 0..... 0. 0...... 0........ o ...... 0. 0. 0.... 0. 000.. 0.... 00...... 0.. 0. 14
504 Spare parts ............................................................................. 0...... ... .. .. .............. 14
5.5 Required details for enquiries and orders ........................................................... 14
5.6 After-sales service by BURGMANN ......... ........................................................... 15
1.1 Manufacturer and country of origin
FEODOR BURGMANN
Dichtungswerk GmbH & Co
D- 82502 Wolfratshausen
1.2 Declaration
Within the meaning of the EC-directive >>MACHINERY<<
A mechanical seal does not function independently it is intended to be

)
incorporated in to or assemble with machinery.
1.3 Type designation
09-H75F2/1 OO-EX2 (Non-drive end)
For non drive end seal please refer to drwg. 09-H75F2/1 OO-EX1
Materials according to drawing and/or to order.
1.4 Operating conditions

Medium to be sealed Boiler feed water
Temperature of medium 165°C
( I Stuffing box cooling by pump jacket cooling
\. J Pressure to be sealed 25 bar
Supply at API 610 Plan 23 + filter
Shaft diameter at seal 82.53 I 80 (stepped)
Shaft speed (approx.) 1495 rpm
Direction of rotation CCW, seen from the driven end
Mounting position horizontal
Axial movability of M.S. ± 2mm
1.5 Designated use
A different utilization or a utilization going beyond the specification is considered
contrary to its designated use and excludes a liability by the manufacturer.
Operation under conditions lying outside those limits stated in paragraph >>
operating data << is considered contrary to its designated use.
Should the seal be operated under different conditions or at a different application

8URGMANN has to be asked for recognition as safe in advance.
1.6 Drawings, diagrams
Assembly drawing 09-H75F2/1 OO-EX2 (Non-drive end)
The assembly drawing in the original scale and in its latest edition (latest revision)
only is decisive for the design and the use in connection with this manual.
In the following description all figures in parentheses, e.g. (2) define the respective
part item no. in the assembly drawing.
1.7 Description and function
Single, balanced mechanical seal (M.S.) for boiler feed pumps.
Together with the housing parts (6.48, 168) supplied the seal forms a pre-mounted
unit (seal cartridge), assembled at works, ready to be installed without any
adjustment.
Assembly fixtures (9) are provide for holding the cartridge in one piece during
transport, storage, assembly and disassembly.
The seal face (1.1) is loaded by means of multiple springs (1.4). It is arranged
rotating on the shaft sleeve.
The seat (2) is mounted in a cover (48) and arranged Stationary.
Due to the integrated dual pumping screw at Drive collar (1.58), Labyrinth Ring
(168) and pumping sleeve in cover (48) the seal cartridge is un-directional.
Torque transmission from mechanical seal to the shaft by means of a key.
Axial fixing of the shaft sleeve (6) by means of set screw (12a)
1.8 Required space, connecting dimensions
The connecting dimensions of the mechanical seal were checked and approved by
the customer on the main drawing.
The available mounting space given by the machine was decisive for the design of
the housing parts of mechanical seal. The connecting dimensions are checked
before shipment with regard to the 8URGMANN drawing.
1.9 Power requirements

The total power consumption of the mechanical seal under the considerable
influence of the turbulence losses of the rotating seal parts has been calculated for
the individual application. To ensure a safe operation the required quantity of
circulated liquid will be individually determined by the seal manufacturer by
modifying the pumping device in the mechanical seal.
The total calculated power consumption of one seal cartridge is approx. 17.4 KW.
The pump manufacturer has to take this additional load into consideration when
designing the drive.
1.10 Additional equipment
I For a safe operation of the mechanical seal a circulation circuit is required, from the
)
seal through a heat exchanger (if necessary, also through an additional magnetic
separator or filter ) back to the seal, as described in API 610, plan 23. When the
shaft rotates the liquid is circulated by a pumping device in the mechanical seal.
Jacket cooling of the stuffing box is provide in the pump and should be operated for
reasons of longer service life.
Safe operation can be expected when observing the following seal circuit
• warning temperature : 55° C
• shut-off temperature : 65° C
• standstill temperature : 75° C
( ) 1.11 Emissions
A mechanical seal is dynamic seal that cannot be free of leakage due to physical
and technical reasons. Seal design, manufacture tolerance, operating conditions,
running quality of the machine etc. Mainly define the leakage value. In fact,
compared to other sealing systems (e.g. packings) there is few leakage.
Small seal leakage is desirable and admissible, because of longer operating life of
mechanical seal. If however, leakage exceeds a value of 8 litres per hour, the seal
is damaged . It has to be replaced.
Hot medium or even steam may splash out if the seal fails. Personal injury may be
prevented by the user providing for splash protection and wearing safety goggles.
Care has to be taken by the user for proper disposal of the leakage.
Components which may get in contact with the leakage have tooe erosion
resistant or have to be adequately protected.
1.12 Copyright
The FEODOR BURGMANN Dichtungswerke GmbH & Co. (FRG) has the copyright
in this Manual Buyer, planner and user of the product are authorized for use in
connection with further documentation.
2. SAFETY NOTES
Any person at the user's shop being involved in assembly, disassembly, start up,
operation and maintenance of the BURGMANN Mechanical Seal must have read
and understood this instruction Manual and in particular the safety notes we
recommended the user to have this confirmed.
BURGMANN Mechanical seals are manufactured on high quality level and they
keep a high working reliability. Yet, if they are not operated within their intended
purpose or handled unexpertly by untrained personnel they may cause risks.
The user is asked to check as part of his security program what effect a failure of
the mechanical seal might have on the environment and what additional safety
measures have to be taken to prevent personal injury.
Any operation mode that affects the operational safety of the mechanical seal is not
permitted.
The pump must be positioned in a way that no persons are endangered if product
splashes out in case of seal failure. Leakage of product has to be disposed
properly.
BURGMANN mechanical seals must be operated maintained or repaired by

authorized, trained and instructed personnel only.
neither operating nor pressurized, ensure the equipment at room temperature.
The responsibilities for the respective jobs to be done have to be determined

clearly and observed in order to prevent unclear competencies form the point of
security
Apart from the notes given in this manual the general regulations for worker's
protection and those for prevention of accidents have to be observed.
Unauthorized modifications or alterations are not permitted as they affect the

operational safety of the mechanical seal.
3. TRANSPORT, STORAGE, INSTALLATION
3.1 Recommendation for transport and storage
11 PACKING AND SHIPMENT

If not specified differently in the order the BURGMANN standard packaging is used,
suited for dry transport by truck, train or plane. The signs and notes for handling on
the packaging have to be observed.
In addition seaworthy packing may become necessary.
• STORAGE AND PRESERVATION
• Range of validity
The following recommendations apply to all BURGMANN Mechanical Seals which

have been supplied and stored in their undamaged original packing as well as to
seals which have been installed in a component of a plant (e.g pump, compressor,
agitator, etc.) but have not yet been put into operation.
• General
BURGMANN mechanical seals for components of power plants are super finished
and tested machine elements whose handling during the erecting and start-up
period of a power plant as well as during the storage period (in particular of spare
parts) entails certain measures to keep the full efficiency of the seals. ·
Sliding materials and elastomers are subject to material-specific and time-based

alterations (distortion, aging) which might reduce the full efficiency of the seals.
Yet, such processes must not occur automatically
The mechanical seal may be stored welded onto vapour-safe plastics sheets by
adding a drying agent e.g. ''SILICAGEL".
( I
' )
Damages caused by improper storage may not be claimed on the BURGMANN
company with reference to their warranty.
• INSTALLED BURGMANN - M.S.
Components of power plants which are equipped with BURGMANN mechanical

seals are usually delivered in a completely mounted state. Often the parts were
tested at works beforehand.
• Start-up at the power plant
For the start up of BURGMANN mechanical seals as well as of possible

accessories extra instructions have to be observed which consider the respective
-r--------conditions:--.------~---~-------------------'-----~
New product plants often have erection times of up to 10 years. In such cases the
period between the production of the M.S. and its installation and start-up may
exceed the usual period of approximately 2-3 years.
BURGMANN recommend to disassemble such seals in time before the planned

start-up of the components of power plant and to sent the seals to the manufacturer
or the nearest BURGMANN service centre where they can be checked and
reconditioned, if necessary.
If this is not possible for primary reasons (distance, dispatch conditions, etc.) other
companies (never other seal manufacturers!) may be charged if they are suitably
equipped and have the know-how required. Yet, BURGMANN'S confirmation for
recognition as safe is absolutely necessary in particular with regard to claims under
warranty.
• Preservation in case of installation
Check in case of a preservation of complete plants with mechanical seals installed
• the compatibility of the chosen preservation agent with the seal materials and
with elastomers.
• No impairment of the seal's axial movability by conglutination or by gumming.
We recommend to dry the seal parts after the preceding functional test and to
keep them dry when being installed. Values of < 50 % relative humidity are
considered as dry condition. If there are uncertainties as to the correct proceeding
please contact BURGMANN.
• STORAGE OF BURGMANN-M.S.
Premises
The mechanical seals have to be stored in dry, dust free, moderately ventilated and
tempered rooms. We recommend relative air humidity below 65 % temperature
between 15°C and 25°C.
Direct exposure of the mechanical seal to heat (sun, heating) as well as to oxone,
present or produced by ultraviolet light (halogen of fluorescent lamps), must be
avoided because of the risk of embrittlement of elastomer materials.
Handling
• Store the seals in their original packing lying on a flat surface.
Thus a protection from shocks and from damage of edges is provided.

For storage the mechanical seal is welded into vapour-safe plastic sheets by
adding the drying agent" SILICAGEL ".Thus the humidity inside the packaging is
stabilized.
The packaging should be periodically checked for damage.
An easy control of the package contents is provide due to the transparent

polyethylene sheet as well as by the attached package list or the package label.
Check the mechanical seal :
• after a storage period of approximately 2-3 years.
• after a damage of the packing

I '
• after a shock on the mechanical seal (e.g. by dropping the packed seal)
);> at the manufacturer's or at the nearest service centre.
If necessary, a different, evident component authority may be contacted. Yet,

BURGMANN must be informed about this fact, as BURGAMANN's confirmation for
recognition as a safe is absolutely necessary.
!NOTE:! An installation of the M.S. is possible if the prescribed checks cannot

be carried out for special reasons, yet, only if the seal parts have no
visible damages.
BURMANN must be informed about this kind of installation. Otherwise a warranty

as to leakage and/or operational reliability will be refused by BURGMANN.
/
A possibly increased leakage during start-up will decrease to a normal quantity
(
after the running in period of the sliding faces.
If this is not the case or if there are other malfunctions the mechanical seal has to
be shut down, removed and checked for reasons of safety.
BURGMANN agency, a BURGMANN service centre or the BURGMANN
headquarters.
• Control of humidity inside the packaging
All water vapour-proof sheets inside the package are supplied with humidity
- t - - - - -_ _ ___:_:in~dicators which show the relative air humidity inside the packaging. On a scale the
colour cnanges-from-blue-(=dry)-to-pink-(=humid).,---.- - - - - - - - - - - - - -
For check of the stored mechanical seals which should be carried out periodically
and should be recorded in-plant the following points have to be observed :
• Humidity is indicated with values> 50% rei. humidity:
• Humidity is indicated with values < 50% rei. humidity, yet the storage period of
2-3 years is exceeded.
3.2 Preparation for assembly
Check the parts of the machine for :
• Chamfered edges (sliding cones i.e. 30°/2 mm or in accordance with DIN

24960).
• radiused transmissions
• Mating fits and 0-ring surfaces: fine finished Rz 10 J.lm (=N?=CLA 63).
• Shaft surface in the area of the M.S.: fine finished Rmax. 5 J.lm (=N6=CLA 32)
Check at the machine :
• Damage of connecting surfaces to the M.S.
• Mating dimensions, rectangularity and concentricity to the shaft axis.
• Direction of rotation must comply with the seal drawing, otherwise contact
BURGMANN immediately.
• Insert a parallel key into the groove provided.
• Lubricate the shaft slightly in the area of the seal.
);.- Elastomers made of EP-rubber must never come into contact with
lubricants on the base of material oil (swelling, decomposition)
~ Lubricant for elastomers (o-rings etc.) recommended by BURGMANN.
~ TURMOPOLGREASE SH2 << make Lubricant Consult (LUBCON)
3.3 Assembly I installation
· The mechanical seal is supplied as a cartridge unit, pre-mounted at works, and

does not require any adju.stment during installation. This document provides the
required information for Installation and removal of the cartridge only.
For installation the assembly drawing 09-H75F2/1 OO-EX2 has to be on hand.
The mechanical seal has to be installed very carefully and under the cleanest
conditions.
Do never force during installation.
The order of assembly to install the mechanical seal into the pump depends on the
design of the pump and should advisably be determined by the pump
manufacturer.
Possible installation order :
• Check of o-rings (5 and 7) have been installed.
f
I
• Feed the complete seal cartridge onto the shaft.
);;> The key in the shaft has to be engage into the keyway in the shaft sleeve (6).
);;> Avoid bumping the seal cartridge against the shaft or shaft steps as the brittle
ceramic components break easily.
• Bolt the mechanical seal to the assembly flange in such a way that the
connections for supply and disposal are positioned in accordance with view
"X" in the drawing.
• Tighten the set screw (12a) uniformly & firmly.
• Remove the assembly fixtures (17) and keep them for a later removal of the
seal.
3.4 Supply connections

( \
)
The supply connection is designated as a female threaded NPT connection.
The connection for supply is marked on the mechanical seal.
• Remove the plastic protection cap from the supply connection after
installation.
Supply piping :
• Use pipes of stainless steel with a big cross-section.
• Install the pipes continuously rising, as short and convenient as possible for
the flow to ensure self-venting.
• Avoid air inclusions ana proviae-forventing-connections-;-if-necessary-;--.- - - - - -
• Clean the piping thoroughly. Fasten all pipe connections pressure-sealed.
_j.
4. OPERATION
4.1 Instructions for start up
Safety checks before start up
• Seal assembly fixtures disengaged
• Torque transmission and axial fixing between mechanical seal and shaft duly
installed.
• Supply connections tightened pressure-sealed.
For a safe operation of the mechanical seal a circulation circuit is required. Design
in accordance with the scheme in the assembly drawing. Supply fluid flows from
stuffing box through a filter and a cooler back to stuffing box, similar to API 610,
Plan 23.
Forced circulation of the fluid when the shaft rotates by means of a unirotational
pumping device in the seal.
Jacket cooling of the stuffing box is provided in the pump and should be operated
for reasons of longer service life.
• Flood pump and seal cavity (stuffing box) with medium.
• Thoroughly vent seal cavity and circulation system.
• After a short startup period repeat the venting procedures several times with
the pump being at standstill.
o Now the seal is ready for operation.
4.2 Instructions for safe operation :
Safe operating can be expected when observing the following seal circuit
• Warning temperature
• Shut-off temperature
• Standstill temperature
If the operation limit values and the instructions given in this manual are followed a
trouble-free operation of the mechanical seal can be expected.
4.3 Instructions for worker's protection :

Hot medium or even steam may splash out if the seal falls. Personally injury many
be prevented by the user providing for splash protection and wearing safety
goggles. Care has to be taken by the use for proper disposal of the leakage.
4.4 Directives in case of failure
Try to define the kind of failure and record it.
In case of failure due to high leakage the amount of leakage should be observed.
Changes of the operating conditions have to be recorded. In case of an
unacceptable temperature rise the mechanical seal must be shut down for reasons
of safety.
A damage of the mechanical seal is indicated by a continuous, flowing leakage.

I
I
BURGMANN agency, a BURGMANN service centre of the BURGMANN
headquarters.
During the warranty period the mechanical seal must only be disassembled or
removed the BURGMANN's approval or when a BURGMANN representative is
present.
5 SERVICING
5.1 Maintenance
A correctly operated mechanical·seal is maintenance-free. Wear parts, however,

have to be replaced, if necessary.
An inspection of the mechanical seal should be carried out during a revision of the
complete plant. We recommend to have this inspection be performed by
authorized BURGMANN personnel.
If the mechanical seal is disassembled during a revision of the plant the sliding
faces should be refinished at the manufacturer and both 0-rings and springs
should be replaced.
5.2 Reconditioning (repair)
If repair is necessary, the complete seal cartridge should be sent to the

manufacturer, as this is the best way to find out which components can be
reconditioned or which parts must be replaced.
Reconditioning of the mechanical seal by the user is not desirable for reasons of
-r-------~operational~safety.,--Hepair~should~only_b_e_carried out by BURGMANN service
personnel or by trained personnel of the machine manufacturer in suitaol"y---
equipped clean rooms. Seal cartridges only should be replaced by the user if
possible.
5.3 Disassembly I removal
• Shut down the pump duly procedure, let it cool down an depressurize it.!
• No product should contact the mechanical seal ~ drain the pump, if
necessary.!
• Secure the pump against inadvertent start.!
• Observe the safety notes (safety data sheets)!
Mechanical seal cartridges should possibly not be disassembled or extremely
cleaned during or after removal so that the damages and their causes may be
correctly analysed by qualified personnel of the manufacturer of the user.
neither opeiating nor pressurized.
Follow the valid regulations for preventing accidents when disassembling

mechanical seals as well as handling hazardous substances if the seals have been
already in operation. In case of doubt the necessary information have to be
obtained before starting removal disassembly or repair.
• Remove the supply piping.
• Engage the assembly fixtures (9) into the groove in the shaft sleeve (6) and
fasten them.
• Loosen all the screw's (12a).
• Loosen all screw connections between seal cartridge and the respective
machine parts.
The disassembly (removal of the seal is carried out in the reverse sequence
as described for assembly (set up).
The order of disassembly to remove the mechanical seal out of the pump
depends on the design of the pump and has to be determined by the pump
manufacturer.
5.4 Spare parts
• Only BURGMANN original spare parts must be used. Otherwise
• Risks of a seal failure endangering persons and environment.

)- Risks of a seal failure, endangering persons and environment.
)- The BURGMANN guarantee for the mechanical seal lapses.
• For a quick exchange a complete spare seal should be on stock.
5.5 Required details for enquiries and orders
For enquiries and orders the following details are required.
• BURGMANN commission no.
• Drawing no. of mechanical seal: 09-H75F2/100-EX2

'\
I
i • Part item no. Designation, material, number of pieces ace. of drawing.
5.6 After-sales service by BURGMANN
The range of service offered by BURGMANN not only includes advise during the
planning stages but also technical support after commissioning. This is supported
by a world-wide comprehensive network of subsidiaries, field engineers and
service centers.
In India please contact first :
Headquarter :
BURGMANN INDIA Pvt. Ltd.

Madina Manzila Compound
S.V.Road, Goregoan (West)
Bombay - 400 062
'if 874 1534/1820/1905
Telefax 022-8 74 8810
Branch Offices : Baroda, Pune, Delhi, Calcutta, Madras, Hyderabad, Panvel,

Surat, Kota, Chandigarh, Visakapatnam, Cochin.
SECTION-A
CHAPTER-4
SUB- VENDOR'S DRAWINGS I INSTRUCTIONS

I l
2. HEAT EXCHANGER FOR MECHANICAL SEAL
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06349
06298 OPERATING MANUAL
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HEAT EXCHANGER
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06349
06298 TABLE OF CONTENTS PAGE
0. Foreword 1
1. General Information 2
2. Product Information 3-5
2.1 Manufacturer and country of origin 3

2.2 Type designation 3
2.3 Design Data 3
2.4 Drawings, Diagrams 3·4
2.5 Description and function 5
2.6 Other details 5
2.7 Required space, connecting dimensions 5
2.8 Manufacturer - Explanation 5
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3. Safety Notes 6
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4. Transport, Storage and Installation 7-8
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4.1 Packing & Storage 7
4.2 Assembly 7
4.3 Production of the joints 8
r- 9
5. Operation
5.1 Instructions for safe Operation 9

c.o 5.2 Tips for safe Operation 9
5.3 Designated Use 9
5.4 Directives in case of failure 9
l.()
6. Servicing 10-11
"<t
6.1 Maintenance 10
6.2 Buffer Fluid 10
6.3 Replacement Parts 10
r0 6.4 Necessary details of enquiries and orders 10
6.5 After-sales service by BURGMANN 10·11
6.6 Reconditioning 11
N 6.7 Spare Parts 11
6.8 Disposal of BURGMANN Heat Exchanger 12
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7. Copyright 13
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fBURGMANN Operating Manual
No.
06349
06298 FOREWORD
Dear Sir.
Section
0 Thank you for purchasing the Burgmann Heat Exchanger. We at Burgmann are
confident that your new purchase will greatly. expand your working capacity and
efficiency.
This Operating Manual shows you how to get the most out of your new Burgmann
Page 1 of 13 Heat Exchanger. Whether you are installing, operating or servicing . this manual will
show you how to do it - quickly and easily.
Please take some time to go through this manna! before installation. You don't have to
read it all at once. We just want you to know what a great Heat Exchanger you have.
We've taken a great deal of care in preparing this !Tlannal so that you will never be left
/ wondering how to perfom1 a certain fimction. Nevertl1eless. even after reading this
0
..- manual if you still aren't" sure about something, please feel free to contact your nearest
sales or service center of Burgmann or our HQ. We shall be too glad to answer your
queries.
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BURG MANN
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8BURGMANN Operating Manual
06298
1. GENERAL INFORMATION
SR. NO. DESCRIPTION DETAILS
Section
I Customer BHEL- Hyderabad
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II Customer P 0 No.
III Drawing Nos. 09-WED 311 0/A I 00-E I

Page 2 of 13
IV Burgm::mn Conm1ision No. 119455
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No.
06349 2. PRODUCT INFORMATION
06298
2.1 MANUFACTURER AND COUNTRY OF ORIGIN

Section
2
FEODOR BURGMANN
Dichtungwerke GmbH & Co.
D-82515 Wolfratshausen
Page 3 of 13
2.2 TYPE DESIGNATION

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BURGMANN HEAT EXCHANGER
09-WED3110/Al00-E1
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2.3 DESIGN DATA

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WED 3110/ AlOO

Jacket Pipe
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Content Liter 1.8 0.75
Design Pressure 1) barg 110 16
Inlet temp. deg. C 65 30
!
L{) Amount of Flow 2) 3) m3/h 3 6
Refrigerating capacitv 3) kW 36
Weight, empty kg 24
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Des1gn temp. deg. C 150 !
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1) These values form the basis of the calculation of stability.
2) These values form the basis of the thermic calculation.
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3) Reffering to water
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2.4 DRAWINGS, DIAGRAMS
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Assembly drawing.. - 09-WED 3110/AIOO-El
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Figures in brackets. e.g (2) in the subsequent descriptions signify the respective
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No.
06349 2.5 DESCRIPTION AND FUNCTION
06298
The model of the BURGMANN heat exchanger type WED 3110/A 100 is a bundle
of pipes - The heat exchanger brings about high refrigeration capacity at low
Section dimensions. It is therefore especially fit for installation for supply circulations
(block circulations) for double a,'{ial face seals in "back to back" or "face to face"
2 arrangements.
The heat exchanger has all the necessary connections.

Page 5 of 13 The cold water is led through the pipe, tl1e blocking fluid through the jacket space.
2.6 OTHER DETAILS

\
)
All the connecting supports possess connection according to DIN ISO 228 or NPT.
0
,..... If appropriate tube fittings are used in the pipe work. then the problem of impurities
of the blocking circulation through threaded seal medium does not arise
The heat exch<mger can be assembled in horizontal as well as vertical position.
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2.7 REQUIRED SPACE, CONNECTING DIMENSIONS
The connecting dimensions according to

assembly drawing . : 09-WED3110/A100-El
2.8 MANUFATURER- EXPLANATION
In the Sense of EG-Guidelines appendix II B.

The manufacturer e:\']Jlains. that the aforementioned product is designed for
installing in a machine. or for assembling with other machines into one
( machine and it is not capable of functioning independently. the operation of
the product is prohibited , till it is not ascertained, that the machine. in
which is to be constmcted. corresponds to the regulations of the EG-
Guidelines for machines (89/392/EWG). The harmonized standards used :
En 292 Tl + T2.
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1iBURGMANN
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.- Operating Manual
No.
06349 3. SAFETY NOTES
06298
3.1 Any person at the user's shop being involved in assembly, disassembly, sta11
Section
up, operation and maintenance of the BURGMANN Heat exchanger must
3 have read and understood this Instruction Manual and in particular the
safety notes. We recommend the user to have this confirmed.
Page 6 of 13 BURGMANN Heat exchangers are manufactured on a high quality level

(IS09000) and they keep a high worl<ing reliability. Yet. if they are not
operated wilhiu their intended purpose or haudled inexpe1·tly by untra111cd
personnel the)' m;ly cnusc risks.
The user is asked to check as part of Ius security program what effects a
fnilurc of the heat exchanger might have on the environment ;md what
additional safety measures have to be taken to ru·event personal injury.
BURGMANN het~t exchanger must be operated. maintt~ined or repaired by

authol'ised, tmined and instructed pcrssoHnel only.
Any worl< to be done on the heat exchanger is only permitted when it is

neither operating no1· pressurised.
The responsibilities for the respective jobs to be done have to be detennined

clearly and observed in order to prevent unclear competencies from the point
of security.
Apart from the notes given in tlus manual the general regulations for
worl,er's protection and those for prevention of accidents have to be
observed.
Unnuthorised modifications or alteration are not permitted as they affect the

operational safety of the heat exchanger.
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No.
06349
06298
4. TRANSPORT, STORAGE & INSTALLATION
Section
4.1 PACKING AND STORAGE
4
If not specified differently in the order the BURGMANN standard packaging is
used. suited for dry transport by tnick. train or plane. The signs and notes for
handling on the packaging have to be observed.
Page 7 of 13
Notes for income ins11ection:
• Check packaging for visible damages .
• Open packaging carefully. Do not damage or lose pm1s supplied separately.
• Check if consignment is complete (delivery note) . Inform the supplier
immediately in writing if parts are damaged or missing.
( I These recommendations apply to all BURGMANN heat exchanger which have

0
I
..... been supplied and stored in their undamaged original packaging. as well as to heat
exchangers which have been installed in a component of a plant. (e.g. pump.
compressor. etc.) but have not yet been put into operation.
Cj)
Damages caused by imprope1' storage may not be claimed on the

BURGMANN company "vitll regard to their warranty.
IX)
Store the Heat Exchanger in the original pacldng lying on a flat surface.
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4.2 ASSEMBLY
Tile installation should be carried out by an e:-.1Jert staff. Rules valid at the spot
CD
of installation especially for accident prevention should be observed. This holds
·good for the installation of the heat exchanger as well as for laying the entire pipe
line.
1.0 '
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The heat exchanger should be installed in such a way that the operation. i
supervision and maintainence is as good as possible. Pipes to the seal should be
/
( \ as sh011/ small as possible.
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Installation of the heat exchanger should always be higner than the axial face seal.
so that the system gets automatically de-aerated.
t')
Pipes in the supply circulation Should be of cold drawn stainless steel precision
pipes with the dimension 0 18 .x 1.5nun . The connections to the. heat exchanger
should be manufactured through the tube connections.
N I
I
The direction of the line between the axial face and the heat exchanger should
be as short and favourable to the ~ow as possible. Lay the pipes constantly I
.,... ascending so as to avoid air tappings. To change the directions use tube bends
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and ball vilives exclusively for blocking.
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No.
06349 4.3 PRODUCTION OF THE JOINTS
06298
Identification and laying the joints on the heat exchanger.
Nl Cold water IN
N2 Cold water OUT
Section Nl Medium IN (warm coming from GLRD)
N4 Blocking medium OUT (cold back to GLRD)
4 N51NC> Vent Tube Side
N7/NS Drain Shell Side
The joints N3 and N4 in horizontal constn1ction should lie below
The joiuts N I.N2 <111d N4 ill vertical constmction should lie below
Page 8 of13
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06349
06298 5. OPERATION <: :.!i! l-~ ':
Section
5.1 INSTRUCTIONS FOR SAFE OPERATION
5 -
.Fill the blocking circulation ( See the instn1ctions for GRLD too)
De-aernhon of the heat exchanger and the blocking circulation (N7/N8)
De-aeration of the cold circulation (NS)
Page 9 of 13
5.2 TIPS FOR SAFE OPERATION
If the operational limiting values mentioned are observed and the tips given
in this instmction manual are followed, tl1en the heat exchanger operates
smoothly.
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.,.... 5.3 DESIGNATED USE
Operation under conditions lying outside those limits stated in paragraph >> 2.3
DESIGN DATA << is considered contmry to its designated use.
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The Heat Exchanger should not be operated under several limiting values at the
same time as there is risk of malfunction. which could result in a danger for staff.
equipment and environment.
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Should t11e Heat Exchanger be operated tmder conditions otl1er than those detailed
BURGMANN has to be asked for recognition as safe.
t-
co 5.4 DIRECTIVES IN CASE OF FAILURE

T1y to define the kind of failure and record it.
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If there is a malfunction which you cannot repair on your o·wn. or if the cause
of malfunction is not clearly recognizable please immediately contact the nearest
BURGMANN Branch or the Burgmann headquarters.
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06349 6. SERVICING
06298
6.1 "MAINTENANCE
Section The heat exchanger by itself does not need maintenance. depending upon the
composition (nature) of cold water, the area of cold water needs to be cleaned
6 mechanically after opening the lid.
The total system should be checked once in six months as regards leakages.
loosened pipe fittings and other damages and these should be repaired.
Page 10 of 13 6.2 BUFFER FLUID
When operating the heat exchanger care must be taken to ensure cuculation
of the buffer fluid. The pressure of the buffer fluid should be I .5··2 bar
higher than the internal pressure and the rate of flow should be adjusted so
that the outlet temperature does not exceed 60°C. The outlet must be located
at the lughest point of the stuffing-box to prevent bubble formation.
If you have any special problems please contact BURGMANN Head Quatrters
or the corresponding sales/service office in your area.
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6.3 REPLACEMENT PARTS
The replacement parts should be obtained from BURGMANN only. Only

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Burgmann original replacemt components or foreign parts released by
Burgmann can be used. Non observance may lead to malfimctioning. which
can be dangerous to men. machines and environment. Tllis also expires the
guarantee.
6.4 NECESSARY DETAILS FOR ENQUIRIES AND ORDERS
BURGMANN - Commision No. See the order

Heat exchanger drawing No. See paragraph "Drawings"
Individual component Pos. No .. Name. Material : ace. to the assembly
drawing
6.5 AFTER-SALES SERVICE BY BURGMANN
The range of services offered by Burgmann not on!)' includes advice during the
planning stages but also technical support after commissioning. This is support
by a world comprehensive network of subsidiaries. field engineers and service
C\1 centres.
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IBURGMANN Operating Manual
No.
06349 Address of the headqum1ers
06298
FEODOR BURGMANN
Dichtungswerke GmbH & Co.
AuBere Sauerlacher Str. 6-10
Section
6
Federal Republic of Gennany
Tel +49-81-71-23 1215

Fax +49-81-7!--23 1449
Page 11 of 13
Headquarter :
BURGMANN INDIA PVT. LTD.
\
I \ Madina Manzi! Compound
I ....0 S. V. Road, Goregaon (West)
Mumbai 400 062.
'
(j) Tel 8741534 I 1820 I 1905
Fax 022-874 8810
00- Branch offices : Baroda, Pune, Delhi, Calcutta, Madras, Hyderabad. Panvel.
Surat. Kota. Chandigarh, Visakhaptanam, Cochin, Mangalore.
1"-
6.6 RECONDITIONING (repair)
10
Reconditioning of the Heat Exchanger by the user is not desirable for
reasons of operational safety. Repair should only be carried out by
BURGMANN service 1iersonnel o•· by trained personnel of the machine
I
manufacturer in suitably equipped, clean rooms.
L() I
6.7 SPARE PARTS

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0 Only BURGMANN original spare parts must be used. I

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0 Disassembled pm1s must not be reworked at the user.
(") Otherwise !
};- Risks of a Heat Exchanger failure with endangering persons and

environment '
:;.. The BURGMANN guarantee for the Heat Exchanger latlses.

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0 For a quick ·replacing a complete spare should be on stock.
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No.
06349
06298 6.8 DISPOSAL OF BURGAMNN HEAT EXCHANGER
Usually. the BURGMANN Heat Exchanger can be easily disposed after a thorough
Section
cleaning.
0 Metal pm1s (steels. stainless steels. non-ferrous heavy metals divided
6 11110 the different groups belong ro scrap metal waste.
0 S~'uthetic materials/ plastics ( elastomers. PTFE )special waste.
r Attt~ntion ! Milterial containing fluorine must not be burnt.
Page 12 of 13
:,;:; . S01ne synthetic materials div1ded iuto the difJereut groups call be
recycled
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No.
06349
06298 7. COPYRIGHT ®
Section
7 The FEODOR BURGMANN Dichnmgswerke GmbH & Co. (FRG) has a copy
right in this manual. Buyer. planner and user of the product are authorised
for use in com1ecUon with fiuther documentation.
Page 13 of 13 We reserve the right to carry out technical modifications which might
become necessa·ry to improve our products but are not mentioned in this
manual yet.
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Burgmonn supply
74,8 Magnet filter
52 39.2 magnetic filter -----..,

18 17
FILTRE MAGNETIOUE
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Burgmann supply
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NPT 112"
PLUGGED
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thermo-couple
SONDE DOUBLE DE TEMPERATURE
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OECLENCHEMENT
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NATIONAL THERMAL POWER CORPORATION LTD_
.... "' STAGE-Ill, UNIT-IX & X, 2x500MW
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"' MAIN PLANT TURNKEY PACKAGE
MECHANICAL SEAL FOR BOOSTER PUMP

,r-~~~tf~.~~~.~~-,M~.;~r~Loc~t;~~--(1 1--- BHEL DRG. No.: HY-DG-209-139-0060, REV.01
I 72.5
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Nr. 241 oesichert!
IParts de!feosed
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and fixed
No.241
I 87.5
NTPC DRG. No.: 2240-108-04HY-PVM-C-103, REV.01
SHEET20F2
-
KUNDE/CUSTOMER BHARAT HEAVY ELECRTICALS L TO.
BETREIBER/ULTIMATE USER· NTPC VINDHYACHALSTAGE -Ill, 2X500 MW
-i-- PUMPENTYP/PUMP TYPE FA-18-75
OREHZAHL/SPEED 1495 (RPM)
MEDIUM/FLUID BOILER FEED WATER
TEMPERATUR/TEMP 165 ( •c)
DRUCK/PRESSURE 15 (bar)
KEY 19 PASSFEOER 01N68BS

NON DRIVE END
SET SCREW 12a GEIIINOESTIFT OIN916-MBX10 (Drive End see Drg. No_ 09-H75F2/100-E4)
HEXAGON BOLT 9o ISECHSKAHTSCHRAU8E OIN933-M5Xl0
ASSEMBLY FIXTURE 9 jMONTAGELEHRE WN73-4
-
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DRIVE (OLLAR 1.58
max. zut. Axiolversotz der SPRING 1.4
-
Welle ZUII Uellneuse t. 1 mm
max. allowed axial movement ~~
1.58 1.4 1.7 1..3 1.2 1.1
THRUST RING
O·RING
1.3
12 RUNOOICHTRING V 1 ji04.14X5.33
of the shaft to !he housing SEAL FACE 1.1 IGLEITRING I8UK003•1.4401 /CARSON 1 Enlstanden aus I Ori~incted from
·~ mm
OET AIL -'X' Pos. I IteR I Bnennung I Description Br.rgmonn ~~~;,~ 5
~ Bemerkung I Remarks 09-H75F2/100-E3
415 475
625
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553 553
I 1250
675
1350 I Jsp MECHANICAL SEAL SKID, DES. No.: F1779 VALID FOR
NTPC VINDHYACHAL STAGE-Ill, 2x500MW
21 FLOW GLASS INDICATOR 55316 4 112" SW ROTOR TYPE

20 FLANGE 314" SS316 8 ANSI 8 16.5 CL 300 SORF
~
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19
18
17
R£()JCER 1 1/2"X1" BW
SUPPORT PLATE
MOUNTING PLATE
55316
M5
M5
2
4
ANSI 8 16.9 SCH.SO
200X200X20
16 I ANGLE i MS ISIEO.i.
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15
14
13
12
IMECH. SEAL FILTER
MECH. SEAL COOLER
THERMOWELL
1/2'" PIPE
SS316
55316
55316
55316
4
4
12
09-MAF2001/NPT112'"-EI
09-WE03110/ AlbO-EI
4 180 39 1 7111 REV.O
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II 3/4" PIPE 55316 ,. ,.. SCH.SO
10 I 1/2" PIPE 55316 ,. ..., SCH.SO
9 PIPE UNION 1/2'" 5S316 16 1/2" NPT
8 ISOLATION VALVf. V2" SW I 55316 24 CL 800
7 TEE 1/2" BW I 55316 24 I ANSI 8 16.9 SCH.BO
I 6 ITEE 3/4" 8W 55316 4 ANSI 8 16.9 SCH.80
5 ITEE I" BW SS316 2 ANSI B 16.9 SCH.BO
I 4 limJCER 3WXI/2" 8W ISS316 12 ANSI 8 16.9 SCH.80
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3 R£()JCER 1"X314" 8W 55316 4 ANSI 8 16.9 SCH.80
2 FLANGE 1/2" SS316 56 ANSI 8 16.5 CL. 300 SORF
18
-----------------
20 Thk. VIEW-X (SIMPLE SHOWN)
COOLING WATER RETURN VIEW-X (SIMPLE SHOWN)
HOTE,- COOLING WATER SUPPLY Oo.te llo.•e
1) COOLING WATER, SEALING WATER INLETS AND OUTLET SHALL BE lt.12~02 SAFUll
'l'ii.1.2G02 IUHESl-1:
TERMINATED WITH SORF FLANGES ALONG WITH COUNTER fLANGES, Burgmann Indta Pvt. Ltd. Mullbo.t - ~ 062
'!'>.too s
l
J.JIHA
GASKETS, BOLTS & NUTS. sca.te TITLE:
2 SEAL SKIO SHALL BE SUPPLIED ALONG WITH BASE PLATE g SCREWS.
3 ALL OPENINGS SHALL BE COVEREO WITH PLUGS & BLANKS.
4) THREADED PLUGS TO BE PROVIOEO FOR THERMOWELL.
o/o SKID FOR MECH. SEAL AUXILLARIES
5) COOLERS & FILTERS SHALL BE HYORAULICALL Y TESTED INOEPEHDENTAL Y.
OET AIL FOR PART NO 11 6)MAX ALLOWABLE PRESSURE FOR SEAL , SO Kg/cm2 o AMB. TEMP.
6)MAX ALLOWABLE PRESSURE FOR COOLING LINE ;· 19 Kg/cm2 a AMB. TEMP. Ref. Na.
( II
SECTION-A
CHAPTER-4
,,
3. MAGNETIC FILTER FOR MECHANICAL SEAL
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fBURGMANN
06349
FOR.
BURG MANN
MAGNETIC FILTER
MAF2000/NPT 1/2'' -00
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Please read this manual carefully and Observe the infonnation contained as to :
C SAFETY C INSTALLATION C OPERATION
C STORAGE C MAINTENANCE
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..- If there are any unclear points please contact Burgmann India .
en
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CIO
FEODOR BURGMANN
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N 0 AuBere Sauerlacher Str. 6-10
c: -o -g D-82502 Wolfratshausen. Federal Republic of Germany
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0. Foreword 1

2.3 Design Data 3
2.4 Drawings, Diagrams 3-4
2.6 Other details 5
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3. Safety Notes 6
Ol 4. Transport, Storage and Installation 7
4.1 Installation 7
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4.2 Assembly 7
5. Operation 8
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5.1 Tips for Safe Operation 8
5.3 Directives In case of Failure 8.
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6. Servicing 9-10
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6.1 Maintenance 9
6.3 Necessary details for enquiries and orders 9
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6.4 After-sales service by BURGMANN 9-10
6.6 Spare Parts 10
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6.7 Disposal of Burgmann Magnetic Filter 10
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7. Copyright 11
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fBURGMANN Operating .Manual
No.
06349
06298 FOREWORD
Dear Sir,
Section
Thank you for purchasing the Borgmann Magnetic Filter. We at Burgnirum are
0 confident tlwt your new purchase will greatly expand your working capacity and
efficiency.
Page 1 of 11 Magnetic Filter. Whether you are installing, operating or servicing . tltis manual will
Please take some time to go through this manual before installation. You don't have to
read it all at once. We just want you to know what a great Magnetic Filter you have.
We've taken a great deal of care in preparing this manual so that you will never be left
wondering how to perform a certain function. Nevert11eless, even after reading tllis
0 mmmal if you still aren't. sure about something, please feel free to contact your nearest
......
sales or service center of Borgmann or our HQ. We shall be too glad to answer your
queries.
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BURGMANN
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RBURGMANN
'C;1 Operating Manual
No.
06349
06298
Section
I Customer BHEL- Hydcrnbad
1
II Customer P.O.No
III Drawing Nos. MAF2000/NPT 1/2"-00

Page 2 of 11
IV Burgmrum Conm1ision No. i 19455
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06298
2.1 MANUFACTURER AND COUNTRY .OF ORIGIN

Section
2
FEODOR BURGMANN
Page 3 of 11
/ 2.2 TYPE DESIGNATION
BURGMANN MAGNETIC FILTER

MAF2000/NPT 1/2"-00
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1---f-----+--+----1 2.3 DESIGN DATA
Max Operating Pressure 63 Bar

Test Pressure 82 Bar
Max. Operating Temp 150°C
Volume 0.3 L
(, __

Assembly drawing - MAF2000/NPT 1/2''-oo
Figures in brackets. e.g (2) in the subsequent descriptions signify the respective
position no. of their individual components ace. to the assembly drav.·ing
accompanying. ..
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No.
06298
BURGMANN Magnetic Filters are used for cleaning the media in the cooling
circuits. The combination of filter screen and magnetic rod retains both magnetic
Section and non-magnetic pmticle~ up to a specific grain size. For Assembly, the direction
of flow indicated on the filter should be noted. It is required to vent the filter by
2 its venting screws before putting it into operation for the first time or after cleaning
it.
Page 5 of 11
2.6 OTHER DETAILS
• Venting screw at the filter inlet and outlet.
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• Filter insert is protected by intemal screen (only MAF 200l)a:gainst damage
by retum flow of n1edium.
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• Connections at choice Gl/2 to Gl (DIN ISO 228) or NPT intemal thread .
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• Maintenance indicator or measurement of pressure difference to be connected
instead of venting screws via the filter.
CO" • In special cases, the magnetic filter can be operated without the screen insert
and only with magnetic rod.
1'- • Seals with high shut-down temperatures up to 150" C should be equipped

with EP mbber 0-Rings because of safety reasons(Special design).
tO 2.7 REQUIRED SPACE, CONNECTING DIMENSIONS
The connecting· dimensions according to

Ll"l assembly drawing : MAF2000/NPT 1/2"-00·
) 2.8 MANUFACTURER-EXPLANATION
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The manufacturer explains. that the aforementioned product is designed for i
C')
machine and it is not capable of functioning independently, the operation of
the prodi1ct is prohibited , till it is not ascertained, that the machine, in
N which is to be constructed. corresponds to the regulations of the EG- I
Guidelines for machines (89/392/EWG). The hannonized standards used :
En 292 Tl + T2. . .
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No.
06298
3.1 Any person at the user's shop being involved in assembly, disassembly, start
Section
up, operation and maintenance of the BURGMANN Magnetic Filter must
3 have read and understood this Instruction Manual and in particular the
safety notes. We recommend the user to have this confirmed.
Poge 6 of 11 BURGMANN Magnetic Filters are manu.llictured on a high quality level

(IS0 1JOlHl) and they keep a high working reliability. Yet. if they are not
operated WJtlun their intended purpose or handled inexpc1ily by untrained
personnel they may cause •·islts.
The user is asked to check as part of his seclllity program what effects a
failure of the Magnetic Filter might have on the env1ronment and what
additional safety me;\sures have to be taken to prevent pe1·sonal injury.
BURGMANN Magnetic Filter must be operated, maintained or repaired b~

authorised, trnined and instructed personnel only.
Any worl• to be done on the magnetic filter is only permitted when it is is

neither operating nor pressurised.
c:o· The responsibilities for the respective jobs to be done have to be determined
clearly and observed in order to prevent unclear competencies from the pomt
of security.
Apart from the notes given in this manual the general regulations for
worl<er's protection and those for prevention of accidents have to be
observed.
Unauthorised modifications or alteration are not permitted as they affect the

operational safety of the Maguetic Filter.
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No.
06349 4. TRANSPORT, STORAGE & INSTALLATION
06298
4.1 PACKING AND ~TORAGE

Section
4 used, stiited for dry transport by truck, train or plane. The signs and notes for
Notes for income inspection:

• Check· packaging for visible damages.
Page 7 of 11
• Open packaging carefully. Do not damage or Jose pruts supplied separately.
• Check if consignment is complete (delivery note). Infom1 tl1e supplier
immediately in writing if parts are drunaged or missing.
These recommendations apply to all BURGMANN Magnetic Filter which have
been supplied and stored in their undamaged original packaging, as well as to
magnetic filter which have been installed in a component of a plant. (e.g. pump,
0 compressor. etc.) but have not yet been put into operation .
.,....
Damages caused by impi'Oper storage may not be claimed on the

BURGMANN company with regard to their warranty.
Store the Magnetic filter in the original packing lying on a flat surface.
CO·
4.2 ASSEMBLY
The installation should be carried out by an expert staff. Rules valid at the spot
of installation especially for accident prevention should be observed. This holds
good for the installation of the Magnetic Filter as well as for laying the entire
pipe line.
The Magnetic Filter should be installed in such a way that the operation,
supervision and maintainence is as good as possible .
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No.
06349
06298 5. OPERATION \I
))
,':2t
Section
S. I TIPS FOH SAFE OPERATION
5
If the operational limiting values mentiOned are observed and the tips given
in this instruction manual arc followed. then the Magnetic Filter operates
smoothly.
Page 8 of 11
5.2 DESIGNATED USE
Operation under conditions lying outside those limits stated 111 paragraph >:.> 2.3
DESIGN DATA << is considered contrary to its designated usc.
The Magnetic Filter should not be operated 'under several limiting values at the
same time as there is risk of filter malfunction which could result in a danger for
0 staff. equipment and environment.
..-
Should the Magnetic Filter be operated under conditions other than those detailed
m
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5.3 DIRECTIVES IN CASE OF FAILUHE
Tty to define the kind of failure and record it.
1'- If there ts a malfunction which you cannot repair on your own. or if the cause
of malfunction is not clearly recogniznble plense immediately contact the nearest
(()
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06349 6. SERVICING
06298
6.1 MAINTENANCE
Section
Before opening the filter
6
• Open bypass around filter.
• Stop flow through filter by closing shut-off valves before and after filter.
Page9of11
• Reduce pressure inside the filter by opening a venting screw.
Opening and cleaning the filter

• Detach mounting screws (item 8) and remove filter vessel (item 2) .
• Remove filter screen (item 3) and clean with suitable detergent.
(
/ • The Magnetic rod (item 5.6.7) can be unscrewed from filter head. If annular
magnets (item 6) have. been removed make sure that, during assembly they
''
0
..- attract each other by pairs, but are repelled by next pair. separated by disc
(item 5).
(j)
• Before filter assembly check all seals and replace,if necessary. Check
wheather the screen fabric has been damaged.
• The filter is assembled in tlle reverse order.
co
t-
Burgmann original replacement components or foreign parts released by
Burgmann can be used. Non observance may lead to malftmctioning. which
C<Ul be dangerous to men, machines and environment. This also expires the
co guarantee.
LO 6.3 NECESSARY DETAILS FOR ENQUIRIES AND ORDERS

I
BURGMANN - Commission No. See the order
(
I
'<!" Magnetic Filter drawing No. See paragraph"Drawings"

Individual component Pas. No .. Name.Material : ace. to the assembly i
drawing.
I
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The range of services offered by Burgmann not only includes advice during the
planning stages but also technical Sl~)pOrt after commissioning. This is support
by a world comprehensive network of subsidaries, field engineers and service
..-
centres.
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- ---- - ------------ --------=--··
\
_j -
f BURG!\.J!AI\JI\J Operating Manual
No.
06349 Address of the hendqunt1ers
06298
FEODOR BURGMANN
Dichtungswcrke GmbH & Co.
AuBcrc Saucrlacher Str. 6-10
Section
6
Federal Rcpubllc of Germany
Tel t-4\1-81-71-23 1215

Fax +.:I'J-81-71-21 1-149
Page10of11
In India please contact first
Headquarter .
Madina Manzi! Compound
S. V. Road. Gorcgaon (West)
Mumbai 400 062
Tel 8741534 I 1820 I 1905

Fax 022-874 8810
co Branch offices : Baroda. Pune. Delhi. Calcutta. Madras, Hyderabad. Panvel

Sural. Kola. Chandigarh. Visakhaptanam, Cochin, Mangalore.
Reconditioning of the magnetic filter by the user is not desirable for reasons
of operational safety. Repair should only be carried out by BURGMANN
service personnel or by tl'llincd personnel of the machine manufacturer in
suitably equipped. clean rooms.
6.6 SPARE PARTS
o Only BURGMANN originnl spare parts must be used.

o Disassembled parts must not be reworked at the uset:
Othem·ise
,. Risks of failure with endangering persons and environment
;... The BURGMANN guarantee for the magnetic filter lapses.
o For a quick replacing a complete spare should be on stock.
6. 7 DISPOSAL OF BURGAMNN MAGNETIC FILTER

N
Usually, the BURGMANN magnetic filter can be easily disposed after a thorough
cleaning. ..
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o Metal p:uts (steels. stainless steels. non-ferrous heavy metals divided
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fBURGMANN · Operating Manual
06349
Section
7 The FEODOR BURGMANN Dichnmgswerke GmbH & Co. (FRG) has a copy
right in this manual. Buyer, pla1mer and user of the product are authorised
for use in connection with further documentation.
Page 11 of 11 We •·eserve the right to cany out technical modifications which might
become necessary to improve our products but are not mentioned in this
manual yet.
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FABRICATION NO IMPRINTED FABRICATION NO. IMPRINTED
160
135
20
20
I
I 75
r
I
1
r 4
375
2
16
17
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180 100
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250 65
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9 20 6 8 14 13
SHELL TUBE 20 PLATE BRIDGE 1.4401 ss 316 1

19 GASKET PTFE 2
TEST PRESSURE 143 bur 21 bur
18 SCREW PLUG IA4-50 ss 316 2
a.) HOR!ZONT AL 17 GASKET PTFE 2
16 SCREW PLUG A4-50 ss 316 12
~~~ IS D-RING VI TON 12

TEST MEDIUM WATER WATER
14 U-WASHER 1.4401 ss 316 16
13 SCREW A4-70 ss 316 16
CODLING WATER FLOW RATE
APPROX.
6 M3th f
N3
I
N4
CODLING WATER 12
11
10
NUT
SPACER
THREADED BARS
A4
1.4401
.1.4401
ss 316
ss 316
ss 316
4
4
4
DESIGN TEMPRATURE GUIDE COVER 11.4401 ss 316
150"( 150"( FROM/TO SEAL 9 1
FOR CALCULATION 8 INLET COVER 11.4401 ss 316 1
b) VERTICAL 7
NO. FUNCTION SIZE 6 BRACKET 1.4401 ss 316 2
N1 WATER IN 112" NPT N3 5 GUIDE PLATE 1.4401 ss 316 5
4 TUBE 1.4401 ss 316 62
N2 WATER OUT 1/2'' NPT 3 CONNECT ION BLOCK 1.4401 ss 316
N3 MEDIUM IN 1/2" NPT
2 CONNECTION BLOCK 1.4401 ss·316
FROM/TO SEAL SHELL 1.4401 ss 316
N4 MEDIUM OUT 112" NPT POS. DESCRIPTION MATERIAL OTY REMARKS
APPLICATION DETAILS
NS - VENT TUBE SlOE ~ -G 1/4" ~ 12
TEMP. Of SEAL WATER AT INLET Df COOLE!< 95"C N4 Su.rlii.Ce Va.lu.estn
N6 G 114"
TEMP. Of SEAL WATER AT OUTLET Of COOLER, 60"C VENT TUBE SIDE '"•)
TEMP. OF COOLING WATER AT INLET Of COOLE!< 38"C 112"
N7 DRAIN SHELL SIDE
TEMP. Of COOLING WATER AT OUTLET Of COCUR, 46"C
COOLING WATER Burqna.nn lndlo. Pvt Ltd. r•...u~< - ~ 062
NB DRAIN SHELL SIDE G 112" N2 N1
TOTAL WEIGHT: 30 KG HEAT EXCHANGER
09-WED 3110/A100-E1
'----1---t---------------~~-- Alt!Si.rw&ons.a.l"t!<.rciJIIIc.ntes.sar~sp«ifiltd. Ref. 11o.
f'teJ.SI! a.Sic H in OO,JJ;Jt.
z
_,_ KENNlJATEN I DATA
Ansicht Z Zul. lletriebsuberdruck

View --···------- -------=---Nax-.-op-ei'u-t-ing~p.!'esaure-:- - ti3-bar-
M8 20 tief
Priifiiberdruck:
14 13 (£nt/iiftung)
(venting)
8 Test pressure: !:!2 bar
·115
1 Zul. Betriebstemperatur
Max. operating temperature:
/
12
{ft <±>-~ Inhalt
Volwne 0,3 1
~ $~!
/
/
/
/
-+---m- ------1-
10
tl!
~ _!CrS. flC_~-
Gewicht 7,8 kg
§ displaced 11 weight
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.( 6 15 NATIONAL THERMAL POWER CORPORATION LTD .

5 76 STAGE-Ill, UNIT-IX & X, 2x500MW
=
Anzugsmoment MA 38 Nm , torqu:::e_ _ _ __
( :;,cnraube teJct'lt geo/t; , (screw sriglltty luor. J
3G
MECHANICAL SEAL STRAINER FOR BFP & BP
BHEL DRG. No.: HY-DG-209-139-0062, REV.OO
3 NTPC DRG. No.: 2240-108-04HY-PVM-C-105, REV.OO
SHEET 1 OF 1
7 16 RIBBED NAIL . ss
15 NAME PLATE ss
14 GASKET PTFE
2 13 VENTING SCREW ss 316
12 SPRING - 1.4301-
11 '0' RING VI TON
10 '0' RING VI TON
9 CYLINDR. PIN 1.4401
8 HEX. HEAD SCREW ss 316
6 MAGNETIC DISC
5 WASHER PTFE
4 SPACER RING 1.4401
khtiJflg : Die Rift~ $ind $0 zu montieren , 3o SUPPORTING SIEVE 1.4301
dtJif .;. sich potNWeiH tN~Zieh•n , 3 SIEVE ELEMENT 1.4301
lO'n nat:hs ,., lr4Ggnetpaar' dui-c;h die
2 FILTER POT 1.4401
Scheibe getrwmt., aber obstoflen ! FILTER HEAD 1.4401
POS. ll::SCRIPTION
AtllntiOII : The magnetic discs are to be mounted
in SYch o way tltat they attract each other Su.r-facl! 011 3141 LiR!o 3
in pairs but l'epM adjo,.,t pairs from which Dll ISO 1302
tn.y .arw s•porated by o spocer !
Drawn 06/n/Ol RUPESH OUR6MANN
-- = = = co~nkd.~- ==CCC. - au.rgmO:iln. ini:fla. Pvt: Ltd.tt.um~i-- ~- 062
Scole TITLE :
1:1 MAG~~ETIC FILTER

. __ /
Ref. No.
-'----1----1---------~---· ····-~----
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SECTION- B
CHAPTER-4
4. THRUST BEARING
Michell Bearings
Operations, and Maintenance
Instructions.
.I
.I
Omega OT Series
Thrust Rings
Michell Bearings '
Michell Bearings is a trading division of Vinters Engineering PLC.
A member of the Rolls Royce Group.
Issue 00
Table of Contents
GENERAL DRAWING OF OT THRUST RING ASSEMBLY WITH SHIMS& LINERS----------- 4

1. INTRODUCTION-------------------------------------------------------------------------------------------- 5
1.1 About the Product------------------------------------------------------------------------------------- 5
1.2 About this Manual --------------------------------------------------------------------------------- 5
1.3 Warranty CIa ims -------------------------------------------------------------------------------------- 6
2. SAFETY------------------------------------------------------------------------------------------------------- 7
3. HA NOLl NG THE BEARING------------------------------------------------------------------------------ 8

3. 1 Genera I ------------------------------------------------------------------------------------------------ 8
4. P REPARA Tl ON FOR Fl RST INSTALLA TION ------------------------------------------------------ 9

5. ASSEMBLY OF THE BEARING -----------------------------------------------------------------------10
5. 1 Genera I ----------------------------------------------------------------------------------------------1 0
5.2 Assembly of the Thrust ring---------------------------------------------------------------------1 0
5. 2. 1 Fitting the Thrust Pad set. -----------------------------------------------------------------10
5. 2. 2 Fitting Ring Stop, and Liners if applicable ---------------------------------------------11
5.3 Assembling the Thrust rings into the Bearing Casing --------------------------------------11
5. 3. 1 Miscellaneous ---------------------------------------------------------------------------------12
5. 3. 2 Instrumentation -----------------------------------------------------------------------------12
6. 0 P ERATl NG ------------------------------------------------------------------------------------------------13
6.1 Preparation and Inspection before Operation ---------------------------------------------13
6. 2 Tria I Run --------------------------------------------------------------------------------------------1 3
6. 3 Norm aI 0 pe ration -------------------------------------------------------------------------------14
6.4 Preparation for Operation after Standstill------------------------------------------------------14
7. CARE AND MAl NTE NANCE ---------------------------------------------------------------------------15
7. 1 Genera I -----------------------------------------------------------------------------------------------1 5
7. 2 Too Is and Equipment -----------------------------------------------------------------------------1 5
7. 3 Maint en an ce Sch ed uIe--------------------------------------------------------------------------1 6
7. 4 0 iI Change -------------------------------------------------------------------------------------------16
7. 4. 1 GeneraI -----------------------------------------------------------------------------------------16
7.4. 2 Procedure for draining oi/---------------------------------------------------------------------16
7.4.3 Procedure for refilling the bearing -self contained bearings ------------------------17
7.4.4 Procedure for refilling the bearing - bearings with circulating oil--------------------17
8. DISMANTLING AN INSTALLED 8 EARl NG --------------------------------------------------------18
8 .1 Genera I ----------------------:.------------------------------------------------------------------------1 8
8. 2 Pre pa ration --------------------------------------------------------------------------------------1 8
8.2.1 Strip down the bearing until the thrust rings are visible. -----------------------------18
8.2.2 Disconnect and remove any thermometry and instrumentation.--------------------19
8. 3 Removing th rust rings ------------------------------------------------------------------------------1 9
8.4 Removing the Liners, and Shim Pack. Where Applicable. --------------------------------19
8.5 Removing the Thrust Pad Set--------------------------------------------------------------------19
9. CLEANING AND CH EC Kl NG --------------------------------------------------------------------------20
9. 1 Genera I ------------------------------------------------------------------------------------------------2 0
9.2 Checking the Thrust Pad. --------------------------------------------------------------------------21
10. BEARING PRESERVATION DU Rl NG STORAGE ---------------------------------------------22 ·
2
10.1 Before Insta llatio n -----------------------------------------------------------------------------------22
10.2 Corrosion Protection for Standstill Periods up to 6 Months --------------------------------22
10.3 Corrosion Protection for Standstill Periods between 6 Months to 1 Year---------------22
10.4 Corrosion Protection for Standstill Periods longer than 1 year----------------------------22
11. BEARING PRESERVATION DURING TRANSPORT --------------~--------------------------22
12. A PPEN DICES -------------------------------------------------------------------------------------------2 2

12. 1 0 rd e ring Spa res --------------------------------------------------------------------------------------22
---- _)___ _
8 HEX. SOCKET CSK SCRE Vl6 STEEL
7 UNERASSY 2 STEEL
""" 6 SlllMPACK 2
5 DOWEL PIN 2 STEEL
4 PAD STOP 16 STEEL
3 THRUST PAD SET 2 STEELWM
2 RETAINING RING I STEEL
I RETAINING RING I STEEL
REF PART NAME QTI MATERIAL
- - -
6 3 2 7
O=n
(p
O=n
O=n
/
4
OT Omega Thrust Ring Assembly With Shim Pack, And Liners

11.1 About the Product
The "Omega" Series Thrust Rings supplied are part of a standard range of components
manufactured by Michell Bearings. The thrust rings are intended to be fitted within a casing
supplied by a customer. Depending on the demands specified, the thrust rings will be
designed to absorb:
a) A constant load along the shaft in one direction.

b) A constant load along the shaft in either direction.
c) A constant load in one direction and a temporary load in the opposite direction.
Within the "Omega" Series a range of sizes are catered for. All "Omega" thrust rings require
continuous lubrication from a pumped oil supply. In some cases, the thrust rings will have
machined oil channels and in other cases restriction jet holes.
The system of restriction holes is known as 'Low Loss' lubrication and will give lower power
losses than conventional fully immersed rings.
In order to measure pad temperature, Resistance Temperature Devices (RTDs) can be fitted
to a number of pads specified by the customer.
11.2 About this Manual
• This manual contains information about the bearing and its safe operation, and should
therefore be read carefully in full before starting work.
• Since the bearing has a wide range of applications, this manual has been written to cover
all current configurations.
• This manual is to be used by qualified engineers only.
• The following formats are used to draw attention to particular details:
& This symbol signiffes a warning. These are instructions that, if ignored, could
result in death or injury. Danger!
@ This symbol signiffes an important point which, If ignored, could result in

+--------minor-injury-or-fai/ure-to-earry-out-a-process-con~ectly.,----------------------J.-
)
----,-~-,------ ---------
I
I
<:{ This symbol signifies additional instructions. This is usually a check. Missing
out this stage could lead to an error going unnoticed.
In addition, brackets after a reference to a part description, e.g. thrust pads set (3),
retaining ring (2) refer to an item number on a general sub-assembly drawing at the
front of this manual. These are used as a reference for the engineer.
J1.3 Warranty Claims
• Unless otherwise stated all warranty claims shall be dealt with in accordance with Michell
Bearings.
• These warranty obligations will automatically become void if the product is:
1. Improperly handled or installed.

2. Supplied with spare parts (or repaired), not approved by Michell Bearings.
3. Exceeding the design operating parameters shown on the arrangement drawing.
4. Subjected to environmental conditions not previously specified.
6
When installing, operating or maintaining the bearing, danger may arise to the user, the
product and plant and/or other assets. Therefore all users responsible for the operation of the
machine must understand this manual fully and make sure that all the safety procedures are
strictly adhered to.
Pay particular attention to the following general safety notes:
.6
machine .
Under no circumstances should the engineer worlc alone when operating the
.6 At least one of the engineers should be trained in basic first aid techniques
and wear identification that he/she is a first-aider.
.6 No maintenance, assembly, adjustment or any other work should be carried

out on the bearing whilst the shaft is rotating or capable of movement. To avoid
accidents, the entire machine should be isolated, with control gear locked off and "Not
to be used" signs applied to the control panels .
.6 Personnel that manipulate the product should be sufficienOy trained.
No modifications of the product should be made unless it is approved by

Michell.
More specific safety notes are also given in the relevant sections, and should be adhered to.
7
\3. Handling the Bearing
j3.1 General
This section outlines essential information, which must be referred to when handling the thrust
rings.
• The thrust rings are supplied fully assembled (see arrangement drawing for mass of
complete bearing).
• Omega "OT" Series thrust rings are not usually fitted with lifting holes. A complete ring
may be lifted using straps or slings.
• When transporting the bearing, it should remain in its packaging.
• Make sure thrust rings are stored in the intended mounting position, in a dry room only.
Please check all product equipment to ensure that it is complete before installation. Any
damage due to transit must be reported to Michell immediately.
• See Section 8 for instructions on how to disassemble the bearing .
.& Before using any lifting equipment ensure that it is certified to carry a load
greater than that of the bearing or component.
© T a k e care not to damage bearing components and the running surfaces of the
shaft collar by contact with the lifting equipment.
.& If in doubt, always use mechanical devices where possible. Remember to

bend the knees and not the back when lifting manually.
8
j I i
,i! ,,, ',
• All Omega "OT" Series thrust rings are supplied complete. All thrust rings are, for ease of
assembly, capable of being split in two halves. If the rings supplied are to be split the
RTDs and their cabling should be removed prior to this.
• Remove all packaging.

• Refer to Sections 2 and 3 for safety and handling instructions.
• Dismantle the bearing referring to Section 8, ignoring any references to the shaft or
machine.
• When dismantled, please check all product equipment to ensure that it is complete before
installation. Any damage due to transit must be reported to Michell Bearings immediately.
• All parts are coated in a rust preventative. This must be removed and all parts thoroughly
cleaned before installation begins. To remove the rust preventative, white spirit or a strong
spirit based cleaner should be used. Note! Do not use paraffin (Kerosene).
• It is recommended that the bearing casing and all other internal parts are cleaned to
prevent dirt getting between the collar and the thrust rings.
@ H the thrust rings are being fitted into a bearing that has previously been
used, ensure that the lubricating pipes have been cleaned to remove any deposits. If
there is any dirt in the lubricating system it will damage the new parts fitted;
.& There may be fumes given off during the cleaning process. Clean parts in a
well-ventilated area. Always follow cleaner manufacturers' instructions.
@ U s e a lint free cloth when cleaning the bearing. Particles from other cloths
could otherwise get into the lubricating oil and cause overheating, and in extreme
cases, failure of the bearing.
• Once all parts are inspected and cleaned the bearing is ready for installation.
• Refer to Section 10 if the bearings are to be stored for a period of time before operation.
9
. c ·-·--·---- T
l
Is. Assembly of the Bearing
15.1 General
The following general points should be noted:
6 The disassembling and reassembling of the equipment by an individual who is

inexperienced can cause danger. Michell will not take on any liability for any damage
resulting from non-compliance with details given in this manual. If in doubt refer to our
Service Dept.
© O n l y use tools, which fit correcUy to avoid damage to fasteners,
6 Do not use excessive force.
~Use a liquid screw locking compound (e.g. Loctite 222) on all fasteners.
6 Always follow the instructions on adhesives.
~ Remove all impurities and foreign objects (e.g. bolts, washers, etc.) from inside
the bearing. Ensure bearing is covered when left unattended.
This assembly procedure has been generalised to cover most eventualities. As such it may
contain more information than is directly applicable to the bearing being worked on. Read all
text and simply ignore any reference to irrelevant items.
15.2 Assembly of the Thrust ring
5.2. 1 Fitting the Thrust Pad set.

• Coat all bearing surfaces in clean oil. Refer to bearing general arrangement drawing for
information on the correct grade of lubricant.
• Place thrust pad set (3) into retaining ring halves (1), (2).
~ Ensure that the correct handed pads are fitted. The direction of rotation
stamped on the pad must agree with that shown on the arrangement drawing.
• Secure thrust pad (3) in place with pad stop (4) with hole located in back of thrust pads (3).
10
\
!
• Ensure that stop (4) Is fully locked ln place with Loctite 222 or similar adhesive.
•& Always follow instructions on adhesives.
• Make sure pads (3), can move freely, and are not trapped.
@ Take care not t~ trap hands when handling the compone,;,.
5.2.2 Fitting Ring Stop, and Liners if applicable

• Place shim pack (6), and liners (7), on retaining ring halves (1 ), (2), and sercuer in place
with hex, socket counter sunk screw (8).
• Ensure that screws (8) are fully locked in place with Loctite 222 or similar adhesive.
• Fit ring stop (5).
• Ensure that stop (5) is fully locked in place with Loctite 222 or similar adhesive.
& Always follow instructions on adhesives.
ls.3 Assembling the Thrust rings into the Bearing Casing
• Coat the thrust pads surfaces with clean oil of the correct grade.
• Some OT Series bearings are supplied with machine liners; these should be fitted at the
same time as each thrust ring assembly.
• Horizontal Bearings: Fit the lower half of the thrust ring(s).
• Vertical bearings: Fit the entire lower thrust ring:
@Care should be taken when handling the components to avoid the risk of
trapping hands when assembling.
- -. - -tower the shaft, complete with collar into-the bearing:--- --
• Horizontal Bearings: Fit the top half of the thrust ring(s), either onto the top of the lower
ring, or into the top half casing. Secure the ring with stops.
• Horizontal bearings: Rotate the thrust ring around until the stop (5) engages in the casing,
if half the ring is secured into the top half of the casing, ensure that the bottom half is flush
with the casing joint and complete assembly.
• Vertical Bearings: Fit upper thrust ring and secure in place with stop (5).
• Check the bearing alignment, and complete assembly.
(~)
11
15.3.1 Miscellaneous
• Where applicable, connect up oil inlet and outlet.
• Connect external pipework.
15.3.2 Instrumentation
• Fit RTDs and instrumentation as necessary.
<{ Ensure that temperature probe assembly is not damaged and is working
correctly before fitting it.
<{
•
Check that the bearing is complete and is fully sealed.
For temperature probe fitted bearings; run the bearing and establish a steady state
operating temperature then set temperature alarm to soc above the steady state operating
temperature. Shut down temperature alarm is to be set at 1ooc above steady state
operating temperature .
.& Note! Prior to running the bearing EC regulation state: - The entire machine
has received a Declaration of Conformity, or has been declared exempt from the
Supply of Machinery (Safety Regulations) Act 1992 and the Machinery Directive.
Where applicable
.& Do not use the bearing unless the lubricating system is operating.
It must be emphasised that any declaration of incorporation issued by
Michell Bearings is for the thrust rings and their components and not for
the entire bearing.
The bearing is now complete; it must not be used until the below items
have been dealt with;
1. Lubricating oil has been passed though the bearing.
2. The lubricating oil must be a mineral based turbine oil inhibited
against oxidation, corrosion and foaming, with an ISO viscosity grade
as indicated on the arrangement drawing.
The use of any other oil should be referred to Michell Bearings.
If in doubt with installation please use our Service
Department!
12
js.1 Preparation and Inspection before Operation
• Where necessary fit the temperature probes for measuring the thrust pads, and/or the
sump temperature in the relevant connection holes.
<:If
fitting.
Ensure that RTD assembly is not damaged and is working correcOy before
&
•
Always follow sealant manufacturers' instructions.
Where applicable retighten external oil supply connections.
• Fill Bearing with oil or start oil system as described in Section 7.4.
Check:
1. That the oil quantity at bearing oil inlet is as specified by Michell Bearings, where
applicable.
2. That the temperature monitoring equipment works.
• The bearing is now ready for operation. It must not be used until the below items have
been dealt with:
1. The entire installation has received a Declaration of Conformity, or has been declared
exempt from the Supply of Machinery (Safety Regulations) Act 1992 and the Machinery
Directive.
3. Local safety regulations have been met.
js.2 Trial Run
-• -For temperature probe fitted bearings, run the bearing and establish_a l)teacjy ~tate
operating temperature. Set temperature alarm to soc above this steady state operating
temperature. Shut down temperature alarm should be set at 10°C above steady state
operating temperature.
• Supervise the bearing during the trial run period (approx. 5-10 operating hours).
• Pay special attention to the following:
1. Oil flow rate and oil inlet pressure in circulating oil system (where applicable)
2. Bearing temperature
3. Occurrence of inadmissiole vi6raflr1omn~s-.- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
4. Unusual noises or odours
(_)
13
• If any or all of the above cause concern, or if the monitoring equipment triggers an alarm,
stop the machine immediately and carry out an inspection of the bearing to find the cause.
ls.3 Normal Operation
.&
•
Do not touch any moving parts.
If the bearing has been correctly assembled using the procedure already given, there is
only a marginal risk of the bearing failing which would normally be due to inadmissible
operating conditions. Examples of these conditions are; overspeed, low lubrication levels
and excess load. To avoid these situations, follow the following recommendations:
• Label Control Panels with the bearing limitations.

• Do not operate the bearing below the transition speed values indicated in the bearing
calculation.
• Stop the shaft immediately if: Bearing temperature exceeds normal operating
temperature by 10°C.
• Never remove plugs, RTDs or seals while the bearing is operating.
• Regularly inspect all seals and pipework. Any large leakage of lubricant or coolant will
indicate that a seal or joint is failing. Maintenance must then be carried out as soon as
possible.
© T h e bearing surface and any pipeworlc may be hot during operation.

16.4 Preparation for Operation after Standstill
• Clean the external parts of the bearing. Dust and dirt impede the radiation of heat.
• Check with the maintenance schedule in Section 7.3 to see if an oil change is necessary.
If required, carry out the oil change as indicated in Section 7.4.
• Start operating the oil supply system, where applicable, and check that it is working
correctly. The supplied oil quantity at the bearing inlet must equal the value indicated in
the Michell Calculations.
• Check the functioning of the temperature monitoring equipment.
• The bearing is now ready for operation.
14
\
1
!1.1 General
• Before carrying out any maintenance or inspection work, switch off machinery. Lock off the
controls and secure and the isolate shaft .
.& Ensure control gear, barring gear and any other equipment capable of moving
the shaft is locked out and labelled "Not to be used", or similar.
.& Do not touch any moving parts.
\7.2 Tools and Equipment
The following tools and equipment may be necessary to carry out maintenance on the
bearing:
• Allan key set
• Wrenching key set
• Open-jawed spanner set
• Feeler gauges.
• Emery paper, plain scraper
• Lifting equipment
• Permanent sealing compound (e.g. Curii-T)
• Liquid screw locking compound (e.g. LOCTITE 222)
• PTFE sealant tape.
• Oil with the viscosity indicated (see bearing inspection plate)
• Detergents
• Clean cloth
.~·
'\ ..)
15
j7 .3 Maintenance Schedule
• For a bearing that is operating constantly, routine maintenance should take place annually.
• If the user only operates the bearing periodically, maintenance periods may be able to take
place less frequently. This is however, at the users' discretion. An annual inspection is
recommended as a minimum service requirement.
• A basic guide to maintenance is given in Table 1.
Maintenance work Schedule

Oil Change (see Section 7.4) • Bearing in reversing operation: every 3 Months
• Bearing in continuous operation: every 6 Months

Bearing Inspection During preventative maintenance work for machine or
immediately if:
• Bearing temperature exceeds 1ooc over the indicated

value (see calculations)
• Unusual noises or odours occur
• Unusual changes in the oil colour are visible .
• Inadmissible vibrations occur .
• Oil flow rate and oil inlet pressure readings drop

below admissible values,
Table 1: Maintenance Schedule
• These are estimates only, and frequency may alter depending on site environment.
Michell can advise the user accordingly.
17.4 Oil Change
17.4.1 General
• Oil changes will be at differing periods depending on the frequency of bearing operation
and the conditions in which the bearing is operating. Approximate oil change times are
indicated in Section 7.3.
• Please observe the instructions for the use of the lubricating oil. The manufacturer
can provide information on waste oil disposal.
.&. Risk of Pollution:
17.4.2 Procedure for draining oil

• Run the bearing to warm up the oil. This will ease the flow of oil from the bearing, and also
remove any impurities and residues.
16
• Shut down the machine and secure it against unintended operation.
• Shut down the oil supply system where applicable.
& Do not disconnect the oil inlet and outlet pipework until the bearing has been
drained of oil.
© A n y oil spillage should be collected in suitable containers.

• Let off and collect the lubricating oil in the oil supply system where applicable.
• Loosen and remove the drain plug and washer, and fully drain the bearing of oil.
& Beware hot oil.
©Collect and dispose of used oil under the correct regulations.
<1( ff the oil is visibly altered in colour, or contains unusual residues, an inspection
is recommended to eliminate the cause.
17.4.3 Procedure for refilling the bearing -self contained bearings

• Pour the correct grade of lubricating oil into the filling hole in the casing top. Use the
approximate quantity required as shown on the bearing arrangement drawing as a guide.
• Let the oil settle into the bearing. Check the oil level is approximately at the centre of the
oil level gauge, and top up if necessary. Where applicable.
17.4.4 Procedure for refilling the bearing- bearings with circulating oil
• Clean the oil container and fill up the oil supply system with the correct grade of lubricating
oil.
• Start the o-il suppiYsystem In order to fill upthe -be-aring with oil:
<1( Check for leaks.
<1( Not enough lubricant leads to temperature rises and therefore damage to the
bearing. Too much lubricant leads to leaks.
+-----------'4 When pouring, take care not to spill lubricating oil onto the machine or
surrounding area.
17
Js. Dismantling an Installed Bearing
la.1 General
• The Procedure given in this section is a full stripdown of a generic Omega "OT" series
bearing. As such it may contain more information than is necessary in some cases.
Simply ignore the sections not relevant to the bearing being worked on. Any technical
queries can be referred to the Engineering Team at Michell Bearings.
• Michell recommends that the below safety advice is followed when carrying out
maintenance on any bearings. It may be necessary to change the dismantling procedure
to suit the design of the bearing casing.
la.2 Preparation
• Check through the safety procedures at the start of Section 2. Understand and follow the
instructions very carefully.
• Switch off machinery. Lock off controls. Secure and isolate shaft, drain and disconnect
cooling system, where applicable. Refer to manufacturer instructions.
& Ensure control gear, barring gear and any other equipment capable of moving
the shaft is locked out and labelled "Not to be used".
• Switch off and drain the lubricating oil and oil system (where necessary) as described in
Section 7.4.
• Disconnect and remove any thermometry and instrumentation.
<t Make sure the workspace is clean. Contamination and damage to the bearing
affect operating performance and could lead to premature failure.
& Do not use any violence or force.
© T a k e care not to jam hands when manipulating components.
IB.2.1 Strip down the bearing until the thrust rings are visible.
• Horizontal Bearings: Where applicable, remove the top half of the thrust ring(s).
• Vertical Bearings: Remove upper thrust ring (where fitted).
• Vertical Bearings: Jackshaft up until it's clear of the lower thrust pads.
18
& Follow lifting instroctions and safety guidelines in Sections 2 and 3.
& Ensure the jacking equipment is safely positioned and certified to cany a load
greater than the mass of the shaft.
& Once the shaft is raised, secure it into position using other equipment Do not
rely on jacking equipment alone.
Js.2.2 Disconnect and remove any thermometry and instrumentation.

• Remove RTDs, and instrumentation connections.
4
Js.3
Take care not to damage instromentation.
Removing thrust rings

Vertical Bearings: Remove lower thrust rings.
• Horizontal Bearings: If the bottom half of the thrust rings are not visible, follow the below
procedure;
• Tap one end of the ring until the opposite end is visible.
• Rotate the ring out and remove.
Js.4 Removing the Liners, and Shim Pack. Where Applicable.
• To fully dismantle the thrust ring follow the below procedure:
• Remove liner retaining screws (8), liners (7), and shim pack (6) from the back of the
retaining ring halves (1 ), (2).
(
\ ../ Js.s Removing the Thrust Pad Set
-. -Remove thrust pad stops (4) from retaining rings-(1 ),- (2).
• The thrust pads (3) can now be removed from the retaining ring (1 ), (2).
©Take care not to jam hands when manipulating components.
4 Take care not to damage thrust pad white metal surface.
19
Is. Cleaning and Checking
19.1 General
.& Only use non-aggressive detergents such as VALVOUNE 150 or Alkaline

cleaning compounds with pH-value 6 to 9, and a short reaction time .
.& Please observe the Instructions for use of the detergents .
<:I{ Use a lint free cloth when cleaning the bearing. Thread from such cloths could
get into the lubricating oil and cause overheating, and in extreme cases, failure of the
bearing.
• Clean the following parts thoroughly:
1. Thrust pad set.

2. Retaining ring.
3. Liners, where applicable
4. Shim pack.
5. Thrust pad stops.
• In addition inspection may be required on the bearing components, according to the

Maintenance Schedule outlined in Section 7.3.
• The remaining part of this section gives basic inspection guidelines for some major bearing
components. However, if any wear or damage is evident on any of the bearing
components, consult Michell Bearings immediately as it may adversely affect bearing
performance.
• The following sections assume the bearing has been dismantled according to Section 8.
20
19.2 Checking the Thrust Pad.
• Examine the Thrust Pads. The appearance of the running surface should be that shown in
Figure 11 below.
Direction of Rotation
Matt Surface
Dull Finish
Figure 11: Thrust Pad Appearance After Use
• Inspect the collar su·rface for any signs of damage. If it is necessary to change the pads,
the collar should also be replaced or repaired, otherwise the replacement pads will only
have a short life. There may be some scoring and wear on the pads. Provided wear is no
greater than 0.125mm the pads are still serviceable. If there is any sign of the bearing
surface coming away from the backing material, the pads must be replaced.
21
/10. Bearing Preservation during Storage
110.1 Before Installation
110.2 Corrosion Protection for Standstill Periods up to 6 Months
• Dismantle the bearing (see Section 8).

• Clean the bearing (see Section 9).
• Assemble the bearing (see Section 5).
• Put a bag of desiccant (silica gel) inside to absorb humidity and prevent the formation of
condensation in the bearing.
110.3 Corrosion Protection for Standstill Periods between 6 Months to 1 Year
• Repeat the preservation procedures detailed in Section 10.2.
110.4 Corrosion Protection for Standstill Periods longer than 1 year
• Dismantle the thrust rings according to Section 8.

• Preserve and store bearing parts separately.
/11. Bearing Preservation During Transport
When the bearing is fitted to the machine during transport:

• Carry out the corrosion protection procedure described in Section 10.2.
• Apply liberal lubricant to the running surfaces of the bearing.
• Secure the shaft against axial and radial movement.
/12. Appendices
112.1 Ordering Spares
• As a minimum, it is recommended that replacements should be carried for all Whitemetal

components. Consideration should also be given to stocking the parts listed below:
• Jointing compound (i.e. Curil-T)
• RTD Assemblies (where applicable)
22
- ·BoltSize-(mm) Tightening Torque (Nm)
6 4
8 10
10 20
12 35
I
16 80-90
20 155-175
24 275-305
30 545-605
........ ---
36 950-1050
_
42 1520-1680
48 2300-2520
56 3690-4070
64 5560-6150
23
Michell Bearings Service Department.
Scotswood Road Direct: +44(0191) 2565319
Newcastle Upon Tyne

NE15 6LL Repair Department.
Great Britain Direct: +44(0191) 2565309
Tel: (0191) 273 0291

Fax: (0191) 272 2787
Michell Bearings reserve the right to amend these instructions.

© Michell Bearings 2004.
24
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14
15
16
17
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PART- 4
SECTION- 8
_)
BOILER FEED PUMP

PART-4
EQUIPMENT DETAILS
SECTION- B
BOILER FEED PUMP
\.
LIST OF CONTENTS
j
. I
CHAPTER TITLE
1. Description
2. Operating Instructions
3. Maintenance Instructions
4. Sub-Vendor's Drawings /Instructions

SECTION- B
BOILER FEED PUMP
CHAPTER -1
DESCRIPTION
LIST OF CONTENTS
1 Introduction
2 Technical Data (Ref. BFP data sheet)
Motor driven pump
Turbine driven pumps
3 Description
3.1 Pump casing
3.2 Discharge cover
3.3 Suction guide
3.4 Ring section assembly
3.5 Rotating assembly
3.6 Mechanical seals
3.7 Journal and thrust bearings
3.8 Bearing housing
3.9 Hydraulic balance

CHAPTER-1
DESCRIPTION
1. INTRODUCTION :
FK4E36 type Boiler Feed Pump is a four stage horizontal centrifugal pump of
barrel design casing.
The pump internals are designed as a cartridge which can be easily removed for
maintenance without disturbing the suction and discharge pipe work, or the
alignment of the pump and the turbo coupling.
The pump shaft is sealed at the drive end and non-drive end by Mechanical Seals.
The rotating assembly is supported by plain white metal lined journal bearings and
axially located by a double titling pad thrust bearing.
3. DESCRIPTION:
3.1 Pump Casing:
The pump casing consists of a forged steel barrel with welded suction, discharge
branches, inter stage tapping and mounting feet. The drive end of the casing is
closed by a suction guide which is entered from the non-drive end of the casing
and is located by a spigot against the outer face of the casing.
A metaflex joint is located between the suction guide spigot and the casing
outer face to prevent leakage between the barrel casing and suction guide. A split
pull up ring is secured to the pump casing and suction guide by a ring of screws.
Leakage between the suction annulus and the discharge annulus of the pump
casing is prevented by a copper coated mild steel joint located between the inner
--------------------face-ofthe-casing-and-the-first-stage-ring-section-spigot.-l"he-non ... drive-end-of-the-------
casing is closed by a discharge cover secured to the casing by a ring of studs,
washers and nuts, sealing being effected by a Metaflex joint located in a machined
recess in the pump casing. On each side of the casing, on its horizontal centre
line, are two support feet which are secured to the base plate pedestals by spacer
pieces, washers and holding down bolts, thus allowing for expansion. Transverse
keys in the drive end pump feet and longitudinal keys under the casing transfer
moments and thrust to the base plate, while allowing the casing, freedom to
expand.
Provision is made on the pump casing for a drain connection and temperature
---------------~reees~.------------------------------------------------------------~
\
3.2 Discharge Cover
The discharge cover closes the non-drive end of the pump casing and also
forms the balance chamber which, in turn, is closed by the gland housing. The
discharge cover is a close fit in the casing bore and is held in place by a ring of
studs and nuts. A spring disc is located between the last stage diffuser and out let
guide to provide the force required to hold the ring section assembly in place
against the drive end of the barrel before start-up. Once running, the discharge
pressure assists the spring disc in holding the ring sections in place. The last
stage diffuser is free to slide over the out let guide.
Two holes are drilled radially through the periphery of the discharge cover
to provide outlet connections through which the liquid from the balance chamber is
returned to the pump suction piping and two similarly drilled holes are also
provided in the discharge cover for the welded connections of the kicker stage
deliveries. The non-drive end bearing housing is attached to the gland housing
secured to the outer face of the discharge cover by socket head screws and dowel
pins.
To assist in removing the cover, two tapped holes are provided on the
flange for the use of starting screws and a tapped hole is provided on top of the
cover for an eye-bolt.
3.3 Suction Guide
The suction guide closes the drive end of the pump casing and forms the
suction annulus. As a section of the pump cartridge, the suction guide is not
secured to the pump casing but is held against an internal shoulder in the casing
by the pull up ring.
The drive end bearing housing is secured to the outer face of the suction
guide by cap screws and dowel pins.
3.4 Ring sections
The ring section assembly consist of ring sections which locate one to
another by radial dowel pins and are secured to each other by socket head screws
in counter bored holes, sealing being effected by metal-to-metal joint faces.
Diffusers are dowel and spigot located to the ring sections and secured to the ring
section with socket head screws. The outlet guide for the kicker stage impeller is
secured to the discharge cover by means of cap screws which are locked in
position with plugs. Packing rings are shrunk into the bores of the ring sections
and diffusers and are secured by grub screws, the purpose of the packing rings
being to restrict the recirculation of the pumped liquid between the stages.
The ring sections and diffusers form the transfer passages from the
impeller outlet of one stage of the pump to the impeller inlet of the next stage, and
the diffusers are designed to convert some of the kinetic energy of the product into
pressure energy.
The first stage ring section is spigot located to the suction guide and is
radially located by means of a slot in the ring section and a cast key block in the
suction guide. At the non-drive end a dowel pin fitted to the outlet guide is located
in a hole in the last stage diffuser thus the ring section assembly is kept in its
correct position relative to the casing. A circular spring disc is located in the last
stage diffuser and over the inner end of the outlet guide. A shoulder on the outlet
guide bears against the spring disc and clamps the ring section assembly and
suction guide in position.
3.5 Rotating Assembly

(
\
The dynamically balanced rotating assembly consists of the,- shaft,

impellers, abutment rings, keys, seal sleeves, shaft nuts, balance drum, thrust
collar and the pump half coupling.
The shaft is chromium plated at each end where it is supported by the

journal bearings, and its diameter increases in increments from the non-drive end
towards the drive end to facilitate the fitting and removal of the impellers.
The impellers are of the single entry shrouded inlet type and are keyed
and shrunk onto the shaft, the keys, one per impeller, being alternately fitted on
diametrically opposite sides of the shaft to maintain rotational balance.
The hub of each impeller butts against a split shear ring fitted in a groove
in the shaft. The shear ring is retained by an extension of the impeller hub.
The balance drum is keyed and shrunk on the shaft and held in place
against the shaft locating shoulder by the balance drum nut and lock-washer. The
inner end of the balance drum is recessed and the bore of the recess is a close fit
-------------- over -tne--k:icl<efstage impeller-flu~- Tne-face-ortne-oalance-drum- incorporates__ _
tapped holes for withdrawal purposes.
The rotating parts of the seals are fitted to the shaft where it passes
through the seal housings. The seal sleeves are keyed to the shaft and are
clamped in position by shaft nut and shaft lock-nuts.
The thrust collar which is keyed to the non-drive end of the shaft, has the
thrust collar probe indicator fastened and doweled to its hub and is located against
a shoulder on the shaft by the thrust collar nut, locked by a lock washer.
NOTE: The thrust collar nut has left hand thread.
The pump half coupling is located on the tapered end of the shaft by keys
and it is secured by a coupling nut locked by a grub screw.
3.6 MECHANICAL SEAL
The drive and non-drive end stuffing boxes are fitted with mechanical
seals mounted on seal sleeves and located within seal cooling jackets to prevent
feed water escaping along the shaft. Tapped holes are provided on each seal
plate and cooling jacket for clarified cooling water inlet and outlet connections.
3. 7 Journal and Thrust Bearings
The rotating assembly is supported at each of the shaft by a white metal

lined journal bearing and the residual thrust is carried by a titling pad double thrust
bearing mounted at the non-drive end of the pump.
The journal bearing shells are of mild steel, white metal lined, thick wall
type and are split on the horizontal plane through the shaft axis. Each bearing is
secured in a bearing housing and prevented from rotating by a dowel pin located
in the bearing keep.
The thrust bearing has eight white metal lined titling pads held in a split
carrier ring positioned on each side of the thrust collar. The carrier rings are
prevented from rotating with the shaft by dowel pins in each ring which engage in
slots in the bearing housing top half. The thrust pads are retained on the carrier
rings by a special pad stops screwed into the rings.
A split floating oil sealing ring is located in a groove in the thrust bearing
housing to restrict the escape of lubricating oil from the thrust bearing chamber. To
ensure that the thrust bearing remains flooded, an orifice is fitted at the oil outlet.
Machined spacers are fitted behind the carrier rings to effect the axial
position setting of the rotating assembly on the original build. The bearings are
supplied with lubricating oil from the forced lubrication oil system.
3.8 Bearing Housings
The bearing housings are in the form of cylindrical castings split on the
horizontal shaft axis. The top and bottom halves, of each bearing housing, are
located by fitted bolts and secured together by cap screws. The journal bearing in
each housing is located by a dowel pin in the bearing keep and the bearing keep is
dowel located to the bottom half housing and secured by cap screws. On the top
half housing there is provision for an air vent, vibration probes and a temperature
check point. On the bottom half housing there is provision for oil inlet and oil outlet,
R.T.D. probe and a temperature gauge.
The drive end bearing housing is secured to the suction guide by cap
screws and is radially located by dowel pins fitted in the flange of the suction
guide. Oil guards fitted in a groove at each end of the bearing housing are dowel
located and serve to prevent oil escaping from the housing.
. An air breather is screwed into a tapped hole in the top half bearing
housing and a tapped hole is provided for a temperature gauge. Connections for
an oil inlet and an oil outlet are provided in the bottom half bearing housing.
The non-drive end bearing housing, which contains both the journal and
thrust bearings, is located by taper dowel pins and secured to the gland housing
by cap screws. In addition to the features common to both bearing housings the
follow features are included. On the top half housing there are connections for
reverse running indicators, an accelerometer and a thrust bearing temperature
check point. On the bottom half bearing housing the additional provision is for
thrust bearing temperature gauges. Leakage of lubricating oil from the non-drive
end bearing housing is prevented by an oil guard in the inboard side of the
housing.
3.9 Hvdraulic Balance :
The rotating assembly is subject to varying forces due to the differential

pressure forces acting on the impellers. The pump has therefore been designed so
that the shaft is kept in tension by the location of a balance drum at the non-drive
end, and is hydraulically balanced so that only a small residual thrust remains,
which is carried by the thrust bearing. The main components of the hydraulic
balancing arrangement are the balance chamber machined in the discharge cover,
the balance drum which is secured to the shaft and the balance drum bush fitted in
the bore of the discharge cover. The thrust caused by the discharge pressure
acting on the area outside each impeller wear ring on the inlet side of the impeller
wear ring is balanced by the same pressure acting on an equal area on the outlet
side of each impeller. The thrust caused by the suction pressure acting on the
( -:-\ area inside the wear ring on the inlet side of each impeller is overcome by the
much greater thrust caused by the discharge pressure acting on an equivalent
area on the outlet side of each impeller. The resultant thrust force, due to the
--~------------different-pressures -acting -on these- equal areas-,-tends- -to-move-the- rotating--------
assembly towards the drive end of the pump.
The thrust force will vary with the load on the pump but the hydraulic
balance arrangement will reduce its effect, enabling the residual thrust to be taken
by the titling pad thrust bearing. This bearing has a double face so that the surges
in opposite directions which occur during the start-up period and during tranl?ient
conditions will be accommodated.
The hydraulic balance arrangement operates as follows:-
The pump product passes from the kicker stage of the pump between the
balance drum and the bush, and enters the balance chamber at a pressure
approximately equal to the suction pressure. Two ports in the discharge cover
allow the product to be piped back to the pump suction side. The pressure
differential across the balance drum is therefore equal to the across the impellers.
The cross-sectional area of the balance drum is sized to give a small residual
thrust towards the drive end of the pump.
SECTION- 8
BOILER FEED PUMP
CHAPTER -2
LIST OF CONTENTS
(
- __ ,..1
1. Introduction
2. Preparation for starting
3. Start- up
4. Routine checks
5. Trip condition
6. Shut-down
7. Stand by conditions
8. Fault finding
CHAPTER-2
1. INTRODUCTION
The 50% tandem Boiler feed pump set is an integral part of the boiler feed
system and the following instructions should be read in conjunction with those for
the operation of the associated equipment and the system.
2. PREPARATION FOR STARTING
CAUTION : The pump set suction and discharge pipe work and valves are not in
pumps supply. Reference, therefore, should be made to the system operating
instructions for the control of the valve.
(1) Check that the deaerator is filled to normal working level.
(2) Check that the control air and electrical supplies are available for the
instrumentation, leak-off equipment and valves.
(3) Ensure that the suction filter has been primed and ready for operation.
(4) Check that the following valves are shut :-
(a) Pump set suction isolating.

(b) Booster stage pump drain isolating.
(c) Interconnecting pipe drain isolating.
(d) Boiler Feed pump drain isolating.
(e) Pump discharge isolating.
(5) Check that the following valves are open :-
(a) Leak-off control valves inlet and outlet isolating.

(b) Leak-off control.
(c) Booster stage pump mechanical seal control and outlet isolating.
(d) Boiler feed pump magnetic separator inlet and outlet isolating.
(6) Check that all the instrument tapping point isolating valves are open and
that all drain and equalizing valves are shut.
(7) Crack open the pump set suction isolating valve.
(8) Open the booster pump air vent valve and vent any trapped air or gases
from the pump casing.
(9) Shut the booster pump air vent valve when water issues freely from it.
•. - ••.-!
(10) Open the interconnecting pipe work air vent valve and vent any trapped air
or gases from the interconnecting pipe.
(11) Shut the interconnecting pipe work vent valve when water issues freely
from it.
(12) Shut the leak-off drain regulating and drain isolating valves when water
issues freely from them.
(13) Fully open the pump set suction isolating valve.
(14) Ensure that the station general service cooling water available for the
pump set.
(15) Prepare the driving motor for starting. Refer to manufacturer's instructions.
,~
''-·..--·.I )
(16) Prepare the turbo-coupling and lubricating oil system for starting. Refer to
the manufacturer's instructions in part 3.
(17) Ensure that all instruments and coolers have been primed and vented •.
(18) Ensure that the pre-start checks for the leak-off equipment are carried out.
Refer to the manufacturer's instructions. ·
3. START-UP
Refer sequential interlocking conditions.
4. ROUTINE CHECKS
(1)
Check that the driving motor ammeter reading is normal.
(2)
Check that all pressure and temperature readings are normal.
(3)
Check that the lubricating oil is flowing freely through the following flow
indicators :-
--------- -------(a) --Booster~pump~drive~endand-non-driveend~bearingdrain flow.--------------
(b) Booster pump side and turbo coupling side driving motor bearing drain
flow.
(c) Boiler feed pump drive end and non-drive end bearing drain flow.
(4) Check that the cooling water from the BFP and booster pumps mechanical
seals is flowing freely.
(a) Cooling water from motor coolers.
(b) Cooling water from mechanical seal coolers.
(c) Cooling water from cooling water jackets in BFP and booster pump
(d) Cooling water from lubricating oil coolers.
(e) Cooling water from working oil coolers.
--------(5)--Gheck-the-oil-level-in-the-fltJid-eotJpling-tank-and-top-tlp-as-neeess-ary·-.- - - - - - - l - -
(7) Check all joints and valve glands for leakages.
\. /
. ·----
(8) Check the security of all keys and fastenings, paying particular attention to
the holding down bolts.
(9) Check for leakage from BFP and booster pump mechanical seals.
(1 0) Refer to the manufacturer's instructions for the routine checks of the turbo
coupling and the driving motor.
5. TRIP CONDITION : Refer sequential inter locking conditions.
6. SHUT - DOWN
(1) Shut the discharge valve.

(2) Stop the driving motor by opening the boiler feed pump motor ACB.
(3) Check that the electrical lube oil pump starts up as the pump set slow
down.
(4) Check the pump reverse running indicator.
(5) Stop the electrical lube oil pump 15 minutes after the Boiler feed pump set
has stopped.
(6) Close the cooling water valves to the driving motor air cooler and the
working oil cooler of the turbo coupling.
7. STAND BY CONDITIONS
Refer sequential interlocking conditions.
8. FAULT FINDING
(1) Pump fails to (a) Driving motor fault Check motor

start.
(b) Power supply fault. Check motor Breaker.
(c) Seizure of Pump set. Disconnect couplings and

locate seizure. Overhaul as
necessary
(d) Deaerator level low- Check deaerator water level
low switches & gauge glass for
any Blockage.
(e) Pump set tripped. Investigate cause.
Reset trips.
(2) Pump (a) Driving motor faculty Check operation of motor.

performance
low (Pump
Discharge
pressure low)
• (b) Incorrect rotation Check motor
connections.
electrical
(c) Booster stage pump Check booster stage pump

faculty. (Refer to part 1, chapter 2).
(d) Excessive wear of Dismantle pump and inspect
pump internals components.
(e) Low Speed Check Speed Regulation
System
(f) Strainer Chocked Clean strainer.
(3) Bearings (a) Defect in lubricating oil Check lubricating oil system.
overheating. system. Oil flow to bearing. (Refer to
manufacturer's instructions in
Part 3).
,.-- .......,_
(b) Bearings worn of Examine Bearings.
/
misaligned.
(c) Misalignment of Check alignment.
pump.
(4) Mechanical Seal
Temperature high
(a) Insufficient cooling Check Heat Exchanger for
Water to cooler. blockages and cleari.
(5) Excessive noise

and/or vibration
(a) Misalignment of pump Check alignment
set.
(b) Bearing misalignment Examine bearings.
(c) Holding down bolts Tighten holding down bolts.
loose. And maintain Dim as per Drg.
(d) Excessive clearance Check clearances overhaul as
of pump internals. necessary.
(e) Rotating assembly out Check dynamic balance.
of balance.
-~-~--~~~---~~~-~--~-~-~--~--------~-~----~---(f)~--Excessive-piping-loads--eheck-piping-support-and-re----- ~-
acting on pump adjust.

branches.
(g) Hydraulic Flow Increase flow through pump.
Disturbances Avoid long runnings on low
flows.
(6) High Diffl. (a) No flow through pump a) Check R.C. Valve
Temp across
suction and
discharge of
BFPS.
(o)-Piotstarn>f-st~:rn-d-uy-~JJ)-e>p-en-in-g-cas-ing-drain~&
Pump. R.C. line drains.
(c) Mal-Operation of c) Check RTD & diff temp.
Instruments. switches.
(7) H.C. Fusible (a) Entrap-off foreign a) Check pump freeness/
plugs blown - particles between rotation. If hard, open
off pump internals or and inspect pump
pump seizure internal.
SECTION- B
BOILER FEED PUMP
CHAPTER-3
LIST OF CONTENTS
----~·
~··. 1 Introduction
1.1 Periodic and preventive maintenance
1.2 Routine checks
2 Maintenance particulars
2.1 Estimated weights
2.2 Joints
2.3 Recommended torque values for
threaded fasteners
2.4 Recommended lubricants
3 Maintenance Procedures
3.1 Preparation for maintenance
3.2 Examining the drive end journal and
thrust bearing.
-~" 3.3 Examine the non-drive and journal and
thrust bearing.
3.4 Checking the axial running position and
______________________________________Jhrustbearingclearance. ___________________________________ .
4 Overhaul
4.1 Preparation for overhaul
4.2 Withdrawing the pump cartridge
4.3 Dismantling the pump cartridge
4.4 Inspection, renewal and repair
procedures
4.5 Assembling the pump cartridge
4.6 Installing the pump cartridge
______________________4~.7~--------~F~in=a~la=s=s=e~m~bly____________________________________~
5 Parts Identification
CHAPTER-3
1. INTRODUCTION :
It is recommended that a system of routine inspection be established

during which the condition of the pump can be determined and recorded for
comparison with later inspections. Any defects should be repaired or the
components renewed at the earliest opportunity. Certain inspections can only by
made when the pump is under shut down but others can be made under operating
conditions.
A high degree of cleanliness of each pump and of the surrounding areas
should be maintained, as this will assist in the early detection of minor leaks or
defects which, if unnoticed, could lead to more serious operational or maintenance
problems.
1.1 Periodic and Preventive Maintenance
The pump performance should be used as the criterion for the need to
renew wearing parts. The pump performance may deteriorate due to excessive
leakage past the impeller/diffuser wear rings or vibration may indicate that the
wear rings or bearings are worn.
Note: The recommended renewal clearances are 1.5 times the clearances
shown on the Sectional Arrangement Drawings. If the pump performance
has declined it may be necessary to renew the wearing parts before the
recommended clearances are reached.
1.2 Routine Checks
It is essential that the routine checks given in Chapter-2, Section-5 are

carried out regularly. The checks concerned with the mechanical condition of the
pump are repeated here for the convenience of the maintenance engineers.
1.2.1 Periodic Checks
It is recommended that the following checks are carried out at regular

intervals :-
(1) Check that the suction and discharge pressures are normal.
(2) Check that the pump bearing lubricating oil pressures and temperatures
are normal.
(3) Check for any leakage from the mechanical seals.
(4) Check all joints and valve glands for leakage.
(6) Carryout a visual check on all keeps and fastenings, paying particular
attention to the holding-down bolts.
2. Maintenance particulars
2.1 Estimated Weights (for lifting purposes)
Item Weight. kg
Cartridge assembly 1752

Discharge cover 1200
Suction guide 216
Pump shaft 303
Ring section, 1st stage 138

Ring section, 2nd /3rd stage 144
Ring Section, last stage 131
Diffuser 48.5
Bottom bearing housing, drive end 55
Top bearing housing, drive end 85
Bottom bearing housing, non-drive end 145
Top bearing housing, non-drive end 91.5
Thrust bearing cover 30.5
Thrust collar 28.8

Balance drum 33
· Gland housing 191
/
2.2 Joints
- -
All the various types of joints, CAF, Metaflex etc. used on the pumps, are
to be found in the parts lists on sectional assembly drawings.
2.3 Recommended Torque Values for Threaded Fasteners
The following torque figures must be used when assembling the pump. All
threads and undersides of heads must be lubricated.
Threaded Fastener Recommended Torque (Nm)

Pull up rings screws 175
Gland housing/discharge 430
cover screws
Diffuser Screw 40
Last stage diffuser screws 40
Thrust collar nut 2850
Ring section screws 95
2.4 Recommended Lubricants
This lubricating oil for the journal and thrust bearings of the Booster and
Boiler feed pumps will be supplied from the lubricating oil system associated with
the turbo coupling.
3. MAINTENANCE PROCEDURES
WARNING : IT IS ESSENTIAL THAT THE PLANT SAFETY RULES AND

REGULATIONS ARE OBSERVED AT ALL TIMES DURING MAINTENANCE
PROCEDURES.
Note : The FK4E36 Boiler feed pump is an integral part of the tandem Boiler feed
pump set. The following instructions should, therefore, be read in
conjunction with those for the Booster pump in Part 1.
3.1 Preparation for Maintenance
Before commencing any maintenance procedures, the pump must be

isolated as follows :-
(1) Isolate the electrical power supplies to the pump driving motor and the
lubricating oil system.
(3) Check that the pump set suction, discharge and leak-off isolating valves
are shut.
(4) Check that the Mechanical seal lines have been isolated.
(5) Open the drain and vent connections, and drain the pump casing.
WARNING: BEFORE PROCEEDING WITH ANY MAINTENANCE ON THE

PUMP, BE SURE THAT THERE IS NO PRESSURE WITHIN THE
PUMP CASING.
3.2 Examining the drive end (DE) journal bearing.
(1) , Disconnect and remove any instruments which could interfere with the
housing by two fitted bolts. Care must be taken to avoid damage to
the bolts or the holes in the top and bottom half housing.
(2) Withdraw the two fitted bolts and remove the cap screws securing the top
half bearing housing to the bottom half bearing housing. Also remove the
cap screws securing the top half bearing housing to the suction guide.
(4) Use two jacking screws in the top half bearing housing to separate it from
the bottom half.
guards away. Remove the top half journal bearing from the shaft with the
assistance of applying jacking screws to the bearing keep.
(7) Take the weight of the pump shaft and rotate the bottom halves of the
journal bearing and oil guards around the shaft and lift them away.
(8) Examine the journal bearing and shaft journal for signs of damage, scoring
of deterioration and examine the journal bearing and the oil guards for
wear. Reference should be made to the sectional arrangement drawings,
for the clearances of the journal bearing and oil guards.
-----------------------Note:- Lightly -smearthe-shaftandjournal bearing surfaces- with-oil- before-final---------

assembly.
(9) Rotate the bottom halves of the journal bearing and oil guards around the
shaft and into position in the bottom half bearing housing. Release the
weight of the pump shaft.
(10) Locate the top half journal bearing in position on the pump shaft. Locate
the bearing keep on the dowels and secure it with the cap screws.
-----------·guards-onto-the-bottom-half-bearing-housing-.- - - - - - - - - - - - - - + - -
- /
fitted bolts, then secure to the bottom half and the suction guide with the
cap screw.
(13) Replace the instruments and the turbo coupling/pump drive coupling
guard.
3.3 Examing the Non-drive End CNDE) Journal and Thrust Bearing
(1) Disconnect and remove any instruments which could interfere with the
dismantling procedure.
(2) Remove the fluid coupling/pump drive coupling guard.
(3) Remove the fluid coupling/pump drive coupling spacer and element
assemblies.
(4) Remove the set screws securing the bearing housing end cover to the top
half bearing housing.
(5) Withdraw the fitted bolts and remove the cap screws securing the top half
bearing housing to the bottom half bearing housing and the gland housing.
(6) Use four jacking screws in the top half bearing housing to separate it from
the bottom half.
CAUTION : The thrust cover is located on the bottom half bearing housing by
four dowel pins. Care must be taken to avoid damage to the dowels
or the locating holes. ,
(8) Remove the cap screws securing the thrust cover to the bottom half
bearing housing. Use four jacking screws to separate to the thrust cover
from the bottom half bearing housing and lift it way.
(9) Lift the top halves of the floating seal carriers away, then take the weight of
the pump shaft and rotate the bottom halves of the journal baring, oil guard
and floating seal carries around the shaft and lift them away.
(1 0) Unclip the springs and remove the split floating oil seals from the bearing
housing.
Note : The thrust carrier ring split line is at goo to the bearing housing horizontal
surface.
(11) Remove each thrust carrier ring in turn as a complete unit as follows :-
Rotate the complete carrier around the shaft until the half ring with the stop
pin can be removed, then rotate the other half ring around the shaft until it
can be lifted clear of the shaft. Repeat with the second carrier ring on the
other side of the thrust collar.
(12) Examine the journal.bearing, shaft journal, thrust pads, thrust collar, split
oil seal and oil guard for damage or deterioration. Under normal operating
conditions it is not expected that any measurable wear will take place on
the thrust pads other than a dulling of the white metal surfaces. It is
recommended that when this dulling has spread to more than half the
surface area of the pads, they should be renewed.
Refer to the sectional arrangement drawing for the clearances and renew the
·journal bearing and oil guard if necessary.
Note : Lightly smear the shaft, thrust collar faces and baring surfaces with oil
before final assembly.
(13) Install each split floating oil seal on the pump shaft with the spring.
(14) Take the weight of the -pump shaft and rotate the bottom halves of the
journal bearing, oil guard and floating seal carriers around the shaft and
into position in the bottom half baring housing. Release the weight of the
pump shaft.
(15) Install each thrust carrier ring in turn as a complete unit as follows:-
,;r;·{:.:.~,
Take the half carrier ring without the stop pin and place it over the shaft
I -~ ..
with the pad faces touching the thrust collar and rotate it into the bottom
half bearing housing, then place the other half carrier ring with the stop pin
upon the first and rotate the complete carrier ring until the stop pin locates
-------- -------------------on -the-horizontal-face of-the-bottom- ha If bearing-housing .-Repeat-with-the---------
second carrier ring on the other side of the thrust collar.
Note: The thrust carrier ring split line is at goo to the bearing housing horizontal
surface at the stop pin locates in a slot in the top half bearing housing.
CAUTION : Do not insert feeler gauges between the thrust collar and the thrust
pads; this may give an inaccurate reading and cause damage to the
white metal and surface.
(16) Check the axial clearance by moving the pump shaft towards the drive end
-----------s.-o-th·at-th·e-thrust-collaris:o..hard-against-the-inner-thrust-pads-;-'then-using----1--
feeler gauges between the outer thrust bearing spacer and the thrust
housing inner wall check the clearance. Refer to the Sectional
Arrangement Drawing for the original total axial clearance. Any
measurable variation should be investigation.
(17) Lift the thrust cover onto the bottom half bearing housing ensuring that the
dowel pin for each floating seal carrier are properly located. Locate the
thrust cover to the bottom half bearing housing with the dowel pins, then
secure the thrust cover with the cap screws.
(18) Locate the top half journal bearing in position on the pump shaft.
(19) Lift the top half bearing housing complete with the top half oil guard onto
the bottom half bearing housing, ensuring that the oil guard and stop pin
are properly located.
fitted bolts, then secure to the bottom half and gland housing with the
appropriate cap screw.
(21) Fit a new joint and secure the bearing housing cover to the top half
housing with the set screws.
(22) Install the coupling/pump drive coupling spacer and element assemblies.
(23) Replace the instruments and the coupling pump drive coupling guard.
3.4 Checking the Axial Running Position and Thrust Bearing clearance
Note: This operation is to be carried out during the assembly of the drive end
and non-drive and bearing housings.
(1) The drive end bearing housing should be assembled without the following
components in place.
(a) Top half bearing housing and top half journal bearing.
(b) Oil guard and oil throwers.
(2) The non-drive end bearing housing should be assembled without the
following components in place.
(a) Top half bearing housing, top half journal bearing and thrust cover.
(b) Thrust bearing carrier ring assemblies.
(c) Oil guard and oil thrower.
(3) Check the axial running position of the rotating assembly as follows:-
(a) Move the rotating assembly as far as possible towards the drive end
of the pump and, using the outer face of the thrust collar as a datum,
scribe a line on the horizontal surface of the bottom half bearing
housing.
(b) Move the rotating assembly as far as possible towards the non-drive
end of the pump and, using the same datum, scribe a second line on
the bottom half bearing housing. Measure the distance between the
two lines; this should be approximately 8 mm.
CAUTION : The minimum acceptance total axial travel is 6 mm.
(c) Position the inner halves of the thrust bearing carrier rings and
spacers in this bottom half housing and move the rotating assembly
as far as possible towards the drive end of the pump. Scribe a third
line on the surface of the bottom half bearing housing.· Using the
same datum as before: this line should be offer 0.50 mm towards the
non-drive and from midway between the other two lines.
CAUTION : Do not insert feeler gauges between the thrust collar and the thrust
pads; this may give an inaccurate reading and cause damage to the
white metal pad surface.
(4) Check the thrust bearing axial clearance as follows :
(a) Position the outer halves of the thrust bearing carrier rings and
spacers in the bottom half housing.
(b) Check the axial clearance by moving the pump shaft as before and
carefully measuring the difference: alternatively, move the pump shaft
so that the thrust collar is hard against one set of thrust pads and use
feeler gauges between the opposite thrust bearing spacer and the
bearing housing. The total axial clearance was Originally as shown on
Drawing Nos. measurable variation should be investigated.
(5) If spare thrust bearing assemblies are fitted, proceed as follows:
--'-----------------------(a)--With Jhe-rotating_assembly_ in the_ axiaLrunning _position ,_accurately__________ _

· measure the distance between the bottom half bearing housing wall
and the inner thrust collar face and record the reading. Repeat the
procedure between the outer thrust collar face and the bearing wall
and record the reading.
(b) The spacers should now be removed form the inner and outer thrust
carrier ring halves and machined accurately to give the correct
thickness as follows:-
(i) Inner thrust ring spacer thickness - Measured distance between

-----------'---____,_h_,_,.o,_,u=s'-'--'ing wall and inner collar face minus thrust ring,~t~h~ic~kn~e~s~s~.- - - - - - + -
(ii) Outer thrust ring spacer thickness - Measured distance between

housing wall and outer collar face minus (thrust ring thickness + axial
bearing clearance).
(c) Secure the spacers to the thrust carrier ring halves and repeat step
as previously described.
4. OVERHAUL
WARNING: IT IS ESSENTIAL THAT PLANT SAFETY AND REGULATIONS ARE

OBSERVED AT ALL TIMES DURING MAINTENANCE
PROCEDURES.
The following instructions apply when the pump cartridge is to be removed and
dismantled for a complete overhaul.
Note: If a replacement cartridge is available, this should be prepared and

installed as described in Section 4.6 before proceeding to dismantle and
repair the worn cartridge as described in Section 4.3. Reference numbers
on components should be re-marked as necessary to facilitate
assembling.
4.1 Preparation for Overhaul
(1) Prepare the pump for maintenance as described in Section 1.1
(2) Disconnect and remove the following pipes and fittings :-
(a) The lubricating oil pipe work to and from the pump bearings.
(b) The mechanical seal pipe work.
(c) The balance chamber return pipe work from the discharge cover.
(d) The gland well drain pipe work from the suction guide and the
housing.
(e) Remove the interstage spool piece and interstage tube.
(f) Remove air vents from the drive end bearing housing and the suction
guide.
(3) Disconnect and remove any instruments which could interfere with the
(4) Remove the fluid coupling/pump drive coupling guard.
(5) Remove the fluid coupling/pump drive coupling spacer and element
assemblies.
(7) Check that all lifting equipment and special tools are in good condition.
i
;
4.2 Withdrawing the Pump Cartridge
(1) Remove the set screws securing the split pull-up ring to the pump casing.
The ring can now be removed, the upper half being located by two dowel
pins.
(2) Secure the first extension sleeve (5) to the drive end bearing housing with
screws (12) and (24).
(3) Enter the cartridge tensioning screw (1 0) through the hold on the end plate
of the first extension sleeve and screw it into the tapped hole in the end of
the pump shaft. Run the nut (11) on to the end of the tensioning screw and
tighten it until all cartridge movement is taken up.
Note : The cartridge axial movement between the last stage diffuser and the
outer guide is approximately 2.5 mm.
(4) Locate the suction and support jack (7) on the base plate pad. Centralise
the roller using the slots provided on the jack base. Jack up the roller until
good contact is made with the first extension sleeve (5). Tighten the
screws to secure the support jack to the base plate.
CAUTION : The support jack (7) is intended to take the weight of the drive end of
the pump cartridge and so facilitate removal of the cartridge. Due to
the fine diametrical clearance which exists between the suction guide
and the pump casing, extreme caution must be observed when
adjusting the height of the support jack roller to avoid over tightening,
which may lead to damage to the suction guide or pump casing when
withdrawal is attempted.
' (5) Remove and retain the stud caps.

j
(6) Remove the pump casing/discharge cover nuts, using the hydraulic stud
------------------------------tensioningequipmentasfollows:----------------------- __________________
(a) Locate the jacking ring and load cell assembly over two pairs of I
diametrically opposite casing studs and nuts as shown.
(b) Screw the load cell onto the stud until it abuts the jacking ring.
(c) Connect the load cells to the hydraulic pump by means of the manifold
and pipe work.
(d)
Operate the pump and prime the system with oil, then raise the
pressure in the system specified by the supplier of the hydraulic
_ _ _ _ _ _ _ _ _ _ _ ____,_t-en-s--.-io-n---.i-ng_e_q___:ui~p-m__,e~n-.--t,---.-t-o-relieve tile pre-loaaing on file stua-=-s-.- - - - - - - 1 -
(e) Slacken back the casing nuts using a tommy-bar in the holes in the
nuts.
(f) Relieve the pressure in the hydraulic system and return the oil to the
pump by operating the valve on the pump.
(g) Unscrew and remove the inserts from the studs, then remove the load
cell assemblies from the studs.
(h) Unscrew and remove the casing nuts from the casing studs.
(i) Repeat the above procedure (a) to (h) to remove the remaining
discharge cover nuts, ensuring that the sequence shown is adopted to
avoid distortion of the cover.
(7) Fasten the support columns (15-MD I 16-TD) to the foundation plate
(27-MD I 31-TD) with screws (23,26&30).
(8) Locate the support rail assembly (A) on the base plate and on the support
columns (15-MD I 16-TD). Fit the bracket (2) and wheel mounting
assemblies (3-MD I 4-TD) to the discharge cover with screws (14).
(9) Using the slots provided in the bracket mounting assembly (2), centralize
the bracket by using the jacking screws (19) at each side until the support
rails (1) make contact with the rollers. The support rails (1) must be level
during this operation.
(1 0) Retain the bracket mounting assembly (2) by tightening the holding down
set screws (18). Lock the jacking screws (17) in position with lock-nuts
(28).
(11) Position the hinged wheel stops across the support rails.
(12) Screw the starting screws (A1) into the discharge cover and unseat the
cartridge from the pump casing. The suction end support jack (7) and the
jacking screws (19) on the support rail assembly (A) which is positioned
over the support columns (15-MD I 16-TD) may require individual
adjustment to ensure smooth removal of the cartridge.
(13) Ensuring that the stops on the support rails (1) are in place, withdraw the
cartridge to the first stop.
(14) Install the second extension sleeve (6), using screws (29&30). The
cartridge can now be withdraw to the second stop position. Repeat this
Step until the cartridge is withdrawn to the final stop position.
(15) Position the support plate (8) on the pump casing studs and a distance
tube (9) on each stud. Then using discharge cover nuts to lock the tubes
(9) and support plate (8).
(16) Withdraw the dowel pin, from the suction guide, that locates the pull up
ring.
(17) Secure the lifting plate (21) to the suction guide with the four set pins (22).
(18) Secure an eye-bolt (20) into the tapped hole provided in the discharge
cover. Attach suitable slings to the eye-bolt (20) and the lifting plate (W)
and take the weight of the pump cartridge.
(19) Unbolt the second extension sleeve (6) from the first extension sleeve (5))
and separate each at the spigot location.
(20) Carefully lift the pump cartridge away to a maintenance area and suitably
support it on wooden trestle. Ensure that the mounting wheel assembly is
clear of the floor.
Note : The cartridge tensioning screw (1 0) must not be released during transit of
the cartridge.
(21) Remove the lifting equipment (20,21 &22), mounting wheel assemblies (3-
MD /4-TD) and bracket mounting assembly (2) from the pump cartridge.
CAUTION : The cartridge tensioning screw (1 0) must not be removed .
. (22) Remove and discard the suction Metaflex joint.
4.3 Dismantling the Pump Cartridge
CAUTION : During dismantling of the pump cartridge, it is essential that the

cartridge be firmly supported. The initial dismantling is carried out in
the horizontal position, and the final stages with the cartridge
supported vertically as shown in the drawing. At no time should be
weight of the cartridge be carried by the shaft.
4.3.1 Removing Pump Half Coupling Hub
(1) Remove the Cartridge as described in Section 4.2.
(2) Install the support frame over the suction guide from the drive end bearing
side, then clamp the discharge cover, ring ~ections and suction guide
tggether with the stay rods, location washers and nuts.
(3) Relea~-~--th~-~~t:-~~~urin~ ~he- c:rtri~ge-te~~i~~~~-:~:: ~nd -:move~h-:--------~

screw from the shaft end. Remove the screws securing the first extension
sleeve to the drive end bearing housing and lift away the first extension
sleeve.
(4) Remove the coupling nut grub screw, then using the special spanner
supplied, unscrew and remove the coupling nut.
(5) Withdraw the pump half coupling hub from the pump shaft. Remove and
retain the coupling keys.
4.3.2 Removing the D. E. Bearing Assembly and Mechanical seal.

bearing housing to the bottom half bearing. Also remove the cap screws
securing the top half bearing housing to the suction guide.
(2) Use two jacking screws in the top half baring housing to separate it from
the bottom half.
guards away. Remove the top half journal bearing from the shaft with the
assistance of applying jacking screws to the bearing keep.
journal bearing and oil guards a·round the shaft and lift them away.
(5) Using suitable lifting gear, take the weight of the bottom half bearing
housing.
(6) Withdraw the two taper dowel pins and remove the cap screws securing
the bottom half bearing housing to the suction guide, then lift the bottom
half housing away.
(7) Slacken the grub screws and withdraw the oil thrower from the shaft.
Discard the "0" ring from the groove in the bore of each oil thrower.
NOTE Refer to Manufacturer's instructions when dismantling the

mechanical seals.
(8) Using the pin spanner supplied, unscrew and remove the seal sleeve
locknut and seal nut from the shaft. Discard the '0' ring from the shaft
sleeve.
(9) Engage the assembly fixtures (eccentric washers) into the groove in the
shaft sleeve and fasten them.
(1 0) Loosen all screw connections between seal cartridge· and the respective
machine parts.
(11) Remove the screw connections between seal cartridge and the respective
machine parts.
(12) Take the weight of the bearing bracket, then remove the Hexagonal socket
head cap screws securing the bracket to the suction guide and remove the
bracket.
(13) Screw the clamping plate on the shaft and secure it to the suction guide
with four bolts.
4.3.3 Removing the N.D.E. Bearing Assembly and Mechanical Seal
(1) Remove the set screws securing the end cover to the bearing
housing, then remove the end cover klingerite joint.
bearing housing to the bottom half bearing housing and the gland housing.
(3) Use four jacking screws in the top half bearing housing to separate it from
the bottom half.
CAUTION : The thrust collar is located on the bottom half bearing housing by
four dowel pins. Care must be taken to avoid damage to the dowels
or the locating holes.
(5) Remove the cap screws securing the thrust cover to the bottom half
bearing housing. Use four jacking screw to separate the thrust cover from
the bottom half bearing housing and lift it away.
(6) Lift the top halves of the floating seal carriers and oil guard away.
(7) Unclip the springs and remove the split floating oil seals from the bearing
housing.
Note: The thrust carrier ring split line is at 90° to the bearing housing horizontal
surface.
'··~
(8) Remove each thrust carrier ring in turn as a complete unit as follows:-
-- -------
------~---- --- Rotate-the-com-piete-carnerrfng-arol.l-ncllfle tne----------

shatfuntil the halrrlng with
until it can be lifted clear of the shaft. Repeat with the second carrier ring
on the other side of the thrust collar.
journal bearing and the oil guard around the shaft and out of the bottom
half bearing housing.
CAUTION : The bottom half bearing housing is located on the gland housing by
two dowel pins. Care must be taken to avoid damage to the dowels
--------------------------~
or tile noles infllenousing7glana-nousing.
(1 0) Using suitable lifting gear, take the weight of the bottom half bearing
housing.
(11) Withdraw the dowel pins and remove the cap screws securing the bottom
half bearing housing to the gland housing, then lift the bottom half bearing
housing away.
(12) Unlock the lock-washer, then using the special spanner, unscrew and
remove the thrust collar nut and lock-washer from the pump shaft.
Note : The thrust collar nut has left hand thread.
(13) Using withdrawal gear as shown on illustration, withdraw the thrust

collar/probe indicator assembly from the shaft and remove and retain the
thrust collar key from the keyway on the shaft.
(14) Check the location of the oil thrower on the shaft for assembly purposes.
(15) Slacken the grub screw and withdraw the oil thrower from the shaft.
Discard the '0' ring from the groove in the bore of the thrower.
(16) Using the pin spanner, unscrew and remove the shaft lock-nut and seal
nut from the shaft. Discard the '0' ring from the shaft sleeve.
(17) Engage the assembly fixtures (eccentric washers) into the groove in the
shaft sleeve and fasten them.
(18) Loosen all screw connections between seal cartridge and the respective
machine parts.
(19) Remove the screws securing the seal housing to the gland housing and
remove the seal housing. Remove and discard the '0' rings from the
grooves of the outside diameter of the seal housing.
(20) Withdraw the three angled locating dowels on the gland housing.
(21) Take the weight of the gland housing, then remove the cap screws
securing the gland housing to the discharge cover.
(22) Separate the gland housing from the discharge cover by applying four
jacking screws. Discard the Metaflex joint between the joint faces.
4.3.4 Dismantling the Ring Section Assembly
(1) Install the support frame and secure it in position with the stay rods.
(2) Secure the lifting eyebolt to the discharge cover and to the support frame.
(3) Using suitable lifting gear carefully lift the ring section assembly into the
vertical position.
(4) Lower the ring section assembly into the support trestle until the support
frame rests on the support trestle.
Remove the lifting gear.
(5) Remove the socket set screws that lock the outlet guide plugs, then
unscrew the outlet guide plugs. The cap screws securing the outlet guide
to the discharge cover can now be removed. Remove the two socket set
screws that lock the locating dowels for the outlet guide to the discharge
cover.
CAUTION : Care must be taken when raising the discharge cover to avoid
damage to the balance drum or the balance drum restriction bush.
~\ (6) Remove the top nuts and washers from the stay rods securing the
i discharge cover in position, then using suitable lifting gear, slowly lift the
discharge cover clear of the pump shaft.
(7) Release the lock-washer and using the special spanner provided, unscrew
and remove the balance drum nut and lock-washer from the shaft·.
Note : The balance drum nut has left hand thread.
(8) Withdraw the balance drum from the pump shaft using withdrawal gear
similar to that shown on illustration. Remove and retain the balance drum. I
I
i
(9) Remove the stay rods from the support frame.
(1 0) Using a gas heater ring, apply heat to the kicker stage impeller hub, then
remove the impeller from the shaft. Remove and retain the shearing and
the key from the shaft.
', Note : Should the attempt the remove the impeller be unsuccessful immediately
after heating, the impeller and the shaft temperature must be allowed to
cool down to the ambient temperature before another attempt is made to
_________________________ .removeJhe_impeller.This p(Ocedure applie_sjo_ajl_tbejrop_elle($_._ _______.__________
(11) Remove the outlet guide, then remove and retain the disc spring.
(12) Remove the socket head screws securing the last stage diffuser to the last
stage ring section. Lift the last stage diffuser clear of the pump shaft.
(13) Apply heat to the rear hub of the fourth stage impeller and pull the impeller
from its location on the shaft. Remove the impeller, shear ring and impeller
key.
WARNING : THE INTERESTAGE DIFFUSERS AND RING SECTIONS ARE

---------====-~tOC~TED-TO-EA:Gri-OTriER-BY-DOWEt-PINS-ANIJ-Witt---+
PROBABLY LIFT AS AN ASSEMBLY. CHECK THAT THE
DIFFUSER IS SECURED BEFORE LIFTING OVER THE SHAFT.
(14) Remove the outlet guide, then remove and retain the disc spring.
(15) Suitably sling and lift the last stage ring section clear of the pump shaft.
(16) Remove the socket head screws securing the last stage diffuser to the last
stage ring section. Lift the last stage diffuser clear of the pump shaft.
(17) Repeat steps (13) to (15) to remove the remaining impellers, ring sections
and diffusers.
(18) Screw the lifting eye-bolt onto the non-drive end of the pump shaft, then
using suitable lifting gear take the weight of the pump shaft.
(19) Unscrew and remove the clamping plate from the drive end of the pump
shaft.
(20) Carefully lift the pump shaft until the drive end of the shaft is clear of the
suction guide.
4.4 Inspection. Renewal and Repair Procedures .
The pump components should be completely cleaned before inspecting for

any signs of wear including scoring, wiping or ridging.
All diametrical clearance should be measured with internal and external

micrometers.
4.4.1 Clearances
Refer to the Sectional Arrangement Drawings for details of the clearances.

It is recommended that when the pump internal clearances have reached 1.5
times the figure quoted or are expected to do so before the next overhaul, the
component or components should be renewed. The main considerations,
however, are pump performance and motor power consumption.
4.4.2 Pump Shaft
(1) Examine the shaft for any signs of damage or bowing and check for
concentricity; it should be within 0.05 mm full indicator movement.
(2) Check that all threads are in good condition.
(3) Check that the keyways are free from burrs.
4.4.3 Impellers
(1) Examine the impellers for signs of wear or erosion, particularly at the
waterways and the tips of the blades.
(2) Check that the keyways are free from burrs.

(3) Examine the impeller wear rings for wear or ovality. Renew or repair as
necessary.
CAUTION : If the impeller wear rings required to be renewed it is important to

note that the impeller is balanced during manufacture. However, if it
is considered expedient to assemble and operate the pump without
checking the balance, BHEUPUMPS, should first be consulted.
4.4.4 Ring Sections. Diffusers. Balance Drum and Suction Guide
(1) Examine the ring sections, diffusers and suction guide for signs of wear or
erosion, particularly in the flow passages.
(2) Examine the bores of the ring section and diffuser wear rings and the
balance drum bush for signs of wear or ovality. Renew or repair as
necessary.
(3) The wear rings and balance drum bush are a shrink fit in their respective
components, and are secured radially by grub screws.
(4) The wear rings should be renewed as follows .:-
(a) Remove the grub screws and machine the wear ring from its seating.
(b) Thoroughly clean the seating and shrink the new ring into position.
(c) Secure the war ring in position with grub screws. Lock the grub
screws by lightly punching with a centre punch at the thread junction.
(d) Lightly machine the internal or external surface of the wear ring to
rectify any distortion which may have occurred during fitting.
{
The impeller wear rings supplied as spares are left 3 mm oversize on

__ __ ____ __ ____ ______ _ __ _ the outside diameter for final machining after fitting and due note
--- sho-uiCn)e-faken -oflnTs-wnen- assessin~fflfe-possil:>le renewal-of tile---·------·
ring section and diffuser wear rings. The ring section and diffuser
wear rings supplied as spares are left 3 mm undersize in the bore for
final machining.
4.4.5 Journal Bearings
Inspect the journal bearings for signs of wear or damage and renew as
necessary.
4.4.6 Thrust Bearings
Under normal operating conditions it is not expected that any measurable

wear will take place on the thrust pads other than a dulling of the white metal
surfaces. It is recommended that when this dulling has spread to more than half
the surface area of the pads, they should be removed.
4.4. 7 Mechanical Seals
A correctly operated mechanical seal is maintenance free, wear parts,

however, have to be replaced, if necessary.
4.4.8 Joints
All joints and '0' rings should be renewed on assembly, as should any
backing ring which shows signs of damage or distortion. Apply soft soap to all '0'
rings prior to assembly.
4.4.9 Studs. Bolts. Screws and Nuts
The threads of all studs, bolts, screws and nuts must be clean, well formed
and free from burs. If the threads are damaged in any way the component must be
renewed.
4.4.1 0 Dowels
All dowels must be clean and free from damage. Worn or damage dowels
must be renewed.
4.4.11 Keys
All keys must be a good fit in their keyways and must also be flat, parallel and free
from burrs. Worn or damage keys must be renewed.
4.4.12 Cleanliness
All components must be perfectly clean and all bores and oil ways must be
cleaned out before the pump is assembled.
4.4. 13 Dynamic Balance
Each components of the rotating assembly is first dynamically balanced

individually during manufacture, then the entire assembly consisting of shaft, shaft.
sleeves, impellers, balance drum, pump half coupling, thrust collar, nuts, keys and
rotating seal faces is assembled and dynamically balanced as a unit. Always
consider the effect on dynamic balance when renewing or repairing individual
parts.
If it is considered expedient to assemble and operate the pump without
checking the dynamic balance, BHEL Pumps Ltd., should first be consulted.
When suitable workshop facilities are available the recommended method

of checking the dynamic balance of the resulting assembly is as follows :
(1) Support the assembly at the bearing centre lines and check that it is
dynamically balanced with 630M g em

N
Where M = rotor weight (kg)
N =pump speed (rev I min.)
(2) nynamic balance is to be achieved by removing metal from the impeller

\ shrouds within the following limits.
CAUTION : (a) The thickness of the impeller shroud must not be reduced by
more than 1.6 mm at any point.
(b) No metal is to be removed from an impeller within 12.7 mm of the

periphery.
(c) The weight of metal to be removed is to be calculated in the form

of a segment, the arc length of which does not exceed 0.1 of the
circumference of the impeller.
(d) If the amount of the metal to be removed exceeds the limits

imposed by (a) and (c), BHEL pumps Ltd., should be consulted.
Note : The dynamic balance can be checked and trimmed in-situ by BHEL,
Pumps Personnel, using specialized equipment to establish the degree
~·.\ and location of the unbalance and correcting this by adding balance
weights to the peripheries of the coupling flange and the thrust collar.
------ - - - - - - - - - ------------ -
4.5 Assembling the pump cartridge
To assist the assembling procedures all fittings and threads should be

smeared with anti-scuffing paste.
4.5.1 Assembling the ring Section Assembly
(1) Ensure that the inspection, repair, and renewal procedures have been
properly carried out.
(2) Suitably support the shaft on wooden trestles in the horizontal position.
(3) Insert the driveend gland sleeve key and the first stage impeller key in
their keyways in the shaft. Also, locate the shearing in the shaft recess
provided for the first stage impeller.
(4) Apply heat evenly around the hub of the first stage impeller, using a gas
heating rings, then slide the impeller over the shaft and key until it butts
against the shearing.
CAUTION : Force should not be used when fitting the impeller. If the impeller
does not butt against the shaft shoulder, remove the impeller and
check for burrs or dirt which may have been overlooked during
inspection. Clean up as necessary and repeat step (4). Do not
attempt to fit the impeller if the shaft is above ambient temperature.
(5) Replace the support frame on the top of the support trestle, then lift the
suction guide and lower and secure it into the support trestle as shown on
Drawing.
(6) Lift the first stage ring section and lower it onto the suction guide,
ensuring that the slot at top dead centre engage over the key block on the
suction guide.
(7) Screw the lifting eye-bolt onto the non-drive end of the pump shaft, then
suitably sling and carefully lift the shaft into the vertical position.
(8) Carefully lower the drive end of the pump shaft into the suction guide bore
until the impeller eye wear ring enters the first stage ring section casing
wear ring. Remove the lifting lug from the pump shaft.
(9) Screw the clamping plate onto the pump shaft and secure it to the suction
guide.
(1 0) Suitably sling and lift the interstage diffuser over the shaft and into position
on the first stage ring section. Ensure that the dowel pins are properly
located then secure to the first stage ring section with the cap screws.
(11) Suitably sling and lift the second stage ring section over the shaft and into
position on the interstage diffuser and first stage ring section. Ensure that
the radial dowel position marks match-up with the same marks as that on
the first stage ring section.
(12) Secure the second stage ring section to the first stage ring section with the
socket head screws.
(13) Before Proceeding any further with the assembly, check the total axial
travel as follows :-
(a) Screw the lifting eye-bolt onto the non-drive end of the pump shaft
and suitably sling.
(b) Take the weight of the pump shaft and allow the first stage impeller
to rest on the first stage ring section.
(c) Using the upper face of the second stage ring section as a datum,
mark a pencil line on the shaft.
(d) Remove the screws securing the clamping plate to the suction guide,
then unscrew the clamping plate along the shaft until the plate has a
gap of slightly more than 10 mm from the suction guide flange.
Reposition the securing screws finger tight.
(e) Lift the pump shaft as far as possible towards the non-drive end of
the pump and, using the same datum, mark a second line on the
pump shaft.
(f) Measure the distance between the two lines: this should be
approximately 9 mm.
CAUTION : The minimum acceptable total shaft travel is 7.5 mm.
(g) Lower the shaft until the first stage impeller rests on the first stage
ring section then raise the shaft by about 2 mm and place suitable
packing between the floor and the shaft drive end, to take the weight
of the shaft assembly. Allow the shaft to rest on the packing. This will
now permit the following impeller to about firmly against the shear
ring, rather than the casing wear ring on the ring section. Remove the
sling and lifting eye - bolt from the shaft.
(14) Insert the second stage impeller key in the shaft keyway, then locate the
impeller split shearing in the shaft recess.
(15) Apply heat evenly around the hub of the second stage impeller, using the
gas heating ring, then slide the impeller onto the shaft and key until it butts
against the split shear ring.
(16) Repeat stops (1 0) to (15) to install the remaining interstage diffusers/ ring
sections and impellers.
(17) Lift the last stage diffuser over the shaft and into position on the last stage
ring section.
--~- ~--- -------------------(-18)-- --Secure-the last stage-diffuser-tothelaststage_ring_section_with_the_sockeL _____ _

head screws.
(19) Lift the disc spring over the shaft and into position on the last stage
diffuser spigot.
(20) Lift the outlet guide over the shaft and into position on the last stage
diffuser.
(21) Position the shear ring on the shaft recess and the impeller key for the
kicker stage impeller.
(22) Apply heat evenly around the hu5 pfli19RicRer stage impeller using gas
heating ring, then slide the impeller over the shaft until it butts against the
shear ring.
(23) Insert the balance drum key into its keyway in the shaft, then using the gas
heating ring supplied, heat the balance drum and slide it onto the shaft and
key until it butts against the shaft shoulder, place a new packing ring and
the packing ring follower in the bore of the balance drum.
(24) Locate the new lock-washer against the balance drum, then screw on and
tighten the balance drum nut, finally locking the nut in position with the
lock-washer.
Note: The balance drum nut has left hand thread.
(25) Screw the four tie rods into the support frame as shown in the Drawing.
(26) Suitably sling the discharge cover and lift it to a position above the shaft.
(27) Carefully lower the discharge cover over the shaft and tie rods into position
on the last stage diffuser, taking care to prevent fouling between the
balance drum and bush. Ensure that the dowel pins are properly located.
(28) Replace the location washers and nuts on the tie rods and secure the ring
section assembly together as shown in the Drawing.
(29) Secure the clamping plate to the suction guide by drawing up the fixing
screws.
(30) Secure the lifting eye-bolt onto the discharge cover and support frame.
(31) Using suitable lifting gear, carefully lift the ring section assembly clear of
the support trestles.
(32) Lower the ring section assembly into the horizontal position and support it
at each and with wooden support trestles.
(33) Remove the lifting gear, lifting eye-bolts and clamping plate.
4.5.2 Installing the mechanical seals :
CAUTION: The rotating assembly must be supported on wooden trestles during

the assembly.
1. For installation the assembly drawing shave to be on hand.
2. The mechanical seal ·has to be installed very carefully and under the
cleanest conditions.
3. Do never force during installation.
4. To facilitate assembly, surfaces over which 0-rings are to be fed may be

thinly lubricated with water, alcohol or silicon grease. Elastomers made of
EP rubber must never come into contact with lubricants on the base of
mineral oil (swelling, decomposition).
5. As lubricant for elastomers (0-rings etc.) should be used.
6. The mechanical seal is supplied as a cartridge unit, pre-mounted at works

and does not require any adjustment during assembly.
7. Bolt the mechanical seal to the pump housing in the way that the
connections are positioned.
8. Insert 0-rings on the shaft.
9. Clamp the shaft sleeve axially with special nuts. Apply the torque smoothly
and without interruption. Do not knock the wrench.
10. Remove the assembly fixtures and keep them for a later removal of the
seals.
/
I
4.5.3 Assembling the D.E. Bearing Assembly
(1) Ensure that the bearing bracket is located and secured to the suction
guide with the dowel pins, studs and nuts.
(2) Locate a new '0' ring in the groove of each of the oil throwers, then slide
the throwers onto the shaft.
(3) Lift the bottom half bearing housing into position and locate and secure it
to the suction guide with the taper dowel pins and cap screws.
(4) Position the throwers to correspond with the reference made during
dismantling and secure each thrower to the shaft with the grub screw.
Note: Lightly smear the shaft and journal bearing surfaces with oil before final
assembly.
journal bearing and oil guards around the shaft and into position in the
_bg_tt_o'!l_~(l!f_t>_~arjng ho_ll~~n_g._ J3.~1~a~~J~e ~eight of_!~_e e_u_mE_~-~~·- _______ _
(6) Locate the top half journal bearing in position on the pump shaft and install
the bearing keep which is positioned by the two dowel pins and secured by
cap screws.
guards onto the bottom half housing.
(8) Locate the top half bearing housing to the bottom half with the dowel pins,
then secure the top half housing in position with the cap screws.
--------,(9)--lnsert-the-coupling-keys-inte-the-keyways-in-the-shaft-,---then-install-the----+-
pump half coupling over the keys and onto the shaft.
(1 0) Screw the coupling nut onto the shaft and tighten with the special spanner
provided. Lock the nut in position with the grub screw.
4.5.4 Assembly the N.D.E. Bearing Assembly
(1) Ensure that the gland housing is located and secured to the discharge
cover with the dowel p9ins and cap screws.
(2) Locate a new "0" ring in the groove of the oil thrower, then slide the
thrower onto the shaft.
(3) Insert the thrust collar key into the keyway in the pump shaft.
(4) Apply heat evenly around the thrust collar hub, using the gas ring supplied,
then slide the thrust collar onto the shaft and over the key until it abuts the
shoulder on the shaft.
(5) Allow the thrust collar to cool to ambient temperature, then slide the probe
indicator onto the shaft to locate on the dowels and abut the thrust collar.
Secure with the cap screws.
(6) Locate a new lock-washer on the shaft and secure the thrust collar nut on
the shaft and lock it in position with the lock-washer.
Note: The thrust collar nut has a left hand thread.
(7) Lift the bottom half bearing housing into position and locate and secure it
to the gland housing with the taper dowel pins and cap screws.
(8) Position the thrower to correspond with the reference made during
dismantling and secure the thrower to the shaft with the grub screw.
Note : Lightly smear the shaft, thrust collar faces and journal bearing surfaces
with oil before final assembly.
journal bearing and oil guard around the shaft and into po~ition in the
bottom half bearing housing. Install the split floating oil seals on the pump
shaft with the spring. Release the weight of the pump shaft.
(1 0) Install each thrust carrier ring in turn as a complete unit as follows:
Take the half carrier ring without the stop pin and place it cover the shaft
with the pad faces touching the thrust collar and rotate it into the bottom
half bearing housing, then place the other half carrier ring with the stop pin
upon the first and rotate the complete carrier ring until the stop pin locates
on the horizontal face of the bottom half bearing housing. Repeat with the
second carrier ring on the other side of the thrust collar.
Note : The thrust carrier ring split line is at goo to the bearing housing horizontal
surface and the stop pins locate in a slot in the top half bearing housing.
(11) Check the total axial clearance (refer to Section 3.6).
(12) Locate the top half journal bearing in position on the pump shaft and install
the bearing keep which is positioned by the two dowel pins and secured by
cap screws.
(13) Lift the top half bearing housing complete with the top half oil guard onto
the bottom half bearing housing, ensuring that the carrier ring stop pins are
properly located.
(14) Locate the top half bearing housing to the bottom half bearing housing
with the dowel pins, then secure the top half housing in position with the
cap screws.
(15) Secure the bearing housing and cover to the housing with the set pins.
i
4.6 Installing the Pump Cartridge
Note : The following instructions assume that the withdrawal equipment as shown
on Drawing has not been disturbed.
(1) Secure the first extension sleeve (5) to the drive end bearing housing.
(2) Enter the cartridge tensioning screw (1 0) through the hole on the end plate
of the first extension sleeve and screw it into the tapped hole in the end of
the pump shaft. Run the nut (11) on the end of the tensioning screw and
tighten it until all cartridge movement is taken up.
(3) Remove the nuts, spacers and the stay rods securing the ring section
assembly together.
(4) Check that the Metaflex joint is properly located on the discharge cover
~
spigot.
:.,
(5) Locate the Metaflex joint on the suction guide spigot.
~-- - ---
(6) Locate the joint on first stage ring section spigot.
(7) Withdraw the dowel pin from the suction guide that locates the pull up ring.
(8) Secure the lifting plate (21) to the suction guide with the four set pins (22).
(9) Screw and eye-bolt (20) into the tapped hole provided in the discharge
cover. Attach suitable slings to the eye-bolt and lifting plate (21) and take
the weight of the pump cartridge.
(1 0) Secure the cradle roller assembly bracket to the discharge cover with the
-----------s-crews-provided-:-.- - - - - - - - - : - - - - - - - - - - - - - - - - - - - 1 - - -
(11) Carefully lift the cartridge assembly and lower it onto the support rail (1) as
s~own on Drawing.
Note : Provided that the withdrawal gear has remained in position following
cartridge withdrawal the cradle should be correctly aligned for the cartridge
insertion. It is important, therefore, that the cartridge be aligned to the
cradle and not vice versa.
(12) Bolt the second stage sleeve (6), which is still secured to the other three
extension sleeves, to the first extension sleeve (5).
(13) Take the weight of the cartridge extension sleeve assembly (516) on the
drive end support jack (7) roller and remove the distance tubes (9) and
support plate (8) from the pump casing studs.
(14) Remove the slings, lifting plate (21) and eye-bolt (20) from the pump
cartridge. Replace the dowel pin which was removed from the suction
guide to accommodate the lifting plate.
(15) Swing the hinged wheel stops into the stop position on the support rail
assembly (1 ).
CAUTION : When installing the pump cartridge, ensure that the suction guide is
radially central with the casing bore by adjusting the roller support
jack.
(16) Carefully push the cartridge into the pump casing until the outer extension
sleeve (6) can be removed. ·
(17) Repeat step (16), removing the extension sleeves (6) as necessary until
the suction guide and discharge cover are properly located in the pump
casing.
(18) Ensure that the discharge cover is correctly seated, then fit two nuts onto
the casing studs.
(19) Locate and secure the pull up ring on the suction guide and pump casing.
Tighten screws to a torque of 175 Nm.
(20) Fit the remaining nuts onto the casing studs and evenly tighten all around
using the tommy bar supplied.
Note : Check that there is no clearance between the discharge cover and the
pump casing.
(21) Dismantling and remove the tensioning stud (1 0), first stage extension
sleeve (5), drive end support jack (7), bracket mounting assembly (2),
mounting wheel assembly (3-MD I 4-TD), support rail assembly (1) and
support columns (15-MD I 16-TD) from the pump and base plate and
return to store, in readiness for future overhauls.
(22) Tighten the casing nuts using the hydraulic stud tensioning equipment
supplied as follows:-
(a) Locate the jacking ring and load cell assembly over two pairs of
diametrically opposite casing studs until it abuts the jacking ring.
(b) Screw the load cell on to the stud until it abuts the jacking ring.
(c) Connect the load cells to the hydraulic pump by means of the
manifold and pipe work.
(d) Operate the pump and prime the system with oil, then raise the
pressure in the system to 5000 lbf/in 2 and tighten the discharge
cover nuts with the bar.
(e) Relief the pressure in the hydraulic system and return the oil to the
pump by operating the valve on the pump.
(f) Unscrew and remove the load cell from the studs; then remove the
load cell assemblies from the studs.
(g) Repeat steps (1) to (6) until all the remaining nuts have been
tightened.
(h) Repeat steps (a) to (f) until all the nuts have been tensioned to a
pressure which will give a load of 72 kN on the casing studs. See
hydraulic stud tensioning equipment supplier's recommended
pressure to achieve this.
(23) Replace the stud caps and secure in position.
4. 7 Final Assembly
(
(1) Install the pump cartridge as described in Section 4.6.
_________________ _{_2)_ ___ fhec~~he coupli_l"l_g~_lignme_~t.~~!~_r!_()JIIust~~t!~~---------- _____________ _

(3) Install the fluid coupling/pump drive flexible coupling spacer and element
assemblies.
(4) Replace the fluid coupling/pump drive coupling guard.
(5) Install the following fittings and pipes that were removed during the
dismantling procedure :-
(a) The balance chamber return pipes between the discharge cover and
suction side.
(b) The lubricating oil pipes to and from the pump bearings.
(c) The bearing brackets gland well drain pipe work.
1- -
(6) Install and connect all instruments that were removed during the
(7) Replace any lagging and cladding removed during the dismantling
procedures.
When ordering spare parts, reference must be made to the pump Serial or
Job Number, Nomenclature and Sectional Arrangement Drawing, Item Number,
and quantity of each component.
SECTION- B
BOILER FEED PUMP
CHAPTER-4
SUB-VENDOR'S DRAWINGS /INSTRUCTIONS
LIST OF CONTENTS
I
\ /'
1 Mechanical Seals
2 Mechanical Seal Heat Exchanger
3 Mechanical Seal Magnetic Filter
4 Thrust Bearing
-./
SECTION-B
BOILER FEED PUMP
CHAPTER-4
" (
1. MECHANICAL SEALS
...
-- .......... ·---·--·-----------------:------.;,_-
fBURGMANN
6298
OPERATING MANUAL
FOR
BURG MANN
MECHANICAL SEAL (M.S.)
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.....
Please read- this-manual carefully and Observe the-information-contained as to-~-----
C SAFETY C INSTALLATION C OPERATION

C STORAGE C MAINTENANCE
..... If tl~ere are <UIY unclear points please c~ntact Burgmann· India .
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0 ii3 0 :I: FEODOR BURGMANN
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IBURGMANN Operating Manual
0. Foreword 1

2.2 Declaration 3
2.3 Type Designation 3
2.4 Operating Conditions 3
2.6 Description and Function 4
2.7 Required Space, connecting dimensions 4
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3. Safety Notes 7
0> 4. Transport, Storage and Installation 8-10
4.1 Packing and Storage 8-9

(lQ 4.2 Preparation for Assembly 9
4.3 Special Instructions 10
4.4 Installation 10
4.5 Directives in case of Failure 10
.......
5. Servicing 11-13
<0 5.1 Tungsten Carbide Designs 11

5.2 Circulation 11
5.3 Buffer Fluid 11
I() 5.4 After Sales Service by BURGMANN 11-12
5.5 Reconditioning (Repair) 12
5.6 Spare Parts 12
5.7 Disposal of Burgmann Mechanical Seal 13
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6. Copyright 14
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No.
6298
FOREWORD ~
Section
0 Dear Sir.
I
Than!.:. you for purchasing the Burgmann Mec.h~nical Seal (M.S.). We at Burgmann
Page: 1 of 14 are confident that your new purchase will greatly expand your working capacity and
efficiency.
Mechnnicnl Seal (M.S.). Whether you are installing, operating or servicing , this
manual will show you how to do it - quickly and easily.
·- i. Please take some time to go through this manual before installation. You don't have to
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....- read it all at .once. We just want you to know what a great Mechanical Seal (M.S.). I
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you have, !
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We've taken a great deal of care in preparing this manual so that you will never be left
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wondering ho>v to perform a certain fimction. Nevertheless, even after reading this
manual if you still aren't sure about something, P,lease feel free to contact your nearest
. CO'
queries .
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BURGMANN
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No.
6298
Section I Customer BHEL
1 II Machine Manufacturer BHEL
III ·Customer P.O No. ·.
Page: 2 of 14 IV Drawing Nos. SHF2/135-E5
SHF2/162-E5
v Burgmann Commission 119450

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Section
2
FEODOR BURGMANN
Page: 3 of 14
2.2 DECLARATION
Within the meaning of the EC·directive » MACHINERY «
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j 0 A mechanical seal does not function independently. It. is intended to be
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incorporated into or assembled with machinery.
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IX),. MECHANICAL SEAL DRG. NO. SHF2/135-E5

MECHANICAL SEAL DRG. NO. SHF2/162-E5 I
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r-- The materials of the mechanical seal depend on the application and are fixed in
the order. They may vary from those stated in the drawing.
(£)
2.4 OPERATING CONDITIONS

1.0
MECHANICAL SEAL DRG. NO. SHF2/135-E5

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Kind of Machine PUMP TYPE ( FK 4E 36 )
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\ ~ / Medium to be sealed Boiler Feed Water
Pressure 35 atg
------ - -- ----- - --- ------ ---- -----Temperature-Max.-------- -- ---· __ A0-200~C. ____ --------------------------- --- - -
M Speed 6300 Rpm
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MECHANICAL SEAL DRG. NO. SHF2/162-E5
Kind of Machine ... PUMP TYPE ( FK 4E 36 )
' ..- Medium to be sealed Boi!er Feed Water
Pressure 35 atg
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Temperature Max: 40-200°C
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No.
6298 2.5 DESIGNATED USE
A different utilisation or a utilisation going beyond the specification is considered
contrllry to its designated use and exclud~s a liability by the manufacturer.
Section
2 Operation under conditions lying outside tl10se limits stated in paragraph

>> operating data << is considered contrary to its designated use.
Should the seal be operated under different conditions or at a different

application BURGMANN has to be asked for recognition as safe in advance.
Page: 4 of 14
2.6 DESCRJPTION AND FUNCTION
The BURGMANN Mechanical Seal mentioned in clause 2.3 & 2.4 has been
0
supplied in cartridge construction, in this the seal can be installed directly on the
....... pump casfng without any adjustment. The seal fonns a pre-mounted unit (seal
cartridge). asembled at works, ready to be installed without any adjustment.
Assembly Fixtures are provided for holding the cartridge in one piece during
transport. storage. assembly and disassembly.
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The connecting dimensions of the Mech~utical Seal were checked and approved
by the customer on the main drclwing.
The available mounting space given by the macltine was decisive for the design
of the gland parts of Mecluutical Seal. The connecting dimension was checked
before shipment witll regard to t11e BURGMANN drawing.

v Assembly drawing Nos. SHF2/135-E5
SHF2/162-E5
The assembly drawings in the original scale and in its latest edition (latest
('") revision) only is decisive for the design and use.
In the following description all figures in parentheses, e:g.(2) define the respective
part item no. in the assembly drawings.
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ANSICHCXVEREJNEACHTE PARSTELLUNG ( H1:2)
VIEW X St«JWN SM'!..E ( SCALE 1:2)
EIN t IN
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'~// Krelslaufschema
clrculdlon l>l•n
w-o ck& cltcult do bcllo)'1lgo
(REMOVE ALL SHARP

011 SHAFT o
OF SEAL
EDGES
EFIJRE INSTALUTIIN
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=- - KUIIOE/CUSTOM£R
BETREmER/ULTIHATE USER
PUHPDITYP/Plll4P TYPE
B•H·E·L
FK ~E 36
DREHZAHLISPEED 6300ftpoo
HEDIIH/FlUil BDILERfEED II ATER
TEHPERATIIVTEHP ~o-zoo•c
DRUCK/PRESSUftf 35 otg
DRIVE END
lltf'"' slultup. tile operotlng oaoool and

tilt safely notu hoyt to bo PHd ond obHrNI
ANSICHI X VEREIHFACHTE OARSTELLUNG (H1:2)
VIEW X SIMPLE SHOWN (H1:2)
OUT
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Krelslclllfschema.
drcu.la.llon )tlQn
sc'-« 1lu circuit <It ba.la7a110
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BETII!IBfJVUI.TJtATI' USER
B·H•E·l
POO'EHTYP/PUMP TYPE FK 4E 36
I
DRfHZAHL/SI'EED 6300ftpll
HEDIUH/R.UJD BDUR fEED WATER
TEHPERATIIVTEHP 40-.201"(
DI!IJCK/PftESSIJiE 35 at~
NON DRIVE END

(Drlve End, sea Drg. No. SHF2/162-ES)
COOLING JACKET
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fBURGMANN
No.
6298
J. SAFETY NOTES
Section 3.1 Any pet·son at the user's shop being involved m assembly, disassembly,
operation and maintenance of tlle BURGMANN Mechanical Seal must have
3 read and understood this Insti'Uction M:mual and in particular the safety notes.
We recommend the user to have this confirmed.
Page: 7 of 14 BURGMANN Mechanical Seals are manufactured on a high quality level

(ISO 9000) and they keep a high working reliability. Yet, if they are not
operated within their intended purpose or handled inexpertly by untrained
personnel they may cause risks.
\),
j The user is asked to check as part of his security program what effects a
failure of the Mechanical Seal might have on the environment and what
additional safety measures have to be taken to 1>revent personal injury.
Any operation mode that affects the operational safety of the mechanical seal
is not permitted.
BURGMANN mechanical seals must be operated, maintained or repaired by

authorised, trainedr and instructed personnel only.
co
Any work to be done on the mechanical seal is only J>ermitted when the
seal is neithet·. ope•·ating not· pressurised.
10 . IEnsure equipment at room temperature. I
The res1>onsibilities for the respective jobs to be done have to be detennined
clearly and obsen'ed in order to prevent unclear competencies from the point
of security.
Ap:u1 from the notes given in this manual the general regulations for
worker's protection and those for prevention of accidents have to be
N observed.
...
Unauthorised modifications or altenltion are not 1>ermitted as they affect
the opemtional safety of the mechanical seal.
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No.
6298 4. TRANSPORT I STORAGE I INSTALLATION
Section used. suited for dry transport by truck. train or plane. The signs and notes for
4 handling on the packaging have to be observed.
Notes for incoming insQection:

•• Check packaging for visible damages .
Open packaging carefully, Do not dam£lge or lose parts supplied
Page: 8 of 14 separately.
• Check if consignment is complete (delivery note). Inform the supplier
These recommendations apply to all BURGMANN mechanical seals which have

been supplied and stored in their undamaged original packaging, as well as to seals
which have been installed in a component of a plant. (e.g. pump, compressor. etc.)
0
...... but have not yet been put into operation.
A presenration of the BORGMANN mechanical seals is not necessary.
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•
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Do not use corrosion protection agents.
There is the risk of deposition or chemical attack of the
elastomeric secondary seals.
()()•
Checl< in case of a preservation of complete plants "'ith mechanical seals
installed
t- • the compatibility of the chosen preservation agent with the seal
materials and with _the elastomers
• no impairment of the seals axial movability by conglutination or
by gumming
(0
Sliding materials and elastomers are subject to material-specific and time-

based alterations (distortion. ageing) which might reduce the full efficiency of
It) the seals. yet. this may be avoided by observing the storage instmctions.
Damages caused b.Y imJH·oper ~1orage may not be claimed on the

v
Store the seal in the original packing lying on a flat surface.
C")
The mechanical seals have to be stored in dry. dustfree, moderately ventilated
and tempered rooms. We recommend : relative air humidity below 65% .
temperature between 15''C and 25"C.
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Direct eXJ)OSure of the mechanical seal to heat (sun, heating) as well as to

..... ozone, present o•· produced by ultnfviolet light (halogen or fluorescent
.lumps), must be avoided because of the risk of embrittlement of elastomeric
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materials.
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6298 • after a shock on the mechanical seal (e.g. by dropping the
packed seal)
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at the manufacturer's or at the nearest service centre.
I
Section ~I +' I
I
I
4
4.2 PREPARATION FOR ASSEMBLY
Genernl Instructions:
Page: 9of14 Utmost care must be taken to ensure cleanliness during assembly: it is
especially important to avoid damage to the elastomers.
• Observe the assembly dimensions .

• Observe the axial mn-out and concentricity tolerances as stated in the
valid design manual. .
I
\
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), • All the shoulders over which elastomers are to be pushed must be
chamfered by 2mm x 30°. Their surfaces must be free of any damages
....0 and their edges rounded off. '
• The shaft must show the following surface roughness values in the
vicinity of radial sealing elements :
-
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(Dynamic sealing part (spring loaded·m1it of the seal) Ra ~l.O!t.m. Static
seal part of Ra ~ 2.5!t.m)
Q
• For cartridge seals. the seal can be assembled directly after taking
precautions on the shaft. '
I
• Profile rings of Statothenn@ can only be defonned axially (radial

defonnation results in destmction).
r-.. • To reduce frictional forces during assembly of the seal, the shaft is thinly
lubricated with oil or silicon grease in the zone of the seal rings.
co Warning : This does not apply to rubber bellows seals.

" Warning : In the electric dip-painting range the 0-rings mu~1 be free
from silicon grease and mu!l1 be mounted free from silicon grease.
Warning : Under no circum~1ances must 0-rings made of Eth~·Jene
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Propylene rubber come into contact with mineral oil or grease. It is
recommended to use silicon grease•
..
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• Never cover the sliding faces with a lubricant as they must be assembled
completely dry. clean and dust-free.
----- -- ----------------- -- ------
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---- -------- ----- •
--- - ---------
When pressing in stationery s~als. make sure that the pressure
·· distribillion is unifonn.- Tlle-0-riilg- musr befitted using ~vater -or- -
alcohol only.
'
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• For heat dissipation and lubrication of single-acting mechanical seals.
there should be a recirculation from pump discharge to seal (a pipe
connection of 1/4" is usually sufficient).
This measure prevents medilJ.m deposits in the sealing area.
.... • Thoroughly vent the stuffing box before starting and remove the
assem.bly fixture before start-up after tightening the set screws( 12a).
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C» In the event of any particular problems, please contact Burgmann Jndia.
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fBURGMANN Operating M·anual
No.
6298
4.3 SPECIAL INSTRUCTIONS
The Burgmann mechanical seals SHF2 are !iependent of the direction of

rotation. The set screws with cup points must be renewed after every
Section
dismounting: they must be fastened with Loctite Nr. 241 or a similar
4 Product.
Page: 10 of 14 4.4 INSTALLATION
All steps on (in) which the seal is to be mmmted should have a 2 x 30° bevel
and all sharp edges should be chamfered. The shaft surface should be smooth
machined ai1d ground in the areas where radial seal elements are to be located
(R-r = 2.5~L.lll.)
The nutation of the shaft should not exceed 100 Jl.lll. and although the seal
can absorb slight vibration, sources of vibration should be eliminated.
Extreme cleanliness must be observed during installation, and damage to the
seal faces and mounting rings must be avoided. The 0-riugs may be oiled to
reduce friction. during installation of the seal. EP-rubber 0-rings a1·e an
co.
exception, however, and should not come into contact with oil or grease;
In this case lubrication with glycel"ine or water is recommended.
Special care must be taken when mounting 0-rings of double-PTFE-coated

elastomers: apm1 from having a 2 x 30° mm bevel, all edges should be
deburred and rmmded. When mounting 0-l"ings of double PTFE-coated
r.o elastomers care must be tal{en to )Josition the rings with the butt of the
outer coating fncing away from the direction of installation, otherwise
splitting or stri]Jping of the coating is )Jossible.
Crowned drive pins must be reJ>Iaced whenever the seal is dismantled.

During inse1iion of the stationary seals. especially those of special carbon.
care must be taken to exert pressure evenly.
M
4.5 DIRECfNES IN CASE OF FAILURE
Try to define the kind of failure and record it and immediately contact
"' Burgmann India or nearest BURGMANN Service. Centre.
.,... Dming the wananty period the mec1umical seal must only be disassembled or
removed with BURGMANN's approval or when a BURGMANN
0) re)n·esentative is present.
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No.
6298 5 SERVICING
Section
Page: 11 of 14
0 5.1 TUNGSTEN CARBIDE DESIGNS

..-
Are extremely wear resistant but have poor emergency running properties.
For this reason provisions must be made to ensure lubrication.
tO
5.2 CIRCULATION
To reduce frictional.heat and prevent sedimentation in the seal faces a

circulation line from the discharge of the pump to the seal stuffing-box
necessary. Normally a %-inch pipe is sufficie11t.
5.3 BUFFER FLUID
When operating double mechanical seals care must be taken to ensure

circulation of the buffer fluid. The pressure of t11e buffer fluid should be
1.5--2 bar higher than the internal pressure and t11e rate of flow should be
adjusted so that the outlet temperature dose not exceed 60°C. The outlet
must be located at the higl1est point of tl1e stuffing-box to prevent bubble
formation.
------ -- -
If you ha\'e any special problems please contact BURGMANN Head Quarters
or the corresponding sales/service office in your area.
5,4 AFTER-SALES SERVICE BY BURGMANN

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T11e range ot' services offered by Burgmann not only includes advice during the
co planning stages but also technical support after commissioning. This is support
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centres.
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No.
6298 Address of the headqumiers
FEODOR BURGMANN
Section Dichtungswerke GmbH & Co.
Au.Bere Sauerlacher Str. 6-10
5 D-82502 Wolfratshausen
.Page; 12 oj 14 Tel +49-81-71"23 1215

Fax +49-81-71-23 1449
Headqmuier :
0 A.K. Industrial Estate
..-
S. V. Road. Goregaon (West)
Mumbai 400 062.
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Tel 8741534 I 1820 I 1905

Fax 022-874 8810
co
Branch offices : Baroda. Pune, Delhi, Calcutta, Madras, Hyderabad. Panvel.
Surat, Kota. Chandigarh, Visaklmptanam, Cochin, Mangalore.
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5.5 RECONDITIONING (Repair)

(0
Reconditioning of tl1e mechanical seal by the user is not desirable for
reasons of operational safety. ReJ>air should only be carried out b~·
BURGMANN service personnel or by trained personnel of the machine
. r.n
manufacturer in suitably equipped, clean rooms. Seal cartridges only should
be replaced by the user if possible.
'<t
5.6 SPARE PARTS
••
(<) Only BURGMANN Ol;ginal spare plll'ts must be used.
Disassembled pm1s must not be reworl,ed at the user.
Othenvise
N <d'.
Risks of a seal faih~.re witll endangering persons and environment
CjT'
The BORGMANN guarantee forth~ mechanical seal lapses.
...... • For a quick replacing a comp.lete spare seal should be on stoc:k.
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No.
6298 5. 7 DISPOSAL OF BURGMANN MECHANICAL SEAL
Usually. the BURGMANN mechanical seals.can be easily disposed after a thorough

cleaning.
Section
D Metal parts (steels. stainless steels. non-ferrous heavy metals divided
5 into the different groups belong to scrap metal waste.
D Synthetic materials/ plastics ( elastomers. PTFE )special waste.
i- Attention ! Material containi11g fluorine must not be burnt.
Pagei 13 of 14 => Some synthetic materials divided into the different groups can be
recycled.
1:1 Ceramic materials (synthetic carbons, ceramics, carbides ) belong
to waste products. They can be separted from their housing
materials. as they are physiologically recognised as safe.
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JBURG.MANN
No.
The FEODOR BURGMANN Dichtungswerke GmbH & Co. (FRG) has a copy
Section right in this manuaL Buyer, planner and user of the product are authorised
6
We t·eset-ve the right to carry out technical modifications which might
Page: 14 of 14 manual yet.
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ANSICHT X VEREINFACHTE DARSTELLUNG (M1:2}
VIEW X SHOWN SIMPLE (SCALE 1: 2)
-----~------- ----
~~~E_I_N_.__IN____
¢ 14 ECHANGEUR DE CHALEUR
Burgmann supply
Kreislaufschema
circulation plan
CERllFlED THAT THIS DRAWING IS A TRUE COPY OF FlNAL

APPROVED DRG. NO.: 1230-001-04HY-PVM-C-003, REV.OO
OF RIHAND STAGE-II.
NA llONAL THERMAL POWER CORPORATION LTD.

ViNDHYACHAL SUPER THERMAL POWER PROJECT
STAGE-Ill, UNIT-IX & X, 2x500MW
MECHANICAL SEAL FOR BFP-DE

BHEL DRG. NO.: HY-DG-209-139-0061, REV.01
NTPC DRG. NO.: 2240-108-04HY-PVM-C-104, REV.01
REMOVE ALL SHARP EDGES
ON SHAFT BEFORE INSTALLATION SHEET 1 OF 2
OF SEAL
22 DRIVE END
(Non Drive End, see Drg. No. SHF2/135-E5)
KUNDE/CUSTOMER B.H.E.L.
~~~==l===-~~t==jiic====!Ej~~~===~
COOLING JACKET BETREIBER/ULTIMATE USER
PUMPENTYP/PUMP TYPE NlPC VINDHYAa-IAL STAGE-Ill, 2x500 t.tW ~
FK4E36
DREHZAHL/SPEED 6300 RPM
TEMPERATUR/TEMP 40-2oo·c
DRUCK/PRESSURE 35 atg
Vor lnbetriebnahme die Betriebsanleitung und

die Sicherheitshinweise lesen!
Before startup, the operating manual and

the safety notes have to be read and observed!
255±0,05
~~~~~~~~~~~~~~~~~~~~~~~~~~~-~----- ____ AN~~TXVffi8N~~ITDAASIT~UNG(M1:~

143 23.8 VIEW X SIMPLE SHOWN (M1: 2)
! _jL__ ¢ ,40 ----. ---~---
I / IN EIN
l
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heat exchanger
'---------'Jr-+------+.,---i---.,------hL / Burgmann supply
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rb. _ffi ¢ 14
Magnetfilter
magnetic filter
Fll"IRE t.IAGNETIQUE
Surgmann supply
- --
107.5 43.5
-....
Temperaturdoppelfuehler
thermo-coople
SONDE DOUBLE DE TEt.IPERAlURE.~
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23,8 .. Vorwanung
~Emlng~"C
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NPT 3/4
-E V~ OUT Aboeholtung «,
dlaconnectlon --lt.lL.'"C ,
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I
OE<llNCHEMENT
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;:!~lt:!."'~.:c
-E q, '1"'"' ~ AUS ~AXI. A l ARRET
Gleltrlngdlchtung
mechanical seal
GARNilURE t.IECHANIQUE
Kreislaufschema
circulation plan
KUNDE/CUSTOMER B.H.E.L.
BETREIBER/ULTIM ATE USER NTPC VINOHYACHAL STAGE-Ill, 2x500MW
PUMPENTYP/PUMP TYPE FK 4E 36
DREHZAHL/SPEED 6300 RPM
TEMPERATUR/TEMP 40-200'C
DRUCK/PRESSURE 35 atg
CERTIFIED THAT THIS DRAWING IS A TRUE COPY OF FINAL

296 APPROVED DRG. NO.: 123Q-001-04HY-PVM-C-003, REV.OO
OF RIHAND STAGE-II.
~
~ ~
~ ~ NATIONAL THERMAL POWER CORPORAllON LID.
( \
_; ~ ~
"'"S" ~ ~
$ ~ VINDHYACHAL SUPER THERMAL POWER PROJECT
~
\
~
$ STAGE-Ill, UNIT-IX & X, 2x500MW
::::0
MAIN PLANT llJRNKEY PACKAGE
' $
I REMOVE ALL SHARP EDGES '.1 "S MECHANICAL SEAL FOR BFP-NDE
ON SHAFT BEFORE INSTALLATION
OF SEAL · BHEL DRG. NO.: HY-DG-209-139-0061, REV.01
NllPC DRG. NO.: 2240-108-04HY-PVM-C-104, REV.01
SHEET 2 OF 2
21 7 5 A 4 3 2 I6 17
I \ 1\ I I! I I I
- NON DRIVE END
(Drive End, see Drg. No. SHF2/162-E5)
-
It
179.7XS,J3
HSH CAP SCREW 211 ;A-4-70 [llii912-116X25
SHAFT NUT ,'IIEIJ T1§l_ 1.4571
[NOO llER 1.4571
17 [A-4-70
E
16 1.4571
[190,091(3,53
[190,091(3,53
1.4122
o-RING [215).7XS,J3
C(J OEa<EL 1.4571
~A~I;;;nstclllatloflnxtuorfes~=";,~~~ ~~:1 SE CREW IGEWit«lESTFl

llfJE!.SE
[A-4-70
1.4122
[llii915-116X16
12(] )2)(5,3;3
SH SI.EE\£ 1.4122
PIN [snFl 1.45i 4H6X8
COOLING JACKET
~
lo-RING 164,69)(3,53
ISEA1 IJKA20 I SIUCOO ~
ISPRING 1.4571
.-- o-RING 148,59XS,Jl
[SEAL FAr:£ If GLEilRING ' CARBCII
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Poo./""" -'-tion........,.. ........,.,..._.,
~-"""' o.s-s I
; -,---- - ·- ma_x. allowed a_xial
1=: •=...... ± o, I
0010..
s-30
± o.2
30-120
± D,3
120-<100 1 -100--1000 11000-2000
± o.s 1 ± o.s 1 ± 1.2
-~- of tlie shaft to the housing
± 3 mm (± inches) LMQ7
-
-
-- --r- vor lnbetriebnahme die Betriebsanleitung und
die Sicherheitshinweise lesen!
1-+--+---t--1 -
1 1
BURGMANN GLEITRINGDICHTUNG
m~~36: lUll
' ',_
- Before startup, the operating manual and
the safety notes have to be read and observed!
1--1---t---+---! ~-ISHF-2/135-E5 1
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16
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915 ·::Ill ""'

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1300@
2600®
IBFP MECHANICAL SEAL SKID, DES. No.: F0077
VALID FOR
NTPC VINDHYACHAL STAGE-Ill, 2x500MW
1) COOLING WATER. SEALING WATER INLETS AND OUTLET SHALL BE

TERMINATED WITH SORF FLANGES ALONG WITH COUNTER FLANGES.
GASKETS. BOLTS & NUTS.
2) ALL SEAL WATER PIPING, PIPE FITTING. VALVES & FLANGES SHALL
BE OF SS316 MATERIAL.
Of IS,5 -
SHALL BE THOROUGHLY CLEANED
& PAINT OF COLOUR SHADE LIGHT GREY-631 TO BE APPLIED.
s l SEAL SKID SHALL BE SUPPLIED ALONG WITH BASE PLATE & SCREWS.
6 ALL OPENINGS SHALL BE COVERED WITH PLUGS & BLANKS.
7Bl THREADED PLUGS TO BE PROVIDED fOR THERMOIIELL.
COOLERS & fiLTERS SHALL BE HYORAULICALL Y TESTED INOEPENOENTALY.
9) PAINTING fOR RACK,
TWO COATS Of EPOXY ZINC CHROMATE PRIMER SHALL BE APPLIED TOTAL OFT .35
Tl/0 COATS Of ACID ALKALI RESISTANT EPOXY PAINT Of COLOUR SHADE 631 OF
OF IS,5 (LIGHT GREY) SHALL BE APPLIED. TOTAL OFT INCLUDING PRIME COAT , 35 • <,Q.
DETAIL FOR PART NO \1
----···-----·-----
/
SECTION-A
CHAPTER-4
2. HEAT EXCHANGER FOR MECHANICAL SEAL
...
:_,_ fBURGMANN
06349
FOR
BURG MANN
HEAT EXCHANGER
09-WE-D 3110/AlOO-El
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Please read this manual carefully and Observe the information contained as to :
0 SAFETY CJ INSTALLATION 0 OPERATION
N 0 STORAGE 0 MAINTENANCE
...
..- If there are any unclear points please. contact Burg:mann India.
01
~ FEODOR BURGMANN
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~ 1- .,:I: Dichtungswerke GmbH & Co.
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c AuBere Sauerlacher Str. 6-10
c -o al D-82502 Wolfratshausen. Federal Republic of Germany
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06349
0. Foreword 1

2.3 Design Data 3
2.6 Other details 5
0
,....
3. Safety Notes 6
(j)
co 4.1 Packing & Storage 7

4.2 Assembly 7
4.3 Production of the joints 8
1'-
5. Operation 9
5.1 Instructions for safe Operation 9

CD 5.2 Tips for safe Operation 9
5.4 Directives in case of failure 9
1.()
6. Servicing 10-11
""" 6.1 Maintenance 10

6.2 Buffer Fluid 10
(")
6.4 Necessary details of enquiries and orders 10
N 6.7 Spare Parts 11
6.8 Disposal of BURGMANN Heat Exchanger 12
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7. Copyright 13
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No.
06349
06298 FOREWORD
Dear Sir.
Section
Thank you for purchasing the Burgmann Heat Exchanger. We at Burgmrum are
0 confident that your new purchase will greatly expand your working capacity and
efficiency.
Page 1 of 13 Heat Exchanger. Whether you are installing, operating or servicing . this manual will
show you how to do it - quickly and easily. ·
read it all at once. We just want you to know what a great Heat Exchanger you have.
We've taken a great deal of care in preparing this ~anual so that you will never be left
wondering how to perform a cert:'lin fimction. Nevertheless. even after reading this
0
.,.... manual if you still aren't' sure about something, please feel free to contact your nearest
queries.
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BURG MANN
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06J4<J
0629!!
SR. NO. DESCRIPTION DI!:TAILS
Soctlon
I CustomL:r BHEL- Hydcrabad
1
II Customer P 0 No
Ill Drawtng Nos. 09-WED 1 !! 0/A!OO-El

Pogo 2 of 13
IV Burgmann Commtston No. !! 94S'i
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No.
06298

Section
2
FEODOR BURGMANN
Page 3 of 13

0
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BURGMANN HEAT EXCHANGER
09-WED3JIO/AIOO-EJ
co
1---+--+---1---1 2.3 DESIGN DATA
WED 3110/ AIOO

Jacket Pipe
Content Liter 1.8 0.75
Design Pressure 1) barg 110 16
Inlet temp. deg. C 65 30
Amount of Flow 2) 3) m3/h "
.l 6
Refrigerating capacitv 3) kW 36
Weight, empt}' kg 24
Destgn temp. deg. C !50
1----~~---4--~ 1) These values form the basis of the calculation of stability.

2) These values form the basis of the thermic calculation.
3) Reffering to water
.,.... 2.4 DRAWINGS, DIAGRAMS

...
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Assembly drawing-·- 09-WED 3110/AlOO-El
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position no. of their individual components ace. to the assembly drawing I
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No.
06298
The model of the BURGMANN heat exchanger type WED 3110/A 100 is a bundle
of pipes - The heat exchanger brings about high refrigeration capacity at low
Section dimensions. It is therefore especially fit for installation for supply circulations
(block circulations) for double cl.'\ial face seals in "back to back" or "face to face"
2 arrangements.
The heat exchanger has all the necessary connections.

The cold water is led through the pipe, tl1e blocking fluid through the jacket space.
Page 5 of 13
2.6 OTHER DETAILS

.
!
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All the connecting supports possess connection according to DIN ISO 228 or NPT.
.- If appropriate tube fittings are used in the pipe work, then the problem of impurities
of the blocking circulation through threaded seal medi1m1 does not arise
(J) The heat exch<mger can be assembled in horizontal as well as vertical position.
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The connecting dimensions according to

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assembly drawing . : 09-WED3110/A100-El
co 2.8 MANUFATURER- EXPLANATION

r.n The manufacturer explains. that the aforementioned product is designed for
machine and it is ilot capable of functioning independently. the operation of
\
) the product is prohibited , till it is not ascertained, that the machine. in
v
which is to be constmcted. corresponds to t11e regulations of the EG-
Guidelines for machines (89/392/EWG). The harmonized standards used :
-
En 292 Tl + T2.
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No.
06298
3.1 Any person at the user's shop being involved in assembly, disassembly, start
Soctlon
up, operation and maintenance of the BURGMANN Heat exchanger must
3 have read ami understood this lnstmction Manual and in particular the
safety notl·s. We recommend the user to have this confinm~d.
Pogo 6 of 13 BURGMANN Heat exchan~ers arc manufactured on a high quality level

(IS09!l!l0) and they keep a hi~h wnrl<ing reliability. Yet. if they arc not
operated w1th1n their intended purpose or handled inexpertly by untnuncd
pcrsouncl the~ may cause risks.
The use1 1s asked to check as part of Ius sccunty program what effects n
failure of the heat c.xchangcr nught have on the environment and what
0 additional safety measures have to be taken to prevent personal injury.
,...
BURGMANN heat exchanger must be operated. maintained or repaired by
authorised, trained and instmcted perssoancl only.
Ol
Any worl< to be done on the heat exchanger is only permitted when it 1s
neither operating nor pressurised.
The responsibilities for the respective jobs to be done have to be deternuncd

clearly and observed in order to prevent unclear competencies from the pomt
of security.
worker's protection and those for prevention of accidents have to be
observed.
Unauthorised modifications or alteration arc not permitted as they affect the

operational safety of the heat exchanger.
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06349
06298
4. TRANSPORT, STORAGE & INSTALLATION
Section
4
used. suited for dry transport by tnick. train or plane. The signs and notes for
Page 7 of 13
• Check packaging for visible damages .
• Open packaging carefully. Do not damage or lose parts supplied separately.
• Check if consignment is complete (delivery note) . Inform the supplier
r \
)
These recommendations apply to all BURGMANN heat exchanger which have
0 been supplied and stored in their undamaged original packaging, as well as to heat
I .,....
exchangers which have been installed in a component of a plant. (e.g. pump.
compressor. etc.) but have not yet been put into operation.
C1>
Damages caused by impropet storage may not be claimed on the
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Store the Heat Exchanger in the original pacldng lying on a flat surface.
1"-
4.2 ASSEMBLY
The installation should be carried out by an e:\.-pert staff. Rules valid at the spot
c:o of installation especially for accident prevention should be observed. This holds
· good for the installation of the heat exchanger as well as for laying the entire pipe
'
line. '
1.()
The heat exchanger should be installed in such a way that the operation.
.-
supen·ision and maintainence is as good as possible. Pipes to the seal should be
as short/ small as possible.
, __ ,\ '¢
Installation of the heat exchanger should always be higner than the axial face seal.
so that the system gets automatically de-aerated.
- ---
C')
Pipes in the supply circulation should be of cold drawn stainless steel precision
pipes with the dimension 0 18 x l.5nun . The connections to the heat exchanger
should be manufactured through t11e tube connections.
N
The direction of the line between the axial face and the heat exchanger should
I
be as short and favourable to the ilow as possible. Lay tl1e pipes constantly
.,.... ascending so as to avoid air tappings. To change the directions use tube bends
!
and ball v·aJves· exclusively for blocking.
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fBURGMANN
No.
06349 4.3 PRODUCTION OF THE JOINTS
06298
Identification and laying the joints on the heat exchanger
Nl Cold water IN
N2 Cold water OUT
Section N1 Medium IN (warm coming from GLRD)
N..J Blocking medium OUT (cold back to GLRD)
4 N5/NC! Vent Tube Side
N7/NX Drain Shell Side
The joints Nl and N4 in horizontal constmcuon should lie below.
The lOIII lS N I.N2 <llld N4 in vertical construction should lie below
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No.
06349
06298 5. OPERATION <:. 1!!':::
Section INSTRUCTIONS FOR SAFE OPERATION

5.1
5 -
Fill the blocking circulation ( See the instmctions for GRLD too)
De-aeration of the heat exchanger and the blocking circulation (N7/N8)
De-aeration of the cold circulation (NS)
Page 9 of 13
5.2 TIPS FOR SAFE OPERATION
If the operational limiting values mentioned are observed and the tips given
in this instmction manual are fol1owed, then the heat exchanger operates
smoothly.
\
' \
I 0 5.3 DESIGNATED USE
.,....
Operation under conditions lying outside those limits stated in paragraph >> 2.3
DESIGN DATA << is considered contrary to its designated use.
Cl)
The Heat Exchanger should not be operated under several limiting values at the
same time as there is risk of malfunction. which could result in a danger for staff.
equipment and environment.
co - Should t11e Heat Exchanger be operated tmder conditions ot11er than those detailed
BURGMANN has to be asked for recognition as safe .
.....
(.() 5.4 DIRECTIVES IN CASE OF FAILURE

T1y to define the kind of failure and record it.
If there is a malfunction which you cannot repair on your own. or if the cause
\() I
of malfunction is not clearly recognizable please immediately contact the nearest
.BURGMANN Branch or the Burgmann headquarters. '
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No.
o6349 6. SERVICING
06298
6.1 MAINTENANO:
Section The heat exchanger by itself does nol need mawtenancc. depending upon the
composition (nature) of cold water, the area of cold water needs to be cleaned
6 lllr.:!Chanically aller opr.:!ning the lid.
The total system should be checked once in six months as regards leakages.
loosened pipe fittings and other damages and these should be repaired.
Pago 10 of 13 6.2 BlJFFER FLUID
When operatlllg 1he heat exchanger care must be taken to en~u1 c 1.:11 culat wn
of the buffer fl111d The pressure of the buffer fluid should be I )--2 b:1r
h1ghcr than lhe n1tern;Jl pressure and the rate of flow should be adJusted ~o
that the outlet temperature does not exceed 60°C. The outlet must be loc:ltcd
;Jt the h1ghest pmnt of the stuffing-box to prevent bubble fornwt1on
If you have any spec1al problems please contact BURCIMANN !lead Qumrters
or the corresponding salcs/serv1cc oflicc in your area
Ol

tO
Burgmann original replaccmt components or foreign parts released by
Burgmann can be used. Non observance may lead to malfunctioning. which
can be dangerous to men. machines and environment. Tllis also expires the
gu:u an tee
6A NECESSARY DETAILS FOR ENQUIRIES AND ORDERS
BURGMANN - Commision No. Sec the order

Heat exchanger drawing No. See paragraph "Drawlllgs"
Individual component Pas. No .. Name. Material · ace. to the assembl~
drawing
6.5 AFTER-SALES SERVI('E BY BURGMANN
The range of ser.·ices offered by Bnrgmann not only includes advice during the
planning stages but also technical support after commissioning. This is support
by a world comprehensive network of subsidiaries. field engineers and ser.·ice
C'\1 centres
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No.
06349 Address of the headqumiers
06298
FEODOR BURGMANN
Section
6
Tel +49-81-71-23 1215

Fax +49-81-7!-23 1449
Page 11 of 13

.
Headquarter :
' ) 0
I ..-- S. Y. Road, Goregaon (West)
Mumbai 400 062.
0> Tel 8741534 I 1820 I 1905

Fax 022-874 8810
00- Branch offices : Baroda, Pune, Delhi, Calcutta, Madras, Hyderabad. Panvel.
Surat. Kota. Chandigarh, Visakhaptanam, Cochin, Mangalore.
1'--
6.6 RECONDITIONING (r·epair)
10 Reconditioning of the Heat Exchanger by the user is not desirable for

reasons of operational safety. Repair should only be carried out by
BURGMANN service p·ersonnel or by trained personnel of the machine
inanufacturer in suitably ·equipped, clean rooms.
It)
/
6.7 SPARE PARTS
'-
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Cl Only BURGMANN original spare pa1is must be used.
Cl Disassembled pmis must not be reworked at the user.
- --
(") Otherwise
);- Risks of a Heat Exchanger failure with endangering persons and
environment
);- The BURGMANN guarantee for the Heat Exchanger la(lSes.
N
Cl For a quick ·replacing a complete spare should be on stock.
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No.
06349
0629!! 6.!l DISPOSAL OF BURGAMNN HEAT EXCHANGER
lJsually. the BURGMANN Heat Exchanger can be eastly d1sposed alkr a thorough
Soctlon
cleaning.
6 o Metal pnrts (steels. stmnless steels. non-ferrons heavy metals divided

1nto the different groups belong to scrap metal waste
0 S\'nthet1c materials/ plast1cs ( elastomers. PTFE )speual waste_
Attention ! Matenal contamtng fluorine must not be burnt
Pnge 12 of 13
Sun1e wnthet1c ltlatcnals d1v1dcd 11110 the dillcrcnt group~ can be
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06349
Section
7 The FEODOR BURGMANN Dichttmgswerke GmbH & Co. (FRG) has a copy
right in this manuaL Buyer. planner and user of the product are authorised
for llSe in com1ection with further dOC1m1entation.
Page 13 of 13
We reserve the i·ight to carry out technical modifications which might
manual yet.
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FABRICATION NO IMPRINTED FABRICATION NO. IMPRINTED

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19 GASKET PTFE 2
IB SCREW PLUG A4-SO ss 316 2
TEST PRESSURE 143 bar 21 bar a) HOR!ZONT AL 17 GASKET PTFE 2
16 SCREW PLUG IA4-SO ss 316 12
~~~ IS D-RING VI TON 2

TEST MEDIUM WATER WATER
14 U-WASHER 1.4401 ss 316 16
13 SCREW A4-70 ss 316 16
COOLING WATER FLOW RATE - APPROX.
6 M3r• f
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ss 316
ss 316
4
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DES[GN TEMPRATURE 9 GUIDE COVER 1!.4401 ss 316 I
1so·c 1so·c FROM/TO SEAL
FOR CALCULA T[ON 8 INLET COVER 1!.4401 ss 316
b) VERTICAL 7
NO. FUNCTION SIZE 6 BRACKET 1.4401 ss 316 2
N3 5 GUIDE PLATE 1.4401 ss 316 5
N1 WATER [N 1/2" NPT 4 TUBE 1.4401 ss 316 62
N2 WATER OUT 1/2" NPT 3 CONNECTION BLOCK 1.4401 ss 316 11
2 CONNECTION BLOCK 1.4401 ss 316 II
N3 MED[UM [N 112" NPT SHELL 1.4401 ss 316 11
FROM/TO SEAL
Ni, MEO[UM OUT 1/2'' NPT POS. DESCRIPTION MATERIAL OTY REMARKS
APPL!CA T[ON DET A[LS O_to 6 ~10-
NS -VENT TUBE S!Df G 114" ' 12
TEMP. OF SEAL WATER AT INLET OF COOLER, 95•c N4 Su.rf~;~.ce Vc.lu.esin
TEMP. OF SEAL WATER AT OUTLET OF COOLER, 60•C N6 VENT TUBE SrDE G 1/4" (p•)
TEMP. OF COOLING WATER AT INLET OF COOLER, 31J•c

N1 DRA[N SHELL SrDE G 1/2"
TEMP. OF COOLING WATER AT OUTLET OF COOLER, 46°[--
COOLING WATER
NB DRA[N SHELL SrDE G 1/2" N2 N1
TOTAL WEIGHT, 30 KG HEAT EXCHANGER
'---·- CUST[J.£R, 8!£. HY!l:RASAO
09-WEO 3110/ A100-E1

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Ref. 110.
CAD
SECTION-A
CHAPTER-4

( \
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3. MAGNETIC FILTER FOR MECHANICAL SEAL
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fBURGMANN
06349
FOR.
BURG MANN
MAGNETIC FILTER
MAF2000/NPT 1/2 "-00
co
co
Please read this manual carefully and Observe the infonnatiou contained as to :
0 SAFETY Cl INSTALLATION 0 OPERATION

0 STORAGE Cl MAINTENANCE
...
If there are any unclear points please contact Bnrgmann India.
Ol
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c ~ D-82502 Wolfratshausen. Federal Republic of Genmwy
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06349
06298 I
0.
TABLE OF CONTENTS
Foreword
PAGE
1
I

2.3 Design Data 3
2.5 Description nnd function 5
2.6 Other details 5
0
~
3. Safety Notos 6
en 4. Transport, Storage and Installation 7
4.1 Installation 7
co 4.2 Assembly 7
5. Operation 8
r--
5.1 Tips for Safe Operation 8
5.3 Directives In case of Failure 8.
(()
6. Servicing 9-10
LrJ
6.1 Maintenance 9
6.3 Necessary details for enquiries and orders 9
"¢
6.6 Spare Parts 10
("')
6.7 Disposal of Burgmann Magnetic Filter 10
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7. Copyright 11
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fBURGMANN Operati.ng .Manual
No.
06349 -
06298 FOREWORD
Dear Sir,
Section
0 Thank you for purchasing the Borgmann Magnetic Filter. We at Burgnia.nn are
confident tl1at your new purch(lse will greatly expand your working capacity and
efficiency.
Page 1 of 11 Magnetic Filter. Whether you are installing, operating or servicing . tlus manual will
read it all at once. We just want you to know what a great Magnetic Filter you have.
We've taken a great deal of care in preparing thls manual so that you will never be left
(
I wondering how to perform a certain fimction. Nevertheless, even after reading tllls
I 0
...... m;mual if you still aren't. sure about somethlng, please feel free to contact your nearest
sales or service center of Borgmann or our HQ. We shall be too glad to answer your
queries.
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BURG MANN
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No.
06349
06298
Soctlon
I Customer BHEL- Hydembnd
1
II Customer P.O No
III Dmwmg Nos. MAF2000/NPT l/2 II -00

Page 2 of11
IV Burgmann Conumsion No. i 19455
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06298
2.1 MANUFACTURER AND COUNTRY .OF ORIGIN

Section
2
FEODOR BURGMANN
Page 3 of 11
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BURGMANN MAGNETIC FILTER
MAF2000/NPT 1/2"-00
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2.3 DESIGN DATA

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Max Operating Pi-essure 63 Bar I
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Test Pressure 82 Bar
Max. Operating Temp I50°C
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Volume 0.3 L
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Assembly drawing - MAF2000/NPT l/2''-oo !

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Figures in brackets. e.g (2) in the subsequent descriptions signify the respective i
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accompanying.
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No.
06349 2.5 DESCR1PTION AND FUNCTION
06298
BURGMANN Magnetic Filters are used for cleru1ing the media in the cooling
circuits. The combination of filter screen and magnetic rod retains bot11 magnetic
Section and non-magnetic p<Hticle~ up to a specific grain size. For Assembly, the direction
of flow indicated on the filter should be noted. It is required to vent the filter by
2 its venting screws before putting it into operation for the first time or after cleaning
it.
Page 5 of 11
2.6 OTHER DETAILS
• Venting screw at the filter inlet and outlet.
( • Filter insert is protected by intemal screen (only MAF 200 !)against damage
) ·a
.--
by retum flow of n1edium.
• Connections at choice Gl/2 to Gl (DIN ISO 228) or NPT internal thread .
Cl)
• Maintenance indicator or measurement of pressure difference to be connected
instead of venting screws via the filter.
CO" • In special cases, the magnetic filter can be operated without the screen insert
and only with magnetic rod.
1'- • Seals with high shut-down temperatures up to 150° C should be ~quipped

with EP mbber 0-Rings because of safety reasons(Special design).
..
co 2.7 REQUIRED SPACE, CONNECTING DIMENSIONS
The connecting· dimensions according to

10 assembly drawing : MAF2000/NPT 1/2"-00·
/'
2.8 MANUFACTURER-EXPLANATION
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In the Sense of EO-Guidelines appendix II B.

- - The manufacturer explains. that the aforementioned product is designed for I
C')
installing in a machine. or for assembling with oilier machines into one I
I
machine and it is not capable of functioning independently, the operation of
t11e prodi1ct is Jli"Ohibited , till it is not ascertained, that t11e machine, in
N which is to be constructed. corresponds to the regulations of the EG-
Guidelines for machines (89/392/EWG). The hannonized standards used :
En 292 Tl + T2. ..,
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06298
J. J Any person at the user's shop being involved in assembly, disassembly, start
Section
up, operation and maintenance of the BURGMANN Magnetic Filter must
3 have read nnd understood this Instmction Manual and in particular the
snfety notes. We recommend the user to have this confirmed.
Page 6 of 11 BURGMANN Magnetic Filtcn arc manufactured on a high quality level

(IS0')000) and they keep a high worl<ing reliability. Yet. !l they arc not
operated w1tlun thetr intended purpose or handled inexpertly bv untra111cd
personnel they may l'IIUSl' risks.
The user IS asked to check as part of his sccunty program what rff(·cts a
failure of the Magnettc Ftlter might have on the cnvHOllltlcnt and what
0 addition:tl s:tfcty mcnsurcs have to be taken to prevent personal injury.
..-
BURGMANN Magnetic Filter must be operated. maiutaincd or repaired b1
authorised, trnincd and instructed personnel only.
en
Any work to be done on the magnetJc filter is only permitted when it IS 1s
neither operating nor pressuriscd.
co The responsibilities for the respective jobs to be done have to be determined
clearly and observed in order to prevent unclear competencies from the p0111t
of security.
worl<cr's protection and those for prevention of accidents have to be
observed.
Unauthorised modifications or alteration nrc not permitted as they affect the

operational safety of the Magnetic Filter.
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No.
06349 4. TRANSPORT, STORAGE & INSTALLATION
06298
4.1 PACKING AND ~TORAGE

Section
4 used, suited for dry transport by truck, train or plane. The signs and notes for
• Check- packaging for visible damages.
Page 7 of 11
• Open packaging carefully. Do not t11mage or lose parts supplied separately.
• Check if consignment is complete (delivery note). Infom1 the supplier
These recommendations apply to all BURGMANN Magnetic Filter which have
been supplied and stored in their undamaged original packaging, as well as to
,~
magnetic filter which have been installed in a component of a plant. (e.g. pump,
0
..- compressor. etc.) but have not yet been put into operation .
Damages caused by improper storage may not be claimed on the

0> BURGMANN company with regard to their warranty.
Store the Magnetic filte1· in the original J>acking lying on a flat surface.
CO·
4.2 ASSEMBLY
The installation should be carried out by an expert staff. Rules valid at the spot
of installation especially for accident prevention should be observed. Tltis holds
good for the installation of the Magnetic Filter as well as for laying the entire
pipe line.
The Magnetic Filter should be installed in such a way that the operation,
supervision and ntaintainence is as_ good as possible. ..
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f8URGMANN Operating Manual
No.
06349
1./
06298 5. OPERATION Jl
~··
Section 5.1 TIPS FOR SAFE OPERATION

5
If the operational limiting values mentioned arc observed and the tips given
in this instruction manual arc followed. then the Magnetic Filter operates
smoothly
Page B of 11
5.2 DESIGNATED USE
Operation under condllwns lying outside those limits stated in paragraph _,__. 2.3
DESIGN DATA << is considered contrary to its designated usc.
The Magnetic Filter should not be operated 'under several limiting values at the
SlllllC time liS there is risk of filter malfunction which could result in 11 danger for
0
.-- stnff. equipment and environment.
Should the Magnetic Filter be operated under conditions other than those detailed
m
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5.3 DIRECTIVES IN CASE OF FAILURE
Tf! to dctine the kind of fllilure and record It
I'- If there is a malfunction which you cannot repair on your own. or if the cause
of malfunction is not clearly recognizable please immcdilltely contact the nearest
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No.
06349 6. SERVICING
06298
6.1 MAINTENANCE
Section
Before opening the filter
6
• Open bypass around filter.
• Stop flow through filter by closing shut-off valves before and after filter.
• Reduce pressure inside the filter by opening a venting screw.
Page9of11
Opening and cleaning the filte1·
• Detach mounting screws (item 8) and remove filter vessel (item 2).
• Remove filter screen (item 3) and clean with suitable detergent.
(
\
• The Magnetic rod (item 5.6.7) can be unscrewed from filter head. If annular
magnets (item 6) have. been removed make sure that, during assembly they
i 0 attract each other by pairs, but are repelled by next pair, separated by disc
..-
(item 5).
0>
• Before filter assembly check all seals and replace,if necessary. Check
wheatl1er the screen fabric has been damaged.
• The filter is assembled in the reverse order.
co
The replacement p<u1s should be obtained from BURGMANN only. Only

Burgmann original replacement components or foreign parts released by
Burgmann can be used. Non observance may lead to malfunctioning. \Vhich
can be dangerous to men, machines and environment. This also expires the
gnara11tee.
1.0 6.3 NECESSARY DETAILS FOR ENQUIRIES AND ORDERS
(
/
BURGMANN - Commission No. See the order
I
l
\ ) "'<!" Magnetic Filter drawing No. See paragraph"Drawings"
' Individual component Pos. No .. Name.Material : ace. to the assembly
drawing.
-
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The range of services offered by Burg:mann not only includes advice during the
planning stages but also technical stpport after commissioning. This is support
,.....
by a world comprehensive network of subsidaries, field engineers and service
centres.
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No.
06349 Address of the headquarters
0629R
FEODOR nllRGMANN
D1chtungswcrkc GmbH & Co.
AuBcrc Saucrlachcr Str. (>-1 0
Section
D-R2502 Wolfratshauscn
6
federal Republic of Germany
Tel <4<J-Rl-71-2l 1215

Fax +.:!'J-RI-71-21 l-.14<J
Page 10 ol11
In India please contact first
Headquarter .
0
Madina Manzil Compound
S. Y. Road. Gorcgaon (West)
Mumbai 400 OG2
Tel 8741534 I 1820 I 1905

Fax 022-874 8810
co Branch offices · Baroda. Pune. Delhi. Calcutta. Madras, Hyderabad. Panvel

Surat. Kota. Chandigarh. Visakhaptanam, Cochin, Mangalore.
Reconditioning of the magnetic filter by the user is not desirable for reasons
<D
of operational safety. Repair should only be carried out by BURGMANN
service personnel or by trained personnel of the machine manufacturer 111
suitably equipped. clean rooms.
6.6 SPARE PARTS
o Only BURGMANN original spare parts must be used.

o Disassembled parts must not be reworl<ed at the use1:
Othem·ise
,. Risks of failure with endangering persons and environment
,.. The BURGMANN guarantee for the magnetic filter lapses.
o For a quick replacing a complete spare should be on stock.
6. 7 DISPOSAL OF BURGAMNN MAGNETIC FILTER

N
Usually, the BURGMANN magnetic filter can be easily disposed after a thorough
cleaning. ..
..-
o Metal parts (steels. stainless steels, non-ferrous heavy metals divided
a>
a>
into the different groups belong to scrap metal waste.
co o
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N Cl
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No.
06349
Section
7 The FEODOR BURGMANN Dichtungswerke GmbH & Co. (FRG) has a copy
right in this manual. Buyer, plcumer and user of tl1e product are autl10rised
Page11 of11
We •·ese1-ve the right to cany out technical modifications which might
manual yet.
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KENNUATEN I DATA
Ansicht Z Zul. Betriebstiberdruck

View --------- -------------------63 -bar
-- - -
--------i'lax-.- operuting--presfiUr-e-:
MB 20 tiel
Priifiiberdruck:
14 13 {E'ntliiltung) 8 'res,t pressure: !:12 bar
(vMting)
1 Zul. Betriebstemperatur
Max. operating temperature:
/
72
{£)- ~-~ Inhalt
Volume l), 3 1
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$----l---------11
70
E .!~rs. ~!-
Gewicht 7,8 kg
§ displac~d 71 weight
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~ 6 15 NATIONAL THERMAL POWER CORPORATION LTD.

5 16 STAGE-Ill, UNIT-IX & X, 2x500MW
Anzugsmoment MA = 38 Nm , torqu:::e:__ _ _ __
{:;,chraube Ieicht geo!tT--,- (screw slightly 1uor. J
3Q
MECHANICAL SEAL STRAINER FOR BFP & BP
BHEL DRG. No.: HY-DG-209-139-0062, REV.OO
3 NTPC DRG. No.: 2240-108-04HY-PVM-C-105, REV.OO
SHEET 1 OF 1
7 16 RIBBED NAIL ss
15 NAME PLATE ss
14 GASKET PTFE
2 13 VENTING SCREW ss 316
12 SPRING 1.4301
11 '0' RING VI TON
10 '0' RING VI TON
9 CYLINDR. PIN 1.4401
6 MAGNETIC DISC
5 WASHER PTFE
4 SPACER RING 1.4401
khtung: Die Rift~ ~ind ~ zumontieren, 3o SUPPORTING SIEVE 1.4301
sie .sich ~iN (IIIZ~hen,
drJif
3 SIEVE ELEMENT 1.4301
10n niic:hstrt ltfognetpaar, durch die 2 FILTER POT 1.4401
Scheibe getrrtnt.,aber absto!Jen ! FILTER HEAD 1.4401
POS. O:SCRIPTION
Glrwo.l tcUnliU 10 No•lno.L dlm 0 to 6
At,.,tiOII : The magnetic disc:s. are to be mounted DJt 1158 fteQR-size Tolero.nce
in S<Jc:h a way tltat they attract each other Surfo.ce 011 311.1 lin! 3
in ptJira but np.l adja,ent ptJirs from which llJIISDa!2
tn.y .are ••fXIrated by a spacer !

BURGH ANN
-- ----------
A
· Bu:rgmo.-nn lndta Pvt; Ltd. Mullllat - <TOO 062
Sca.te TITLE :
1:1 MAG~~ETIC FILTER
Ref. No.
----'----1----1----------·~~-~
CAD
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SECTION- B
BOILER FEED PUMP
CHAPTER-4
4. THRUST BEARING
I
\ )
Michell Bearings
Operations, and Maintenance
Instructions.
Omega OT Series
Thrust Rings
Michell Bearings
Michell Bearings is a trading division of Vinters Engineering PLC.
A member of the Rolls Royce Group.
Issue 00
( \
)
Table of Contents
GENERAL DRAWING OF OT THRUST RING ASSEMBLY WITH SHIMS& LINERS----------- 4
1. I NTR 0 DUCTI 0 N -------------------------------------------------------------------------------------------- 5

1. 1 About the Product------------------------------------------------------------------------------------- 5
1. 2 About this Manual------------------------------------------------------------------------------------- 5
1 .3 Warranty CIa ims --------------------------------------------------------------------------------------- 6
2. SAFETY ------------------------------------------------------------------------------------------------------- 7
3. HAND Ll NG THE BEARING------------------------------------------------------------------------------ 8
3. 1 Genera I -------------------------------------------------------------------------------------------------- 8
4. PREPARATION FOR FIRST INSTALLATION------------------------------------------------------ 9
5. ASSEMBLY OF THE BEARING ··············----·-·--·-----------------------------------------------1 0

5. 1 Genera I -------------------------------------------------------------------------------------------------1 0
5.2 Assembly of the Thrust ring------------------------------------------------------------------------1 0
5. 2. 1 Fitting the Thrust Pad set. --------------------------------------------------------------------10
5. 2. 2 Fitting Ring Stop, and Liners if applicable -----------------------------------------------11
5.3 Assembling the Thrust rings into the Bearing Casing ---------------------------------------11
5. 3. 1 Miscellaneous -----------------------------------------------------------------------------------12
5. 3. 2 Instrumentation ---------------------------------------------------------------------------------12
6. 0PERATl NG -------------········---------···-···-----------------------------------------------------------13
6.1 Preparation and Inspection before Operation -------------------------------------------------13
6. 2 Tria I Run -----------------------------------------------------------------------------------------------1 3
6. 3 Norm aI 0 peratio n ------------------------------------------------------------------------------------14
6.4 Preparation for Operation after Standstill------------------------------------------------------14
7. CARE AND MAINTENANCE ---------------------------------------------------------------------------15

7. 1 Genera I -------------------------------------------------------------------------------------------------1 5
7. 2 Too Is and Equipment --------------------------------------------------------------------------------1 5
7. 3 Mainte nan ce Sch ed uIe------------------------------------------------------------------------------1 6
7.4 Oil Change ---------------------------------------------------------------------------------------------16
7. 4. 1 Genera l-------------------------------------------------------------------------------------------16
7. 4. 2 Procedure for draining oil--------------------------------------------------------------------16
7. 4.3 Procedure for refilling the bearing -self contained bearings -------------------------17
7. 4. 4 Procedure for refilling the bearing - bearings with circulating oil--------------------17
B. DISMANTLING AN INSTALLED BEARING --------------------------------------------------------18

8. 1 Genera I -------------------------------------------------------------------------------------------------1 8
8. 2 Pre para ti on --------------------------------------------------------------------------------------------1 8
8.2.1 Strip down the bearing until the thrust rings are visible. ------------------------------18
8.2.2 Disconnect and remove any thermometry and instrumentation.--------------------19
8. 3 Removing thrust rings -------------------------------------------------------------------------------1 9
8.4 Removing the Liners, and Shim Pack. Where Applicable. --------------------------------19
8. 5 Removing the Thrust Pad Set ---------------------------------------------------------------------1 9
9. CLEANING AND CHE C Kl NG --------------------------------------------------------------------------2 0

9 .1 Genera I -------------------------------------------------------------------------------------------------2 0
9. 2 C hec king the Thrust Pad. --------------------------------------------------------------------------21
10. B EARl NG PRES ERVA TIO N D URl NG STORAGE---------------------------------------------22
2
' )
10.1 Before Insta II at ion ------------------------------------------------------------------------------------2 2
10.2 Corrosion Protection for Standstill Periods up to 6 Months --------------------------------22
10.3 Corrosion Protection for Standstill Periods between 6 Months to 1 Year---------------22
10.4 Corrosion Protection for Standstill Periods longer than 1 year----------------------------22
11. BEARING PRESERVATION DURING TRANSPORT -----------------------------------------22
12. A PP E N DIC ES -------------------------------------------------------------------------------------------2 2

12 .1 0 rd e ring Spares --------------------------------------------------------------------------------------22
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OT Omega Thrust Ring Assembly With Shim Pack. And Liners
L
11. lnfrodudiol'l
11.1 About the Product
The "Omega" Series Thrust Rings supplied are part of a standard range of components
manufactured by Michell Bearings. The thrust rings are intended to be fitted within a casing
supplied by a customer. Depending on the demands specified, the thrust rings will be
designed to absorb:
a) A constant load along the shaft in one direction.

b) A constant load along the shaft in either direction.
c) A constant load in one direction and a temporary load in the opposite direction.
Within the "Omega" Series a range of sizes are catered for. All "Omega" thrust rings require
continuous lubrication from a pumped oil supply. In some cases, the thrust rings will have
machined oil channels and in other cases restriction jet holes.
The system of restriction holes is known as 'Low Loss' lubrication and will give lower power
losses than conventional fully immersed rings.
In order to measure pad temperature, Resistance Temperature Devices (RTDs) can be fitted
to a number of pads specified by the customer.
11.2 About this Manual
• This manual contains information about the bearing and its safe operation, and should
c •
therefore be read carefully in full before starting work.
Since the bearing has a wide range of applications, this manual has been written to cover
all current configurations.
• This manual is to be used by qualified engineers only.
• The following formats are used to draw attention to particular details:
& This symbol signifies a warning. These are instructions that, if ignored, could
result in death or injury. Danger!
@ This symbol signifies an important point which, If ignored, could result in

1---------minor-injury-or-failure-to-carry-out-a-process-correct/y.
)
/
r- ----~- ------ ---- -----~--~--
,
'
<1{ This symbol signifies additional instructions. This is usually a check. Missing
out this stage could lead to an error going unnoticed.
In addition, brackets after a reference to a part description, e.g. thrust pads set (3),
retaining ring (2) refer to an item number on a general sub-assembly drawing at the
front of this manual. These are used as a reference for the engineer.
11.3 Warranty Claims
• Unless otherwise stated all warranty claims shall be dealt with in accordance with Michell
Bearings.
• These warranty obligations will automatically become void if the product is:
1. Improperly handled or installed.

2. Supplied with spare parts (or repaired), not approved by Michell Bearings.
3. Exceeding the design operating parameters shown on the arrangement drawing.
4. Subjected to environmental conditions not previously specified.
6
,I
.. ,.
When installing, operating or maintaining the bearing, danger may arise to the user, the
product and plant and/or other assets. Therefore all users responsible for the operation of the
machine must understand this manual fully and make sure that all the safety procedures are
strictly adhered to.
Pay particular attention to the following general safety notes:
6
machine.
Under no circumstances should the engineer work alone when opera6ng the
(
\ 6 At least one of the engineers should be trained in basic first aid techniques
and wear identification that he/she is a first-aider.
6 No maintenance, assembly, adjustment or any other work should be carried

out ori the bearing whilst the shaft is rotating or capable of movement. To avoid
accidents, the entire machine should be isolated, with control gear locked off and "Not
to be used" signs applied to the control panels.
Personnel that manipulate the product should be sufficiently trained.
No modifications of the product should be made unless it is approved by

Michell.
c More specific safety notes are also given in the relevant sections, and should be adhered to.
,-
)
--------------- -- ---------------~---------------- -~--7----~------------
J3. Handling the Bearing
j3.1 General
This section outlines essential information, which must be referred to when handling the thrust
rings.
• The thrust rings are supplied fully assembled (see arrangement drawing for mass of
complete bearing).
• Omega "OT" Series thrust rings are not usually fitted with lifting holes. A complete ring
may be lifted using straps or slings.
• When transporting the bearing, it should remain in its packaging.
Please check all product equipment to ensure that it is complete before installation. Any
damage due to transit must be reported to Michell immediately.
• See Section 8 for instructions on how to disassemble the bearing .
.& Before using any lifting equipment, ensure that it is certified to carry a load
greater than that of the bearing or component.
© T a k e care not to damage bearing components and the running surfaces of the
shaft collar by contact with the lifting equipment.
.& If in doubt, a/ways use mechanical devices where possible. Remember to

bend the knees and not the back when lifting manually.
8
14. Preparation for Fir~fln§iallation - -- .I
• All Omega "OT" Series thrust rings are supplied complete. All thrust rings are, for ease of
assembly, capable of being split in two halves. If the rings supplied are to be split the
RTDs and their cabling should be removed prior to this.
• Remove all packaging.

• Refer to Sections 2 and 3 for safety and handling instructions.
• Dismantle the bearing referring to Section 8, ignoring any references to the shaft or
machine.
• When dismantled, please check all product equipment to ensure that it is complete before
installation. Any damage due to transit must be reported to Michell Bearings immediately.
• All parts are coated in a rust preventative. This must be removed and all parts thoroughly
cleaned before installation begins. To remove the rust preventative, white spirit or a strong
('
\ spirit based cleaner should be used. Note! Do not use paraffin (Kerosene).
• It is recommended that the bearing casing and all other internal parts are cleaned to
prevent dirt getting between the collar and the thrust rings.
© If the thrust rings are being fitted into a bearing that has previously been
used, ensure that the lubricating pipes have been cleaned to remove any deposits. If
there is any dirt in the lubricating system it will damage the new parts fitted.
c © U s e a lint free cloth when cleaning the bearing. Particles from other cloths
could otherwise get into the lubricating oil and cause overheating, and in extreme
cases, failure of the bearing.
• Once all parts are inspected and cleaned the bearing is ready for installation.
• Refer to Section 10 if the bearings are to be stored for a period of time before operation.
).
. ----- ---------------------9--~---------------
Js. Assembly of the Bearing
js.1 General
The following general points should be noted:
& The disassembling and reassembling of the equipment by an individual who is

inexperienced can cause danger. Michell will not take on any iiability for any damage
resulting from non-compliance with details given in this manual. If in doubt refer to our
Service Dept.
© O n l y use tools, which fit correctly to avoid damage to fasteners.
& Do not use excessive force.
<{Use a liquid screw locking compound (e.g. Loctite 222) on all fasteners.
& Always follow the instructions on adhesives.
<1f Remove all impurities and foreign objects (e.g. bolts, washers, etc.) from inside
the bearing. Ensure bearing is covered when left unattended.
This assembly procedure has been generalised to cover most eventualities. As such it may
contain more information than is directly applicable to the bearing being worked on. Read all
text and simply ignore any reference to irrelevant items.
js.2 Assembly of the Thrust ring
5.2.1 Fitting the Thrust Pad set.

• Coat all bearing surfaces in clean oil. Refer to bearing general arrangement drawing for
information on the correct grade of lubricant.
• Place thrust pad set (3) into retaining ring halves (1), (2).
<1f Ensure that the correct handed pads are fitted. The direction of rotation
stamped on the pad must agree with that shown on the arrangement drawing.
• Secure thrust pad (3) in place with pad stop (4) with hole located in back of thrust pads (3).
10
... ·-- _/.....---......
•& Always follow instructions on adhesives.
• Make sure pads (3), can move freely, and are not trapped.
© Take care not to trap hands when handling the components
5.2.2 Fitting Ring Stop, and Liners if applicable

• Place shim pack (6), and liners (7), on retaining ring halves (1 ), (2), and sercuer in place
with hex, socket counter sunk screw (8).
• Ensure that screws (8) are fully locked in place with Loctite 222 or similar adhesive.
• Fit ring stop (5).
ls.3 Assembling the Thrust rings into the Bearing Casing
• Coat the thrust pads surfaces with clean oil of the correct grade.
• Some OT Series bearings are supplied with machine liners; these should be fitted at the
same time as each thrust ring assembly.
• Horizontal Bearings: Fit the lower half of the thrust ring(s).
•. Vertical bearings: Fit the entire lower thrust ring.
( © C a r e should be taken when handling the components to avoid the risk of

trapping hands when assembling.
• Lowerih-e shaft, complete with collar into the bearing.
• Horizontal Bearings: Fit the top half of the thrust ring(s), either onto the top of the lower
ring, or into the top half casing. Secure the ring with stops.
• Horizontal bearings: Rotate the thrust ring around until the stop (5) engages in the casing,
if half the ring is secured into the top half of the casing, ensure that the bottom half is flush
with the casing joint and complete assembly.
l - - - - - - - - - •_ _,.V.::::.e,_,rt,ic""a'-'1B""e"'"'a"'-r.!!.in=s: Fit UQQer thrust ring and secure in l2c:..::la""c:.:::e~w~i~th~s~t~or::_l2_l5~._ _ _ _ _ _ _ _ _ _ _ _ __,_
• Check the bearing alignment, and complete assembly .
. ---------------------~----~-----·-·-- ------Ll~--~---- ~--·-

is.3.1 Miscellaneous
• Where applicable, connect up oil inlet and outlet.
• Connect external pipework.
is.3.2 Instrumentation
• Fit RTDs and instrumentation as necessary.
<:If Ensure that temperature probe assembly is not damaged and is working
correctly before fitting it.
<:If
•
Check that the bearing is complete and is fully sealed.
For temperature probe fitted bearings; run the bearing and establish a steady state
operating temperature then set temperature alarm tosoc above the steady state operating
temperature. Shut down temperature alarm is to be set at 1ooc above steady state
& Note/ Prior to running the bearing EC regulation state: - The entire machine
has received a Declaration of Conformity, or has been declared exempt from the
Supply of Machinery (Safety Regulations) Act 1992 and the Machinery Directive.
Where applicable
& Do not use the bearing unless the lubricating system is operating.
It must be emphasised that any declaration of incorporation issued by
Michell Bearings is for the thrust rings and their components and not for
the entire bearing.
The bearing is now complete; it must not be used until the below items
2. The lubricating oil must be a mineral based turbine oil inhibited
against oxidation, corrosion and foaming, with an ISO viscosity grade
as indicated on the arrangement drawing.
If in doubt with installation please use our Service
Department!
12
1:~ . .Qperati ner:
Is. 1 Preparation and Inspection before Operation
• Where necessary fit the temperature probes for measuring the thrust pads, and/or the
sump temperature in the relevant connection holes.
4fitting .
Ensure that RTD assembly is not damaged and is working correcily before
.&
•
Always follow sealant manufacturers' instructions.
Where applicable retighten external oil supply connections.
• Fill Bearing with oil or start oil system as described in Section 7 .4.
(
Check:
1. That the oil quantity at bearing oil inlet is as specified by Michell Bearings, where
applicable.
2. That the temperature monitoring equipment works.
• The bearing is now ready for operation. It must not be used until the below items have
been dealt with:
·1. The entire installation has received a Declaration of Conformity, or has been declared
exempt from the Supply of Machinery (Safety Regulations) Act 1992 and the Machinery
Directive.
ls.2 Trial Run
• For temperature probe fitted bearings, run the bearing and establish a steady state
operating temperature. Set temperature alarm to 5°C above this steady state operating
temperature. Shut down temperature alarm should be set at 1ooc above steady state
• Supervise the bearing during the trial run period (approx. 5-10 operating hours).
• Pay special attention to the following:
1. Oil flow rate and oil inlet pressure in circulating oil system (where applicable)
2. Bearing temperature
3-:-0ccurrence ofinaamissiolevi6rafions.
4. Unusual noises or odours
13 -----------------
• If any or all of the above cause concern, or if the monitoring equipment triggers an alarm,
stop the machine immediately and carry out an inspection of the bearing to find the cause.
ls.3 Normal Operation
&
•
Do not touch any moving parts.
If the bearing has been correctly assembled using the procedure already given, there is
only a marginal risk of the bearing failing which would normally be due to inadmissible
operating conditions. Examples of these conditions are; overspeed, low lubrication levels
and excess load. To avoid these situations, follow the following recommendations:
• Label Control Panels with the bearing limitations.

.. Do not operate the bearing below the transition speed values indicated in the bearing
calculation.
• Stop the shaft immediately if: Bearing temperature exceeds normal operating
temperature by 1ooc.
• Never remove plugs, RTDs or seals while the bearing is operating.
• Regularly inspect all seals and pipework. Any large leakage of lubricant or coolant will
indicate that a seal or joint is failing. Maintenance must then be carried out as soon as
possible.
© T h e bearing sudace and any pipe work may be hot during operation.
ls.4 Preparation for Operation after Standstill
• Clean the external parts of the bearing. Dust and dirt impede the radiation of heat.
• Check with the maintenance schedule in Section 7.3 to see if an oil change is necessary.
If required, carry out the oil change as indicated in Section 7.4.
• Start operating the oil supply system, where applicable, and check that it is working
correctly. The supplied oil quantity at the bearing inlet must equal the value indicated in
the Michell Calculations.
• Check the functioning of the temperature monitoring equipment.
• The bearing is now ready for operation.
14
17.1 General
• Before carrying out any maintenance or inspection work, switch. off machinery. Lock off the
controls and secure and the isolate shaft .
.& Ensure control gear, baiTing gear and any other equipment capable of moving
the shaft is locked out and labelled "Not to be used", or similar.
.& Do not touch any moving parts.
17.2 Tools and Equipment
The following tools and equipment may be necessary to carry out maintenance on the
bearing:
• Allan key set
• Wrenching key set
• Open-jawed spanner set
• Feeler gauges.
• Emery paper, plain scraper
• Lifting equipment
• Permanent sealing compound (e.g. Curii-T)
• Liquid screw locking compound (e.g. LOCTITE 222)
• PTFE sealant tape.
• Oil with the viscosity indicated (see bearing inspection plate)
• Detergents
• Clean cloth
- j
--~---~----~~-~ ------~--15------------------
17.3 Maintenance Schedule
• For a bearing that is operating constantly, routine maintenance should take place annually.
• If the user only operates the bearing periodically, maintenance periods may be able to take
place less frequently. This is however, at the users' discretion. An annual inspection is
recommended as a minimum service requirement.
• A basic guide to maintenance is given in Table 1.
Maintenance wo;k Schedule

Oil Change (see Section 7.4) • Bearing in reversing operation: every 3 Months
• Bearing in continuous operation: every 6 Months
Bearing Inspection During preventative maintenance work for machine or
immediately if:
• Bearing temperature exceeds 1ooc over the indicated

value (see calculations)
• Unusual noises or odours occur
• Unusual changes in the oil colour are visible .

• Inadmissible vibrations occur .
• Oil flow rate and oil inlet pressure readings drop
below admissible values,
Table 1: Maintenance Schedule
• These are estimates only, and frequency may alter depending on site environment.
Michell can advise the user accordingly.
17.4 Oil Change
17.4.1 General
• Oil changes will be at differing periods depending on the frequency of bearing operation
and the conditions in which the bearing is operating. Approximate oil change times are
indicated in Section 7.3.
• Please observe the instructions for the use of the lubricating oil. The manufacturer
can provide information on waste oil disposal.
& Risk of Pollution:
17.4.2 Procedure for draining oil
• Run the bearing to warm up the oil. This will ease the flow of oil from the bearing, and also
remove any impurities and residues.
16
• Shut down the machine and secure it against unintended operation.
• Shut down the oil supply system where applicable.
& Do not disconnect the oil inlet and outlet pipeworlr until the bearing has been
drained of oil.
© A n y oil spillage should be collected in suitable containers.

• Let off and collect the lubricating oil in the oil supply system where applicable.
• Loosen and remove the drain plug and washer, and fully drain the bearing of oil.
/
& Beware hot oil.
(
©Collect and dispose of used oil under the com!ct regulations.
<1flf the oil is visibly aiiBred in colour, or contains unusual residues, an inspection
is recommended to eliminate the cause.
17.4.3 Procedure for refilling the bearing -self contained bearings

• Pour the correct grade of lubricating oil into the filling hole in the casing top. Use the
approximate quantity required as shown on the bearing arrangement drawing as a guide.
• Let the oil settle into the bearing. Check the oil level is approximately at the centre of the
oil level gauge, and top up if necessary. Where applicable.
17.4.4 Procedure for refilling the bearing - bearings with circulating oil
(
• Clean the oil container and fill up the oil supply system with the correct grade of lubricating
oil.
• Start the oil supply system in order to fill up the bearing with oil.
<If Check for leaks.
<If Not enough lubricant leads to temperature rises and therefore damage to the
bearing. Too much lubricant leads to leaks.
~ When pouring, take care not ID spill lubricating oil onto the machine or
surrounding area.
- ------~------1-7------ - I
Ia. Dismantling an Installed Bearing
\8.1 General
o The Procedure given in this section is a full stripdown of a generic Omega "OT" series
bearing. As such it may contain more information than is necessary in some cases.
Simply ignore the sections not relevant to the bearing being worked on. Any technical
queries can be referred to the Engineering Team at Michell Bearings.
• Michell recommends that the below safety advice is followed when carrying out
maintenance on any bearings. It may be necessary to change the dismantling procedure
to suit the design of the bearing casing.
\8.2 Preparation
• Check through the safety procedures at the start of Section 2. Understand and follow the
instructions very carefully.
• Switch off machinery. Lock off controls. Secure and isolate shaft, drain and disconnect
cooling system, where applicable. Refer to manufacturer instructions.
& Ensure control gear, barring gear and any other equipment capable of moving
the shaft is locked out and labelled "Not to be used".
• Switch off and drain the lubricating oil and oil system (where necessary) as described in
Section 7 .4.
• Disconnect and remove any thermometry and instrumentation.
<{ Make sure the workspace is clean. Contamination and damage to the bearing
affect operating performance and could lead to premature failure.
& Do not use any violence or force.
© T a k e care notto jam hands when manipulating components.
\8.2.1 Strip down the bearing until the thrust rings are visible.
• Horizontal Bearings: Where applicable, remove the top half of the thrust ring(s).
• Vertical Bearings: Remove upper thrust ring (where fitted).
• Vertical Bearings: Jackshaft up until it's clear of the lower thrust pads.
18
& Follow lifting instructions and safety guidelines in Sections 2 and 3.
& Ensure the jacking equipment is safely positioned and certified to carry a load
greater than the mass of the shaft.
& Once the shaft is raised, secure it into position using other equipment Do not
rely on jacking equipment alone.
IB.2.2 Disconnect and remove any thermometry and instrumentation.

• Remove RTDs, and instrumentation connections.
<1f Take care not to damage instrumentation.
ls.3 Removing thrust rings

Vertical Bearings: Remove lower thrust rings.
• Horizontal Bearings: If the bottom half of the thrust rings are not visible, follow the below
procedure;
• Tap one end of the ring until the opposite end is visible.
• Rotate the ring out and remove.
ls.4 Removing the Liners, and Shim Pack. Where Applicable.
• To fully dismantle the thrust ring follow the below procedure:
• Remove liner retaining screws (8), liners (7), and shim pack (6) from the back of the
(··. retaining ring halves (1 ), (2).
ls.s Removing the Thrust Pad Set
• Remove thrust pad stops (4) from retaining rings (1 ), (2).
• The thrust pads (3) can now be removed from the retaining ring (1 ), (2).
© T a k e care not to jam hands when manipulating components.
<1f Take care not to damage thrust pad whitemetal surface.
\_
-· --- - . ---- --- --- ---- -- -~ ------ - --~-- --- -- - ----~---~----~~-------~--~- -~----19-~----- ------------- -
Is. Cleaning and Checking
j9.1 General
& Only use non-aggressive detergents such as VALVOLINE 150 or Alkaline

cleaning compounds with pH-value 6 to 9, and a short reaction time.
;';\
I : \ Please observe the instructions for use of the detergents.
& There may be fumes given off during the cleaning process. Clean parts In a
~ Use a lint free cloth when cleaning the bearing. Thread from such cloths could
get into the lubricating oil and cause overheating, and in extreme cases, failure of the
bearing.
• Clean the following parts thoroughly:
1. Thrust pad set.

2. Retaining ring.
3. Liners, where applicable
4. Shim pack.
5. Thrust pad stops.
• In addition inspection may be required on the bearing components, according to the

Maintenance Schedule outlined in Section 7.3.
• The remaining part of this section gives basic inspection guidelines for some major bearing
components. However, if any wear or damage is evident on any of the bearing
components, consult Michell Bearings immediately as it may adversely affect bearing
performance.
• The following sections assume the bearing has been dismantled according to Section 8.
20
ls.2 Checking the Thrust Pad.
• Examine the Thrust Pads. The appearance of the running surface should be that shown in
Figure 11 below.
Direction uf Rotation
s1
Matt Surface
Dull finish
~-
Figure 11: Thrust Pad Appearance After Use
• Inspect the collar surface for any signs of damage. If it is necessary to change the pads,
the collar should also be replaced or repaired, otherwise the replacement pads will only
have a short life. There may be some scoring and wear on the pads. Provided wear is no
greater than 0.125mm the pads are still serviceable. If there is any sign of the bearing
surface coming away from the backing material, the pads must be replaced.
1--------·- -·-·--- ------ ------ -~--- ---- ------------------------- __21 __ _

110, Bearing Preservation during Storage
j10.1 Before Installation

110.2 Corrosion Protection for Standstill Periods up to 6 Months
• Dismantle the bearing (see Section 8).

• Clean the bearing (see Section 9).
• Assemble the bearing (see Section 5).
• Put a bag of desiccant (silica gel) inside to absorb humidity and prevent the formation of
condensation in the bearing.
110.3 Corrosion Protection for Standstill Periods between 6 Months to 1 Year

• Repeat the preservation procedures detailed in Section 10.2.
110.4 Corrosion Protection for Standstill Periods longer than 1 year
• Dismantle the thrust rings according to Section 8.

• Preserve and store bearing parts separately.
111. Bearing Preservation During Transport
When the bearing is fitted to the machine during transport:

• Carry out the corrosion protection procedure described in Section 10.2.
• Apply liberal lubricant to the running surfaces of the bearing.
• Secure the shaft against axial and radial movement.
112. Appendices
112.1 Ordering Spares
• As a minimum, it is recommended that replacements should be carried for all Whitemetal

components. Consideration should also be given to stocking the parts listed below:
• Jointing compound (i.e. Curil-T)
• RTD Assemblies (where applicable)
22
\
r
Bolt Size (mm) Tightening Torque (Nm)
6 4
8 10
10 20
12 35
16 80-90
20 155-175
24 275-305
30 545-605
36 950-1050
42 1520-1680
48 2300-2520
56 3690-4070
64 5560-6150
:------------------------------- ---~- ---------------------~- -------------------------~- ----------- --- -------~ _2_3________ -

Michell Bearings Service Department.
Scotswood Road Direct: +44(0191) 2565319
Newcastle Upon Tyne
NE15 6LL Repair Department.
Great Britain Direct: +44(0191) 2565309
Tel: (0191) 273 0291
Fax: (0191) 272 2787
Michell Bearings reserve the right to amend these instructions.

© Michell Bearings 2004.
24
DRG No. Ml/1/214730 PARTS LIST RR EEIIliNG 203232
PART NM1E QTY WATEIIAL PATERK
lHRIJST
lHRUST PAD
PNJ
1lRJST PAD ASSBtBLY 2 STEa/llol
(RlD) 4 STmjlll
12 STEEL/*
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HALF RETNNING RtHG 2 STEEL
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7 SR/)C/100050
8 SR/)C/100009
9 U/3/203480 li£R HALF ASSBIBLY 2 STE£1..
- U/3/203480 L11ER HALF 2 STm
- U/X/203487 liER HALF 2 STEB..
10 0</4/2<>3494 R1lHiiUPL£X 4-VIIRE 4
11 BKJ)C/104645 CABLE a.P 14 PLASTIC
12 AD/)C/203o405 C1BLE G1...N11D 2 BRASS
13 SR/)C/100036 8UTION t£AD SCREW 14 STEEL
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PLAN VIEW (SHOWING RING STOPS) v HEVICASTLE UPON m£ 1£15 6U.
(SCALE - 1:2.5) BASIS Ml/1 /203232
""'""BY PN
DRG. NO. Ml/1/214730 Q£ct<ED BY
1RAC8l BY
INSTRUCTIONS
INST ALUNG & OPERATING
INC.
NE269 (8X8) THRSUT BEARING
BHARAT HEAVY ELECTRICALS LTD.
Hyderabad,
P. 0. No. F603P608
September 2005
KINGSBURY. IN C.
10385 Drummond Road. Philadelphia. PA
Phone: 215-824-4000
Fax: 215-824-4233
Kingsburv Reference No. K033016
\ _)
CONTENTS
Page
No.
CHAPTER 1 - GENERAL INFORMATION
1.1 INTRODUCTION .................................................................................................. I
1.2 PRINC 'IP AI, DATA ................................................................................................ I
1.3 ILLUSTRATIONS ................................................................................................. !
1.4 GENERAL DESCRIPTION ................................................................................... 1
1.5 DETAILED DESCRIPTION .................................................................................. I
CHAPTER 2- INSTALLATION
2.1 DISASSEMBLY, CLEANING, AND INSPECTION ........................................... 3
2.2 INITIAL ASSEMBLY ............................................................................................ 3
2.3 END PLAY ............................................................................................................ .4
2.4 FINAL ASSEMBLY .............................................................................................. 5
CHAPTER 3- OPERATING INSTRUCTIONS
3.1 LUBRICATION AND COOLING ......................................................................... 6
3.2 GRADE OF OIL ..................................................................................................... 6
3.3 OPERATION .......................................................................................................... 6
CHAPTER 4 - CARE AND MAINTENANCE
4.1 TROUBLESHOOTING .......................................................................................... 7
4.2 INSPECTION AND REPLACEMENT .................................................................. 7
4.3 SERVICE ................................................................................................................ 8

CHAPTER 1 -GENERAL INFORMATION
1.1 Introduction
a. The NE8269 thrust bearing assembly consists of two subassemblies. Each

subassembly has eight pads, four of which are equipped with Resistance Temperature Detectors
(R.T.D.). The subassemblies are split with an attached split filler plate.
1.2 Principal Data
NE8269 Non-Equalizing (NE) Bearing
Outer diameter of bearing (mm) ............................................................................................. 297.0
Inner diameter of bearing (mm) ............................................................................................... 160.0
Number of pads (each side) ............................................................................................................ 8
Recommended end play (mm) ....................................................................................... 0.36- 0.46
1.3 Illustrations
Kingsbury Drawing #481202 ............................................................................................. Figure 1
1.4 General Description
a. The double thrust bearing assembly presented in Figure 1 is a non-equalizing

design, which means that the axial pad positions have very limited adjustment capability under
load. Eight thrust pads are positioned on each side of the collar. The assembly is capable of
accommodating thrust load in either axial direction. The thrust of the rotating element is
transferred through the collar to the pads, the carrier ring, the housing, and foundation.
/ .. -:~,
!i'
b. In operation, each pad is free to pivot slightly in relation to the collar surface.
This allows the oil to form wedge-shaped films between the pads and collar. These films,
thickest at the leading edge, are self-renewing, as long as the shaft rotates and lubrication is
provided. r
1.5 Detailed Description (See Figure 1)

'
a. The thrust bearing assembly consists of two split carrier rings (1), in which the
I
thrust pads (2, 3) are equally spaced between pad retainer and screws (4, 4-1). The head of the '
pad retainer holds the pads loosely in position by engaging recesses machined in the radial sides
of each pad.
)
b. Socket head shoulder screws (8) are used to locate and hold the instrumented
thrust pads (3) located near the carrier ring joint.
c. The thrust pads (2, 3) are made of steel and arc faced with babbitt. They arc free
to tilt slightly, allowing the wedge-shaped oil films to develop. The plain pads arc
interchangeable. However, the pads equipped with R.T.D.s have specific locations within each
subassembly and must not be interchanged. Instrument lead wires must be routed through the
grooves provided in the carrier ring. The leads may be secured using the wire clamps (7) and
screws (7.1) provided.
d. The carrier rings arc located in the housing and secured against rotation by anti-
rotation keys (6) secured with screws (6-1).
e. The Iiller plates (5) arc used to set rotor end play (See Section 2.3), which is the
axial clearance between the thrust bearing sub-assemblies. The filler plates arc secured to the
back of each carrier ring (I) with Iiller plate mounting screws (5-1).
2
CHAPTER 2- INSTALLATION
2.1 Disassembly, Cleaning, and Inspection
a. As packed for shipment, the bearing elements and surfaces are protected against
physical abuse and corrosion. They have been brushed with a neutral waterproof coating and are
protected against contact with wood or damp packing material. Subsequent damage may occur if
the proper precautions are not observed during storage, inspection, and installation.
b. Remove the packaging materials from each bearing assembly and lay the
assembly on a clean, flat surface.
c. Separate the thrust bearing subassemblies at the joints.
d. Remove the pad retaining screws (8) from the back face of the subassemblies.
Remove the loose pads (3).
e. Loosen and remove the pad retainer screws and pad retainers (4, 4-1) in sequence,
removing all loose thrust pads (2).
f. Clean off all anti-rust preservative with a mixture of oil and solvent or kerosene.
Use lint-free rags or cloth for cleaning.
CAUTION
A poorly cleaned bearing will score and wear out rapidly.
A bearing surface is not clean until a white cloth wiped
over it shows no soil.
CAUTION
Protect the babbitted pad faces at all times!
g. Inspect all parts after cleaning. Remove any raised metal on the babbitt faces
with a scraper.
h. Remove displaced metal or rust on the collar face using a fine oil stone. Deep
rust requires refinishing.
2.2 Initial Assembly
a. Oil all parts when assembling.
b. Place the carrier ring halves (1) on a clean, flat surface.
T---------------------------------------~3----------------------------------~----~
c. Refer to Figure I. Starting ncar the carrier ring joint (the end without the thru-
holc for the shoulder screw (8)), place a plain thrust pad (I) atop the carrier ring, followed by a
pad retainer (4) atop the threaded hole in the carrier ring. The retainer must engage the slot in
the side of the pad.
d. Continue placing pads, followed by retainers, until all of the plain pads and
retainers have been located.
c. Secure the retainers in place by installing the flat head socket screws (4-1 ).
f. Place the instrumented pads (3) into the remaining positions and secure with
socket head shoulder screws (8).
g. End play must now he accounted for. Refer to Section 2.3, End Play.
2.3 End Play
a. End play is defined as the axial float of the thrust collar between the thrust
bearing sub-assemblies. It is provided to allow for oil film formation and thermal expansion.
b. Thrust bearing end play is determined by the thickness of the filler plates (5)
fastened to the back of each carrier ring.
c. To determine the required filler plate thickness, place each thrust bearing sub-
assembly on a surface plate and lay a flat plate atop the pad surfaces. Use an inside micrometer
or snap gauge and measure the height between the surface and top plate adjacent to each pad.
Average the eight readings to determine the average stacked height.
NOTE
For accurate results, the flat plate should have a 32 rms finish
and be flat within 0. 03 mm. The plate should weight at least 45
kgs.
CAUTION
Babbitt is a soft metal that is easily damaged. Do not drop or
twist the surface plate atop the babbitted surfaces!
d. Use an outside micrometer to measure the filler plate thickness. Record the
measurement.
4
e. With the thrust collar (rotor) in the desired running position, use an inside
micrometer to measure the average available space. Carefully measure and record the space
between the collar and each end of the housing. Perform measurements in at least three
locations. Average the readings to determine the average available space.
f. The difference between the average stacked height and average available space
(for each side of the collar) represents the. desired filler plate thickness. The calculated filler
plate thickness in the normally unloaded bearing must be further reduced by the desired end play
(See Section 1.2).
g. If the filler plates are not the required thicknesses, they must be ground.
NOTE
The filler plates should be ground on the side of the filler plate
mounting screw (5-1) counter bores.
The filler plate must be ground flat within 0.013 mm. The.
surface finish should be 32 rms or better.
h. Once installation is complete, verify the end play by moving the rotor fore and aft
while accurately measuring the change in position. Correct as required.
2.4 Finali\ssembly
a. i\ttach the finished filler plates (5) to the carrier rings (1) using the filler plate
mounting screws (5-1).
b. Wet the collar faces with oil.
c. Bump the rotor to one side to provide clearance for one thrust subassembly
installation.
d. Place the lower half of the partial assembly (the halves without the anti-rotation
key (6)) over the shaft and roll it into the housing, bringing the bearing joint even with the
housing joint.
e. Place the upper half atop the lower and roll the subassembly to seat the anti-
rotation key.
T----------------------------------------5----------------------------------------~
)
CAUTION
The iustrument lead wires are easily damaged by rough or care/e.\·.\·
handling. Assist the leads each time the assembly is mtated.
f. Bump the rotor against the bearing and install the second subassembly as noted
above.
g. Pour oil over the entire assembly.
h. Complete housing assembly.
6
CHAPTER 3- OPERATING INSTRUCTIONS
3.1 Lubrication and Cooling
a. These bearings are intended for lubrication from the main oil system. The rate of
circulation should keep the oil outlet temperature within 14-l7°C above the inlet temperature.
b. Control the oil flow by throttling or using orifice plugs on the oil inlet only.
3.2 Grade of Oil
a. Correct oil viscosity is important. Changing to a lighter oil may cause the
lubricating films to become dangerously thin. The use of a heavier oil will needlessly increase
friction and power losses.
b. Oil must be clean and free from grit and other abrasive substances. Fine grit has a
scouring action, and dirty or old oil may cause corrosion or sludge.
3.3 Operation
a. The bearing surfaces, when running, are completely separated by oil. Since there
is virtually no wear, no adjustment is provided. The original dull gray appearance of the thrust
pad faces may remain the same after years of service. This can be expected if the unit is clean
when installed and is supplied with clean, cool oil of proper viscosity.
b. Oil flow through the bearings must be established prior to shaft rotation.
CHAPTER 4- CARE AND MAINTENANCE
4.1 Troubleshooting
SYMPTOM CAUSE REMEDY
Low oil flow Check & clean filters & sump.

HIGH
High oil inlet Check oil cooling medium. Increase cooling
BEARING
temperature water flow. Check for proper oil level.
TEMPERATURE
Contaminated lube Check and clean lube oil system.
oil Filter/replace oil.
Damaged journal Disassemble and inspect.
BABBITT LINING: Low oil flow Increase oil flow. Replace pads.
Scored Dirty Oil Filter/replace oil and replace pads.
Cracked Excessive vibration Balance rotor. Replace pads.
Separated from Poor bond Replace pads.

pad body
4.2 Inspection and Replacement
a. An inspection of the thrust pads or collar faces cannot be performed without

raising the housing cover. Thrust bearing end play, pad temperature, oil outlet temperature, and
oil filter condition should be used to assess bearing health.
b. When distress is suspected, secure the unit and lift off the upper portion of the
housing.
c. With the cover raised, the radial edges of the thrust pads and exposed collar
surfaces can be inspected.
d. If babbitt overlay along the pads' radial edges is not visible, withdraw a pad for
full surface inspection.
e. If the pad does not exhibit displaced babbitt, it is unlikely that the remaining pads
will be damaged. When the babbitt becomes hot enough to flow, it is picked up by the rotating
collar and is quickly carried through all of the pads.
8
f. If an overlay of babbitt is evident along the pads' radial edges, the bearing must be
disassembled. The severity of damage determines the extent of repair.
g. Refer to Section 2.2 for the reinstallation procedure.
4.3 Service
a. In correspondence and when ordering parts, refer to the Kingsbury Drawing and
Order numbers.
b. Prompt service is available. Please contact:
. Kingsbury, Inc.
Repair and Service Division
3615 Davisville Road
Hatboro, PA 19040 U.S.A.
Phone:215-956-0565
Fax: 215-956-9027
9
481202.dwf: Library
R.T.O. MINCO MODEL #S30SP04Sl60BO,

RECOMMENDED TOTAL END PLAY .36mm [.0141 TO .46mm [.0181. PLATINUM,l{IQ OHMS @O"C (32'F), 4-WIRES.#30-AWG,
STRANDED, 4064.0/160.00 LG. LEADS, TEFLON
INSULATED & ST AlNLESS STEEL BRAID OVERALL
G
THRUST COLLAR FACES MUST BE
; - - - - FLAT&SQUAREWITHSHAITAXIS
FINISH VERY SMOOTH{l6RMS)
BY LAPPING OR OTHERWISE
COLLAR ¢194.0mm.(7.G4in]I.D.
BY KINGSBURY OF FILLER PLATE
7.1
S S-1
¢297.0 mm [ll.69 in] TYP

EXTERNAL PADDrAMETER
.8mm[.03in]
.s E
THIS SIDE ONLY

E
4 4-1
SECTION B-B SECTION A-A

GR.rn'DTHISSIOEONL
SCALE 112 SCALE 1/2
l5.0mm [.59 ~;~~.m [.59 in)
: ··[lm
TOTAL AXL\LCLEARANCE
)
OF 0.5 mm (.02 in) INCLUDED
IN TOTAL BRG. WIDTH
NGSBURY TO SUPPLY 15m m(.:591]

NOMINAL THK PLATE,
CUSTOMER TO GRIND PLATE TO
OBTAIN DESIRED END PLAY.
(AROUN"D -9.649ul m (.3799])
[.13in]
SECTION E-E
SCALE I /2
TECHNfCAI DATA:
-SHAFTDIA.= 138.0 mrn [5.43 in]
-ROTATIONAL SPEED, DESIGN/MAX.= 5465/6100 rpm
-THRUST LOAD, MAX.= I20 KN

-THRUST SURFACE AREA= 1.635.0 sq.mm. [64.37 sq.m.]
-THRUST PRESSURE= 2,889 KN/m.sq.

SECTION C-C -TOTAL AXIAL CLEARANCE=O.S mm [.02 m.]
SCALE!: I
-POWER LOSS= 43 KW
-OIL GRADE= 32/46-ISO VG
-OIL VISCOSITY POISE= 0.18
-OIL INLET TEMPERATURE= 55"C
-OIL FLOW= 5.673 literslhr PER SIDE
1 of 1
----
---- -~---'--·-
PART-4
SECTION- C
CONDENSATE
EXTRACTION PUMP
TYPE : EN6J40/500
. I
-~--~---~----1 -
PART-4
EQUIPMENT DETAILS
SECTION -C
LIST OF CONTENTS
CHAPTER TITLE
1 Description
2 Operating Instructions
3 Maintenance Instructions
4. Sub-vendor's Drawings I Instructions
)
I
----~----~-------~---~----------1
I
I
SECTION -C
CHAPTER-1
DESCRIPTION
LIST OF CONTENTS
1 General specification
2 General Description
3 Associated equipment
3.1 Canister and foundation ring
3.2 Discharge headpiece
3.3 Motor Stool
3.4 Stuffing box assembly
3.5 Combined thrust and journal
Bearing Assembly
3.6 Coupling
4 Driving motor
T
CHAPTER-1
DESCRIPTION
1. GENERAL SPECIFICATION
Pump Designation EN6J40/500
Type Vertical, canister
Number of Stages 6
Number of Pump Set 3
2. GENERAL DESCRIPTION
The condensate extraction pumps are of the vertical centrifugal canister type with the
driving motor supported on a fabricated motor stool. The motor stool is supported on
a fabricated head piece which is secured to a fabricated canister. The canister is
secured to a foundation ring which is held to the floor with nuts on foundation bolts.
The pump stage casings form an interconnected assembly which is attached to the
underside of the headpiece and is suspended within the canister.
The head piece is provided with a stuffing box which contains a mechanical seal to
prevent pump leakage. Small bore pipe work, for sealing purpose, is connected to the
stuffing box. The head piece also supports the water cooled oil lubricated thrust and
journal bearing.
The pump discharge branch and vent pipe are integral with the head piece and the
pump suction branch is integral with the canister.
The motor stool, secured to the top of the head piece, supports the driving motor.
Cooling water pipe work along with the oil filling/vent pipe and gauge glass extension
pipe are attached to the motor stool.
Apertures formed on the motor stood and head piece provide access to the coupling,
thrust bearing and mechanical seal.
I
-I
i
I.
Each pump is driven by an electric motor mounted on the motor stool. The motor is
supplied by BHEL, Bhopai/Hardwar. The motor shaft is connected to a top shaft via a
flexible spacer coupling and the top shaft connects to the intermediate shaft via a
solid muff coupling. The intermediate shaft in turn is connected to a bottom shaft
through a muff coupling. The top shaft passes through the combined thrust and
journal bearing and stuffing box, and also carries the fourth to sixth stage rotating
assemblies. The intermediate shaft carries second and third stage rotating
assemblies. The bottom shaft carries the first stage rotating assembly. The shafts are
supported by two cutless rubber bearings at the first stage and by a single cutless
rubber bearing at the second to sixth stages. The thrust bearing absorbs the
downward axial thrust from the pump rotating assembly, and the white metal lined
journal bearing with in the thrust bearing assembly supports the shafts along with the
cutless rubber journal bearing within each intermediate stage assembly and element
assembly.
A snubber secured into the bottom of the canister engages the suction bell mouth
fitted to the first stage casing. This arrangement provides support to the bottom end
of the pump.
3. ASSOCIATED EQUIPMENT
3.1 Canister and Foundation Ring
The canister is a fabricated tubular chamber formed with a dished bottom end which
is closed by a snubber which is located and secured to the bottom of the canister by
screws, tab-washers and dowels. Leakage between the canister and snubber is
prevented by a joint, and a cylindrical extension of the snubber provides rigid support
to the first stage pump casing assembly.
A suction branch integral with the canister is positioned above floor level
and a flange provided below the suction branch accommodates screws for
securing the canister to the foundation ring. The canister top flange supports the
discharge head piece.
The foundation ring is provided with holes for foundation bolts and
tapped holes for canister securing screws. The foundation bolts and foundation
ring are grouted to the floor.
3.2 Discharge Head piece
The fabricated head piece, secured to the pump canister with screws,
incorporates the discharge branch and supports the thrust bearing housing and
motor stool. The head piece is sealed where the shaft passes through by a stuffing
box which incorporates a mechanical seal.
Small bore pipe work connects to the stuffing box, for inlet and outlet
sealing water. The outlet pipe work, which returns the sealing water to tfle pump
suction, is provided with two orifice plates. A vent pipe provided with a spigot
flange is incorporated within the structure of the head piece for connecting to
condenser. A Valve is provided for installing between the vent pipe and
condenser.
Tapped holes on the inner flange situated on the underside of the head
piece provide location for the top rising main screws and holes drilled through the
outlet of the outer flange provide location for screws which secure the head piece
to the canister flange. Tapped holes provided on the inner flange situated
on the topside of the head piece, provide location for the stuffing box securing
screws. Tapped holes on the topside outer flange provide location for the motor
stool securing bolts.
Apertures formed on the head piece provide access to the stuffing box and
are closed by wire mesh guards.
Lugs are situated at the top of the headpiece for lifting purposes.
. ( '
I
I
3.3 Motor Stool
The fabricated motor stool is dowelled to the head piece and secured by
bolts. A recess formed on the top flange of the motor stool locates the driving
motor, which is secured with screws to the motor stool.
Small bore pipe work is provided within the motor stool for thrust bearing
inlet and outlet oil cooling water. A combined oil filler and vent pipe extends
through the side of the motor stool. The thrust bearing oil level gauge glass is
secured to a pipe which also extends through the side of the motor stool.
Apertures formed on the motor stool provide access to the flexible spacer coupling
and thrust bearing, and are closed by wire mesh guards.
3.4 Stuffing Box Assembly
3.4.1 Mechanical Seal : The stuffing box is secured to the head piece with
screws, leakages being prevented by a joint.
The entry of pumped condensate at the underside of the stuffing box is

restricted by a gap between a restriction bush, secured with screws to the stuffing
box and a sleeve secured to the shaft with "Loctite".
The stationary seal face of the mechanical seal is retained by an "0" ring
in the seal plate, and the rotating components of the mechanical seal are retained
on a sleeve held by a retaining collar. The retaining collar is secured to the sleeve
with grub screws and secured to the shaft with grub screws.
The seal is of 'cartridge' type and seal setting is done by seal manufacturer
at their works itself.
The seal plate is spigot located and secured to the stuffing box with
screws, leakage being prevented by an "0" ring. Tapped holes are provided on the
seal plate for jacking screws, to assist with dismantling. Small bore pipe work
connects to the seal plate to sealing water purposes.
Two additional orifice plates are supplied for each pump to be installed in
client's small bore pipe work which connects to the common discharge. This
feature enables an adequate flow of flushing water to be maintained at the stuffing
box, during the time the pump is on standby.
Further particulars for the mechanical seal are contained in Chapter- 4.
3.5 Combined Thrust and Journal Bearing Assembly
The combined thrust and journal, water cooled bearing assembly is

mounted on the head piece and absorbs the pump hydraulic downward thrust, and
takes the weight of the pump rotating assembly.
The casing base plate is spigot-located on to an adaptor plate which also

locates by spigot to the head piece. The casing base plate and adapter plate are
secured together with nuts on studs, and the adaptor plate is secured to the head
piece with screws.
The thrust collar which is a tight fit and keyed on the shaft is retained
against a shoulder on a shaft by the thrust collar nut. Tapped holes are provided
on the collar for fitting and removal purposes. The thrust is absorbed by the white
metal faced thrust pads fitted to the base plate, under the collar. White metal lined
/
journal pads are fitted in the casing and locate the collar radially.
The casing top is closed by a split cover secured to the casing with bolts,
the halves of the split cover being secured together with nuts on fitted studs and
nuts on bolts. Taped holes on the split covers facilitate eye-bolts for lifting and
removal purposes. Provisions is also available for a temperature probe. Leakage
between the split cover and casing is prevented by a joint. Leakage between the
sleeve and the underside of the base plate is prevented by a joint. The bearing
casing is supplied with inlet and outlet cooling water connections, an oil level
gauge, a combined air vent and oil filler and an oil drain plug on the base P::...:.la=t=e.::_.- - - - ' - -
Tapped holes in the casing facilitate jacking screws for dismantling purposes.
Leakage between the casing and base plate is prevented by an "0" ring fitted in a
groove machined in the base plate.
For further particulars refer to the bearing manufacturer's instructions

contained in Chapter-4.
3.6 Couplings
The drive from the motor to the top shaft is transmitted via a spacer type
flexible coupling. Each half coupling is a tight fit and keyed to its respective shafts,
the halves being connected by means of a spacer which interconnects via flexible
membranes at each end.
The coupling is designed to accommodate a certain amount of both offset

and angular misalignment and also any free end float or vertical movement of the
shafts.
The top shaft half coupling abuts the thrust collar nut, and a recess
machined in the bore of the top shaft half coupling accommodates a thrust plate
which corresponds with the LEF button.
For further particulars refer to the spacer coupling manufacturer's

instructions contained in chapter-4.
4.0 DRIVING MOTOR
The vertical driving motor is mounted and secured to a spigot flange

provided on the motor stool.
For further particulars and information for the driving motor, refer to the
motor manufacturer's instructions not contained in this manual. The driving motor
is supplied by BHEL, Bhopai/Hardwar.
T
SECTION -C
CHAPTER-2
LIST OF CONTENTS
1. Introduction
2. Pre-start checks
3. Start-up
4. Pump running checks
5. Normal shut-down
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6. Preparing a pump for standby
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7. Stud-down when the pump is to be isolated
8. Fault finding
- - - - - - - - - ~---------~
CHAPTER-2
1 INTRODUCTION
The following operating instructions are applicable to the mentioned type

of condensate extraction pumps, and should be read in conjunction with those for
the operation of the pump driving motor and the station operating instructions.
The pump driving motor, pump suction and discharge pipe work, valves
and control equipment are not supplied by BHEL, Hyderabad therefore the
installation should include all the necessary ancillary equipment to facilitate
satisfactory operation and prevent any malfunction at an early stage.
The three condensate extraction pumps are designed as 50% duty pumps
and their normal mode of operation permits two pumps running, and one on
standby.
To obtain the maximum attainable working life, continuous running is

recommended.
2 PRE~TARTCHECKS
Following an overhaul or maintenance procedure, check that the following

steps have been carried out along with the motor manufacturer's instructions.
(1) Ensure that the power supply is available to the driving motor.
(2) Check the oil level in the thrust bearing gauge glass. Top up the thrust
bearing, if necessary.
(3) Ensure that the cooling water is available to the thrust bearing.
(4) Ensure that the sealing water is available to the stuffing box.
(5) Ensure that the pump discharge isolating valve is shut.
CAUTION : If the pump is to be started with the discharge valve open, it is

essential that the discharge line is full to prevent the pump running
out of its characteristic, and imposing an overload on the driving
motor.
(6) Ensure that the pump suction isolating valve is open.
(7) Ensure that the discharge pressure gauge isolating valve is open.
(8) Ensure that the valve on the air vent pipe to the condenser is open. The
valve should be locked in the "Open" position.
3 START- UP
(1) Ensure that the pre-start checks have been carried out.
CAUTION : (a) The pump must not be started unless the canister is full of
condensate.
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(b) The suction isolating valve must not be used for throttling the
pump output: the discharge valve should be used for this
purpose.
(2) Refer to the motor manufacturer's instructions and start the driving motor.
Ensure that the motor direction of rotation is correct.
CAUTION : The pump must not be run for an extended period with the discharge
valve closed.
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(3) Slowly open the discharge valve and fill the system pipe work with
condensate. When the system pressure stabilizes fully open the discharge
isolating valve.
(4) Check the following readings if the appropriate instruments are available.
(a) Pump suction pressure.
(b) Pump discharge pressure.
(c) Pump suction temperature.
(d) Motor current. Refer to the motor manufacturer's instructions.
(5) Check the oil level in the thrust bearing gauge glass.
(6) Check the mechanical seal for leakage.
(7) Check all joints above floor level for leaks.
4 PUMP RUNNING CHECKS
The following checks should be carried out at regular intervals :-
(1) Check that the following readings are normal if the appropriate
instruments are available.
(a) Suction pressure.
(b) Discharge pressure.
(c) Suction temperature.
(d) Motor current. Refer to the motor manufacturer's instructions.
(2) Check the oil level in the thrust bearing gauge glass; top up if necessary.
(3) Check the mechanical seal for leakage.

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(4) Check all joints above floor level for leaks.
(5) Check the accessible fastenings for security.
5 NORMAL SHUT-DOWN
(1) Stop the pump driving motor. Refer to the motor manufacturer's
instructions.
(2) Shut the pump discharge isolating valve.
(3) Unlock and shut the valve on the air vent pipe to the condenser. Lock the
valve.
Note: Refer to the station operating instructions.
6 PREPARING A PUMP FOR STANDY
If a duty pump should fail or extra duty is required, the standby pump
should be ready for immediate start-up. To prepare a pump for standby, the
following procedures must be carried out in conjunction with the motor
manufacturer's instructions and the station operating procedures.
'
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(1) Check the oil level in the thrust bearing gauge glass; top up if necessary.
(2) Ensure that cooling water is available to the thrust bearing.
(3) Ensure that sealing water is available to the mechanical seal.
Note: Constant sealing water is supplied to the stuffing box mechanical seal on
each pump from the common discharge pipe work via small bore pipe
work, which prevents the ingress of air when a pump is stationery. Two
orifice plates are fitted in each set of small bore supply pipe work ..
(4) Ensure that the pump discharge isolating valve is shut.

CAUTION : If the pump is to be started with the discharge valve open, it is
essential that the discharge line is full to prevent the pump running
out of its characteristic and imposing an overload on the driving
motor.
(5) Ensure that the pump suction isolating valve is open.
(6) Ensure that the canister is full.
(7) Ensure that the discharge pressure gauge isolating valve is open.
(8) Unlock and open the valve on the air vent pipe to the condenser. Lock the
valve in the open position.
7 SHUT -DOWN WHEN THE PUNP IS TO BE ISOLATED :
(1) Stop the pump driving motor. Refer to the motor manufacturer's
instructions.
(2) Shut the pump discharge isolating valve.
(3) Shut the pump suction isolating valve.
(4) Isolate the electrical power supply from the pump driving motor. Refer to
the motor manufacturer's instructions.
(5) Isolate the cooling water supply to the thrust bearing.
(6) Isolate the sealing water supply to the mechanical seal.
(7) Unlock and shut the valve on the air vent pipe to the condenser. Lock the
valve.
Note : Refer to the station operating instructions.
(8) Evacuate the accumulated condensate from the canister.

8 FAULT FINDING

(1) Pump fails to start (a) Electrical supply to Check the electrical supply.
the driving motor Refer to the motor
isolated or faulty. manufacturer's instructions.
(b) Seizure of the pump Remove the pump set.
or motor. Disconnect the pump from
the motor to establish
locality and cause of
seizure. Dismantle and
renew the pump or motor
components as necessary.
(c) Thrust and journal Remove and examine thrust
bearing seized. and journal bearings. Refer
to Chapter 3.
(2) Pump (a) Motor power faulty. Check the motor and
performance
electrical supply. Refer to
low
motor manufacturer's
instructions.
(b) Incorrect rotation. Check the motor terminals at
the starter. Refer to the
motor manufacturer's
instructions.
(c) Discharge valve not Check the valve.
fully open.
(d) Excessive clearance Remove the pump set,
\ between the impeller dismantle the pump and
wear rings and renew components as
casing wear rings. necessary, Refer Chapter 3.
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(3) Excessive (a) Pump or motor Dismantle the pump or
noise and/or rotating assembly motor and check
vibration out of balance. components for dynamic
balance. Refer to dynamic
balance, Section 8.11,
Chapter 3.
(b) Journal bearing, Dismantle the thrust bearing
thrust bearing, or and dismantle the pump and
bearing bushes on check the pump and shaft
the pump, or bottom bushes; renew as
shaft worn. necessary. Refer Chapter 3.
(c) Journal bearings on Refer to the motor
the motor worn. manufacturer's instructions.
(d) Excessive wear of Dismantle the pump and
pump internals. check for wear. Renew
components as necessary.
Refer to Chapter 3.
(e) Excessive wear in Refer to the motor
motor internals. manufacturer's instructions.
(f) Securing Ensure that all accessible
arrangements loose. fastenings and
corresponding pipe work are
secure.
SECTION- C
CHAPTER-3
LIST OF CONTENTS
1 Introduction
\
I 1.1 Periodic and preventive maintenance
1.2 Routine checks
2 Tools
3 Recommended lubricants
4 Weights
5 Maintenance procedures
5.1 Examining the combined thrust and journal
bearings
6 Removing the driving motor
7 Dismantling procedures
7.1 Preparation prior to removing the motor stool,
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headpiece and pump
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\_ 7.2 Removing the motor stool, headpiece and
pump.
7.3 Dismantling the headpiece and pump
8 Inspection and renewal
8.1 Clearances
8.2 Impellers
8.3 Shaft sleeves and bearings
8.4 Pump Shafts
8.5 Combined thrust and journal bearing
8.6 Mechanical seals
8.7 Flexible couplings
8.8 Keys
8.9 Nuts, Bolts & studs
8.10 Joints, "0" rings and locking device
8.11 Dynamic balancing
8.12 Cleanliness
9 Assembling procedure
9.1 Assembling the pump and head piece
10 Installing pump, head piece and motor stool
11 Installing the drive motor
12 Final assembling and connection
13 Parts identification
CHAPTER-3
1 INTRODUCTION
It is recommended that a system of routine inspection and maintenance is

established during which the condition of the various components in the pump set
can be determined and recorded for comparison with later inspections. Any
defects should be repaired or the components renewed at the earliest opportunity.
Certain inspections can only be made when the plant is shut down, but
others can be made under operating conditions.
It is essential that all lifting tackle and equipment is maintained in a

· serviceable condition and that safety rules and regulations are observed at all
times.
A high degree of cleanliness of the equipment and surrounding area

should be maintained as this will assist in the detection of minor leaks and defects
which, if unnoticed, could lead to more serious defects.
/ 1.1 Periodic and Preventive Maintenance

\..
The following are the primary criteria for examination and renewal of wearing parts
and it is recommended that these aspects are checked regularly during every shift.
(1) Reduction in pump performance, ie., reduction in discharge pressure or a

sustained increase in motor power consumption.
(2) Excessive vibration.
(3) Excessive leakage at the pump mechanical seal plate.

1.2 Routine Checks
It is essential that the pump running check given in Chapter 2, Section 4,

are carried out regularly. The checks concerned with the mechanical condition of
the pump set are repeated here for the convenience of the maintenance
engineers.
(1) Check that the pump discharge pressure is normal.
(2) Check that the motor current is normal.
(3) Check the oil level in the thrust bearing gauge glass.
(4) Check the stuffing box for excessive leakage.
(5) Check the accessible joints for leaks.
(6) Check the accessible fastenings for security.
2 TOOLS
The following tools and equipment are available for use on the pumps.
When not in use they should be safety stored. Any defects or shortages should be
remedied at the earliest opportunity, otherwise maintenance and overhaul may be
hindeied.
No. off Tool and Purpose

1 "C" spanner for impeller nuts and muff coupling nuts.
1 set Withdrawal and fitting gear, thrust bearing.
1 set Withdrawal and fitting gear first stage.
3 RECOMMENDED LUBRICANTS
Refer to the thrust bearing manufacturer's instructions in Chapter 5 for the
recommended lubricant.
4 WEIGHTS
Item Weight. kg
Pump (less motor, canister and foundation ring) 5080
Rotating assembly 547
Canister 1920
Foundation ring 145
}
/ Head piece 1032
Shaft, bottom 109
Impeller, 1st stage 50
Impeller, 2nd to last stage 31
Ring main, top. 7 stage 93
Ring main bottom 145
Suction bell mouth 64
Casing, 1st stage 640
Casing, intermediate 2nd stage 235
Casing, last stage 191
/ Shaft, top I intermediate 171
\_ ... )
Motor stool 417
5 MAINTENANCE PROCEDURES
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5.1 Examining the combined thrust and journal bearing
Note : The following instructions should be read in conjunction with the thrust
bearing manufacturer's instructions contained in Chapter-4.
(1) Ensure that the shut-down procedures in Chapter 2, Section 7 have been
carried out.
(2) Remove the access covers from the motor stool and headpiece.
(3) Remove the nuts and bolts and remove the spacer and membranes from
the pump and motor half couplings.
Note : The flanges of the spacer and half couplings should be marked in relation
to each other for ease of assembling.
(4) Remove the drain plug from the base plate and drain the oil from the thrust
bearing.
(5) Remove the oil gauge glass and pipe extension to avoid any damage.
(6) Disconnect and remove the combined oil filler and vent pipe to avoid any
damage.
(7) Remove the bearing inlet and outlet cooling water pipe work.
(8) Remove the bearing cover securing screws and remove the halves of the
cover, with the cooler attached.
Note : Tapped holes are provided in the cover for lifting purposes.
(9) Unlock the lock-washers and remove the anti-vortex shroud securing
screws. Raise the shrouds to gain access to the journal pads.
(1 0) Remove the journal pads from the casing, by inserting a suitable screwed
rod into the tapped hole provided on each journal pad. Carefully slide each
pad around and out from the casing.
(11) Examine the journal bearings. Refer to the bearing manufacturer's

instructions contained in Chapter-4.
(12) Apply a film of oil to each journal and install the pads into location in the
casing and around the shaft. Remove the temporary screwed rod from
each journal pad.
(13) Locate a temporary face plate on the pump shaft end and a similar
temporary face plate on the motor shaft end. Secure each face plate to its
respective shaft end with a center bolt.
(14) Locate temporary bolts and nuts between the motor and pump half
couplings.
Note: Do not tighten the temporary nuts and bolts between the half
couplings at this stage.
(15) Remove the nuts securing the bearing casing and base plate to the
adapter plate.
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/ (16) Remove the access guards from the head piece.
(17) Disconnect the inlet and outlet mechanical seal sealing water pipe work.
This will avoid any unnecessary strain and protect the seal, during any
movement of the shaft, whilst examining the thrust pads.
(18) Remove the screws on the seal plate and slacken the grub screws which
lock the seal retaining collar and seal sleeve to the pump shaft.
Note : Check that the seal plate is free within its normal location.
(19) Insert starting screws into the tapped holes provided in the thrust bearing
casing and carefully break the seal between the casing and base plate.
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(20) Tighten the nuts on the temporary bolts between the half couplings, and
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raise the shaft assembly by 8 mm, to ensure that the thrust collar is clear
of the thrust pads.
(21) Lift the thrust casing from the base plate to gain access to the thrust pads.
Support the thrust casing on temporary supports placed between the base
plate and casing. Remove the starting screws from the casing.
CAUTION : Avoid any damage to the "0" ring provided in the base plate.
_ _ _ _ _ _ _ _(22)_Witb_sufficienLaccess_av:ailable_to_tbe_tbwsLpads,_remov:e_eacb_pad_from _ _ _ _,
the groove formed in the base plate.
(23) Examine the thrust pads. Refer to the bearing manufacturer's instructions
contained in Chapter-4.
(24) Apply a film of oil to each thrust pad and install the pads into the place in
the groove formed in the bas plate.
Note : Ensure that the thrust pads are correctly fitted and prevented from
rotating by means of the thrust pad stop.
(25) Lift the thrust casing, remove the temporary supports and lower the casing
onto the base plate.
(26) Unscrew the nuts on the temporary bolts, between the half couplings and
carefully lower the shaft assembly to return to its original position. The
thrust collar will rest on the thrust pads.
(27) Locate and secure the seal plate with the screw to the stuffing box.
(28) Secure the thrust casing to the base plate with the nuts on the studs.
(29) Locate the anti-vortex should into the thrust casing and secure it with the
screws the new lock-washers to the casing. Lock the screws with their
lock-washers.
(30) Fit a new cover joint to the casing and locate and secure the cover halves,
with attached cooler, to the casing with screws.
(31) Install and connect the pipe extension and oil gauge glass to the casing
assembly.
(32) Fit the drain plug to the thrust bearing base plate
(33) Connect and secure the combined oil filler and vent pipe to the casing.
(34) Remove the combined air vent/oil filler and fill the bearing to the correct
level with the recommended lubricant. Replace the combined air vent/oil
filler.
(35) Connect and secure the bearing inlet and outlet cooling water pipe work.
(36) Remove the temporary nuts and bolts from the coupling halves and
remove each temporary face plate from the pump and motor shaft ends.
(37) Check the coupling alignment. Refer to the information contained in
illustration P2424.
(38) Ensure that the seal assembly is secured with its screws to the stuffing
box. Refer to the instructions indicated on the seal drawing.
Note : The mechanical seal must be removed during the dismantling in Section
and renewed during the assembling in Section 9.
(39) Secure the inlet and outlet sealing water pipe work to the mechanical seal
plate.
,,
i 1 (40) Secure the access guards to the headpiece.
\ }
(41) Install and secure the coupling spacer and membranes to the respective
pump and motor half couplings, with the nuts and bolts. Refer to the
coupling manufacturer's instructions in Chapter-4.
(42) Secure the access guards to the motor stool.
(43) Prepare the pump for start-up. Refer to Chapter-2, Operating Instructions,
Section-2, Pre-Start Checks.
6 REMOVING THE DRIVING MOTOR
Note: The following instructions should be read in conjunction with the motor
manufacturer's instructions.
/
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(1) Ensure that the shut-down procedures in Chapter 2, Section 7 have been
carried out.
(2) Isolate and remove the electrical supply cables from the driving motor.
Refer to the motor manufacturer's instructions.
(3) Remove the access covers from the motor stool.
(4) Remove the nuts and bolts and remove the spacer and membranes from
the pump and motor half couplings. Refer to the coupling manufacturer's
instructions in Chapter-4.
Note: The flanges of the spacer and half couplings should be marked in
relation to each other for ease of assembling.
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(5) Attach suitable lifting gear to the lifting lugs provided on the motor.
Unscrew and remove the screws securing the motor to the motor stool,
and carefully lift the motor from the motor stool with its half coupling
attached.
(6) Lower the motor onto suitable supports and remove the lifting gear.
7. DISMANTLING PROCEDURES
7.1 Preparation Prior to Removing the Motor Stool, Headpiece and Pump
(1) Ensure that the procedures for removing the driving motor in Section 6
have been carried out.
(2) Withdraw the half coupling from the pump top shaft with the withdrawal
gear provided. Remove the half coupling key from the shaft and retain it.
Refer to the coupling manufacturer's instructions in Chapter-4.
(3) Remove the oil drain plug from the thrust bearing and drain the oil into a
suitable container. When the oil has drained replace the drain plug. Refer
to the thrust bearing manufacturer's instructions in Chapter-4.
(4) Disconnect and remove the thrust bearing cooling water inlet and outlet
pipe work. Remove the combined air vent/oil filler pipe work, oil level
gauge associated pipe work and oil drain pipe work.
7.2 Remove the Motor Stool, Headpiece and Pump
Note : Ensure that the preparation procedures have been carried out in
Section 7.1.
(1) Attach suitable lifting gear to the motor stool, then remove the motor stool
securing screws and carefully remove the motor stool from the head piece.
(2) Remove the access covers from the headpiece.
(3) Disconnect and remove the inlet and outlet sealing water pipe work from
the stuffing box.
(4) Disconnect the seal assembly . Refer to the instructions given on the seal
drawing.
(5) Remove the thrust collar lock-nut from the shaft with the spanner provided.
Note: As the lock-nut is unscrewed, the rotating assembly will gradually drop
to its lowest position, with each impeller resting in its casing.
(6) Remove the bearing cover securing screws and lift and remove the cover,
with the cooler attached, to gain access to the internals of the thrust
bearing. Remove and discard the cover joint.
Note: Tapped holes are provided in the cover for lifting purposes.
(7) Unlock the lock-washers and remove the anti-vortex shroud securing
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) screws. Remove the shroud to gain access to the journal pads.
(8) Remove the journal pads from the casing, by inserting a suitable screwed
rod into the tapped hole provided on each pad. Carefully slide each pad
around and out from the casing.
(9) · Attach suitable lifting gear to the thrust collar and with the withdrawal gear
supplied withdraw the thrust collar from the shaft. Remove and retain the
collar key. Lower the thrust collar onto supports and remove the lifting
gear.
Note: During removal of the thrust collar, ensure that the corresponding
bearing faces are not damaged.
\ ... (1 0) Remove the nuts from the studs securing the casing and base plate to the
adaptor plate. Attach suitable lifting gear to the casing and remove the
casing clear from the base plate and shaft.
(11) Lower the casing onto suitable supports and remove the lifting gear.
(12) Remove the thrust pads from the groove formed in the base plate.
(13) Refer to the bearing manufacturer's instructions in Chapter-4. Insert

jacking screws into the tapped holes provided on the base plate. Screw in
the jacking screws to separate the base plate from the adaptor plate. Lift
-----------the-base-plate-away-with-the-sleeve-atta-che-d.
(14) Remove the screw securing the sleeve to the base plate. Remove the
sleeve and remove and discard the joint. Remove and discard the "0" ring
from the base plate.
(15) Remove the seal assembly from the stuffing box. Refer to the mechanical
seal manufacturer's instructions on the seal drawing.
(16) Remove the seal nut from the shaft and remove the seal plate from the
stuffing box.
(17) Remove the stuffing box securing screws and screw in jacking screws into
the tapped holed provided. Attach suitable lifting gear and remove the
stuffing box from the headpiece and shaft. Lower the stuffing box onto
suitable supports and remove the lifting gear. Unlock-washers then
remove the screws from the underside of the stuffing box and remove the
restriction bush.
(18) Remove the nuts and bolts securing the discharge branch to the discharge
pipe work.
(19) Attach suitable lifting gear to the lugs provided on the head piece.
(20) Remove the screws securing the headpiece to the canister. With the lifting
gear attached, carefully raise the headpiece and pump assembly from the
canister. Remove and discard the joint. Cover the canister opening with a
suitable temporary cover.
(21) Transport the headpiece and pump assembly to a suitable maintenance

area. Carefully lower and support the headpiece and pump assembly in
the horizontal position.
CAUTION : The pump must not pivot on the first stage casing.
7.3 Dismantling the Head piece and pump:
CAUTION : (a) The head piece, pump casing and rising mains must be
supported on the horizontal position.
(b) The pump top shaft must be suitably supported in the
horizontal position.
(c) Before dismantling the assembly, mark the headpiece, pump

casings, rising mains and bell mouth to ensure correct
assembly.
(1) Before proceeding any further check the total axial travel as follows:-
(a) Push the pump shaft until it abuts at the suction end. Lay a straight
edge across the face of the head piece, at the stuffing box adjoining
'i face, and with a pencil scribe a line on the top shaft.
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(b) Pull the pump shaft until it abuts at the discharge end.
(c) Lay the straight edge across the face of the head piece and scribe a
second line on the top shaft.
(d) Measure the distance between the two scribe lines which indicate
the total axial travel of the rotating assembly.
Note: The correct total axial travel should measure 8 to1 0 mm.
CAUTION: The pump to shaft and casings must be supported.
(2) Attach suitable lifting gear to the suction bell mouth, unlock the tab
washers and remove the screws securing the bell mouth to the first stage
pump casing, then lift the bell mouth clear off the pump shaft. Discard the
tab-washers and the "0" ring. Lower the bell mouth on suitable supports
and remove the lifting gear..
Note: The bell mouth incorporates a casing wear ring and Gutless rubber
bearing.
(3) Release the lock-washer securing the shaft nut and using the special
spanner supplied, remove the nut from the shaft. Discard the lock-washer.
(4) Remove the first stage bottom sleeve from the shaft.
(5) Attach lifting gear to the first stage impeller and withdraw the impeller from
the pump shaft using the withdrawal gear supplied. Remove and retain the
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impeller key. Lower the impeller onto suitable supports and remove the
lifting gear.
(6) Attach lifting gear to the first stage pump casing, unlock the tab-washers
and remove the screws securing the first stage casing to the Element-1.
Insert starting screws into the tapped holes provided in the first stage
casing and tighten them to assist with removal of the casing. Move the
first stage casing along and clear from the shaft. Remove and discard the
"0" ring, and Lower the casing onto suitable supports. Remove the lifting
gear.
Note : The first stage casing incorporates a casing wear ring and a Gutless
rubber bearing.
(7) Remove the grub screws and remove the shaft tube from the first stage
casing. Discard the "0" ring.
(8) Remove the first stage top sleeve from the shaft.
Note : Support the shaft.
9) Attach lifting gear to Element-1, unlock the tab washers and remove the
screws securing the Element-1 to Element-11. Insert starting screws into the
tapped holes provided in Element-1 and tighten them to assist removal of
the Element. Move the Element-1 along and clear from the shaft. Remove
and discard the '0' ring and lower the casing onto suitable supports.
Remove the lifting gear.
Note : The Element -1 incorporates a cutless rubber bearing.
10) Remove the grub screws and remove the shaft sleeve of Element-1.
Remove and retain the sleeve key.
11) Repeat step (9) to remove Element-11.
12) Attach separate lifting gear to the bottom shaft. Remove the lock washer
and slacken back the lock nut securing the bottom shaft to the muff
coupling. Screw the coupling nut clear off the coupling, and withdraw the
bottom shaft from the coupling and lift it away. Remove and retain the
coupling key and shear ring halves.
Note : Support the intermediate shaft prior to withdrawal of bottom shaft.
13) Repeat step (12) to withdraw the muff coupling from intermediate shaft.
14) Repeat step (9) and (10) t remove Element-Ill.
Note : Support the intermediate shaft. Element-Ill incorporates a cutless rubber

bearing.
15) Release the lock washer securing the second stage impeller nut, then
using the special spanner provided, remove the nut.
16) Pull the shaft sleeves from the bottom of second stage impeller, remove
\ and retain the sleeve keys.
Note : Support the shaft.
17) Using the withdrawal gear supplied, withdraw the second stage impeller
from the shaft, remove and retain the impeller key.
18) Attach lifting gear to the second stage pump casing, unlock the tab
washers and remove the screws securing the second stage casing to the
third stage casing, then remove the second stage casing from the shaft.
Discard the tab-washers and the "0" ring.
Note: The second stage casing incorporates a casing wear ring and a Gutless
rubber bearing.
19) Pull the intermediate sleeve from the shaft.
20) Repeat Steps (17 to 19) to remove the third stage impeller and pump
casing.
21) Attach lifting gear to the bottom rising main, unlock the tab-washers and
remove the screws securing the rising main to the fourth stage pump
casing. Lift the rising main clear off the shaft. Discard the tab-washers and
the "0" ring.
22) Attach separate lifting gear to the intermediate shaft. Release the lock-
washer and slacken back the lock-nut securing the bottom shaft to the muff
coupling. Screw the coupling nut clear of the coupling, and withdraw the
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intermediate shaft from the coupling and lift it away. Remove and retain the
coupling key and the shear ring halves.
23) Repeat step (22) to withdraw the muff coupling from the top shaft.
24) Repeat steps (17) to (19) to remove the fifth and sixth stage impellers and
pump casings.
Note : Continue to support the shaft.
25) Attach a suitable lifting sling to the top shaft and remove it from the head
piece. Lower the shaft onto suitable supports and remove the lifting sling.
Note: The head piece should remain supported in the horizontal position.
8. INSPECTION AND RENEWAL
8.1 Clearances
(1) Refer to the sectional arrangement for details of clearances. It is

recommended that when the pump internal diametrical clearances have
reached twice the mean of the figures quoted or are expected to before
the next overhaul, the component or components should be renewed. The
main considerations, however, are pump performance and motor power
consumption.
(2) Casing wear rings and impeller wear rings are normally supplied undersize
and oversize respectively on the wearing surfaces, so that they can be
machined to give the appropriate clearance.
Note : (a) The impeller wear rings are pressed on to the impellers and retained
by grub screws, and the casing wear rings are pressed into their
respective casings and also retained by grub screws.
(b) if the impeller or casing wear rings require to be renewed the wear
rings must be machined from the casing or impeller, and new wear
rings pressed on and secured by grub screws.
(4) A shaft sleeve fitted to the top shaft, in way of the mechanical seal, is held
by loctite. If the sleeve has to be renewed it must be machined from the
shaft and a new sleeve fitted and secured by loctite.
8.2 Impeller
( 1) Examine the shaft sleeves for wear and damage. Renew as necessary.
(2) Ensure that the impeller wear rings are correctly fitted and secured.
8.3 Shaft Sleeves and Bearings
(1) Examine the shaft sleeves for wear and damage. Renew as necessary.
(2) Examine the journal bearings from wear and damage. Renew as
necessary. Refer to Section 8.1 Step (4).
8.4 Pump Shafts
Examine the shafts for damage or bowing and check for concentricity. Each shaft
must be within 0.05 mm full indicator movement.
8.5 Combined Thrust and Journal Bearing
Refer to the manufacturer's instructions in Chapter 4.
8.6 Mechanical Seal
(1) Renew the mechanical seal. Refer to the seal manufacturer's instructions
in Chapter-4.
(2) Check that the water passageways formed on the seal plate are clear.
(3) Examine the stuffing box restriction bush. Renew as necessary.
8. 7 Flexible Coupling
Refer to the manufacturer's instructions in Chapter-4.
8.8 Keys
All keys must be a good fit in their keyways and reference marks must be
clearly legible. They must be flat, parallel and free from burrs. Worn or damaged
keys must be renewed.
8.9 Nuts. Bolts and Studs

Examine all studs, nuts and bolts for damage or deterioration. Renew as
necessary.
8.10 Joints, "0" Rings and Locking Devices
All joints "0" rings and locking devices must be renewed on assembly.
8.11 Dynamic Balance
If any of the impellers or the coupling hub are renewed, it should be noted
that the new components are dynamically balanced during manufacture. If,
however, the dynamic balance of any components is checked and is found to be
out with the limit of 2835 MIN g em per plane of measurement, the following rules
must be adhered to when removing metal to effect the balance.
Note M =weight of the component (kg)
N = pump speed (rev/min)
CAUTION: (1) The thickness of the impeller shroud must not be reduced by
more than 1.6 mm at any point.
(2) No meal is to be removed from the impeller within 12.7 mm of

its periphery.
(3) The weight of metal to be removed is to be calculated in the

from of segment, the arc length of which does not exceed 0.1
of the circumstance of the impeller.
(4) If the amount of metal to be removed exceeds the limits

imposed by (1) and (3), BHEL, Hyderabad, should be
consulted.
8.12 Cleanliness
All components must be perfectly clean and free from burrs, and all water
passages must be cleaned out before the pump is assembled. Check that all small
bore pipe work is clear.
9 ASSEMBLING PROCEDURES
9.1 Assembling the Pump and Head piece

During assembly, it is recommended that colloidal graphite or similar is
applied to the shaft and bores of the impeller and shaft sleeves, allowed to dry and
then polished.
CAUTION The pump shaft and casings must be suitably supported in the
horizontal position whilst assembling the pump.
Note : (a) The following torque figures must be used when assembling the
pump:-
Sixth stage casing to head piece. 700 Nm
First to third and fourth to last stage castings, inclusive 1350 Nm
Bottom rising main to third and fourth stage casing 140 Nm
Bell mouth to first stage casing 50Nm
Head piece to canister 290 Nm
Motor stool to head piece 220 Nm
(b) Observe the match marks made prior to dismantling to ensure

correct assembly.
(1) Ensure that the head piece is supported in the horizontal position.
( I (2) Install the last stage shaft sleeve on the top shaft, to abut the sleeve fitted
J
on the shaft by loctite.
(3) Attach lifting gear to the top shaft, and carefully install the shaft in the head
piece. Support the shaft and remove the lifting gear.
Note: When installing the sixth stage casing, adjust the top shaft supports to
the ensure that the shaft is supported at all times.
(4) Locate a new "0" ring on the spigot of the last stage pump casing, attach
lifting gear and install the casing on the top rising main. Secure the pump
c-a-sing-to-th-e-rising-main-with-the-s-crews-and-n-ew-taiJ-washers.
Note: (a) Observe the note following Step (4).

(b) When installing the pump casing, ensure that the Gutless
rubber journal bearing does not become damaged.
(c) Do not bend over the lock-washer tabs meantime.
(6) Install the sixth stage impeller k<;:Jy in the shaft, then install the impeller on
the shaft, to locate on the key and abut the last stage shaft sleeve.
(7) Repeat Steps (5) and (6) to install the fifth and fourth stage pump casing
and impellers.
(8) Screw the impeller nut onto the shaft and, using the special spanner
provided, tighten the nut against the hub of the fifth stage impeller.
(9) Before proceeding further, check the total axial travel as follows :-
(a) Push the pump shaft until it abuts at the suction end. Lay a straight
edge across the face of the head piece, at the stuffing box adjoining
face, and with a pencil scribe a line on the top shaft.
(b) Pull the pump shaft until it abuts at the discharge end. Lay the
straight edge across the face of the head piece and scribe a second
line on the top shaft.
(c) Measure the distance between the two scribed lines which indicate
the total axial travel to the rotating assembly.
(e) The total axial travel is 8 to 10 mm, and if this is not achieved, the
cause must be established and the fault must be corrected before
proceeding.
(1 0) Slide the muff coupling nut, lock-nut and a new lock-washer onto the top
shaft, beyond the shear ring groove in the shaft, then install the shear ring
halves in the groove, and the coupling key in the shaft.
(11) Slide the coupling sleeve onto the shaft, to abut the shear ring, then screw
the coupling nut into the bore of the sleeve. Tighten the nut to pull the
sleeve hard against the shear ring and secure it with the lock-nut and lock-
washer.
(12) Install the muff coupling nut, lock-nut, new lock-washer, shear ring halves
and coupling key on the bottom shaft as described in Step (8). Sling the
bottom shaft and install it in the muff coupling sleeve, ensuring that the
spigot on the shaft end engages in the recess in the end of the top shaft.
Tighten and lock the coupling nut as described in Step (9). Support the
bottom shaft and remove the lifting gear.
(13) Install the bottom rising main as described in step (4), then install the third
and second stage pump casings and impellers as described in Steps (6) to
(7). Continue to support the bottom shaft and the pump casings.
(14) Install the sleeve keys on the shaft, at the bottom of the second stage
impeller. Install the sleeves to locate on the keys and abut the second
stage impeller.
(15) Repeat steps (8), (9) and (5) to assemble impeller, nut, check total float
and assemble Element-IV.
(16) Install the sleeve keys of Element-Ill on the shaft. Install the sleeve to
locate on the key and abut the shoulder on the shaft. Lock the sleeve on
to the shaft with grub screws provided.
(17) Repeat steps (1 0,11 &12) to assemble the muff coupling and bottom shaft.
(18) With the total axial travel checked, and corrected as necessary, bend over
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the tabs on the tab-washers on all the pump casing screws, stages 2 to 6.
(19) Ensure that the first stage shaft tube is in place in the first stage pump
casing, with new "0" rings, then locate a new "0" ring on the spigot of the
first stage casing.
(20) Sling the first stage pump casing and carefully install it over the shaft, to
locate on the second stage casing, and secure it with the screws and new
tab-washers. Do not bend over the washer tabs meantime.
(21) Install the first stage top sleeve on the shaft, to abut the shoulder on the
-----------s,haft;-and-lo-cate-the-first-sta-g-e-imp-ellerkey-in-the-keyway-in-th-e-shaft.
i
(22) Sling the first stage impeller and install it on the shaft, to abut the first
stage top sleeve.
Note : Ensure that the direction of rotation of the impeller is correct.
(23) Install the first stage bottom sleeve on the shaft and secure the assembly
with the shaft nut and new lock-washer.
(24) Install the bell mouth on the first stage casing, with a new "0" ring, and
secure it with the screws and new tab-washers.
(25) Check the total axial travel as described in Step (9) then bend over the
tabs on the lock-washers.
10 INSTALLING PUMP, HEAD PIECE AND MOTOR STOOL
(1) Attach suitable lifting gear to the lugs on the head piece. Carefully lift the
head piece and pump from the horizontal to the vertical position and use
adequate supports as necessary.
CAUTION Care must be exercised to ensure that the pump does not pivot
on the first stage casing or attached bell mouth. Ensure that the
pump is supported thus avoiding the possibility of bowing.
(2) Remove the temporary cover from the canister.
(3) Lower the pump and head piece into the canister and ensure that the
pump discharge pipe is in line with the corresponding discharge pipe work.
Continue to lower the assembly until the head piece rests on the canister.
Ensure that the suction bell mouth is engaged on the snubber within the
canister and that the holes in the head piece correspond with the holes in
the canister.
(4) Secure the headpiece to the canister with the screws and remove the
lifting gear from the head piece.
(5) Secure the pump discharge pipe work to the pump discharge branch.
(6) Secure the restriction bush with screws and lock-washers to the underside
of the stuffing box or seal housing.
(7) Locate the seal sleeve key in the key way in the shaft, and secure it with
the countersunk screw.
(8) Install the mechanical seal. Refer seal manufacturer's instructions on the
seal drawing.
Note: The mechanical seal is of cartridge design.
CAUTION : Do not tighten the seal plate securing screws at this stage.
(a) Screw the seal sleeve nut and the lock-nut/thrower onto the shaft and
leave loose meantime.
(9) Locate and secure the adaptor plate with screw to the top of the head
piece.
Note: During manufacture of the pump set, the adapter plate is machined to
a specific thickness and locates between the thrust bearing base plate
/
and headpiece. The adaptor plate determines the position of the
rotating assembly when the thrust bearing is assembled.
(1 0) Fit a new joint to the sleeve and insert the sleeve into the thrust bearing
base plate. Secure the sleeve to the base plate with the screws and fit a
new "0" ring to the base plate. Refer to the bearing manufacturer's
instructions.
(11) Lift the bearing base plate onto the adaptor plate studs.
Note : Ensure that the drain hole on the base plate is positioned to
accommodate the drain pipe work. When the motor stool is assembled.
(12) Apply a film of oil to the thrust pads and insert the thrust pads onto the
base plate and move the pads around the groove to abut the pad stop.
Refer to the bearing manufacturer's instructions.
(13) Lift the bearing casing onto the base plate.
(14) Secure the bearing casing and base plate to the adaptor plate with nuts on
the adaptor plate studs.
Note : Ensure that the casing is located to accommodate the corresponding oil
level gauge pipe work.
(15) Fit the collar key to the shaft and attach suitable lifting gear to the thrust
collar. Engage the collar onto the shaft and with the use of the assembly
gear fit the collar to the shaft. Remove the assembly gear.
(16) Screw the thrust collar nut onto the haft, to abut the thrust collar, then
using the special spanner provided, tighten the nut to raise the pump shaft
into its corrected running position.
(17) Apply a film of oil to the journal pads and locate the journal pads, between
the casing a·nd collar. Locate the journal pads by inserting a screwed rod
into the tapped hole provided in each pad. Remove the screwed rod.
(18) Locate and secure the anti-vortex shroud with lock-washers and screws to
the casing. Tighten the screws and secure the screws with the lock-
washers.
(19) Fit a new cover joint to the casing. Install the cover with attached cooler.
Secure the cover to the casing with screws. Refer to the bearing
Note : (a) Tapped holes are provided in the cover for lifting purposes.
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(b) Ensure that the cover is located in the casing to accommodate the
corresponding cooling water small bore pipe work.
(20) Fit the half coupling to the shaft. Attach suitable lifting gear to the half
coupling and lift the half coupling on the shaft to abut the thrust collar nut,
using the assembly gear supplied. Remove the assembly gear from the
half coupling.
(21) Tighten the seal plate securing screws. Tighten the grub screws in the seal
sleeve until they contact the shaft. Disengage the eccentric washers I
assembly fixture from the seal sleeve.
Mechanical seal is of cartridge design.
Refer to the seal manufacturer's drawings I instructions.
(22) Secure the inlet and outlet sealing water pipe work to the stuffing box.
(23) Attach suitable lifting gear to the motor stool and lift the motor stool onto
the spigot flange provided on the headpiece.
Note: Ensure that the motor stool is positioned on the headpiece to
(
accommodate cooling water, oil level, oil filling pipe work and oil drain
''-._ pipe work associated with the thrust and journal bearing.
(24) Secure the motor stool with the screws and remove the lifting gear from
the motor stool.
(25) Connect and secure the thrust bearing cooling water inlet and outlet pipe
work, oil filter and air vent pipe work, oil level pipe work and gauge. Fit the
oil drain pipe work to the thrust bearing and fit the drain plug.
--------t29)-~ill-the-thr:ust-bear:iRg-tG-the-GG>r:reGt-level-with-the-r:eGGmmeRded-lubr:iGaRt,_.- - - - ' -
Refer to the thrust bearing manufacturer's instructions.

11. INSTALLING THE DRIVING MOTOR
Note: The following instructions should be read in conjunction with the motor
(1) Ensure that the motor half coupling is fitted. Refer to the coupling
manufacturer's drawings I instructions.
(2) Attach suitable lifting gear to the lifting hooks provided on the motor. Lift
the motor onto the motor stool.
Note: Ensure that the motor is positioned on the stool to accommodate the
associated supply cables and cooling water pipe work, etc.
(3) Secure the motor to the stool with the nuts and bolts, and remove the
lifting gear.
(4) Check the alignment between the pump and motor half couplings. Refer to
illustration for Checking coupling alignment.
(5) With the coupling alignment checked and satisfactory, assemble the
coupling spacer and membranes.
Note The flanges of the spacer and half couplings were previously marked
in relation to each other for assembly purposes. Ensure that the marks
on the flanges coincide.
(6) Secure the half couplings, spacer and membranes with the nuts and bolts.
Refer to the coupling manufacturer's drawings I instructions.
(7) Secure the access covers to the motor stool.
12 FINAL ASSEMBLING AND CONNECTION

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• (1) Connect and secure the air vent pipe to the pump.
(2) Ensure that the cooling water is available to the thrust bearing.
(3) Ensure that the sealing water is available to the stuffing box.
(4) Connect and secure the electrical power supply cables to the driving
motor. Refer to the motor manufacturer's instructions.
(5) Return all tools and lifting gear to their storage area. Refer to Chapter 2
' and carry out the Pre-start checks.
)
When ordering spare parts reference must be made to the pump Serial or
Job Number, Nomenclature, the Sectional Arrangement Drawing, the Item
Number, and the Quantity of each components.
/
I
SECTION- C
CHAPTER-4
SUB-VENDOR'S DRAWINGS /INSTRUCTIONS
1 Mechanical Seal
2 Thrust & Journal Bearing

SECTION- C
CHAPTER-4 ·

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1. MECHANICAL SEAL
IBURCMANN OPERATING MANUAL
OPERATING MANUAL
FOR
BURG MANN
MECHANICAL SEAL (M.S.)
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IBUROrv1Ailjf~ OPERATING MANUAL
TABLE OF CONTENTS PAGE
0 Foreword 1
1 General Information 2
2 Product Information 3-5

2.2 Declaration 3
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2.3 Type Designation 3
2.4 Operating Conditions 3
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2.6 Description and Function 4
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2.7 Required Space, connecting dimensions 4
2.8 Drawings, Diagrams 4
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3 Safety Notes 6
CD 4.1 Packing and Storage 6
4.2 Preparation for Assembly 6-7
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4.3 Special Instructions 8
4.4 Installation 9
4.5 Directives in case of Failure 9
"" 5. Servicing 10-13
5.1 Tungsten Carbide Designs 10
(") 5.2 Circulation 10
5.3 Buffer Fluid 10
5.4 After Sales Service by BURGMANN 10-12
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5.5 Disposal of Burgmann Mechanical Seal 12

6. Copyright 13
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IBURGMANN OPERATING MANUAL
FOREWORD
Dear Sir,
Page 1 of 13 Thank you for purchasing the Burgmann Mechanical Seal (M.S.).
We at Burgmann are confident that your new purchase will greatly
expand your working capacity and efficiency.
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....0 This Operating Manual shows you how to get the most out of your new
Burgmann Mechanical Seal (M.S.). Whether you are installing,
operating or servicing, this manual will show you how to do it - quickly
and easily.
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Please take some time to go through this manual before installation. You
don't have to read it all at once. We just want you to know what a great
co Mechanical Seal (M.S.). you have.
We've taken a great deal of care in preparing this manual so that you will
never be left wondering how to perform a certain function. Nevertheless,
...... even after reading this manual if you still aren't sure about something,
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please feel free to contact your nearest sales or service center of
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Burgmann or our HQ. We shall be too glad to answer your queries.
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SR. DESCRIPTION DETAILS

Page 2 of 13 NO.
I Customer Bharat Heavy Electricals Ltd
II Machine Manufacturer B.H.E.L
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...... Ill Customer PO No. F6 04 0989
IV Drawing Nos. 09-H75N/1 OO-E3
v Burgmann W.O. 14910
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IBURCMANN OPERATING MANUAL
Page 3 of 13 BURGMANN INDIA PVT. LTD.

A. K. Industrial Estate, Veer Savarkar Flyover,
Goregaon (West)
Mumbai-400 062.
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INDIA .
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', within the meaning of the EC-directive >> MACHINERY <<
A mechanical seal does not function independently. It is intended
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to be incorporated into or assembled with machinery.
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MECHANICAL SEAL DRG. NO. : 09-H75N/1 OO-E3
The materials of the mechanical seal depend on the application and

ll) are fixed in the order. They may vary from those stated in the
drawing.
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I 2.4 OPERATING CONDITIONS
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MECHANICAL SEAL DRG. NO. : 09-H75N/1 OO-E3
Kind of Machine --
N Medium to be sealed -
Suction Pr. :FULL VACUUM
Discharge Pr. :3 Kg/cm 2
Temperature Max. :200° c
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0 Speed : 1000 RPM
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IBURGfviAi~i~ OPERATING MANUAL
2.5 DESIGNATED USE
This mechanical seal is exclusively designed for the use in the

specified machine. A different utilisation or a utilisation going
beyond the specification is considered contrary to its designated
use and excludes a liability by the manufacturer.
Page 4 of 13 Operation under conditions lying outside those limits stated in

paragraph >> operating data << is considered contrary to its
designated use.
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Should the seal be operated under different conditions or at a
different application BURGMANN has to be asked for recognition as
safe in advance.
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2.6 DESCRIPTION AND FUNCTION

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The BURGMANN Mechanical Seal mentioned in clause 2.3 & 2.4 ,

has been supplied in cartridge construction, in this, the seal can be
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installed directly on the pump casing without any adjustment. The
seal forms a pre-mounted unit (seal cartridge), asembled at works,
ready to be installed without any adjustment.
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Assembly Fixtures (24) are provided for holding the cartridge in one
piece during transport, storage, assembly and disassembly.
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The connecting dimensions of the Mechanical Seal were checked

and approved by the customer on the main drawing.
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The available mounting space given by the machine was decisive

for the design of the gland parts of Mechanical Seal. The
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connecting dimension was checked before shipment with regard to
the BURGMANN drawing.

Assembly drawing Nos. 09-H75N/1 OO-E3
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The assembly drawing in the original scale and in its latest edition
(latest revision) only is decisive for the design and use .
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IBUROMANN OPERATING MANUAL
D 3. SAFETY NOTES
Any person at the user's shop being involved in assembly,

disassembly, operation and maintenance of the BURGMANN
Mechanical Seal must have read and understood this
Page 5 of 13 Instruction Manual and in particular the safety notes. We
recommend the user to have this confirmed.
...
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BURGMANN Mechanical Seals are manufactured on a high
quality level (ISO 9001) and they keep a high working reliability.
Yet, if they are not operated within their intended purpose or
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handled inexpertly by untrained personnel they may cause risks.
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The user is asked to check as part of his security program what
effects a failure of the Mechanical Seal might have on the
environment and what additional safety measures have to be
taken to prevent personal injury.
Any operation mode that affects the operational safety of the

mechanical seal is not permitted.
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TRANSPORT I STORAGE /INSTALLATION
PACKING AND STORAGE
ISectio~ II If not specified differently in the order the BURGMANN standard

packaging is used, suited for dry transport by truck, train or plane.
The signs and notes for handling on the packaging have to be
observed.
Page 6 of 13 Notes for incoming inspection
Check packaging for visible damages.
Open packaging carefully. do not damage or lose parts-
supplied separately
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..... Check if consignment is complete (delivery note). Inform the
supplier immediately in writing if parts are damaged or
missing.
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These recommendations apply to all BURGMANN mechanical seals
which have been supplied and stored in their undamaged original '
packaging, as well as to seals which have been installed in a
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component of a plant. (e.g. pump, compressor, etc.) but have not
yet been put into operation.
,.._ A preservation of the BURGMANN mechanical seals is not ,

necessary.
Do not use corrosion protection agents.
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There is the risk of deposition or chemical attack of the
elastomeric secondary seals.
Check in case of a preservation of complete plants with

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mechanical seals installed:
the compatibility of the chosen preservation agent with the
seal materials and with the elastomers
'<I' no impairment of the seal's axial movability by
conglutination or by gumming
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Sliding materials and elastomers are subject to material-specific
and time-based alterations (distortion, ageing) which might reduce
the full efficiency of the seals. yet, this may be avoided by
observing the storage instructions.
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Damages caused by improper storage may not be claimed on

the BURGMANN company with regard to their warranty.
Store the seal in the original packing lying on a flat surface.

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(!) The mechanical seals have to be stored in dry, dustfree, moderately
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humidity below 65%, temperature between 150C and 25oc.
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4.1 PACKING AND STORAGE ( cont.. .. )
Direct exposure of the mechanical seal to heat (sun, heating) as

well as to ozone, present or produced by ultraviolet light
(halogen or fluorescent lamps), must be avoided because of the
risk of embrittlement of elastomeric materials.
Page 7 of 13
Check the mechanical seal:
after a storage period of approximately 4 years
- aft era d amage o fth e pac k agmg
0 - after a shock on the mechanical seal (e.g. by dropping
.....
the packed seal)
- at the manufacturer's or at the nearest service centre.
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\, I 4.2 PREPARATION FOR ASSEMBLY

CIQ General Instructions
I Utmost care must be taken to ensure cleanliness during assembly;
it is especially important to avoid damage to the elastomers.
""' - Observe the assembly dimensions.

- Observe the axial run-out and concentricity tolerances as stated in
the valid design manual.
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Page 8 of 13 - All the shoulders over which elastomers

are to be pushed must be chamfered by 2mm x 30°. Their
surfaces must be free of any damages and their edges rounded
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-The shaft must show the following surface roughness values in the
vicinity of radial sealing elements :
(Dynamic sealing part (spring loaded unit of the seal) Ra =:;1.01J.m.
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Static seal part of Ra =:; 2.51J.m)
- For cartridge seals, the seal can be assembled directly after
taking precautions on the shaft.
00 Profile rings of Statotherm® can only be deformed axially (radial
deformation results in destruction).
- To reduce frictional forces during assembly of the seal, the shaft ;
...... is thinly lubricated with oil or silicon grease in the zone of the seal
rings.
Warning : This does not apply to rubber bellows seals.

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Warning : In the electric dip-painting range the 0-rings must be
free from silicon grease and must be mounted free from silicon
grease.
lO Warning : Under no circumstances must 0-rings made of
Ethylene Propylene rubber come into contact with mineral oil
or grease. It is recommended to use silicon grease.
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- Never cover the sliding faces with a lubricant as they must be

assembled completely dry, clean and dust-free.
- When pressing in stationery seals, make sure that the pressure
M
distribution is uniform. The 0-ring must be fitted using water or
alcohol only.
- For heat dissipation and lubrication of single-acting mechanical
N
seals, there should be a recirculation from pump discharge to
seal.
This measure prevents medium deposits in the sealing area.
- Thoroughly vent the stuffing box before starting and remove the
assembly fixture before start-up.
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7 IBUROMANN OPERATING MANUAL
4.3 SPECIAL INSTRUCTIONS
The Burgmann mechanical seals H75N are independent of the

direction of rotation. The set screws with cup points must be
renewed after every dismounting; they must be fastened with
Loctite Nr. 241 or a similar Product.
Page 9 of 13
4.4 INSTALLATION
All steps on (in) which the seal is to be mounted should have a 2 x

30° bevel and all sharp edges should be chamfered. The shaft
...
0
surface should be smooth machined and ground in the areas where
radial seal elements are to be located (R1: = 2.51J.m.)
( ", The nutation of the shaft should not exceed 100 IJ.m. and although
' the seal can absorb slight vibration, sources of vibration should be
eliminated. Extreme cleanliness must be observed during
CIO installation, and damage to the seal faces and mounting rings must
be avoided. The 0-rings may be oiled to reduce friction, during
installation of the seal. EP-rubber 0-rings are an exception,
however, and should not come into contact with oil or grease;
In this case lubrication with glycerine or water is
recommended.
Special care must be taken when mounting 0-rings of double-

PTFE-coated elastomers; apart from having a 2 x 30° mm bevel, all
edges should be deburred and rounded. When mounting 0-rings
of double PTFE-coated elastomers care must be taken to
position the rings with the butt of the outer coating facing
away from the direction of installation, otherwise splitting or
stripping of the coating is possible.
(
"-)
Crowned drive pins must be replaced whenever the seal is
dismantled. During insertion of the stationary seats, especially
those of special carbon, care must be taken to exert pressure
evenly.
4.5 DIRECTIVES IN CASE OF FAILURE
Try to define the kind of failure and record it and immediately

contact Burgmann India or nearest BURGMANN Service Centre.
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During the warranty period the mechanical seal must only be
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disassembled or removed with BURGMANN's approval or when a
(!)
-;------II=F¥4-=-=--J-;;;;;---BURGMANN_representati:-L.e_is_pre_s_e_ot.
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D I 5 SERVICING -
- - - - - --------------·-·· ··-···- -----------
-- n I 5.1 TUNGSTEN CARBIDE DESIGNS
ED 5 Are extremely wear resistant but have poor emergency running

properties. For this reason provisions must be made to ensure
lubrication.
Page 10of 13
5.2 CIRCULATION
To reduce frictional heat and prevent sedimentation in the seal

...
0 faces a circulation line from the discharge of the pump to the seal '
stuffing-box necessary. Normally a %-inch pipe is sufficient.
m
5.3 BUFFER FLUID
When operating double mechanical seals care must be taken to

ClO
ensure circulation of the buffer fluid. The pressure of the buffer fluid
should be 1.5--2 bar higher than the internal pressure and the rate
of flow should be adjusted so that the outlet temperature dose not
,._ exceed 60°C. The outlet must be located at the highest point of the
stuffing-box to prevent bubble formation.
(I)
If you have any special problems please contact BURGMANN Head

Quarters or the corresponding sales/service office in your area.
It)
'<I' The range of services offered by Burgmann not only includes advice
during the planning stages but also technical support after
commissioning. This is support by a world comprehensive network of 1
subsidaries, field engineers and service centres.
C'?
MUMBAI (HEAD QUARTERS)

N BURGMANN INDIA PVT. LTD.
A.K.INDUSTRIAL ESTATE,
VEER SAVARKAR FLYOVER,
GOREGAON(WEST)
MUMBAI-400 062.
TEL: 022-28741534
FAX: 022-28748810.
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SERVICE CENTRES
BAN GALORE BARODA
ISedio~
3390/41 ,3rd Cross,51h Main, 17-A Nutan Bharat Society,
I RPC Layout,Vijayanagar, Near Nutan Bharat Club,
· Bangalore- 560 040. Alkapuri,
Tele Fax: 080-23305137 Baroda - 390 007.
Email : bangalore@burgmannmail.com Tel.: 0265 233 9151
Page 11of 13 Fax.: 0265 233 9149 I
Email: baroda@burgmannmail.com
CHENNAI CO CHIN
"N" Block, New No. 5,01d No.320, 34/749A, Thrikkovil Road, .',
0
..... 25 Street, Anna Nagar (East), Edapally,Cochin- 682 024 .
Chennai- 600 102. Kerala, India.
Telefax.: 044 2620 6968. Telefax. : 0484 2331 708
Q)
Touchtel: 52020649 Email : cochin@burgmannmail.com
Email : chennai@burgmannmail.com '
( \
)
\ I
DELHI HYDERABAD
co 40/55, 1st Floor, 50, Dhruvatara Apartments,
Chittaranjan Park, Amruta Estate, Somajiguda,
New Delhi -110 019. Hyderabad - 500 482.
Tei:011 26422533,01126483347 Telefax : 040 2331 6577
"" Fax : 011 2648 3275 Email: hyderabad@burgmannmail.com
Email : delhi@burgmannmail.com
CD
KOLKATA KOTA
903-Krishna, Ashirwad Peari,10-F-12,
224 Acharya Jagdish Chandra Bose Flat No. S1 ,Parijat Scheme
Road, Mahaveer Nagar Ill,
II) Kolkata-700 017. Kota, Rajasthan,
Tel. : 033 2240 9829 Kota- 324 005.
Fax: 033 2240 6480 T elefax : 0744 24 7 6537
Email : kolkata@burgmannmail.com Tele/Answering Machine 0744
"" 3090472
)
Email : kota@burgmannmail.com
\..._,
C') PUNE VISAKHAPATNAM
H- 198, Mantri Market, Flat No. 301, Eswar Homes,
Pune Solapur Road, 3rd Floor 1st Lane
' '
Hadapsar, Dwarakanagar,
N
Pune- 411 028. Visakhapatnam- 530 016.
Telefax: 020 2682 1713 Telefax: 0891 254 0360
Email : pune@burgmannmail.com Tele : 0891 551 6503
Email: vizag@burgmannmail.com
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- - - - - - - ------ - - - - -
OPERATING MANUAL
,-------------------------------------·------··
SERVICE CENTRES
MUMBAI PANVEL
Excl Industrial Products Pvt. Ltd., Excllndustrial Products Pvt. Ltd.,
A.K. Industrial Estate, 1st Floor, Om- Hari Darshan Apts.,
Veer Savarkar Flyover, Plot No. 34, V. M. Road,
S.V.Road, Goregaon (W), Sector 1, Opp. CIDCO Office,
Mumbai - 400 062. New Panvel - 410 206.
Page 12of 13 Telefax: 022 2877 6896 Telefax: 022 2746 9152/3958 1948
Email: Email : excl@burgmannmail.com
exclmum@burgmannmail.com
0
..- PUNE SURAT
Excllndustrial Products Pvt. Ltd., Excllndustrial Products Pvt. Ltd.,
C- 2, Amar Enclave, 8 1/14, Vishal Nagar,
m
Opp. A.S.P.T. Near Gujarat Gas Circle,
Wanowire, Above Vijay Dairy,
Pune- Solapur Road, Adajan Road,
Hadapsar, Surat- 395 009.
CIO Pune- 411 013. Telefax: 0261 269 3538
Tel. : 020 2681 6646/4024366/2682 Email : exclsurat@ burgmannmail.com
1943
Fax.: 02026877000
.....
Email : info@ burgmannmail.com
<D 5.7 DISPOSAL OF BURGMANN MECHANICAL SEAL
Usually, the BURGMANN mechanical seals can be easily disposed

ll) after a thorough cleaning.
Metal parts (steels, stainless steels, non-ferrous heavy metals
divided into the different groups belong to scrap metal waste.
""" - Synthetic materials/ plastics ( elastomers, PTFE )special waste.
- Attention! Material containing fluorine must not be burnt.
M Some synthetic materials divided into the different groups can
be recycled.
- Ceramic materials (synthetic carbons, ceramics, carbides ) belong
N to waste products. They can be separated from their housing
materials, as they are physiologically recognised as safe.
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6. COPYRIGHT
BURGMANN has a copy right in this manual. Buyer, planner and
user of the product are authorised for use in connection with further
documentation.
We reserve the right to carry out technical modifications which

Page 13of 13 might become necessary to improve our products but are not
mentioned in this manual yet.
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. -
SECTION -C
CHAPTER-4
3. THRUST CUM JOURNAL BEARING

Michell Bearings
A Vickers company
Operations and Maintenance

Instructions for Standard Vertical Bearings
Customer: B.H.E.L - Hyderabad
Project : COND. EXTRN PUMP FOR 500MW TPS
Drawing Number: 58227
Bearing Model : 8 DNT
Version date -14 December 1998

0
----~-~ ~~--~~ ~-
Operation and Maintenance Instructions for
Standard Vertical Bearings.
1 P RELI Ml NARY NOTES. ---------------------------------------------------------------------------- 2
.1 Introd ucti on. ---------------------------------------------------------------------------------------- 2
.2 Safety. ----------------------------------------------------------------------------------------------- 3
2 DES C Rl PTI 0 N. --------------------------------------------------------------------------------------- 5
. 1 Introd u cti on. ---------------------------------------------------------------------------------------- 5
3HANDLING THE BEARING. ----------------------------------------------------------------------6

. 1 Introd u cti on. ---------------------------------------------------------------------------------------- 6
.2 Points on Handling. ------------------------------------------------------------------------------- 6
4 I NSTA LLA Tl 0 N. -------------------------------------------------------------------------------------- 7
. 1 Introd u cti on. ---------------------------------------------------------------------------------------- 7
.2 Assembly of the Bearing. -----------------------------------------------------------------------8
.3 Points before use.------------------------------------------------------------------------------- 14
5 0 PERA Tl NG. ---------------------------------------------------------------------------------------- 15
. 1 Introd u cti on. -------------------------------------------------------------------------------------- 15
.2 0 pe rating Risks. --------------------------------------------------------------------------------- 15
6 CARE AND MA I NTENA NC E. ------------------------------------------------------------------- 16
.1 Introduction. -------------------------------------------------------------------------------------- 16
.2 Procedures.--------------------------------------------------------------------------------------- 16
. 3 M a inten an ce Sched uIe. ----------------------------------------------------------------------- 17
.4 Dismantling . -------------------------------------------------------------------------------------- 18
.5 Maintenance. ------------------------------------------------------------------------------------- 21
APPEND IX 1 (SPA RES). --------------------------------------------------------------------------- 25
.1 Ordering. ------------------------------------------------------------------------------------------ 25
APPENDIX 2 (TABLE OF TORQUE'S). -------------------------------------------------------- 26

Operation and Maintenance Instructions for Standard Vertical Bearings
! -
1·1 Introduction.
This manual is to be used by qualified engineers only. It contains information
that will familiarise the user with the machine and its safe operation. It is
recommended that the health and safety advice given in this manual is
followed and is kept in mind throughout all aspects of installation, storage,
operation, etc.
- General points on safety can be found in the first section.
- More specific points on safety can be found in each separate section.
* Make sure that all safety points are clearly understood and carefully noted. *
Warrantee.
Unless otherwise stated all warranty claims shall be dealt with in accordance
with Michell Bearings.
These warranty obligations will automatically become void if the product is:
(
\ 1) Subjected to overloads.
2) Improperly handled.
3) Supplied with spare parts not approved by Michell Bearings.
4) Exceeding, or falling short of the technical characteristics specified.
,.2 Safety.
When operating the machine danger may arise to the user, the product and
plant and/or other assets. Therefore when running the machine make sure
that all the safety procedures given in this manual are strictly adhered to.
The below procedures should be noted.
1 Under no circumstances should the engineer work alone when operating the
machine.
2 At least one of the engineers should be trained in basic first aid techniques
and wear clear identification to show that he/she is a first aider.
3 No maintenance, assembly, adjustment or any other work should be carried

out on the bearing whilst the shaft is rotating or capable of movement.
4 Personnel that manipulate the product should be sufficiently trained.
5 No modifications of the product should be made unless it is approved by

Michell.
6 All users responsible for the operation of the machine must understand the
chapters fully and be familiar with the associated dangers described. These
are instructions that, if ignored, could result in death or injury.
Page 3
Before working on the bearing the engineers should familiarise themselves

with the layout of the manual.
Attention is drawn to the following formats:
6 This symbol signifies a warning. These are instructions that, if

ignored could result in death or injury.
@ This symbol signifies that attention should be made by the

operator. If ignored it could result in minor injury or failure to carry out a
particular process correctly.
<{This symbol signifies additional instructions. This is usually a

check. Missing out this stage could lead to an error going unnoticed.
(,'_. _./
\__ j
I
Page_4~~~~------~--!
I
I
12 DESCRIPTION.
,.1lntroduction.
The bearing supplied is one of the Michell Standard Vertical Series, as

manufactured by Michell Bearings. The Standard Vertical Series are a
standard range of vertical bearings.
Within the series a range of types are catered for;
i) S Type: This is a single thrust and guide bearing. It is designed to absorb
lateral forces from a rotating shaft, as well as a force along the shaft in one
direction only.
ii) D Type: This is a double thrust and guide bearing, designed to absorb
lateral forces from a rotating shaft, as well as a force along the shaft in either
direction.
The standard S Type may also be supplied with a Surge ring, designed to
absorb a temporary upward force.
All types of bearing can be fitted with a variety of Resistance Temperature

Devices (RTDs) to measure the temperature of the lubricating oil or pads. The
Standard Vertical Series are usually self contained with water coolers, the
bearings can also be modified for different methods of cooling (i.e. natural air
cooled, fan cooled and circulated oil variations) with minimum modifications to
the basic casing.
The bearing can also be insulated as an option to protect against stray

currents whilst the machine is in operation.
Page 5
,.1 Introduction.
This section points out the relevant information essential when handing the
bearing.
The bearing is supplied fully assembled (see arrangement drawing for mass
of complete bearing). Threaded holes are provided for the fitting of eyebolts
on the bearing casing and other components.
It is advisable to keep the bearing within any casing and packaging until it is
necessary to remove it for assembly.
,.2 Points on Handling.
Under no circumstances should the completed bearing be

handled manually.
6 Before using any lifting equipment, ensure that it is certified to

carry a load greater than that of the bearing.
& When handling the bearing use only provided lifting points.
Make sure bearings are stored in the intended mounting position in a dry
room only.
Please check all product equipment to ensure that it is complete before
installation. Any damage due to transit must be reported to Michell straight
away.
!-~--~-----~~---~-~~--~-~--~~- ----~-----~-
141NSTALLATION.
I
1·1 Introduction.
Prior to installation the bearing should be dismantled into a series of sub-
assemblies.
& Do not touch moving parts.
Additionally the following sub-assemblies may also be present and can be

handled manually; Circular Cooler(s), Journal Pads, Oil level gauge, RTD
assembly, Air Vent, Lower Thrust Pads and Anti-Vortex Shroud or Upper
Surge face.
The bearing is also supplied with Curil T sealant.
Remove all packaging. All parts are coated in a rust preventative. This must
be removed and all parts thoroughly cleaned before installation begins. To
remove the rust preventative, white spirit or a strong spirit based cleaner
should be used.
& There may be fumes given off during the cleaning process. Clean
parts in a well ventilated area. Always follow cleaner manufacturers'
instructions.
© Use a lint free cloth when cleaning the bearing.
Page 7
j.2 Assembly of the Bearing.·
& The disassembling and reassembling of the equipment by an

individual who is inexperienced can cause danger. Michell will not take
on any liability for any damage resulting from non-compliance with
details given in this manual.
To assemble the bearing the below procedure should be followed which if

carried out correctly could increase the working life of the machine.
1. Coat all bearing surfaces in clean oil of the correct grade.
2. Place jointing on the sleeve.
@Care should be taken when handling components to avoid the
risk of trapping hands when assembling.
3. Secure the sleeve to the baseplate with tapbolts.
(
4 If the bearing is fitted with dust seals, do not fit tapbolts.
4. Dust Seal Fitted Bearings:
• Fit seal housing to the sleeve and secure it in place with screws.
• Fit seal into housing.
• Fit seal cover and secure with tapbolts
( '
\' __ /
I
1---------~~-- -- -----------"'Page_8_ --~---------~-1

1
I
© Dust seals require some time to bed in. Do not fully tighten the
securing bolts. For the first month operation, gradually tighten the
tapbolts.
5. Position the baseplate on to the studs located on the supporting structure
and set baseplate concentric with centreline of machine.
6. Fit thrust pad stop to baseplate.
<1f Ensure that stop is fully tightened and locked In place with Loctite
222 or similar adhesive.
7. Fit lower thrust pads and push well in.
<1f Check that the clearance between the pads is correct. The
clearance is given on the arrangement drawing.
<1f Ensure that RTD fitted pads are in the correct position, as shown
on the arrangement drawing.
8. Place 0-Ring into the groove in the baseplate.
9. Fit collar to the shaft and ensure that it runs true.
1O.Lower the collar until it rests on the lower thrust pads.
Page 9
! --
<1f Check alignment. Follow the below procedure:
• Check that no thrust pads are loose (i.e. all pads are firmly clamped by the
collar).
• Use feeler gauges to check the clearances between the thrust pads pivots
and the baseplate. The clearances should be equal and no greater than
0.04mm.
/
(
©when using feeler gauges, take care not to damage the
Whitemetal surfaces.
11.Fit the journal pad stop to the casing.
<1f Ensure that stop is fully tightened and locked in place with Loctite
· 222 or similar adhesive.
& Always follow the instructions on adhesives.
) 12. Coat both the casing and baseplate mating surfaces with sealant.
& Always follow sealant manufacturers' instructions.
13. Lower casing into position.
14. Secure casing and base plate to the supporting structure using studs and
nuts. Torque nuts to value indicated in Appendix 2.
i
/
@This Appendix should be adhered to as over tightening could
damage the shell.
15. Fit journal pads.
<l Ensure that RTD fitted pads are in the correct position, as shown
on the arrangement drawing.
16.For bearings fitted with anti vortex shrouds, assemble the shroud, and bolt
on to the casing.
17.For double thrust (D type) bearings:
• Assemble the upper thrust rings, pads and stops.
<l Ensure that stop is fully tightened and locked in place with Loctite
222 or similar adhesive.
• Fit thrust ring on top of the journal housing in the casing.
18. For Surge ring fitted bearings;
• Assemble Surge ring.
• Bolt Surge ring to the journal housing in the casing.
19.Piace jointing in position on the casing.
Page II
'i -
20.For bearings fitted with internal cooler, fit cooler to cover.
@Take care not to overtighten the securing bolts on the cooler.
Overtightening may damage the cooler.
21. Fit cover and cooler assembly to the casing. Secure the cover to the
casing. Torque cover securing bolts to value indicated in Appendix 2.
@Check the cooler. Ensure that leakage from the cooler is not
possible.
22. Dust Seal Fitted Bearings:
• Fit the dust seal into the top of the cover.
• Fit seal cover and secure it in place with tapbolts.
23.Fan Cooled Bearings:
• Assemble fan and fit it to the shaft.
• Fit RTDs, pipework elbows and any extension pieces required to allow
connections to pass through fan shroud.
• Fit fan shroud to bearing casing. Secure it in place with capscrews.
4 Ensure that fan shroud does not foul the fan.
24.Fit and seal in oil level gauge, blanking plugs and any thermometry or
detectors.
I
\
Page-12-~ --~-- -- --~-~-'

& Always follow sealant manufacturers' instructions.
© Ensure that RTD assembly is not damaged and is working
COiiectly befoie fitting it.
<:@:Ensure that all plugs, pipework joints and instruments are secure
and sealed.
25. Connect up external pipework.
26. Remove air vent and fill bearing with oil up to the standing oil level
marked on the oil level gauge.
For temperature probe fitted bearings; run the bearing and establish a steady
state operating temperature then set temperature alarm to soc above the
steady state operating temperature. Shut down temperature alarm is to be set
at 1ooc above steady state operating temperature.
Page 13
,.3 Points before use.
The bearing is now complete, it must not be used until the items below
1. The entire machine has received a Declaration of Conformity, or has
been declared exempt from the Supply of Machinery (Safety
Regulations) Act 1992 and the Machinery Directive.
2. Lubricating oil has passed through the bearing and is at the proper
level.
Note!!
The lubricating oil must be a mineral based turbine oil inhibited against
oxidation, corrosion and foaming, with an ISO viscosity grade as
indicated on the arrangement drawing.
& Do not use the bearing unless the cooling system is operating.
---~--~:-----~~-----------~-~~--~--~--~-~-~-----~~~~-~~---flage-14~-------~---
15 OPERATING.
1·1 Introduction.
This section points out the risks that can occur when operating the machine.
& Do not touch any moving parts.
1·2 Operating Risks.

If the bearing has been correctly assembled, using the procedure already
given, there is only a marginal risk of the bearing failing which would be due to
the design conditions being exceeded. Examples of these conditions are;
overspeed, low lubrication levels and excess load. In order to avoid these
situations, it is suggested that;
i) Control panels are labelled with the bearing limitations.
ii) The shaft should be stopped immediately if;
a) Coolant circulation fails.
b) Bearing temperature exceeds normal operating temperature by
10°C.
The users' attention is drawn to the fact that both the pipework and
bearing surface may be hot during operation.
Where bearings are fan cooled, the fan shroud must not be removed whilst
the bearing is operating.
In order to avoid leakage of lubricant, plugs, RTDs and seals must never be
removed while the bearing is operating.
Page 15
J.1 Introduction.
This section demonstrates the care and maintenance needed for the smooth
operation of the machine.
/
,· & Do not touch any moving parts.
J·2 Procedures.
Once the steady state operating temperature has been determined, the alarm
point should be set at 5°C above this. Shut down is to occur at 1ooc above
the steady state operating temperature.
Regular inspection should be made of all seals and pipework. Any large
leakage of lubricant or coolant or sudden increase in leakage will indicate that
a seal or join is failing. Maintenance must then be carried out as soon as
/
possible.
'"
If a bearing is fan cooled, the air inlet and outlets must be periodically
inspected in order to prevent the build up of dirt and waste material. Such a
build up will lead to there being insufficient air flow and overheating will occur.
© Collect used oil and dispose of under the correct regulations.
~~--Fage~l6-~-~---~----
\·3 Maintenance Schedule.
Oil changes will be at differing periods depending on the frequency of bearing

operation and the conditions in which the bearing is operating. Approximate
oil change times are indicated below.
Conditions. Oil Change Period.

Constant Operation, dusty Three Months.
atmosphere.
Constant Operation. Six Months.
Periodic Operation. At routine maintenance.
For a bearing that is operating constantly, routine maintenance should take

place annually. If the user only operates the bearing periodically, maintenance
periods may be able to take place less frequently, this is however at the users'
discretion. An annual inspection is recommended as a minimum service
requirement.
Page 17
1·4 Dismantling.
The below procedure should be followed when dismantling the bearing.
1. Switch off machinery. Lock off controls. Secure and isolate shaft.
& Ensure control gear, barring gear and any other equipment
capable of moving the shaft is locked out and labelled "Not to be
used".
& Beware hot oil. Allow machinery to cool off before proceeding
further.
2. Where a bearing is fitted with continuous circulation of oil, allow the
circulation to continue whilst the bearing is cooling.
3. Switch off, drain and disconnect cooling system.
4. Switch off and drain the oil supply.
( & Do not disconnect the oil inlet and outlet pipework until the
bearing has been drained of oil.
5. Remove drain plug and fully drain oil from bearing.
@ Any oil spillage should be collected in suitable containers.
6. Disconnect and remove any thermometry and instrumentation. With fan
cooled bearings this may not be possible, see next stage.
I . . i
~--~--~---------·----------------~-----~--~--~~--~--Fage-18---------------:
!
7. Fan Cooled Bearings:
• Remove any connections passing through the fan shroud.
• Remove capscrews and lift off fan shroud.
• Dismantle and remove the fan
• Remove any instrumentation, pipework and thermometry now visible.
8. Remove the top dust seal.
9. Remove cover and cooler assembly.
6 Before removing bolts, fit eye bolts and lifting gear to the cover.
Ensure that the eye bolts are tight and secure.
6 Before using any lifting equipment, ensure that it is certified to
carry a load greater than the mass of the component or sub-
assembly.
@When removing the cover and cooler, take care not to damage
any equipment.
1O.Remove upper surge ring, upper thrust ring or vortex shroud.
11.Fit lifting bolts and remove the journal pads from the casing.
@ The surge ring and journal pads will be oily and may stick. They
will also be very slippery when handling. Take care to avoid dropping
and damaging the pads and ring.
Page 19
12.Remove fasteners and lift off casing.
& Before removing bolts, fit eyebolts and lifting gear to the casing.
Ensure that the eyebolts are tight and secure.
& Before using any lifting equipment, ensure that it is certified to
carry a load greater than the mass of the component or sub-
assembly.
13.Jack up the shaft until there is a clearance between the collar and the
lower thrust pads.
& Ensure that jacking equipment is safely positioned and certified
to carry a load greater than the mass of the shaft.
& Once the shaft is raised, secure It in position using other
equipment. Do not rely on jacking equipment alone.
14.Remove thrust pads by sliding out.
© T h e thrust pads will be oily and may stick to the casing. The
pads will also be slippery when handling. Take care to avoid dropping
and damaging pads.
~-~-~~---~Fage-20~--- -----~-- iI
!
1·5 Maintenance.
With the bearing dismantled, (refer to assembly drawing with parts list)
examine the thrust pads, journal pads and surge ring. The appearance should
be that shown in Figure 1 and Figure 2 overleaf. There may be some scoring
and wear on the pads and ring, but provided wear is no greater than 0.125
mm the pads and ring are still serviceable. If there is any sign of the White
metal surface coming away from the pad or ring, they must be replaced.
Examine the jointing between the casing and cover and that between the
base plate and the sleeve. If the jointing has decayed so that it is either
disintegrating or leaking, it should be replaced.
Examine the 0-Ring, if it has started to leak or decay, it should be replaced.
Inspect the collar surface for any sign of damage. If it is necessary to replace
the pads, the collar should also be replaced and repaired, otherwise the
replacement pads will have a short life.
Page 21
sf
Matt Surface
Dull Finish
Figure 1 Thrust Pad Appearance
...
Dull Finish Matt Surface
Figure 2 Journal Pad Appearance
~~-~---~-~-~----~---Page-22- -----~~---~~___ .
_J
Clean the cooler assembly, using the below routine;
1. Remove cooler assembly from bearing cover.
2. Clean the bore of the tubes using a high pressure water jet or steam
cleaning.
3. Any remaining deposits or blockages can be removed by using a cleaning
rod or hypochlorite based cleaning solution.
& There may be fumes given off during the cleaning process. Clean
parts in a well-ventilated area. Always follow cleaner manufacturers'
instructions.
©When using cleaning rods, take care not to damage the cooler
tubes.
Page 23
If the bearing is air or fan cooled, the spaces between each of the cooling fins
must be cleaned. With fan cooled bearings, the fan and shroud should be
inspected for any signs of damage caused by the two fouling each other. If
there is any damage, the parts should be repaired and alignment of fan and
shroud checked on re-assembly.
Where dust seals are fitted, these should be removed from their housings and
inspected. If the seal has started to break up, or has become clogged up with
dust and oil, it should be replaced.
Prior to re-assembly, all the old sealant should be removed and fresh sealant
applied in the positions identified in the section on Installation (4.2).
-~--
~-~---
--
---~Eage-24-~-~-~---------
~ ---~---~---~
!Appendix 1 (Spares).
,.1 Ordering.
As a minimum, replacements should be carried for all Whitemetal

components.
©when replacing thrust and journal pads, please ensure that

these are the correct hand. The direction of rotation stamped on the
replacement pads must be the same as that on the old pads.
Consideration should also be given to holding the consumable parts listed

below:
0-Rings
Casing/Cover jointing
Sleeve/Baseplate jointing
RTD assemblies
Washers
Dust Seals
Page 25
Bolt Size (mm) Tightening Torque (Nm)
6 4
8 10
10 20
12 35
16 80-90
20 155-175
24 275-305
30 545-605
36 950-1050
42 1520-1680
48 2300-2520
56 3690-4070
64 5560-6150
1
~~---------~--------~~--
--------------- -- - ---- -- - --- -

Michell Bearings
Scotswood Road
Newcastle Upon Tyne
NE15 6LL
Great Britain
Tel: (0191) 273 0291
Fax: (0191) 272 2787
Michell Bearings reseNe the right to amend these instructions.
©Michell Bearings 1997.
•
DRG. No58227
DIMENSIONS l.N~MtLEX.C_EJ>..LWI:IE.RCO_TJ:l.E.RW_LSE..._S_l.'.J:.EQ
PROJECTION LIST OF PARTS PER BEARING
REF PART No. PART NAME No. MATERIAL PATTERN REMARKS
OFF
I £90018 BASE PLATE I CAST-! RON -P-I-13903·-
--------·~----·-----------------~--____L=======·-"'"--""·-t-2~lVTr(7/3ti/2.?i1'?2C:58;>:3,-t-;Cc;A~S:-:IN;;:G=:..=_---+~I---1Prc";A';ST;:-;I-;RO~N:-t-;P;;1""713;:7~5;9-;:/2;t--------j
REMOVE AIR VENT TO FILL BEARING 3 E904/8J7 FULL COVER I CAST I RON PI 1402 7/3
112" SSP TAPPING. 4 I
5 SEE TABLE COLLAR I STEEL
~ oll30 P913/8R LOWER THRUST PAD RH 6 STEEL W.M. FACED
~ "\
22
Q! I COLLA~ BORE I 3
3 U.T.L.· PLATINUM RTD'S WITH
WATERPROOF CONNECTOR HEAD, STAINLESS
STEEL SHEATH & STAINLESS STEEL COMPRESSION
P915/8L UPPER THRUST PAD LH IG
STEEL
STEEL
W.M. FACED
W.M. FACED
STEEL W.M. LINED
GLAND. I0 R/X/10 13 CAPSCREW STEEL M8x I. 25:d 6 lONG
RTD'S FITTED TO 2 THRUST PADS & I JOURNAL II
PAD RTD'S ARE DUPLEX WITH 2x4 LEADS. 12 ST/.4l210859 LOWER THRUST PAD STOP STEEL
NB. CONNECTOR HEAD HAS 8 TERMINALS 13 F I 6G/6 12M UPPER THRUST PAD STOP STEEL
ARRANGED FOR 4 WIRE CONNECTION 14 P916/8 JOURNAL PAD STEEL WM L1 NED
ALL CONNECTIONS TO BE LEAK PROOF. IS 4-T0-662 JOURNAL PAD STOP STEEL
RTD ADAPTORS TO BE LOCKED & SEALED IN POSITION IG E920/B UPPER RET. RING STEEL
USING LOCTITE 222 OR SIMILAIR. DO NOT TIGHTEN
17 F91TIB
COMPRESSION GLAND IN POSITION UNTIL FINAL SLEEVE GUN METAL PI 13904
ASSEMBLY. 18 OG/X/100416 OIL LEVEL GAUGE

19 PG/X/100450 ORA IN PLUG STEEL 114· BSPT DIM 909
ON SITE. ON FINAL ASSEMBLY ENSURE THAT RTD 20 I N/3/208609 RTO CTHRUSTJ
PROBES DO NOT COME INTO CONTACT WITH THE PADS 21 IN/3/208GI3 RTD CJNLl
22 ~f/X /10464e2 A I R VENT 1 PLASTIC
23 SR/X/100063 TAPBOLT ICOVERl 12 STEEL ji(!Oxi.Sx25LG.
24 SR/X/100061 "TAP BOLT (SLEEVE) G STEEL M8x I. Sx2SLG.
25 SR/X/100016 CAPSCREW 8 STEEL M8x I.Sx 4() LG
26 4.250.1118 RTD ADAPTOR 3 STEEL
~2~7-fF~1~77~/~2~2~9--~WA~S~H~E~R----------~~3~~F~IB~R~E----t-------~. ----···------
~:8~9~W~A~~7~~8~4~2~7SP~R-IN-G~W~A7SH~E~R~F70R~24~~~6~~s=TE=E~L----t--------i-~¢~.~<B~S4464
0
TYP A
30 WA/X/100842 SPRING WASHER FOR 25 8 STEEL 9)8<BS4464 TYP A
31 PJ/X/W0977 SPLIT COTTER PIN FOR 13 I STEEL 9J2•16LG
32 OS/X/202861 '0' RING I GACO PS RM3193.57
33 GS-3-203419 JOINTING.. CCOVERl I SENTINEL ¢390x¢352x0.75
34 21074-IJ JOINTING. (SLEEVEl I SENTINEL 9)140.¢102x0.75
35 EA927/8/I 0 COOLER I
=~:m 3G NP/4/200686 NAMEPLATE & RIVETS I BRASS
~~
019o.s
r-ffi 37
I·~
38 NP-4-100413 ARROW & RIVETS
ol390
•., '& 39 BT/X/J{)I'JOS3. TRANSIT BOLT STEEL Mz 16x2x60LG
~ill 40 NU/X/100093 TRANSIT NUT STEEL M!Sx2
Jl.ll'i ~~
41
SECTION-YY
CL.O I L LEVEL GAUGE
2 ""~
112" BSP
~RAIN l ~
ill
i 1~ L,
DUTY A
CL OF O.L.G
& ORAl N 'O' RING-J :.OIL @ SHAFT DIA. 86
~ 0
M4 x 0. 7 HOLE IN EACH COLLAR BORE 82
~ JOURNAL PAD RPM 1484
l
"@
I
~O~F~C~07L~LA~R~BO~R~E~&~K~E~r=wA=Y~I=NT~S=l----_, ,, I NORMAL 13760 28708
TOTAL CIRCUMFERENTIAL CLEARANCE THRUST MAX. 26800 40525
SHAFT 9) COLLAR
T COLlA~ BORE
A B PART
NUioiBER
-\\-- BETWEEN JOURNAL PAD & STOP 3 9 : 13
QUARTER PLAN VIEW

LOAD
THRUST SURFACE
RA T1 NG
mm 2
59236
17183
59236
82 :o:o3 82 :o:o 85.3!0:o 12±0.21 F91118/ ~y /C-£.. RTD JNL

THRUST PRESSURE NORMAL KN/m 2 80 I
WITH COVER & RETAINING RING REMOVED
THRUST PRESSURE MAX. KN/m 2 1560
82 :o:o3 82 :o:o 85.3!0: 0 F91118/
12:::1::0.21
I
THRUST PRESSURE KN/m 2
10~1~~ 82 :o:o3 82 ! 0 :0' 85.3!0:o 12±0.21 F911/8/
.,;Jl"" ~
R5
I I
_.,._
I
'·-!._
- COOLER CONN •
2-3/4" NPT TAPPINGS
_L_
I
THRUST LOAD
THRUST SURFACE (MEAN PROJl
THRUST PRESSURE
mm l
<
II 619
~)"@ i.2l _I[_ KN/m
\t·
IN COVER FOR
~©! MACHJINl~.g~NIN~Ig:p \~\ f... ~f- m~~~MEi~~E~si6:P. JOURNAL LOAD MAX. 2010
iii
""/..._
I ...._
f f i l
. ~. rJ ;: JOURNAL SURFACE (MEAN PROJ> mm2 5345
111
tl
I ~ER
~r~- ~+-~-~I 10_L-rt, ·~. ,~.,w- LENGTH INCLUDING JOURNAL PRESSURE MAX.
JOURNAL DIAMETRIC CLEARANCE
TOTAL AX 1AL CLEARANCE
POWER ABSORBED
REOO. COOLING WATER QUANTITY
KN/m 2
KW
L/H
376
0. 2
0.8
I. 47
310
CO::~< ,~j_'~ ~' -~

THRUST PAD STOP & JOURNAL PAD STOP COOL! NG WATER INLET TEMP c 38
t ~~0 BE .PERNMENTLY "LOCKED IN POSITION"
z LIFTING HOLES IN \ / - ""o

OIL ISO VG 46
TOTAL CIRCUMFERENTIAL CLEARANCE

TAPPED MS x I '- BETWEEN UPPER THRUST PAD
' TOTAL CIRCUMFERENTIAL CLEARANCE & STOP' 2.0 ± O.T
HALF PLAN VIEW BETWEEN PAD & STOP = 3. 0::1:: 1. 0 ,, 1>-S-o1 llo/,-,1
I
'
2 Ll FTI NG HOLES
1
"x-Y ,, 3 .$"...()2 II 0~30 _, L!.
TAPPED MIG x 2 __...\Q' ' CL. RTD THRUST I=P S"Oil1.. 1"3 ·5·o2. \I Ob2 '\ " :l,
~"'"' MIG~~
m'"~ b
F6 99 P522 12·8-99 108277 B.H.E.L 6 SPEC FPSOI22 RE"I 17 VAR 07
FG 99 PlOI 29·6-99 108128 B.H.E.L 9 B SPEC FPSOI22 REV 17 VAR 07
FS 99 PlOO 29-6-99 108128 B.H.E.L 9 B SPEC FP50122 REV IT VAR 07
00 , . , ,. F6 97 P339 -T-9T 10632T B.H.E.L 2 A SPEC FP50122 REV 17 VAR OT
,
TAPPED F6 9T P338 ·T-9T 10632G B.H.E.L 6 A SPEC FPSOI22 REV 17 VAR OT
3 JACKING HOLES IN BASE PLATE :=------·-----~----·--·------------· _ -~-----HALE E' Lh N_V_LE_W,"C":"".,..-------.,.--~,......,.,..::c.. =--1-c_u--"'Vc.o.Eo~FM""E"'RL_o_A_T_E....Lo=-R~o=-ER_N_o.~.._c_u_s_To_M~E=R=k0~N~~f:o~=Du"'T±=='-".R"'E""M=A=RK=s===l---'~

- TAPPPE-D ·MI6-x2
QUARTER-PlAN VIEW SHOWINGRETAININGRlNGt-UPPERTHRUSTPADS MICHELL BEARINGS V7 SCOTSWOOO ROAD
9
WITH CASING & COLLAR REMOVED
ITEM 23 WAS 100018 NOW 100063 ITEM 37 {1()04101 DELETED ITEM 23 VIAS SR/X/ 202J, 22. 6 ITEM 28,ADfX/Z07298 AND
A VICKERS COMPANY V NEWCiiSTLE UPON TYNE NE I~ GL
f-~--IITEM 24 WAS 100060 NOW 100061

8 ITEM 36 (1004111 REPLACED WITH 200686
f-51-G~..,.IID_A_T_,E PARTS LIST UPDATED S1G ~ATE
1-:S:-:-lG=-r.DA::-=T::-E I.TEM 41, WA/X/105248 REMOVED. MICHELL VERTICAL DOUBLE THROST.& GUIDE BEARING
SIG .rDATE REMARKS COLUMN MODIFIED
28 09
MJH ~3
.a9 . OLD HEIGHT WAS 103 NOW 92.
JS. o~ 4 AWA g~
03 PT O{T 01
~~ 2 WAS E902/8/22
.
STANDARD No 8. DNT
PARTS LIST UPDATED 4 FOR ORDER 1082T7 & 108128 & SUBSEQUENT
1---..---i ORDERS.
3 ITEM 28 & 41 ADDED 2 ITEM 38 WAS 4-219-4 1 JOURNAL PAD CIRC. CLEARANCE
J--.....,.-,.-...,-l CORRECT
DRAWN BY I.W.H' 7 ?~!9E7 DRAWING
@VICKERS PLC NUMBER l No. OF
SHEETS
J jSHEET
No.
ITEM 36 WAS 4-219-429
;nrlATE s I G I·DA T ITEM 20 WAS 4·276-TST NOW I N/3/208609 SIGfDAT S IG OAT
ITEM 33 WAS E922-8 SIG DAT CHECKED BY 7-7-97 1997
llRG. No58227 Prj\, IH 13119/0 ITEM 21 WA.S 4-276-758 NOW IN/3/2086!3
ORDERS I 082T7 & I 08128 DUTY B APPLIES
ALH fHIG/9- 30/6!9 2/~/97
SCALE 1: 2 58227
jTRANS 56515
PART-S
( SUB-DELIVERY ITEMS
LIST OF CONTENTS
SECTION TITLE
A Connecting Couplings, BFP&HC and HC&Motor
B Suction Strainers before BP & BFP
.I '
c Recirculation Control Valve of BFP
\,~ /
D Connecting Coupling CEP&Motor
E Suction Strainer before CEP
\
/
PART-S
SUB-DELIVERY ITEMS
SECTION -A
CONNECTING COUPLINGS BETWEEN
BFP&HC, HC&MOTOR AND MOTOR&BP

STDOM
EUROFLEX TRANSMISSIONS (India) PVT LTI~.
Ep PLOT N0.99,CIE.PHASE-II, GANDHI NAGAR, BALAN AGAR
HYDERABAD- 500 037.
Page 1 of4
1. Installation and alignment instructions:
Preliminary Checks
All EUROFLEX Couplings are individually numbered and one set of test certificates identifying the Coupling
accompany all supplies. Carry out the following checks prior to proceeding with the installation work.
i. Check the coupling drawing for provision of gagging screws and bushes. These are meant only for transport
purposes and for the purpose of compressing the flexing elements at the time of installation.
The gagging screws and bushes are painted in RED color and are to be necessarily removed prior to coupling
alignment and trial run of the equipment.
Couplings and the equipment should not be allowed to operate with gagging screws in position.
ii. Cross check the following coupling data as per the assembly drawing I dimensional test certificates with those
of the interface dimensions of the equipment shafts and flanges.
Coupling model & Rating

Hub bore and key way dimensions
Locating I Spigot diameter
Distance Between Shaft Ends (DBSE)
or Distance Between Flange Faces(DBFF)
Over all length
iii. Check for method of hub installation i.e., thermal shrink fit, hydraulic fit etc. and arrange for necessary tooling.
( I
iv. The main coupling bolts are generally fully torqued at factory using special tooling and unless otherwise
called for, should not be disassembled, .
v. Check for the tightening torques specified for the various bolting and arrange for necessary calibrated torque
wrenches I special spanners.
vi. Check for clocking bands on coupling flange diameters which are marked at 90 degree intervals with
numbers 1, 2, 3, & 4. signifying 0,90,180 and 270 degree positions of the coupling flange. The accompanying
certificates will show the run out values obtained at the time of dynamic balancing.
These markings of are meant for match marking and the run out values can be used as a guide for accurate
alignment of the equipment.
Prep area A:pprove-d------1--~Bate----1-----'-
SANKAR KVMR 18-06-2003

I \
STDOM
EUROFLEX TRANSMISSIONS (India) PVT LTD.
lj. PLOT N0.99.CIE.PI-IASE-ll, GANDHI NAGAR, BALANMi/\R
IIYDERABAD- 500 037.
Page 2 of 4
vii. Unless otherwise specified the couplings will be supplied in black Oxidized condition for surface protection,
with a coat of oil applied and wrapped in moisture proof polythene shrink film.
For best results it is recommended that the couplings are left in their original packing and are to be removed just
prior to the actual date of installation.
For extended periods of storage in the open, it is recommended that the couplings are returned to their original
packing and stored with a periodic coat of oil re-applied to them.
viii. All coupling bolts, lock nuts, bushes, washers etc. are weigh matched to within 0.1 gram or better and field
replacement with components that do not form part of the original set is not to be done. Always replace these
components as a set.
2. Initial Assembly and Centering:
Correct careful assembly and centering at the initial stage enables the coupling to provide maximum
performance and increases service life.
3. General Limits :
i. Maintain the actual Axial shaft gap to that specified with the following tolerances :
4 bolt couplings : +/- 0.5 mm

As a general rule do not exceed 10% of the maximum axial misalignment capacity specified on the coupling
drawing.
ii.Radial Misalignment: Ensure that the TIR of dial set on opposite flange face is 0.05 mm or lower.
Note : The above values are to be arrived at after taking into

consideration the cold offset values for both axial and radial directions specified by the main equipment
manufacturer.
Prepared Approved Date

l -
STDOM
EUROFLEX TRANSMISSIONS (India) PVT LT
Ep PLOT N0.99,CIE.PHASE-II, GANDHI NAGAR, BALAN AGAR
HYDERABAD- 500 037.
Page 3 of 4
CONFIGURATION-I
Configuration : 1
Couplings with this configuration have hub flanges directly bolting on to the flexing elements. Following is the
sequence installation :
i. Dismantle the coupling bolts and the gagging screws.
ii. Mount the hubs on respective equipment shafts.
iii. Position the equipment to the correct DBSE specified.
iv. If one or both the hubs have a taper fit, cross check both the DBSE and coupling flange to flange distance
(DBFF)
(
specified on the drawing.
\
v. Clamp two dials as shown and align to within 0.05 mm of TIR.
vi. Assemble the flexing elements and spacer in position and hand tighten all coupling bolts, in cylinder head
fashion.
vii. Tighten all coupling bolts to 50% of the specified torque using a calibrated torque wrench, in a cylindrical
head fashion.
viii. Recheck the DBSE and radial run out values. Readjust if the same is found disturbed.
ix. Tighten all coupling bolts to the specified torquing limit.
Preparec~-----1'-----A-pproved----~-J---Oatt>--- - - - 1 - - - -

......_ __ !
I
j __ _
STDOM
EUROFLEX TRANSMISSIONS (India) PVT LTD.
PLOTN0.99,CIE.PIIASE-ll, GANDHI NAGAR, BALANACiAR
IIYDERABAD- 500 037.
Page 4 of 4
IMPORTANT:
Care should be exercised to tighten only the lock nuts by holding the bolt head steady in a socket. Coupling bolts
will have a very close fit in the flange holes and to the flexing element bushes and hence any forced rotation will
result in damage to the close fitting bolt shank and the mating parts.
I 1
I 1 ( /) (/)
i 1
Jl
,,II
ij! II
fI I
-
111 IIIII
~ ~-
A
~ -- f ~ ~- --
- I ~I
1r ( /)- --
r
2
Alignment Procedure I Clamping Arrangment
[ ___ I;;·),
·~---~ --- -· --- -- ---- ----
Fig. No. : 1
Final checking
I _~-Max~rn:_nt_Limli~__:riRmlr!l ~_--· j --- --- -----
l Application Oial1 Dial 2
Fig. No.: 2
[ DRIVER- DRIVEr-:__ ~ ~J~os__
-· - . - - . - - - - - - - - ' - - - - - - ~-- --~------- _ _ _J
Prepared Approved Date

Eurojlex Transmissions (India) Pvt.Limited Format No : QFIDESI07
99, C.I.E, Phase-II, Gandhinagar, Balanagar, Hyderabad-500037 STDOM
Te/:23079775, 23076970,23078243 I Fax: +91-40-23079523 & 27847149
e-mail: eurofle:x@satvam.net.in I Website: www.eurojlex.co.in
Page : 1 off 4
1. Installation and alignment instructions:
Preliminary Checks
All EUROFLEX Couplings are individually numbered and one set of test certificates identifying the Coupling
accompany all supplies. Carry out the following checks prior to proceeding with the installation work.
i. Check the coupling drawing for provision of gagging screws and bushes. These are meant only for transport
purposes and for the purpose of compressing the flexing elements at the time of installation.
( i
The gagging screws and bushes are painted in RED color and are to be necessarily removed prior to coupling
alignment and trial run of the equipment.
Couplings and the equipment should not be allowed to operate with gagging screws in position.
ii. Cross check the following coupling data as per the assembly drawing I dimensional test certificates with those
of the interface dimensions of the equipment shafts and flanges.
Coupling model & Rating

Hub bore and key way dimensions
Locating I Spigot diameter
Distance Between Shaft Ends (DBSE)
or Distance Between Flange Faces(DBFF)
Over all length
iii. Check for method of hub installation i.e., thermal shrink fit, hydraulic fit etc. and arrange for necessary tooling.
( .\ iv. The main coupling bolts are generally fully torqued at factory using special tooling and unless otherwise
called for, should not be disassembled, .
v. Check for the tightening torques specified for the various bolting and arrange for necessary calibrated torque
wrenches I special spanners.
vi. Check for clocking bands on coupling flange diameters which are marked at 90 degree intervals with
numbers 1, 2, 3, & 4. signifying 0,90,180 and 270 degree positions of the coupling flange. The accompanying
certificates will show the run out values obtained at the time of dynamic balancing.
These markings of are meant for match marking and the run out values can be used as a guide for accurate
alignment of the equipment.
PREPARED CHECKED APPROVED DATE

SURESH SANKAR KVMR 18-06-2003
( \
J_ _ _ _ _
Eurojlex Transmissions (India) Pvt.Limited Format No : QF/DES/07
99, C.I.E, Plwse-II, Gandlzinagar, Balanagar, Hyderabad-500037 STDOM
Te/:23079775, 23076970, 23078243 I Fax: +91-40-23079523 & 27847149
e-mail: euro[lex(iil,mtvam.uet.lu I Website: www.euroflex.co.iu
Page : 2 off 4
vii. Unless otherwise specified the couplings will be supplied in black Oxidized condition for surface protection,
with a coat of oil applied and wrapped in moisture proof polythene shrink film.
For best results it is recommended that the couplings are left in their original packing and are to be removed just
prior to the actual date of installation.
For extended periods of storage in the open, it is recommended that the couplings are returned to their original
packing and stored with a periodic coat of oil re-applied to them.
viii. All coupling bolts, lock nuts, bushes, washers etc. are weigh matched to within 0.1 gram or better and field
replacement with components that do not form part of the original set is not to be done. Always replace these
components as a set.
2. Initial Assembly and Centering :
Correct careful assembly and centering at the initial stage enables the coupling to provide maximum
performance and increases service life.
3. General Limits :
i. Maintain the actual Axial shaft gap to that specified with the following tolerances :

As a general rule do not exceed 10% of the maximum axial misalignment capacity specified on the coupling
drawing.
ii.Radial Misalignment : Ensure that the TIR of dial set on opposite flange face is 0.05 mm or lower.
Note : The above values are to be arrived at after taking into

consideration the cold offset values for both axial and radial directions specified by the main equipment
manufacturer.

99, C.I.E, Pltase-II, Gandhinagar, Balanagar, Hyderabad-500037 STDOM
Te/:23079775, 23076970, 230782431 Fax: +91-40-23079523 & 27847149
e-mail: eurotlex@satvam.net.in I Website: www.eurojlex.co.in
Pa e : 3 off 4
(
\
Configuration :
Couplings of this configuration are supplied with a central transmission unit which allows installation
with minimum disassembly of the factory tightened main coupling bolts.
i. Dismantle the coupling hubs by removing the attachment screws.

ii. Mount the hubs on respective equipment shafts.
iii. Position the equipment to the correct DBSE specified.
iv. If one or both the hubs have a taper fit, cross check both the DBSE and coupling flange to flange distance
specified on the drawing.
In case of variation to the specified axial shaft gap , refer to the specific instructions supplied, for using DBSE
adjusting shims supplied with the unit.
v. Clamp two dials on hub flanges as shown and align to within 0.05 mm of TIR.
vi. Disassemble the gagging screws and remove the gagging bush from the position. Re assemble the gagging
screws between the adaptor and spacer flanges. The transmission unit can now be compressed, by tightening
the gagging screws, adequate to facilitate assembly.
vii. Place the transmission unit into the position between the hubs ensuring that the spigot on hubs clears the
locating diameter on the adaptor plates.

99, C.J.E, Plzase-JI, Gmu/lzinagar, Ba/anagar, Hyderabad-500037 STDOM
Te/:2307977.1, 23076970, 230782431 Fax: +91-40-23079523 & 27847149
e-mail: euroflex(lll,wtvam.net.inl Website: www.euro.flex.co.in
Pag_e : 4 off 4
IMPORTANT:
Slowly loosen & remove the gagging screws thus allowing the transmission unit to regain the original free length.
Ensure that the gagging screws are NOT in position at the time of equipment trial run or continuous operation.
Remove & store the gagging screws and bushes carefully for future use.
viii. Recheck the DBSE and radial run out values. Readjust if the same is found disturbed.
ix. Tighten all attachment screws I bolts to the specified torque limit.
/J==i--~JL
f--
E 1--
1----
__ ::-::12
-- --=-= _)
Alignment Procedure I Clamping Arrangment

11!==~=1-==(/ 2
Fig. No.: 1
Max. Allgnmonl Umils TIR·IIU11
Final checking
MIIX. Allgnmonl Umlls TIR-<Ml AppllcaUon .I Dlal1 &2
Application J Olal1 jDial2 DRIVER- DRIVEN L 0.05
Fig. No.: 2
DRIVER· DRIVEN J 0.05 j 0.05

1 ASSEMBLY DRAWING '· QF/DES/02
UIHSS O'I'HERWJSE ST.l.TeD .O.Lt [)I!.IE11510!1S 1H ill lLI'-IETRfS · --· ·-·~----·- ____,_:IBQ~!IGLE.P_flQJE.cJ!)I:l. _______________ _ r--------------------------------------------.------~
DO ~l SCALE IF IN DOIJST .O.Sl\
6 Tapped Holes M6 Thru.

on PCD 200 Equ.Spa. .-------------_::.38~7~{C::::o~ld~S~et'.!::.)-~-=-=--=-=--=-=-==-==========;.::;--~~~--e.:-Tapped-Holes·M6=-"ffiru:~-~---
(Trim Balancing Holes)
-0.074
\on PCD 200 Equ.Spa. -o_
074
112 140 \crnm Balancing Holes} 25 ...Q.022
22-0.022
92
BOOSTER PUMP MOTOR
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0 I
0 102.2 c:i
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c) +
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-
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PONO Date Project T i

-·
F711A00059 13/0712011 . NTECL ENNORE- VAllliR 1x500 WI
Motor.h.ull: _ BS970 080 M40 I EN 8
- 13
F711A00079 1310812011 2x600 ~ J1NDAL INDIA. TPS AT DERANG
I 12 Spacer half#2 BS970 080 M40 I EN 8 1
NOTE:- 1.Tightenlng torque of boHs having threads lubrica1ed w~h MOS2. [ FP 60077 rvAR-03/REV-13/AMD-Oo I ~ _. i 11 Insulating Disk Reinfoo:ed Backeiile 1
Hem No; 2. Coupling bolt tightening torque= 320 Nm ~ 10 Insulating Bush Rein!oo:ed Bad;elite 12
Specification Coupling capacity

Rated Power 1000 KW Continuous torque 700 Kgm 12
Rated Speed 1494 RPM Peak torque 1050 Kgm 12
Rated Torque 433 Kgm Short circuit torque 1600 Kgm 5 Spacer half#1 BS970 080 M40 J EN 8
2 4 Element assembly AlSI 301 2
MaximumTorque 652 Kgm Inertia (GD 2} 0.657 Kgm
3 Overload washer 88970 817 M40 1EN 24 12
Max. lnst Torque 1304 Kgm Torsional stiffness o•18X10E6 Kgm 1rad :t 5.3 mm 1.4 mm OS App~cation:- Motor- ster Pump 2 Coupling bolt BS970 817 M40 I EN 24
(1/J. shaft penetration) . -~-~-. -·----~~~--~~--~-j:..Axial- -Radiale- cAngular~Modei-No:6GBH-'Iti0-S--:Weigt.lt:: 3~ jJs:g._... . 1_ Pump_hub B$9?0 OOO M40 1EN 8
~----------1-------~------~----~+------~------~
~----------~------LB~a=la~na=·n~g~------~-G~2~.5~1~S~0_1~9~40~_J________~,-------------L-M_A~X._M_IS_AL_IG_N_M_EN_T____J_cu_st_om_e~r:-_B_.H_.E_.L__________ ~S._N_o.L_D__
ES_C_R_IP_T_IO_N~--M_A_TE
__R_IA_L__.-~Q_TY~~-~-L: ~ .
EUROFL~DRANS_!1_1SSIONS [JNDfATPV_T. liMIT~P. DRAWN srinlvas DATE 21/0912008 CHECKED TITLE 6GBH~ 1 60-S DRAWINGNO ;REV
99, C. I.E.. Phase-11, Gandhin~gar. Balanagar ~----------------~--------~~-----L-----------------~
ENQUIRY NO.: 1SCALE NTS (AO)
08707-00
Hydecabad 500037. India E!1'lai 1: etJrollex@satyam.net.i'l
Ta13076970. 3079775 Fax 0091-40~30?9sii7847149
LIMITS GENERAL: ±0.25 APPROVED KVMR FLEXIBLE COUPLING 0
20 ·1L?PP~¢irt~~$, Mi~tbn)
~~J~~D#
'£ln?co1356 · · .·
-'~ on•ffi66243
.:@.f?C!J?44P:~g§[~~~~ (~Rul~iH~I~s} . (PtrH~rHol~} QOJ~pf!~-~~~~M§•tn.:.
on P®Q 44o··Equi:,Sg9~cf~ ·
j &!ATI..,S!f:9ej.. ~$&$ . .- f
!FPs7~n1~~~JPJ?'ooi7N~,R~1~~~~-13iJ\Mp~ l
----- ----·---------:--..==--c::--::-:--.~----------·-----
•
ABibby
Cannon Way,
Mill Street West,
Dews bury,
Tt·ansmissions West Yorkshire, WF131EH
Tel:- 01924 460801
Fax:- 01924 457666
Webslte:-www.bibbytransmissions.co.uk ISO 9001 • Rt:G No Q 05(197
E-mail:- sales@bibbytransmissions.co.uk
INSTALLATION, OPERATING AND MAINTENANCE
MANUAL
Coupling : TF0750(2H)
Drg. No.: BH51
/'\
CLIENT :BHEL
( !
"''· ' PROJECT:-VIJAYWADA AND BHOPALPALLI
CONTENTS
1) General Notes
2) Requirements
3) Cautions
4) Attention
5) Handling & Storage
6) Installation Instructions
7) Removal Instructions
8) Maintenance Instructions
9) Recommended Spares
Altra Industrial Motion • Tho Power of Experience
Boston Gear • Warner Electric • Formspi'IJg Clutch • Stieber Clutch • Marland Clutch • Wichita Clutch
--------lndustrlai.Ciutch-•-Ameridrlv.II!LCP.IlP#IJg!> • Nuttall Gear • Delroyd Wonn Gear • Kilian Manufacturing • Inertia Dynamics
Matrix International • Twlflex Umited • Bibby Transmissions • Huco DynatorR-·-wam-ertinear-~Saf!elrFriction---------
Registered Office:- 317-319 Ampthill Road, Bedford, MK42 9RD- Registered in England- Number 158829
•
1:;:>0 tHXJ1 Rlli Nu U OSUY/
1) GENERAL NOTES
• It Is essential that all the Instructions contained in the following documents be carried
out by a competent person. Should any problem be anticipated or encountered then
Bibby Turboflex personnel are available for site visits or, alternatively, repairs and
overhauls can be undertaken In our works. The persons responsible for selection,
handling, installation, use & maintenance shall require & understand these
instructions.
e Prior to performing any maintenance work (including inspections) it is essential that
the power supply is isolated and that no accidental movement of rotating machinery is
possible.
• This product is designed for a specific purpose. It is vital that it is not used for any
purpose other than that for which It is designed and supplied, and that the limits of it's
capacities, as detailed here or in any other document, are not exceeded.
e No liability will be accepted and any other warranty, either expressed or implied, will
be null and void should any component of whatever kind, including nuts, bolts and
washers, be used In the assembly, or modifications be made to all or part of the
product which are not supplied, specified or agreed by Bibby Turboflex.
2} REQUIREMENTS
• The following instructions should be read and understood prior to starting any
assembly or maintenance work on the disc coupling.
• Prior to fitting any component, care should be taken to ensure that it is clean and free
from any dirt.
• Where hub/shaft connections require a standard interference fit the hubs may be
heated in oil at 200-250°C and rapidly positioned on the shaft. It is essential that this
heat is evenly applied over the whole hub and that spot heating is avoided.
3} CAUTIONS
• Do not use any component that is not supplied or approved by Bibby Turboflex in the
assembly of this product.
• Do not attempt to lift the coupling, or component parts, without first ascertaining their
weight from drawings or data sheets. The use of lifting equipment may be necessary.
The inherent balance of these couplings could be disturbed if they are knocked either
by striking or rolling. Care must be taken when transporting and fitting to avoid such
knocks. This is particularly important when a coupling has been carefully balanced
and designed to run at high speed.
4} ATTENTIONS
• IMPORTANT: The necessity for shields & guards varies with individuals installations.
The owner or user must provide the required safety guards. Safety guards or shields
are not furnished by us with this equipments.
Altra Industrial Motion • The Power of Experience
Boston Gear • Warner Electric • Formsprag Clutch • Stieber Clutch • Marland Clutch • Wlch/la Clutch
Industrial Clutch • Amerldrlves Couplings • Nuttall Gear • Delroyrl Wonn Gear • Kilian Manufacturing • Jnet1la Dynamics
Matrix intemational • Twlflex Limited • Bibby Transmissions • Huco Dynatork • Warner Linear • Saffek Friction
•
iSU 9001 -· Ri::G No Q 050!17

5} HANDLING & STORAGE
The coupling is normally dispatched with standard commercial packing and the case should
contain a copy of required documentation. During transport the installation screws will be in a
position to ensure that the elements a[e not in free state. The coupling should be stored in
this condition. On receipt and also immediately before assembly, all· the items should be
checked to ensure that they are all in good condition and free of damage. The coupling
should be stored horizontally. It should be protected against corrosion if stored for long
periods or outdoors.
6} INSTALLATION INSTRUCTIONS
Following installation procedure shall be followed:-
1. Bring the shaft ends of driver and driven machinery together and check that the
distance between shaft ends is as close as possible to the 135mm.
I \
\ 2. Coupling is sent in fully assembled state. It must be dismantled at the hub faces by
removing stitted coupling bolts sr no 7 between hubs and Insulated spacer.By
removing slitted (D head) coupling bolt the drive end hub and driven end hub will be
separated from insulated spacer. Remove the transit bolts and balancing bush from
the transmission unit .(ref fig 1)
3. Fit respective hubs onto driver and driven shafts and align them using your chosen
method. The hub face should be flush in line with shaft end. The misalignment shall
be less than ~th of the maximum misalignment values given on the assembly
drawing. Bibby Turboflex do not recommended any specific alignment method as
many methods are available. The lowest values of misalignment ensure long and
trouble free operation of the coupling & connected machinery. It is recommended to
note down the initial alignment readings.
4. At this stage before any further assembly takes place, provision shall be made to
align match marks on the coupling components.
5. Reinstall the transit bolts and compress each element assembly such that the spacer
unit (which consists of assembly of insulated spacer half along with coupling bolt,
overload washer, element blades, element washer,and self locking nut.) could be
easily inserted between two hub faces such that the clear holes(big holes) of spacer
flange will be in line with the reamed hole (small hole) of hub.
6. Insert slitted coupling bolts between hub flange and spacer flange along with element
washer,element blades ,overload washer and lastly tightened them by self lock
nut.(ref fig 2)
7. Repeat the same procedure to the other end.
8. Position the coupling transmission unit between two hub faces, ensuring all relevant
match marks are aligned. The coupling transmission unit shall be supported to ensure
that the weight is not imposed on the joint during assembly.
9. Ensure that all match marks are aligned, all the transit bolts are removed, all the
fastners are correctly tightened and all the coupling components are in good condition
before operating the machine.
Altra Industrial Motion • The Power of Experience

Boston Gear • Werner Electric • Formspreg Clutch • Stieber Clutch • Marland Clutch • Wichita Clutch
--------/ndustrlei-Ciutch-•__:_Amertdr/v.es_Coup/iflgs • Nuttall Gear • Delroyd Worm Gear • Kilian Manufacturing • Inertia Dynamics
Matrix lntemational • Twlflex Umited • Bibby Transmissions • Huco Dynawrli-·-wa-m-ertinear-·-Set!ekPriclion-------'----
"
11)0 UU01 • RLC No U 0~0g7
7) REMOVAL INSTRUCTIONS
Coupling removal is the reverse of the Installation process - Ensure that on reinstallation the
process Is followed In careful sequence.
8) MAINTENANCE INSTRUCTIONS
General maintenance of the coupling consists of a check of the following during normal
machinery maintenance schedules.
• Axial, Angular & Parallel misalignment to ensure that these are still within the
acceptable limits and that no major movements have occurred. It is recommended
that a record of misalignment readings Is maintained.
• All bolts to ensure that they are correctly tightened.
a The flexible elements, by visual Inspection, for signs of fatigue cracking local to the
washer anchoring points or general signs of fretting corrosion. Slight bowing or "S"
like distortion Is not detrimental to the operation of the unit. Note that any cracking will
begin at the outermost edge of the outside blade. This means that, this Inspection is
still possible without disturbing the element bolting.
• Bibby Turboflex use self locking nuts. This gives a high level of performance over
many reinstallations. It is recommended by Bibby Turboflex that these be replaced
after being re-torqued 8 to1 0 times.
Note : Any requirement for spare parts should be made quoting the original purchasers
original purchase order number and the coupling drawing number. Suggested maintenance
intervals are:-
I) 12 months
ii) At planned machine down time intervals.
9) RECOMMENDED SPARES :
Sr. No. Part Description Qty/Coupling Recommended Qty.

Shim Pack 2 Nos 2 Nos.
2 Bolts with Lock Nut 2 Sets 2 Sets
Altralndu:strla/ Motion • Tho Power of Experience
Boston Gear • Warner Electric • Formsprag Clutch • Stieber Clutch • Marland Clutch • Wichita Clutch
Industrial Clutch • Amerldrive:s Couplings • Nuttall Gear • Delroyd Wo177! Gear • Kilian Manufacturing • Inertia Dynamics
Matrix International • Twlfrex Umited • Bibby Transmissions • Huco Dynatork • Wamor Unoar • Saftok Friction
Registered Office:· 317-319 Ampthill Road, Bedford, MK42 9RD- Registered in England- Number 158829
UNLESS OTHERWISE: STATED AU OlWEHSlONS IN llfiWWETRES THIRD ANGLE PROJECTJOH 00 NO'r SCALE IF IN DOUB-T ASK
---~---------
I~ IEl> 1&-
1 I ............ 0
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~ ~
~
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~~--'"+--+--......,.. ~
-I
+0.022 +0.022
0 0
0133.070 .Z130
(LARGE END)
~~ ~
~
I BFP END !HYD COUPLING END ~aJ

~
.. ~
·~-
~ .... P'
;;I ;; ;::
~ BHEL P.O. NO.:-F710P00009 a o
SPECIFICATIONS
DT.:- 30/10/2010
APPLICATION HYD COUPUNG. TO BFP PROJECT :- MAHAJENCO - CHA,NDRAPUR ~
RATED POWER 10000 KW
·.· -.
il
RATED SPEED 5900 RPM ENQ. NO.-F7 /10/7000006789/KBl TIGHTENING TORQUE - l5
OPERATING TORQUE 1215 Kgm SPEC. NO.- FP60077,REV.-13 1) COUPLING BOLT SR.N0:7 - 287 Nm(oiled)
._.AX TORQUE 1695 Kgm AMND.N0.-00. VAR-01 2) ATIACHMENT BOLT SR.N0:8 - 66 Nrn(oiled)
COUPLING CAPACITY NOTE -

=
I
CONTINUOUS TORQUE BALANCING SUSH 1) AXIAL THRUST 1283 kg.
· 2596.84 kgm 11 BS 970 080 M40 10
2) TRANSIT BOLT SR. N0.1 0 & BALANCING BUSH SR.N0.11
PEAK TORQUE 3505.73 kgm 10 TRANSIT BOLT GR 8.8 10
ARE PROVfDEO FOR TRANS PORTION PURPOSE ONLY. THEY
SHORT CIRCUIT TORQUE 4933.99 kgm 9 SELF LOCKING NUT BS 970 709 M40 40 ARE TO BE REMOVED PRIER TO OPERATION.
MASS 63.1 kg. :
8 ATTACHMENT BOLT BS 970 817 M40 40
lNERTIA (WR2) 0.42 kg-m 2 7 S£LF LOCKING NUT es s7o an M4o 20
GD 2 1.68 kg-m2
6 COUPUNG BOLT BS 970 817 M40 20
TORSIONAL STIFFNESS 0.2189x106 kgm/rad.
5 ELEMENT BLADE ASSLY SS301 2 SET
DYNAMIC BALANCING TO GR. 2.5 150:1940 :0
4 CENTER SPACER SS 970 817 M40 01 ~
~
3 ADAPTOR PlATE BS 970 817 M40 02
MISALIGNMENTS
2 BFP ENO HUB BS 970 817 M40 01 ~
~
MAX. AXIAL DEFLECTION ±2.2 mm. 1 HYO COUPLING END HUB BS 970 817 M40 01
MAX. ANGULAR DEFLECTION o.2s· Deg./STACK. ~
SR NO DESCRIPTION MATERIAL- -QTY~
MAX. RADIAL MISALIGNMENT 1.2 mm.
ISSUE
D-RAWING NO.
tOHS-16- 170 BH404-2

UNU:SS OTHERWISE STATtD All DIW£HSIONS IN loOLUWETRES THIRD ANGLE PROJECTION DO NOT SCALE lr IN DOUBT ASK All£RAT10KS
')
~ ~~~-- ·----··-~---·-----------· -----7-7-2-(Ref.)
~~~ E>
250 ~~ e0
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-0.032
-0.106
fsl_---------.-
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+
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.
193 183
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'S. $. .C'\1
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+0.030
+0.010 0
0200 ¢250-0.020 ~~ Ill
~
IHYD. CPLG. END I IMOTOR ENDI

~ ~ ~~p
~ i
~~., ~
SPECIFICATIONS ~ BHEL P.O. NO.:-F710P00009
0
APPLICATION MOTOR TO HYD. CPLG. DT.:- 30/10/2010

ENQ. NO.-F7/10/7000006789/KBl
RATED POWER . 10000 KW PROJECT :- MAHAJENCO - CHANDRAPUR .
RATED SPEED 1494 RPM SPEC. NO.- FP60077,REV.-13
OPERATING TORQUE 5249 Kgm AMND.N0.-00 , VAR-02
TIGHTENING TORQUE -
MAX. TORQUE 6650 Kgm 1) COUPLING BOLT SR.N0.7 & 8 - 1105 Nm(oiled)
2) ATTACHMENT BOLT SR.N0.9 - 120 Nm(oiled)
13 BALANCING BUSH BS 970. 080 M40 oe
COUPUNG CAPACITY 12 TRANSIT BOLT GR 12.9 oa
CONTINUOUS TORQUE - 7362 kgm. 11 L.E.F". WASHER BS 970 709 M40 08
PEAK TORQUE 9938 kgm 10 HYO. CPLG. END HUB BS 970 080 M40 'Q' 01 FLOAT
SHORT CIRCUIT TORQUE 13987 kgm 9 ATTACHMENT BOLT BS 970 817 f-440 32
MASS 254.3 kg. B COUPLING BOLT LONG BS 970 817 M40 08
INERTIA (WR 2) 5.08 kg-m 2
7 COUPUNG BOLT SHORT BS 970 817 M40 08
co2 20 ..32 kg-m2
SELF LOCK NUT BS 970 817 M40 16
6
TORSIONAL STIFFNESS 2.15x1 Q6 kgm/rad.
5 SPACER BS 970 080 M40 Ot
DYNAMIC BALANCING TO GR. 2.5 ISO: 1940
4 ELEMENT ASSLY. ss 301 2 SET
3 ADAPTOR PtATE BS 970 080 M40 02

MISAUGNMENTS
2 SELF LOCK NUT (ATIACHMENT) as s7o 817 M40 32
MAX. AXIAL DEFLECTION ±1.2mm. 1 MOTOR END HUB as 970 oao M40 01
MAX. ANGUlAR DEFLECTION 0.33. Oeg./STACK.
SR .. NO ·- .. -OES8RIP=fi0N-- ---MATERIAt--- --Ql¥-··
-----~--
MAX.• RADIAL- MISAliGNMENT 0.99 mm.
, ------- ···---·------··-·.-----
I
l
UNU:SS OTHERWISE STATED ALL OIWENSIONS IN WIWMETR£S THIRD ANGLE PROJECTION DO NOT SCALE: If' IN OOU&T ASK
•
J ---~~~~---------------- -~-- -~--347- (Ref.)
113
-
--------~---~--·----------· - ------------ m ·--- ~--
~------~------
~~ ~
DBSE-135 100 ~
..., 0
KEYWAY PARALLEL 91
TO TAPER
22
±0.026 !:c ~
~
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-
0
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w
.........
Cl..
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1()
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~
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p
+0.035 +0.035
0 0
9'182 ~90
(lARGE END)
jBOOSTER PUMP END[ 'MOTOR ENDI
SPECIFICATIONS ~ BHEL P.O. NO.:-F710P00009

ENQ. NO.-F7 /10/7000006769/KBl
APPLICATION MOTOR -TO BOOSTER PUMP DT.:- 30/10/2010
SPEC. NO.- FP60077.REV.-13
RATED POWER 1000 KW PROJECT :- MAHAJENCO - CHANDRAPUR
RATED SPEED 1494 RPM AMND.N0.-00 • VAR-03
OPERATING TORQUE 476 Kgm 15 BAlANCING BUSH BS 970 080 M40 08 TIGHTENING TORQUE -
MAX. TORQUE 652 Kgm 14 TRANSIT BOLT GR 8.8 08 1) COUPLING BOLT SR.N0:7 - 139 Nm(oiled)
13 INSULATED BUSH FISER RAJNFORCED 14 2) ATTACHMENT BOLT(HUB) SR.N0:9 - .30 Nm{oiled)
COUPLING CAPACITY 12 INSULATED PIJI..TE BACKEUTE HYLEM 01
CONTINUOUS TORQUE 960.61 kgm. 11 SELF LOCKING NUT BS 970 817 M40 14 NOTE-
PEAK TORQUE 1296.82 kgm 10 ATTACHMENT BOLT (ADP. PlATE) BS 970 817 M40 14 1) TRANSIT BOLT SR.N0.14 &: BALANCING BUSH SR.N0.15
SHORT CIRCUIT TORQUE 1825.16 kgm ARE PROVIDED FOR TRANSPORTION PURPOSE ONLY .
9 ATTACHMENT BOLT (HUB) GR 12.9 32 THEY ARE TO BE REMOVED PRIER TO OPERATION.
MASS 38.4 kg.
8 SElF LOCKING NUT BS 970 817 M40 16 2) AXIAL THRUST - 686 kg. ~
16---------- -ltrf~!>fto
INERTIA (WR2) 0.18 kg-m2
7 COUPUNG BOLT BS 970 817 M40 T6
GD 2 0.72 kg-m 2 .
6 ELEMENT BLADE ASSLY SS.301 2 SET
TORSIONAL STIFFNESS 0.252658x1 o6kgm/rad.
5 ADAPTOR PIJI..TE 2 as 970 oeo M40 01
DYNAMIC BALANCING TO GR. 2.5 ISO: 1940 I I ~
4 ADAPTOR PLATE 1 8S 970 080 M40 01 r r!t SHANTAHAM ~
M.:mbQl:r I Oosrg11 tflurn 5·~~
MISALIGNMENTS
3
2
ANTI-FLAIL ADAPTOR
BOOSTER PUMP END HUB
. as 970 oeo
BS 970 OBO M40 'Q'
M4-0 02
01
I 6.H.IE.l., Hyderabar.t- .
MAX. AXIAL DEFLECTION ±3.0mm.
. , MOTOR END HUB BS 970 080 M40 'Q' 01
t I=~+--+--!
__ MAX._ ANGULAR DEFLECTION 0.33 Deg./STAC){._ ·--------

- --·· ---
··sR~NO~ DESCRIPTION MATERIAL QTY.
MAX. RADIAL MISALIGNMENT 0.46 mm.
ISSUE
DRAWING liO.
BHB-14-150 BH406-2
~~---------- ----~-- ·-~-~-·· --··---- -~-- ~--~----·----· ---

~-·----~
"-,,_
PART-S
SUB-DELIVERY ITEMS
SECTION- 8
SUCTION STRAINERS
BEFORE BOOSTER PUMP & BFP

....
.-v3000 Removal
2725
1500 1225
--
'A'
12 Thk.
(1
PETAIL-'8'
V.tew- 'X'
21)
.-.!.X'
DETAIL-'C'
(3
"Q
~ 4)
0 <J
:r:
Q. 0
a.
~ (/)
&
oot
N
w c:i
....: ci d
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g ti :::E
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,....
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<0
CX)
'$
I()
;:: -J16!-
<0 pi) <0
I() 10
~ ....0 <0 I()
VlEW-'A'
Drain
NOTE:-
,) ALL DIMENSIONS ARE IM MM UNESS OTHERWISE SPECIFIED.
2) ALL FLANGE HOLE SHALL BE STAGGERED TO CENTRE LINE.
3)) ALL FUNGE FACINGEDGES,

REMOVE-SHARP SHALL BE
FlNISH BURRS. & SERRATED
WELD SPATTERs. .~~~--:--··~@=J~~======t~~~~~~~~~~~~$~~=t~~~~~~~::_m:£~~~~iE~~~alli~iii~:=~~~~~~~~~-~~~
FlNISH TO 125 TO 2§Q ...
5} ALL B.W. SHALL BE CHIPPED BACK D.P.TESTEO &: REWELDED FROM OTHER
SIDE WHEN EYER BACK CHIPPING IS NOT POSSIBLE ROOT SHALL BE }-;:;;:-+~:z--"M~::::::---t:;-;:;-:::fjJ;;;;;:,;:;f---::=-TQ:~11T~E=-fl:iPmct;;th\~;-i~~~~~!!!.;~~~~~~~~~~
WITH TlG WELDING WITH .ARGON PURGU..JG .
\
-
--------------------------------------
....
~~~~,,~~~~-~ --~~-~~~---~~-~---------~-~---~-
2280
REVISED AS PER YOUR COMMENT & MARKED
456 456 456 456
( 11
Stiffner-4 Nos. Handle
( 17 8)
( 16
9)
2285
L.S.Weld
(8 of Perfo.
Sheet PERFORATED SHEET
BUTT WELD DETAIL
'X
4 Nos, 90"
Apart, Eq.Spaced
( 4 Nos, Guide Pin 22"NB Strip 2 Thk. WIRE MESH

15
Eq. Spac. (Typ) 558 0.0. Zig Zag Spot Weld OVERLAPPING DETAIL
(2
( 1S).( 21 ) 4 Nos, 90° DETAIL~'A' 40
Apart, Eq.Spaced
0 ( 11 -H~
N
L{)
(1)
....c
(f)
s
0 30 G x
I"')
L[) Spot Weld
2 Thk.
G X 40W GUJARAT OTOFILT

(AN ISO 9001:2008 Cert.Company)
Plot No.-3712,Phase-IV,G.I.D,C.
Weld Votvo, Ahmedabod-382. 445.
Ph.: 258411 Fox:25842719
I
S ec t .1on=~~ 'X' - 'X'
~~
...
~
250 DESIGN DATA REV DATE DESCRIPTION REV BY CHD BY

1 Description Suction Strainer - B.P. 0 16/02/11 ISSUED FOR APPROVAL HSG BJP
(28 Dovtt \ c c ~~ 2 ~e · cif Strainer Simplex Basket Filter 1 -:24/03/11 REVlSED AS PER YOUR COMMNET &: MARKED & HSG
(/~ .... ·-I' i~ ~1) 3
4
Material Code
Qty.
F"P9760075016
12 Nos. NOZZLE SCHEDULE
u. (2~ 41~ ~2) 6) 5 Spore Filter Element 4 Nos. (Material Code; F"P9760075032) SYI.tBOl SERVICE SIZE. Thk. RATING ANSI STD TYPE FACE REMARK
1~~~:~3) 6 Degree oJ Filtration 315 Micron (50 Mesh x 0.2mm Wire Dia)) N1 Inlet 18ftNB 16 300# 8-16.5 SUP-ONR.F. ----
•y:_." 7 End Conn. 450mmNB ASA 3001. B-16.5 N2 Outlet 18"NB 16 300/1 B-16.5 SUP ON R.F.
8 Fluid to be Handle Feed Water N3 Vent
--
! ~\ ~~ -~~
1"NB 3000N B-16. 11 Cplg. -- with Valve
0 9 Flow Rote I Viscositv 1240 m3/Hr. I 0.10 CP
N N4 Drain l"NB 3000# B 16. 11 Cplg. with Valve
10 Design Pressure 35 Kg/Cm2 (g)
J I! ~.. r'~8)
CX)
25
28" NB v" 190'C I 21 O"C NS Stub-D.P.Gouge 1 /2"NB -- 3000# B-16.11 Cplg. - - with Plug
~ -~ .t?J_ ~kt--r<~o)_, -~J(26}
( ) 11 Oprt./Oesign Temp.
JNS)___ , 16 IThk ...61 7) 12 Hydrotest Pressure 5.3 kg/cm2 (g) (For 30 Minutes) N6 Stub-D.P.Tronsmitter 1/2"NB -- 3000# B-16.11 Cplg. -- with Plug [&
~(/1_ f' 1-(27) ~~.t. ~~H~19~~/~~~~~~~ 13
Max.A!IowoDie Press.urop
at (a) Clean Cond. 0.1 Kg/cm2 (g). NQTE:-1) ALL Olt.IENSIONS ARE 11.1 t.lt.l UNESS OTHERWISE SPECIFIED.
<::lr :;. \~t---,>-~ ,: ~ <~.)::i!~ ~ -----~~

(b) 50%Cl()gged Cond. 0.15 Kg/cm2 (g). 2} ALL Fl.ANGE HOLE SHALL BE STAGGEREO TO CENTRE UNE.
3} ALL FlANGE FACING FINISH SHALL 6E SERRATED FINISH TO 125-250 MRH.
14 Gross/Net Filtration Areo 44064 / 9379 Cm2 4) REMOVE SHARP EDGES. BURRS, .!c WELD SPATTERS.
-~ ! (18~ ~ :~~-~
15 Radiography on B.W.Joint 100" 5) All B.W. SHALL BE CHIPPED BACK D.P.TESTED & REWELDED FROM
16 Weight of Strainer ·{a) Empty: ~1150 Kq. (b) Flooded : -1365 Kg, OTHER SIDE WHEN EVER BACl< CHIPPING IS NOT POSSIBLE ROOT SHALL
' •zjl BE DONE WITH TIG WELDING WITH ARGON PURGING.
1- 17 Shipping Dimension 1.4 mtr. x 1.4 mtr. x 1.73 mtr.
(
{NS)
(29} ?.
,,
iE i. (
144 4
22) (24) 18
19
Fine Mesh 50 Mesh) Wire Dia. - 0.2 mm
Perforated Sheet Thicknes~ 3mm Thk.
.30 Name Plate Brocket
29 Name Plate
1 IS2062GrB
1 S.S.304
STD.
STD.
I~
, (.30)
( 16
(9'-r---VI
,
f- '-" I!
ls209l 1/
(Typ)
170 Nos,12 W ,n)
20 Ratio of Free Flow Area
to C-/S Area of Inlet Pipe 6.36 : 1 c.s. Refer Org.No.: 048 SB 10079
'Sheet 2 of 2}
l_ Pleats 21 Paint-Outer Surface

(15) 2SO'l 85 Nos, 12 W 17}
~ I Pleats
(13)
(14:Y.
...
~ "<t
ii rm ~11)
)
22 Element Shall be for Withstond 2 kg/cm2 (g) Diff. Pre:!;sure
23 Design Code ASME Sec.VIII, Div. 1
2
2
SA 105
C.S.
18"NB.WNRF,300#,ANSI 8-16.5
20111, STD.
~~"-~ ~"\."\."\."\."\.~ ~ ' 24 Corrosion Allowance 3mm SA 1/2"NPT(F), 3000#. STD A.
-L------
! ~~~, ~
1'-.'1 1\.'\. i 1, ~ _......;__---1.
\.c1
CONN. (N1)/(N2) Element Stlffner Detail
4 105
~~~~~~~~~~-+~~~~~--~w~it~h~P~Iu~g~·~~----------~LU
3 Nos,28¢ Hole l f (12r-1 l~ r-(7)
8 S.S.304
IS2062Gr8
Nan.Asbestos
M-10 x 35 lg.
10 Thlc, 620 "_I\~1_- _ _ _
3 Thk, STD.
at 900 PCD
(N3)
90"u-(N4 )
>K-~&Bracket
Nome Plate (29}
(30)
NO~:·s~_,fa~ ~~--\8) 1
IS2062GrB
5.5.316
10 Thk, 675 x 526 •
50 Mesh x 0.2mm Wire Dio.
S,.,k_i~
z ~~~ .rn: ~so· _{>-(~s~_t~?l.Q!!l 1 S.S.304 3 Thk, 8111Hole at 10 Tmglr.Pitch
. . '
. .
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............--. . ~
/
,.......
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J ~ Stiffner
~ 3 Thk-S.S.304 14 Gusset Plate
3
5
SA516GI"60/70
IS2062Gr8
210 X 115 X 16 Thk.
12 Thk.
(Ns) '~.... i:..t.._,,,,
'<:.:::t.l!'f... 250 250• ~-~\\t:~/
,.,
'~~.11!"'\ ,.,.,~"'
•~NS 1""~~~~··,11~ 1.3 Base Plate .3 IS2062Gr8 180 X 135 X 20 Thk.
,~16)
"--7
f--i---1-----l;J ,,fr ~\ l;t--- --;--., J.:: I 22) 12 Bottom Cover 1 SA516Gr60/70 675111 x 40 Thk.
IN ,J;_.f. '-/.=~ / ;~:<. OUT 45 ;(NS) 11 Drain Valve . (N4} 1 C.S. l"NPT(F}, Globe Type STD.
rr---- -- --U~--
,~,
----'-1+1---
I I I
\ \\'
!-· ~ · - _ . .LI.I.t.....---1--'-4~-1--
~ f'.,. ltj:: \~J
Ill I
--·-180" 10 Drain Cplg. (N4) 1 SA 105 1"NPT(F),.3000#.STO,with Nipple
(N2) 144 4 (Typ)
(N1)
--~· ~----\~ i ~'9;)J!./_____ ~~ 9 Shell 1 SA516Gr50/70 28KNB x 16 Thk., F"ab.
(N6) ',:~~--, i ~~~~;/ (N~) 8 In/Out flange (N1/N2) 2

SA 105/
SA516Gr60/70
18"NB, SORF, 300#, 816.5,
58 Thk. -
L--
. . - . :t::. _, . ,. . .
' .....'.... - -( "' ............ , L--
11 "f--<9) 7 In/Out Nozzle (N1/N2) 2 SA5\6Gr60/70 18"NB x 16 Thk, Fob.
-~-
:"t-r.-rr r ; -':1 I
~ " 6 Stud with Two Nuts 36 ~~~~~~~/ M-.30 x 200 Lg
' :I II : :
8 Nos, Allen Bolt at
1
1 ' , 1 1
1I
(~1~5·,l----r-~" 5 Shell Flange 1 SA 105 28 NB, SORF, .300fi,B-16.47,
. ,, SA516Gr60/70 Ser.B 11 58 Thk.
575 PCD For Element :I .; ~ :I
Fixing as Shown ._ __., .. Davit -{ 2B)
270"j ±15
1000
1~
921¢ O.D. (9}--;oj= ~ ~ DESCRIPTION jgrr .MAil. .sJ.Z.E
(27'}---·t't
(21 ~
DETAIL •z•
(2 6
!~t
.36 Nos, .35~ Holes ot
857 PCO, Eq. Spaced" (12
~'1~~j ~11)
/V5
r~T...,
l=;:r GUJARAT OTOFILT
(AN ISO 9001:2008 Cert.Compony)
CLIENT:-
B.H.E.L.(Hyderabad)
I
l :~ ~fl
((::~v 1~ ~ ~:~ :)2

1 L · N4 Plot No.-3712,Phose-IV,G.I.O.C.
f
wi~it:l-tml (\_"\._~ ~~- ~~~o79~~~~~~~F:::~~!i719 P.O.No.: F7,10:~00165,
(3 787¢ R.F ••
w,, 7 )
:"j ?-~-"""-~ V1 ~ E-moil 10 : gofOsify.com DATE:-09t02t2011.
~ lr9.>l!IQ--~.
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--...,.r:.r~ &
'J
• • 36 Nos, Js. Holes i (SIZE :-18"NB)(B.P.-Suctlon) CHD BY B.J.PATEL •,.
¥s~ Q\f ~
ot 857 PCD, Eq. Spaced 28"NB -(g) 1 (ProJect. 4 X 600 t.CW,O P Jindal STPP,Ra!garh Choftlsgarh ORG NO ; -
(9}-V 37 • (5
'-(16)
921111 0.0.
DETAIL OF CONN. (N3) DETAIL •y• ~ILl-
16 Thk.
DETAIL OF CONN. (N4) ~Ct.~~ ·- ~-J·1S7 1~;iE N:o:~~~6~Jdcf; 1 048S8 10079 1
(Project: 4 X 600 MW.O P Jindal STPP.Roigorh Chattl59orh' Sheet 1 pf 2)
...
--------------------- -
M-24 REV DATE DESCRIPTION REV BY CHD.BY

500 ~I 1'"- --- --- ---------- -~···-----!==+===="====-=- =::'::=::::=========·=-· -=-·=-=·-=~==-:-===!=:=::--:----j~-:::: --·
l·
0 16/02/11 ISSUED FOR APPROVAL HSG BJP
FF I
(s r-{4) I ___..--{13) 1 Q4/03/11 REVISED AS PER YOUR COMMENT & MARKED.& HSG BJP
-.-----r---t1H1F-~~~v . I .
I II--____;_:
cs)
~ (8}-- I (5 ~\ I r(4)
0 I 10 CFW
n _f[ ~,----( 12 ) V ~(3) 0
I")
30 Thk. (1}- (4) (3) 6 CFW
~~~ --~~
0
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- - "--- l \
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DETAIL OF HOOK BOLT
(28"NB)'\[f)_ /
- ~
R=
1
I
~
~
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I
,....
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I I
I
I
r 1/ .,.,.,.1 /!\
I
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I
45
I ~2 )
: 711¢ O.D. ~ 22¢ "' / SECTION-"X'-'X' ..
I (28"NB) 1
R-25
12)
NOTE:-
Davit Detail -..-- ( 11) 1) All Dimensions are in mm if not Specified.
2) Refer Main Equipment Drg.No.: 048 SB 10079, Rev-1
.,,,,,,'. ,-.:,,,, ,, . , .... (Sheet 1 of 2)
I I l go·
I
90
;· ~
13
12
Bend
Bolt with Nut 1 H.T.
1 IS 1239 2"NB, Sch-80
M-20 x 100 lg.
11 Plate 2 I$2062GrB 16 Thk, Refer Detail
. / 28"NB. 300#-Cover Flange
10 Snap Head Rivet 1 IS2062GrB Refer Detail
V1ew- 'A'
o
8-16.47,Series-'B' 9 Plate 1 IS2062GrB 10 Thk, 46 O.D x 17 I.D
·- - - . : : 500
.:::::.:::::.------tj
... 30~
7
8 Hook Bolt 1 - IS2062Gr8
Plate for Bush .... 2 -IS2062Gr8
Refer Detail with Two Nuts.
6:3 O;D -x 30 I;D x 12 Thk.
(13)
.-------
r ( 4)
----_ ---+- ,_
~,-...-
~(7 ~ 11" (Typ)
·· X I 1 1,."\,'
I
~
6
5
4
3
Davit Bush Pipe
Rib
Davit Pipe
Dovit Guide Pipe
1
1
2
1
SA 106Gr8
IS2062GrB
SA106Gr8
SA 106GrB
2 fNB,Sch-40, 70 Lg.
10 Thk.
2"NB, Sch-80
2t''NB,Sch-40 x 145 Lg.
-
I 2 Gusset Plate 1 IS2062Gr8 10 Thk, Refer Detail

r /.~ !\ -
, yr
5 CFW7 -.'J "'' 1 Support Plate 1 IS2062GrB 12 Thk x 90 W
I
I 5
) (7~ 7~~ I "-<s) tsJk DESCRIPTION lolY. MATL £ZE
GUJARAT OTOFILT
(AN ISO 9001 :2008 Cert.Company)
CLIENT :-
B.H.E.l.(Hyderabad)
l 2"N8, , )
~ Plot No.-3712,Phase-IV,G.I.D.C.
Votva, Ahmedobod-382 445.
~~::.:....;.;~!.-::...::..:....:..~::.!--!
p .O.No.: F71 OA00165.
• og· ''OZ/Z0 11
1
4 Ph.:{0!9) 2584116.4, Fax:25842719 DATE
9__ I TITLE:- Davit Detail For Basket
E-mail (D : gof@s.fy.com · . - If I
ACAD BY I H.S.GHUBE
------ ~ ........
--.;::-48C~F"W~-~~~~-----::--~--------t===~A\_==--=
111· -. .
ill · B.P.Sucfion Strainer GI-ll'\ sv I
(stzE:-1B"Ns) ---~;;~c- -~~- 1 ce-..:~~rl"\c-Eo · - - -
0 I OA"JL"L -
tII\ 9) {Project: 4 X 600 t.IW,O P Jindal STPP,Ralgarh Chattlsgarh DRG No 1~

~L
3JII flO
DETAIL OF DAVIT PIPE SCALE :- N.T.S TFILE No: 8017B18A Q48SB 1 0079 1
A.O.No.:- 8017 I OATE:-16/02/2011
PART-5
SUB-DELIVERY ITEMS
SECTION- C
BFP RECIRCULATION CONTROL VALVE
(
I
'·
I-
(
Control Valve Data Sheet no. 11200238.10 l:t•l;MI
REG~~~~:;,
Exceltence is our standard
customer: Bharat Heavy Electricals Limit no.: 15510

plant :.iiiltiu• • nz ·MW 1
3 pos. I marking:
quantity: 6 High pressure min flow valve ON 8"
s type: 1315-68 globe valve
e body made of: SA217WC9
1 installation: horizontal
6 connection: welded ends SA217WC9, AE 0219,1 x 32 mm
11 Body class #2500
12 trim: *** 7-stage pressure reducing***
1 perforated cage in the inlet
6 perforated discs of 1.4122
(X35CrMo17)
balanced plug (turcon-glydring)
1 perforated cage in the outlet
jamed seat made of 1.4122 hardened
(X35CrMo17)
13 stem packing: graphite/K80S
14 pneumatic actuator: pneumatic actuator, type PA-N 2160-0-100

mode of operation: air closes/spring opens
spring range 1,5- 3,0 (eff. 1,5- 1 ,95)
supply air 5 kg/cm 2
handwheel top, laterally
Tubing made of CU
air set with filter SMC, type EAW 4000-F04D-GY:z
2 limit switches (1 open, 1 close)
quick opening less than 10s
3/2 way solenoid valve Herion GY.i- 24 VDC, type 2401103 with pneumatic
valve G1
junction box
1s medium: feedwater
1s load conditions: Q P2 kv
(m 3 /h) (kg/cm 2 ) (m 3/h)
hot 400.0 280.0 10.0 270.0 160.5 23.6
cold 105.0 23.0 4.0 19.0 40.0 24.2
,-
'·· Cv:
17 33,5 characteristic: on/off
16 kvs : 29
19 seat 0 70mm stroke: 30mm
20 ~p aclualor : 280 kg/cm 2
21 stress calculation: inlet 320 kg/cm 2 /190 •c outlet 320 kg/cm 2 /190 "C
22 techn. terms of delivery: American valve specification ANSI 816.34-2007
23 acceptance certificate: Inspection certificate 3.1 ace. to EN 10204 and IBR IIIC
24 inspection: Hydrostatic Pressure Test
Seat Leakage Test
Assembled Valve Test
cv-test
2s noise (precalculation ace. VDMA 24 422): <85dB(A) w/o insolation
21 direction of flow: on the plug
2a varnish: type 1815 synthetic resin zinc dust, grey, up to 200 •c
29 leakage class: FCI70-2-2003 class V
_____ c: :_re: : a: .: te.: :_d_:_1 :_: .0:.:_1: :. 20: _1:_:1_:C~hr:.:.:is: : tia: : n.:.e: : M.=ei=er_:_I.:_PT.:_ _ ____,P~hoo!'.LEax:_+_4~9(~0)~52~0i'~-1~89~03:-·~18~-/9~1,!55~-0~·1!·8======~~VV11'1111li.o1.1.2<20i1111P,pa;;gg;e11~of~2------~--
AP PRO~~(j 0
~s\••11'
PRAKASH BH_UTAO~
.....,-s.....,r-"'u•"""'es>~'"""~"""1-,;;l"m:·o~:mT·m~:Mt!M'"o4fta~
SHE.L, MYOf:RABA0-32.
Control Valve Data Sheet no. 11200238.10 l#t•l&MI
R£OELARMATUi1EN )
······ ·-·---------·-- --- E~cell•nce I• our standard
31 identification plate: english
32 10M manual: documentation: english
english
35 packing: standard
Js installation: installation indoor
'.-
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I' \,
High Pressure Min Flow Valve Type 68 ~,._]:~a
ON 200 (Body Closs 2500) ~REGELARMATUREN/
Exa!llenc:e Is our standard
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Proofed 2008
Holter Regelarmaturen GmbH & co. KG
1: t•l;tll
REGELARMATUREN
Heizungs-, Luftungs-, Klimaarmaturen - Industria- und Kraftwerksarmaturen Excellence is our standard
(€
Opeiating Instructions
Valve-Type
68
0412 I 112036 I HORA I GB 68_GB_0412

I#C•l•M
REGELARMATUREN
Excellence is our standard
Contents
1 Address of Manufacturer ........................................................................ 3

2 Right to alteration and copyright ........................................................... 3
3 Comments on Valve-Type ....................................................................... 3
4 Validity of operating instructions ........................................................... 3
5 Use from valve ......................................................................................... 4
6 Sectional drawings ..................................................................................4
7 Handling ························································~~······································~~···6
/
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2/6
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I#C•l;:bl
REGELARMATUREN
1 Address of Manufacturer
Holter Regelarmaturen GmbH & Co. KG

Business Unit Power Technology
Helleforthstra!3,e 58-60
D - 33758 Schlol3, Holte-Stukenbrock
Germany
Phone: +49- (0) - 5207 - 8903- 0

FAX: +49- (0) - 5207 - 88 037
e-Mail: mail@hora.de
Internet: http:llwww.hora.de
2 Right to alteration and copyright
Any regulations, guidelines, norms etc. stated in these operating instructions correspond to the state of
information during preparation and are not subject to alteration services. It is the responsibility of the
operator to ensure that the latest version is used at all times.
The company reserves the right to carry out technical alterations and improvements in connection with any
technical data, statements and images in these operating instructions at any time. Claims for alterations or
improvements on already delivered valves will be excluded.
Copyrights for these operating instructions as well as any rights referring to the possible grant of a patent, or
utility-patented articles, shall remain the property of the manufacturer.
3 Comments on Valve-Type
Valve-Type Specification Possible classifications

Straight pattern type up to PN 400 I Class 2500
68 Flanged cover 1315; 1325
Medium Water
Angle pattern or Z- type up to PN 400 I Class 2500
68 Flanged cover 1335
Medium Water
4 Validity of operating instructions
This operating instruction only apply with the "General Operating Instructions Valves Business Unit Power
Technology".
This operating instructions only apply to the valve type 68.
Please check that type designation and nameplate of valves match before any measures are taken,
especially when ordering any accessories or spare parts!
316
l#[e];f.iJ
REGELARMATUREN
5 Use from valve
The valves consist of the valve itself and the valve operating gear which changes the position of the flow
restrictor (plug) to the seat in accordance with the control unit.
Possible means of actuation are pneumatic and electric linear activator attachments which cause an axial
shift of the cone. Also suitable are multiturn actuators which transform the slewing motion into axial motion
and manual adjustments.
Minimum flow ON/OFF valves are used for protection of pumps from possible damages caused by thermal
and hydraulic overloads. If the pressure to high or the temperature of the pump to high the minimum flow
ON/OFF valve open and a bit of the water is get out of the system to reduce the pressure or the temperature
at the pumps.
·'\ 6 Sectional drawings
The sectional drawings below show examples of the basic construction of valves.
Figure 1: Valve 1325-68
4/6
I:C•l;M
REGELARMATUREN
30
22
23
21
20
19
18
17
14
15
8
10/11
9
10/11
7
6
s
4
3
Figure 2: Valve 1335-68
Position Designation Position Designation

1 Body 18 Valve stem*
2 Welding end 19 Gasket*
3 Throttle bush 20 Guide bush
4 Perforated disk 21 Cover
5 Perforated disk 22 Stud bolt
6 Perforated disk 23 Hexagon nut
7 Perforated disk 24 Button ring
8 Seat bush* 25 Stem packing *
9 Cylindrical pin 26 Pressure bush
10 0-Ring * 27 Flange
11 Back-up Ring * 28 Stud bolt
12 0-Ring * 29 Hexagon nut
13 Back-up Ring * 30 Actuator
14 Thrust ring bush 31 Yoke assembly
15 Piston* 32 Hexagon head screw
16 Sealing cap* 33 Flange
17 Cylindrical pin *
* = spare parts
Table 1: Parts I1st of f1gure 1 and 2
5/6
I#Cel;fA1
REGELARMATUREN
Excel! en~~ is qur standard
7 Handling
Figure 3 shows examples of handling methods during the fitting of valves.

In figure 3a the straps have to be wound round the bonnet. To keep the valves in the position shown and to
prevent vertical tipping, the straps have to run along the left and right hand side of the actuator.
In figure 3b the straps have to be wound round the body and the bonnet. It is important that the straps are
not fastened to the valve stem.
a b
Figure 3: Hoisting of valves for installation in pipeline
&_Hazard
The eyes at the activator attachment should only be used for lifting the activator off the valves. They
must not be used as hoisting eyes for the entire valves.
6/6
- ----1I
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1;Ce];1;11
1
Holter Regelarmaturen GmbH & co. KG I REGELARMATUREN )
Valves for heating, ventilation, air conditioning- for industrial and power plant use Excellence is our standard
Operation and maintenance manual
Pneumatic Actuators
PA-N 300/540/1 080/2160
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\ Excellente is our stand•rd

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Table of Contents
Table of Contents ............................................................................................. 2
1 General information ................................................................................. 3
1.1 Manufacturer's contact address .......................................................................... 3
1.2 Reservation of changes and copyright .... : .......................................................... 3
1.3 Validity of this user manual .................................................................................. 3
1.4 Safety information and regulations ..................................................................... 3
1.4.1 Meaning of the information ................................................................................ 3
1.4.2 General safety information ........... :.................................................................... 3
1.4.3 Qualified personnel ........................................................................................... 4
1.5 Warranty ................................................................................................................ 4
2 Transport, storage and handling ............................................................ 5
3 Description, technical data ...................................................................... 6
3.1 Area of application ................................................................................................ 6
3.2 Function and mode of operation ......................................................................... 6
3.3 Limits for application ............................................................................................ 6
3.4 Sectional drawings with parts lists ..................................................................... 8
3.4.1 PA-N 300 ........................................................................................................... 8
3.4.2 PA-N 540 and PA-N 1080 ................................................................................. 9
3.4.3 PA-N2160 ....................................................................................................... 10
3.4.4 Sectional drawing manual emergency positioning device size I (stroke=max.
30mm) for actuator PA-N 300 .................................................................................. 12
3.4.5 Sectional drawing manual emergency positioning device size II (stroke=max.
60mm) for actuator PA-N 540 ..................................................................................... 13
3.4.6 Sectional drawing manual emergency positioning device size Ill and size IV
(stroke=max. 100mm) for PA-N 1080-2160 ............................................................... 14
4 Fitting ....................................................................................................... 15
4.1 Installation of the actuator onto the valve ........................................................ 15
4.2 Dismantling the actuator off the valve .............................................................. 17
/ 4.3 Connection of the control air conduit and components .................................. 17
4.4 Reversal of the operating mode and exchanging spares ................................ 18
4.4.1 PA-N 300 without manual emergency positioning device ............................... 18
4.4.2 PA-N 300 with manual emergency positioning device .................................... 19
4.4.3 PA-N 540 and PA-N 1080 without manual positioning .................................... 19
4.4.4 Disassembling PA-N 540 and PA-N 1080 with manual emergency positioning
device (see fig. ?) ...................................................................................................... 21
4.4.5 PA-N 2160 without manual emergency positioning device ............................. 21
5 Commissioning & Maintenance ............................................................ 23
5.1 Commissioning ................................................................................................... 23
5.2 Maintenance ........................................................................................................ 23
6 Error search list ...................................................................................... 24
---1-=Figh-tening-to·rques ................................................................................. 2-5
2 I 25
I:C•J;f:.1
REGELARMATUREN
1 General information
1.1 Manufacturer's contact address

Holter Regelarmaturen GmbH & Co. KG
Helleforthstrar..e 58-60 Postfach 14 60
0 - 33758 Schier.. Holte-Stukenbrock 0- 33751 Schier.. Holte-Stukenbrock
Phone: +49 - (0) - 5207 - 8903 - 0

FAX: +49- (0)- 5207- 88 037
E-Mail: mail@hora.de
Internet: http://www.hora.de
1.2 Reservation of changes and copyright

The regulations, directives, standards etc. are compliant with the current state of information at the time of
development and are not subject to modification service. They must be applied by the operator at his own
responsibility in their latest valid version.
Concerning all data, information, and illustrations in this manual we reserve the right of technical modifications and
improvements. No claims can be considered for alteration or rework of already delivered actuators.
The copyright for this operating manual as well as all rights in case of patent awarding or registration of registered
design remains with the manufacturer!
1.3 Validity of this user manual

These operating instructions only apply to actuator types PA-N 300/540/1080/2160 with or without emergency
adjustment device of class I /II /Ill /IV.
The regulations, directives and information stated in this operating manual are valid for the European Community.
Operators outside the EC must, at their own responsibility, regard the stated rules as practised basis for safe operation
and compare their implementation to the national I regional regulations valid for the installation location.
In case you require further information, or if special problems occur that are not treated extensively enough in the
operating manual, please contact your supplier I manufacturer directly.
For queries please specify the data of the type plate.
1.4 Safety information and regulations
1.4.1 Meaning of the information

&oanger: Means that death, serious personal injury or serious material damage may be incurred if the
respective safety measures are ignored.
[!] Attention: Means that material damage or adverse environmental influences may occur if this information is
ignored.
w Information: Means information concerning a certain advantage if this recommendation is adhered to.
1.4.2 General safety information

• For installation, operation and maintenance of the accessories, the respectively valid regulations pertaining to
maintenance of industrial health and safety, accident prevention as well as the EC regulations must be observed
at the operator's own responsibility!
• Every person given responsibility for one of the measures described in this operating manual must have read and
understood this manual!
• Fitting, operating and maintenance staff apply safe working practices at all times and have to avoid any working
methods that could in any way endanger persons or damage the actuators or other assets.
3 I 25
I#C•l$1
REGElARMATUR_EN
Excelfence is our standard
• Before beginning any maintenance and I or repair work the electric leads leading to the valve actuator must be
disconnected in accordance with EC directives by qualified staff. The valve also needs to be depressurised,
cooled down and emptied.
&Danger: During operation, the valve is under pressure and temperature. If the warning information is ignored,
death or serious personal injuries or material damage may be incurred.
Only qualified staff (see 1.4.3) may work on or around these actuators. The personnel must be thoroughly
familiar with all warnings, the installation and the maintenance measures according to this operating manual.
The perfect and safe operation of the actuators requires appropriate transport, correct storage, positioning and
mounting as well as careful, safety-conscious operation and repair.
• The above information and the following warnings do not consider possible additional regional, local or in-
company safety regulations and must be complemented by the operator at his own responsibility if necessary!
• For use in a potentially explosive atmosphere please comply with EN 13463-1: Knowledge about working in an
explosive environment is essential if a potentially explosive atmosphere exists. The actuator design meets the
requirements of device class II (above ground), device category 2.
1.4.3 Qualified personnel

For the purposes set out in these operating instructions, or warning notices, persons shall be considered qualified if
they are familiar with positioning, mounting and commissioning and the operation or maintenance of the actuators, and
have the usual qualifications for this type of occupation. The necessary and prescribed qualifications include:
• Training I instruction or authorization to turn on /off circuits and appliances I systems according to EN 60204 (DIN
VDE 0100 I 0113) and the standards of safety technology.
• Training or instruction according to the standards of the safety technology concerning care and use of adequate
safety and work protection equipment.
• First Aid training.
• Knowledge about working in areas with explosion hazard, when the atmosphere presents explosion hazard.
1.5 Warranty
The scope and period of warranty is stated in the manufacturer's "General Terms of Delivery". The latest valid issue, at
, the time of delivery, is decisive.
i ·,Amongst others no liability shall be accepted for damages to the actuators arising due to one or more of the reasons
stated below:
• Ignorance or non-observance of this operating manual
• Insufficiently qualified installation, operating and I or maintenance personnel
• Natural wear.
• Faulty or negligent treatment of the actuators
• Chemical, electrochemical and I or electrical influences
Furthermore warranty and manufacturer's liability is excluded for:

• Non-observance of the maintenance of industrial health and safety standards, accident prevention regulations, EC
and I or other safety regulations. .
• Modifications or changes of the actuator that were executed improperly or without manufacturer's prior consent
• Faulty installation, incorrect commissionin·g and improper operation
• Inappropriate or improper application, in case of improper use as well as in case of other than the agreed
conditions of use
The risk in case of a violation of the above restrictions shall be borne, in case of personal or material damage,
exclusively by operator!
4 I 25
[_
I:C•l•M
REGl!lARMATUREN
Excellence Is our standard
2 Transport, storage and handling

During transport and intermediate storage the following points should be observed:
• Until installation, the actuator should be stored in a dry place
• Temperature for transport and storage should be between -20°C and +60°C
• The actuator must be protected against external forces (impacts, shocks, vibrations etc.)
• Damage to the corrosion protection (paint, oiled surfaces etc.) must be repaired immediately
• Intermediate storage for more than 6 months must be avoided
• If the actuator is already mounted onto a valve please also observe the conditions for transport, storage and
handling of the valve
• PA-N 540-2160 is provided with lifting eye nuts for transport and handling and these must be screwed down onto
the studs of the bonnet (1) after disassembling the two hexagon nuts (31) (fig. 2,3 and 4 ). They are not suitable for
transport with a mounted valve
It has to be ensured that eye hooks for chain hoists are available at an appropriate height above the assembly bay
Even better than that is the availability of running rails or swivel arms with hoists above the assembly bay.
Figure 1 shows an example of handling options during the assembly of the actuators .
.......
Fig. 1: Handling Actuators
&oanger:
If the actuator is mounted on a valve, the chain hoists used for fitting the assembly group are to be attached to the
valve.
If the warning information is ignored, death or serious personal injuries or material damage may be incurred.
5/25
I:Ce];f;.1
REGEtARMATUR_EN
3 Description, technical data
3.1 Area of application

The pneumatic control actuators are mounted on top of control and lock valves in industrial and power plants for the
actuation of the aforesaid. They achieve high control forces for brief control times. A safety position in case of control
power failure is ensured through the springs.
3.2 Function and mode of operation

By means of the pneumatic actuator pneumatic control signals are converted into a shearing movement. The
necessary reaction force is generated by the pressure springs on membrane plate.
In case of air failure the actuator is reset into the initial position through the spring force.
Unless otherwise agreed on the data sheet stroke limitation is achieved inside the valves or via positioners or limit
switches.
jThe operating mode of the actuator, spring opens - air closes (SO) or air opens - spring closes (SC) is achieved
_. depending on the installation of the springs. For actuators already installed in systems the operating mode can be
changed with simple tools without additional parts.
The pneumatic actuators equipped with an emergency adjustment device can be actuated without control air by
turning the hand wheel.
The actuator spindle is moved upwards by turning the hand wheel clockwise. The manual emergency positioning
counteracts the elastic force.
'*I ATTENTION! After the emergency adjustment device was activated it has to be reset to zero position (chpt. 4.4.2
and 4.4.4).
During normal operation the emergency adjustment device is secured by a chain and lock.
3.3 Limits for application
.- ~To determine the driving force, multiply the membrane area by the pressure of the spring or operating pressure minus
the equivalent spring pressure.
Example: Actuator PA-N 1080 with a spring range of 1.5- 2.4 bar and an operating pressure of 6 bar
Closing pressure of spring with extended spindle: F =108000 mm2 * 0,15 N/mm 2 =16200 N
Closing pressure of spring with retracted spindle: F =108000 mm 2 * 0,24 N/mm2 =25920 N
Opening force due to operating pressure at starting point: F =108000 mm 2 * (0,6- 0,15) N/mm2 =48600 N
Opening force due to operating pressure at end point: F =108000 mm 2 * (0,6- 0,24) N/mm2 =38880 N
6 I 25
----- ---1
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REGELARMATUREN
Excellence Is our standard

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-~-- ---- -- ~--- --- --~- - - - - - ~-- ----- ~~ ~
Table1: Actuator specifications
I* I Attention: Consider allowable ambient temperature of attachments
To ensure perfect working order, the control air required for actuation (max. 6 bar) should meet the following
conditions:
• Air quality for instruments in accordance with DIN/ISO 8573.1, particle size of max. 5 f..Jm, particle density of max.
3
5 mg/m and quality class 3
• Water content: max. dew point +2°C (quality class 4); an relatively different dew point applies to high altitude
locations or low ambient temperatures;
3
• Oil content: max. 25 mg oil per 1m of air (quality class 5) in accordance with DIN ISO 8573.1 with particle sizes
processed by a maintenance unit. If the actuator is operated at temperatures blow zero, dry control air must be
used.
For different control air qualities or special control media please consult the manufacturer.
7 I 25
I#C•1•Yd
REGEt..ARMA'TU_REN
r.--. · Excellence is our standard
3.4 Sectional drawings with parts lists
3.4.1 PA-N 300
Function mode Spring Closing (NC) Mode of action Spring Opening (NO)
22
3 / 32.
"'- ..... ,, .-·
5 2
'
16 17
35 25
30 35
26 30
24 104
21
101
42 .. '• 6
41 ·•.•. . 20
31
12
Fig. 2: Actuator type PA-N 300

1 Bonnet no. 1 24 Protective hose
2 Membrane plate 25 Hexagonal screw
3 Spring centring sheet 26 Hexagonal screw
k
;;4 Spindle* 27 Hexagonal nut ',
5 Bush 28 Cylinder screw

i
6 Driver pad 30 Hexagonal nut
7 Guidance* 31 Groove nut
12 Column 32 Hexagonal nut
I
13 Bonnet no. 2 ~J 35 Disk
14 Clutch 39 Sliding bearing * I
-
15 Clutch 41 Stroke shield
I
16 Pressure spring * 42 Grooved pin
17 Membrane* 101 Hose clip 11
19 Rod seal* 102 Bellows 11 I
20 . 0-ring * 103 Ring IJ i
21 0-ring * 104 Anticorrosive protection cap 11 i

i
22 Ventilation pLug t05 AJ:Jtico~rosive proteGtiGn-GaJ3 _:11_
I
* =
spare parts (recommendation) I
·,
I
Table 2: Parts list for f1g. 2
)1) Optional accessory

'2) When used with manual emergency positioning device replaced by bonnet no. 1
8 I 25
[_
I:C•l;:l!l
RSGELARMATUREN
Excellence is our ~tandara
3.4.2 PA-N 540 and PA-N 1080
11
31
105 ~2
20 22
2
17
34 104
s 25
16 35
30 30
26 104
24
6 21
20
39
31 23
105 19
12 10
102 /,1
103 32
101 42
26 38
30 9
15 8
14 27
Fig. 3: Actuator Types PA-N 540 and PA-N 1080

1 Bonnet 24 Protective hose
2 Membrane plate 25 Hexagonal screw
4 Spindle* 27 Hexagonal screw
5 Bush 28 Hexagonal screw
6 Driver pad 30 Hexagonal nut
7 Guidance* 31 Hexagonal nut
8 Rotary guard 32 Hexagonal nut
9 Guide roller 34 Screw
10 Adapter 35 Disk
11 Cover LJ 36 Disk
12 Foot 38 Securing ring
14 Clutch 39 Sliding bearing *
16 Pressure spring * 42 Grooved pin
17 Membranes* 101 Hose clip '1
19 Rod seal* 102 Bellows 11
20 0-ring * 103 Ring 11
21 0-ring * 104 Anticorrosive protection cap ' 1
22 Ventilation plug 105 Anticorrosive protection cap 11
23 Plug
* = spare parts (recommendation)
Table 3: Parts l1st for f1g. 3
1) Optional accessory
2) Not applicable for manual emergency positioning device
9 I 25
I:Ce1;f41
--·-,· r----- -··· ftEGEt.ARMATUREN
3.4.3 PA-N 2160
31 11
104 .... 36
20 32
34 ........ 22
1. 2
3 17
5 --104
31 . 25
16 ------36
26 ......, . . . . . . . . . . . . 31
24 104
\ 39 - 1
113
=t~~s=mJ-rti!~!~c=-~-= . 36~
1
19 .................... ,___________________
31 ... 4
ID4 n
20 2
17
3
~·-------------- 104
5
25
31 .. 36
16
31
26 -------104
2
~-----==~==~=~~~~1i~iril~~~
tU-----m-----------------------···--'- 21
~"-------------------------------- 6
12 = --------------- 20
104 39
101-----------------------------------------------;r- 31
102 7
23
19
103--- 42
101 . 41
28 4
30 ---10
15 32
14 38
9
8
-----27
Fig. 4: Actuator type PA-N 2160
I
!
10 I 25
I
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I: C•l ;:1!.1
REGI!LAAMATUREN
Excellence is our ~tdndaro
-- ----
1 Bonnet 23 Plug
2 Membrane plate 24 Protective hose
4 Spindle" 26 Hexagonal screw
-- ----
5 Bush 27 Hexagonal screw
6 Driver pad 28 Hexagonal screw
- ~- ----
7 Guidance* 30 Hexagonal nut
8 Rotary guard 31 Hexagonal nut
9 Guide roller 32 Hexagonal nut
10 Adapter 34 Screw
11 Cover L) 36 Disk
12 Foot 38 Securing ring
13 Adapter 39 Sleeve bearing "
15 Clutch 42 Grooved pin
16 Pressure spring " 101 Hose clip''
17 Membranes" 102 Bellows ''
-
19 Rod seal* 103 Ring 11
20 0-ring * 104 Anticorrosive protection cap ,,
21 0-ring * 105 Anticorrosive protection cap
22 Ventilation plug
Table4: Parts l1st for F1g. 4
1) Optional accessory
2) Not applicable for manual emergency positioning device
11 I 25
l#[e];f41
REGEt.ARMAT_4"f(EN
3.4.4 Sectional drawing manual emergency positioning device size I (stroke=max. 30mm)
for actuator PA-N 300
59
Function (NC) Spring Closing Function (NO) Spring Opening 51
76
69
.............. \~. 1?.?.. . . . . 77
56
62
74
75
r- I
0
0\
N
I
7
Fig. 5: Manual emergency positioning device size I
.;\' )Position Designation Position Designation
~
71) Guidance* 62 0-ring * '
19 l) Rod seal* 65 Threaded pin
20 IJ 0-ring * 66 Hexagonal screw
31 lJ Groove nut 67 Hexagonal nut
I'
39 Sliding bearing * 68 Hexagonal nut
50 Column 69 Securing ring
51 Hand wheel 70 Cylinder screw
52 Spindle 71 Clutch
I
53 Bridge 72 Clutch
54 Grooved clamping pin 74 Axial needle ring*
55 Threaded stem* 75 Axial disk* I
56 Threaded bush* 76 Lock I

I
57 Dummy flange 7-7- Gila in

58 Forks 100 Anticorrosion protection kit :<J
59 Protection cap I
=
* spare parts (recommendation) I
t )Table 5 : Parts I1st for fig. 5 I
1) For connection to PA-N 300
-----2)--- --Optional accessory-------- -----1
I
!
12 I 25
i_
I:C•l;T!J
RllGELARMATUREN
Excellence 15 our stJndarc
3.4.5 Sectional drawing manual emergency positioning device size II

(stroke=max. 60mm) for actuator PA-N 540
59
Function (NC) Spring Closing Function (NO) Spring Opening
56
I?JOO
r-
1 I 51
62
75
72 74
70 57
71
77
76
54
50
52
55
53
150 /Bx014 68
1!>1~U
II II' 'I 58
\
I
LK \ ', 60
.~ ) (<
.-:1 61
64
Fig. 6: Manual emergency positioning device size II

50 Trestle 61 0-ring *
51 Hand wheel 62 0-ring *
52 Bush 64 Guide belt*
53 Disk 68 Hexagonal nut
54 Screwed joint 70 Cylinder screw
55 Threaded stem* 71 Cylinder screw
56 Threaded bush 72 Safety disk
57 Dummy flange 74 Axial needle ring*
58 Guide 75 Axial disk*
59 Protection cap 76 Lock
60 Rod seal* 77 Chain
Table 6 Parts list for Fig. 6
13 I 25
I#C•l•!d
REGElARMATUREN
ExceUence is our standard
3.4.6 Sectional drawing manual emergency positioning device size Ill and size IV
(stroke=max. 100mm) for PA-N 1080-2160
Function (NC) Spring Closing Function (NO) Spring Opening
················ ...... ·····.,---+-,---,
\.
';
64

50 Trestle 61 0-ring* 'I
!
52 Bush 64 Guide belt*
I,
53 Disk 68 Hexagonal nut

54 Screwed joint 70 Cylinder screw
I
55 Threaded sJem* :zj C}'linder-Screw I
'
56 Gearbox assembly 72 Safety disk
58 Guidance 76 Lock
60 Rod seal* 77 Chain
iTable 7: * =spare parts (recommendation)
Parts list for fig. 7 - - - - - - - - ---- ----- --- ------- ------ ---------- - - - - ----
------- - - - - - --- - - - - - --------- - - - - -
--- - - -- -------
14 I 25
I:Cel;tlt
REOC'lAHMA1UREN
Excellence is our stand<nd
4 Fitting
&oanger I
Before beginning any work, please observe:
• Switch electrical components voltage-free and secure against unintentional restart!
• Work properly and following the EC safety regulations as well as the warnings and
information in this operating manual.
• Ensure that the pipe section where the valve is located is pressure-free.
• Allow the valve to cool down to about room temperature.
' - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- ---- - - -
--
I* I Attention!
• Please comply with the existing operating instructions for the particular valves and the
optional accessories (e.g. positioner, filter reduction station, block relays etc).
• Selected performance profiles according to the relevant actuator performance and
existing line performance
• Compliance of the technical data of the actuating actuator with the conditions of use
4.1 Installation of the actuator onto the valve

For diagonal installation position the actuator must be installed in a way that the position of the columns/ribs
generate the maximum resistance torque (see fig. 8).
g~9.81m/s"2
Fig. 8: Position of the columns for horizontal installation
I* I Attention: The driving weight of PA-N 540-2160 requires support if its oblique position exceeds 30° in
relation to a vertical line.
15 I 25
l:t•l•M
REGElARMATUREN
Excellence is our standord
Follow the sequence of assembly steps below (see also figure 2, 3 and 4):
• Put the valve spindle in lower seat position.
• Place the actuator on the valve without tightening the nuts or bolts(27) used for fastening of the actuator.
• Connect control air conduit to the actuator (see chapter 4.3)
• If there is a manual emergency positioning device, the swivel lock (72,73)) must be positioned between
the grooves of the columns of the manual emergency positioning device (50) for actuators PA-N
540,1080,2160, for function Spring Closing (NC) the hand wheel must be turned clockwise, for function
Spring Opening (NO) anti-clockwise after free-wheeling up to stop.
• For actuators with mode of clutch-pressure.
Lh Danger: Please ensure that no control air can unintentionally escape from the actuator. A
pressure drop in the actuator may lead to a pre-tension between the valve and the actuator spindle
(4), blowing off the coupling (14.15) (when hexagonal screws (27) are removed).
@" Information: For actuators with manual emergency positioning the spindle (4) can also be brought into
fitting position via manual emergency positioning.
• Connect the valve and actuator spindle (4) in the respective actuator position with the clutch (14,15),
taking care that the turns of thread have sufficient catch (see figure 9) as well as that for NO the stroke
indicator marker on the clutch is pointing at the line at the bottom of the stroke indicator sign (41) when
the actuator is closed.
PA-N 300 PA-N 540-2160
0 JT)
~
( c '-:!;
r X
E 0
E
Fig. 9: Valve connection
• Now tighten the nuts or bolts (27) used for fastening the actuator on the valve cover/tie-bar (tightening
---------to~u~chp~~~~.----------------------------------------------------------------------+-
'.
)
16/25
I: C•l ;1>!01
REOELARMATUREN
Excellence is our stondaro
4.2 Dismantling the actuator off the valve
• Admit just enough air pressure to the actuator to make the actuator spindle (4) react. If there is no
control air or the membrane is defective, relax the compression springs in the actuator space. For this
purpose disassemble the control lines and the hexagon screws (25), then use the hexagon screws (26)
to relax the compression spring (16) (see chpt. 4.4).
&oanger: Please ensure that no control air can unintentionally escape from the actuator. A
pressure drop in the actuator may lead to a pre-tension between the valve and the actuator spindle
(4), blowing off the coupling (14.15) (when screws (28) are removed).
• Loosen screw (28) and take coupling (14.15) off valve and actuator spindle (4). For PA-N 540, 1080 and
2160 unscrew the hexagon nut (32) and disassemble the adapter (10). To achieve this you might
possibly have to move the actuator spindle (4) upwards with the help of control air.
• You might have to relax the actuator again by lowering the control pressure.
• Disconnect control air conduit from actuator (see chapter 4.3).
&oanger: When installing or dismantling the control air conduit please observe that it is pressure-
free, as otherwise parts may be blown off when loosening the connections.
• Securing the actuator (see chpt. 2)

Attention! The actuator spindle might still be spring urged (function Spring Closing only) when the
actuator spindle resting firmly on the valve spindle. In this case detach the actuator by 10 mm from the
valve connection. If the valve spindle continues to rest firmly on the actuator spindle you will have to
relax the compression spring in the actuator space .
., Remove the fastening nuts or bolts on the driving columns or base (12).
• Take actuator off valve.
4.3 Connection of the control air conduit and components
&oanger: When installing or dismantling the control air conduit please observe that it is pressure-
free, as otherwise parts may be blown off when loosening the connections.
Connect the control air duct for mode of action Spring Closing (NC) to the lower bonnet and for mode of
action Spring Opening (NO) to the upper bonnet. For connection thread please refer to table 1.
I* IAttention: The control air conduit may only be impinged with control pressure on the opposite side of
the springs (pressure room). The connection borings on the spring side must be blocked by
the ventilation plug (23) to prevent the penetration of dirt or the escape of air during the
procedure.
If an existing position regulator is dismantled and re-installed, please ensure that the position of the regulator
is not changed. If the position regulator is exchanged the parameters for the new actuator must be adjusted
to the old one. The nominal stroke must not be exceeded.
17 I 25
I:C•l•Y41
REGELARMATUREN
4.4 Reversal of the operating mode and exchanging spares

For all the installations carried out here, the actuator must be taken off the valve (see chapter 4.2).
4.4.1 PA-N 300 without manual emergency positioning device

The following steps are necessary to dismantle the actuator:
• Disconnect control air conduit from actuator (see chapter 4.3).
• Remove the hexagon screws short (25) including spacers (35) from the bonnets.
• Unscrew the hexagon screws long (26) including spacers (35) evenly until the pretension of the
compression springs (16) has been completely relaxed. Then remove the bonnet (13).
• Unscrew the hexagon nut (32) (watch out: Clutch (14, 15) must be mounted on spindle (4))
I* !Attention! The actuator spindle may possibly drop down. Please secure it beforehand!
''
• Remove component parts such as the membrane plate (2), membrane (17), bush (5) and driver pad (6) .
The spring centring sheet (3) (watch out: glued in) Disassemble from bonnet, might have to be warmed
up first. If the guide is to be replaced (7), undo the groove nut (19) and pull the guide (7) from the cover
bottom (1 ).
The following steps are necessary to install the actuator:

• Clean all parts and check them for damage. If necessary, re-work parts or replace with original parts.
• If necessary, plug guide (7) into cover bottom (1). Ensure that the 0-ring (20) is not forgotten. Fasten
with groove nut (31).
• For mode of action NC: Slide driver pad (6) onto spindle (4). Assemble membrane (17), membrane plate
(2) and bush and tighten with cheese-head screw (32). Arrange compression springs (16) evenly on
membrane plate (2). Place spring centring sheet (3) on compression springs (16). Compression centring
sheet (3), use OMNIFIT FD20 to insert an adhesive bulge between the centring 5 em (figure 10).
Fig. 10: Fastening spring centring sheet
• Put on bonnet (13) and tighten it, using the hexagon screws (26) (evenly spread around the
circumference). Tighten the hexagon screws (26) one after the other, 5mm at a time and then do the
same with the one opposite until the bonnets are on top of each other. Mount the hexagon screws (25)
and insert the ventilation plug (22).
• For mode of action NO: On the spring centring sheet at the bottom apply an adhesive bulge by using
OMNIFIT FD 20 between the centrings Scm each (see fig. 10) and insert it in bonnet (1 ). Insert the bush
(5), the membrane plate (2) , the membrane (17) and the driver pad (6), then tighten the cheese-head
screw (32). (Attention! For this purpose leave clutch mounted on spindle (4 ). Put the bonnet (13) on top
and tighten it by means of the hexagon screws (26) (evenly spread around circumference). Tighten the !
18 I 25
I
[_
l:tel;fl1
REGElARMATUAEN
Excellence is our stondorc
hexagon screws (26) one after the other, 5mm at a time and then do the same with the one opposite
until the bonnets are on top of each other. Fit hexagon screw (25). Insert ventilation plug (22) in bonnet
4.4.2 PA-N 300 with manual emergency positioning device

The following steps are necessary to dismantle the actuator:
• Turn the manual emergency positioning device to zero. For this purpose move the swivel lock (72,73)
between the marker on the column (20). In doing so, first remove the chain (77) with lock (76).
• Push grooved clamping pin (54) out of the spindle (52).
• Unscrew hexagonal nuts (67) off the manual positioning columns (50) and remove the whole of the
upper part of the manual positioning.
• The further dismantling procedure is the same as chapter 4.4.1.
The following steps are necessary to install the actuator:

• Clean all parts and check them for damage. If necessary, re-work parts or replace with original parts.
• Installation is initially the same as the installation according to chapter 4.4.1.
• Screw down the spindle (52) in spindle (4) and tighten firmly (the clutch must be mounted when doing
so). Slightly loosen the screws (28) on the clutch and align the spindle on the membrane in such a way
that the boring in spindle (52) is flush with the columns (50).
• Put the upper bonnet with guide unit on top and tighten it by means of the hexagon screws (26) (evenly
around the circumference). Tighten the hexagon screws (26) one after the other, 5mm at a time and then
do the same with the one opposite until the bonnets are on top of each other.
• Fit hexagon screw (25).
• Insert ventilation plug (22) in bonnet.
• Place the top part of the manual emergency positioning device on top of the columns (20) and use the
hexagon nuts (67) to tighten it.
• Turn the threaded spindle (55) to the extend that the hole for the grooved clamping pin (54) in the
spindle (52) is visible through the slits in the threaded spindle (55).
l* lAttention: The spindle (52) must not be twisted, as otherwise damage to the membrane may occur.
• Press grooved clamping pin (54) into the spindle (52), so that it evenly protrudes from the threaded
spindle (55).
4.4.3 PA-N 540 and PA-N 1080 without manual positioning
The actuator is disconnected from the valve and the control lines and possibly other attachments (e.g.
control box) must be removed. The clutch (14,15) is firmly mounted on the spindle (4).
4.4.3.1 Changing the direction of action
• Detach the hexagon nut (31) on the cover (11) including spacers (36). Lift the cover (11 ).
• Undo the hexagon nut (32) (e.g. Geodore K32-3/4"-36 power sprocket) and remove it from the actuator
box.
I*IAttention! The actuator spindle may possibly drop down. Please secure it beforehand!
• If required, remove guide (7) from base (12) and insert new guide (7).
• Undo hexagon nut (31) on base (12).
• Remove complete actuator box and put it back on upside down.
19/25
l#[e];fi)
REGELARMATUREN
Extelfente is our standard
• Screw down hexagon nut (32) (tightening torque chpt. 7)

• Fit cover (11 ), hexagon nut (31) and spacers (36) and tighten hexagon nut (31 ). (tightening torque chpt.
7)
• Fit ventilation plug in other bonnet
4.4.3.2 Disassembling the actuator box

• Undo hexagon nut (32) (e.g. with GeodoreK32-3/4"-36 power sprocket) and remove it from the actuator
box.
• Attention! The actuator spindle may possibly drop down. Please secure it beforehand!
• Undo hexagon screw (25).
• Relax the compression springs evenly by using the long hexagon screws (26).
• Now you can remove the membrane (17), membrane plate (2), bush (5), driver pad (6) and spindle (4).
4.4.3.3 Assembling the actuator box (fig.11)

Mode of action NC:
• Mount membrane (17) on membrane plate (2).
• Insert spindle (4), of not yet mounted and fit clutch (8,9, 14, 15,28,30).
• Put driver pad (6) on spindle (4)
Figure 11 Assembly PA-N 540-1080
• Insert membrane including membrane plate and bush.

• Fit hexagon nut (32).
• Insert compression spring (16) in membrane plate and spread evenly.
----•---P-ut- sp~ing-Gentring-sAeet-en-eemp ressien-spring-and-t~se-8 MN IHT-FD2G to insert an-adh·es·ive-b"ol'fre
between the centrings 5cm. (see fig. 10).
• Put on bonnet (1 ), Spring plate(3) and tighten it, using the hexagon screws (26) (evenly spread around
the circumference). Tighten the hexagon screws (26) one after the other, 5 mm at a time and then do
the same with the one opposite until the bonnets are on top of each other. Mount the hexagon screws
(25) and insert th~venJil~tion_Riug (22).
20 I 25
I:C•l•M
REOEI..ARMAlUREN
Excellence is our stondorc
4.4.4 Disassembling PA-N 540 and PA-N 1080 with manual emergency positioning device
(see fig. 7)
• Loosen cheese-head screw (71) c. 5mm and turn hand wheel clockwise until the gear unit starts lifting
from the trestle (50). Then undo the cheese-head screw (71) and unscrew the top gear unit from the
threaded spindle (55).
• Loosen cheese-head screw (70) by c.1 Omm.
• Undo hexagon nut (31) from upper bonnet (1) and remove trestle (50).
• Disassemble screwed joint (54) and remove threaded spindle (55).
• Disassemble bush (52) with the help of the boring (01 0.5).
• Remove the complete actuator box and put it back on upside down.
• Screw down bush (52) on spindle (4) and tighten.
• Insert threaded spindle (55) with the hexagon nut (68) screwed down and the spacer (53) in bush (52)
and tighten screwed joint (54).
• Place trestle (50) on bonnet (1) and tighten the hexagon nut (31).
• Screw cheese-head screw (70) back down, for function (NC) in lower groove of threaded spindle (55), for
function (NO) in upper groove.
" Unscrew gear unit (for PA-N 540:52,56,57,59,62,74,75- with PA-N1 080:56)
• Fit and tighten cheese-head screw (71 ).
• Put manual emergency positioning device in zero position; in doing so, turn the hand wheel clockwise for
function Spring Closing (NC) and for function Spring Opening (NO) anti-clockwise up to stop.
• Secure hand wheel with chain (77) and lock (76).
4.4.5 PA-N 2160 without manual emergency positioning device
4.4.5.1 Changing the direction of action
The actuator is disconnected from the valve and the control lines and possible attachments (e.g. control box)
have been removed. The clutch (14, 15) is firmly mounted on the spindle (4).
• Undo the hexagon nut (32) (e.g. Geodore K32-3/4"-36 power sprocket) and remove it from the actuator
box.
• Undo hexagon nuts (32) on adapter (1 0).
• Remove complete top part of actuator box.
• Take off adapter (1 0).
• Disassemble upper spindle (4) from lower spindle (4); for this purpose possibly put pipe wrench on upper
actuator spindle in the area shown in figure.
I ~:
I i
Fig. 12 Dismantling spindle
• Loosen hexagon nut (31) on base (12).

• Remove lower actuator box.
21/25
I:Ce1;fl1
REGELARMATUREN:
Excellen<e is our standard
• If the guide needs replacing, pull guide (7) off base (12) and insert new guide.
• Turn lower actuator box and put it back on with the corresponding direction of action.
• Screw down upper spindle (4) onto lower spindle (4).
• Replace the seals (19,20) before doing this.
• Screw down adapter (1 0) from below on upper (with turned direction of action) actuator box, using the
hexagon nut (31) and tighten it. Attention! Assembly according to direction of action
• Place upper actuator box onto lower actuator box and screw hexagon nut (31) hand tight on adapter.
• Tighten hexagon nut (32) on upper spindle (tightening torque chpt. 7).
• Fit cover (11 ), hexagon nut (31) and spacers (36) and tighten hexagon nut (31) (tightening torque chpt.
7).
• Fit one ventilation plugs (22) each in other bonnet.
4.4.5.2 Disassembly actuator box PA-N 2160
Fig. 13 Disassembly PA-N 2160
• Undo hexagon nut (32) (e.g. with GeodoreK32-3/4"-36 power sprocket) and remove it from the actuator
box.
• Attention! The actuator spindle may possibly drop down. Please secure it beforehand!
• Undo hexagon screw (25).
• Relax the compression springs evenly by using the long hexagon screws (26).
• Now you can remove the membrane (17), membrane plate (2), bush (5), driver pad (6) and spindle (4).
• Disassemble upper spindle (4).
• D1sassem6le lower actuator box as described in 4.4.4.3.
22 I 25
l:r•l;lll
nEOELARMATUREN
Exccllc:ncc is t~ur standarc
4.4.5.3 Disassembly PA-N 2160 with manual emergency positioning device (see fig. 8)
• Loosen cheese-head screw (71) by c. 5mm and turn hand wheel clockwise until gear unit starts lifting
from trestle (50). Then undo the cheese-head screw (71) and unscrew the top gear unit from the
threaded spindle (55).
e Loosen cheese-head screw (70) by c.1 Omm.
• Undo hexagon nut (31) from upper bonnet (1) and remove trestle (50).
e Disassemble screwed joint (54) and remove threaded spindle (55).
• Disassemble bush (52) with the help of the boring (12l1 0.5).
• Further disassembly as described in 4.4.5.
Assembly:
• Screw down bush (52) on spindle (4) and tighten.
• Insert threaded spindle (55) with the hexagon nut (68) screwed down and the spacer (53) in bush (52)
and tighten screwed joint (54).
• Place trestle (50) on bonnet (1) and tighten the hexagon nut (31 ).
• Screw cheese-head screw (70) back down, for function (NC) in lower groove of threaded spindle (55), for
function (NO) in upper groove.
• Unscrew gear unit (56).
• Fit and tighten cheese-head screw (71 ).
• Put manual emergency positioning device to zero position and turn the hand wheel clockwise for function
Spring Closing (NC) and anti-clockwise for function Spring Opening (NO) up to the stop.
• Secure hand wheel with chain (77) and lock (76).
5 Commissioning & Maintenance
5.1 Commissioning
For actuators equipped with a manual emergency positioning device zero position is as follows (for PA-N
300: Set stroke display (72,73) between the grooves of the columns (50), for actuators PA-N 540-2160 turn
the hand wheel clockwise for Spring Closing (NC) and anti-clockwise after freewheeling for function Spring
Opening (NO) up to the stop. For this purpose remove chain (77) and lock (76). After setting secure the hand
wheel again with the help of the chain (77) and lock (76).
5.2 Maintenance
The pneumatic actuators are low-maintenance.
Now and then, remove possible dirt on the outside of the actuator. In doing so, do not use high pressure
equipment, or solvents or detergents that are harmful to health or highly flammable.
0-Ring (3), membrane (5), guide assembly (1 0), spindle (4), compression springs (16) and screwed joint
assembly (11) are wearing parts that have to be exchanged, as required.
To ensure perfect working order for the manual emergency positioning device, we recommend to check the
state of the grease on the spindle (35) once a year and to add grease, as required. In doing so, remove the
upper cap (59), for HV size Ill and size IV unscrew the long bush from the gear and squeeze in grease, as
required.
The spindle is lubricated at the factory. For this the lubricant KLOBERPLEX BE 31-502 by
KLOBER/LUBRICATION is used. When using a different, at least equivalent lubricant, all parts that are in
23 I 25
l#[e];f41
REGELARMATUREN
Exoellente is our standard

i
contact with the lubricant must be cleaned thoroughly before re-lubricating, so that mixing and possible
reaction of the two lubricants is excluded. As alternative lubricant we recommend Oest EP by Oest.
Attention: When using other lubricants or when mixing different lubricants the manufacturer shall
not be liable for possible sequential damage.
We recommend a change of lubricant after 8- 10 years:

When a change of lubricant is planned please consult the manufacturer beforehand.
•
•
Man. no. (Fig.14field 1)
Type (Fig. 14 field 2)
Spring (Fig. 14 field 3)
r--
When ordering spare parts, state the information given on the type label (see Fig. 14):
•
;
. 1 ]
• Input air pressure (Fig. 14 field 4) $
• Function (Fig. 14 field 5) Fig. 14: Type plate
• Clutch-pressure (Fig.14 field 6)
\
6 Error search list
Defect/ fault No. Possible causes Measures

Actuator 1.1 • Manual emergency positioning • Put manual emergency positioning device to
spindle not positioning not in zero position. zero position (see chpt. 5.1)
moving 1.2 • No control air applied to • Check control air system
actuator
1.3 • Ruptured membrane • Exchange membrane
1.4 • Valve cone jammed • See error search list for the valve
1.5 • Control force is too weak for the • Check dimension or contact manufacturer of
valve. the overall system.
1.6 • Spring breakage • Exchange compression spring
Actuator 2.1 • Receiving insufficient control air • Check control air system for damage and
spindle sufficient flow.
moves jerkily 2.2 • Control regulator set incorrectly • Correction of the settings (see operating
manual control regulator).
) See error search list for the valve
2.3 • Valve cone has seized slightly • Clean or exchange, as required
due to dirt particles
2.4 • Spring breakage • Exchange compression spring
High air 3.1 • Membranes not pressed in • Re-tighten hexagonal nuts (32) until
consumption properly. membrane pressed in properly (4).
3.2 • Seals worn • Exchange sealing parts (19, 20 as
necessary 61)
3.3 • Inflow conduits to actuator • Check inflow conduits for leaks and replace
leaking. or seal if necessary
If the measures describe_d_ab_oy_e_do_noLmsuiLin_a_satisf¥ing-outcome,tl:le-supplier-/-maAl:lfaet~;~rer-m~;~st-be------+

notified.
24 I 25
- i_
'
I:C•l;llJ
RE.QlilARMATURE.N
Extcllcntc is our >tondaro
7 Tightening torques
(For item numbers see fig. 2, 3, 4, 5, 6, and 7)
Pos.27 Pos.28 Pos.30 Pos.31 Pos.32

PA-N
[Nm] [Nm] [Nm] [Nm] [Nm]
300 87 50 25 25 50
540 87 25 25 40 190
~
1080 87 25 25 40 190
2160 87 25 25 40 190
Pos.67 Pos.68 Pos.70 Pos.71

HV
[Nm] [Nm] [Nm] [Nm]
Size I 25 87 50 -
Size II - 87 50 50
Size Ill - 87 50 50
Size IV - 87 50 50
25/25
~~J NORGREN 24011
"'-'~ HER/ON
3/2 Directional Control Valves

Direct solenoid operated poppet valves
Internal thread G1/4, 1/4-18 NPT or
flanged with NAMUR interface
• Main application: single operated actuators for plants

• TOY-approval based on IEC 61 508, DIN V 19 251
Business probation in plants by statistical proof
• Bases:
Sample approvals: DIN EN 161/3394 DVGW, group Rm
and EN 13611
• Valves released for safety systems to SIL 4 or AK 7
e Standard NAMUR type
- manifold system for easy assembly
- redundancy: 1 of 2
2 of3
- add-on manual override or inductive limit switches
• Protection class EEx me, EEx d, EEx md, XP
• Safety function in the event of power failure provided
by mechanical return spring
Technical Data Ordering Information

Medium: 3/2 Directional control valve, stainless steel, with
Neutral gaseous liquids or aggressive fluids seat seal Viton, port size G 1/4, solenoid 24 V
Operation: DC,
Solenoid operated Type: 2401127.4270.024.00
Flow direction:
Optional TUV-single approval: 0695241
Port size:
G1/4, 1/4 NPT or NAMUR interface
Connectors
Orifice:
ON 5,7 See data sheet 7.7.002
Operating Pressure:
0 to 1 0 bar
Fluid temperature:
-25 •c to +BO ·c (NBR)
A
-1 o ·c to +120 •c (FKM)- water up to +95 •c TUV
-40 •c to +60 ·c (VM Q)
Ambient temperature:
-40 octo+ 100 oc (depending on solenoid) 2 Switching function:
Mounting: Pressure port
at 1, 2 or 3
Optional, preferably vertical
Materials: 13
~-NAMUR interface
Body- stainless steel1.4404/316, brass, hard anodized 3 2
~-~-,-M,-iMtf
aluminium
Seat seal- FKM (Viton), NBR (Perbunan), (VMQ) Silicon
Inner parts- stainless steel, brass I 1
I I
-----------------------------------------------------=~--=~~=-=~1~1 ------------------------l
3 1 2
--------- 08/02- - - ------Nr·-s-.4~306.0_1 __ _

24011
With threaded connection

Brass valves
I .
Syniiiol- -- - -
----------.
Typo Solonold
oroup
Connection : Operating
pressure (bar)
Matorml
Soat snnl
Manual ovorrldo ' Dlmonslonnl
drawlno
1 Wmoht
(kg)
Prulzouon•sso
IEC 61 508" 1
----·---- ------
240t103 xxxx
---------
240t107 xxxx .....
A+B
---
ooOH
- .
G1/4 0 ... 10_ NOR ----_: :·= Mai·----=~c-=·-- --
o_.:__lO ____ ~0!1_ _____ _pJ!!l.!!2~. ___ ~Q1_ __________ .2~------ __ _
~
A+B --
G1/4
~4a11 i!i xxxx~····- A+B
f - " · - - - - - - - - - --- ----- - -
G1/4 0 10 ___ ~'!.. _ _ p)IS_hnn_~!!Jc~. __ --~1 .. _____ ~---- ..
13 2401149 xxxx ..... 11+0 G 1/4 o.:._l_Q____ N!Jf.L.____ MOl 0,65 __ L
2401126
' ·- --.
xxxx .....
- - A+B G 1/4 0 10 MOl 0,05 X
2401135 xxxx ..... II< B G 1/4
--
0 10 ~l<!!'i _______ _p_l!shondlock __ MOl _____ 9~
2401153 XXXX""' G1/4 __________ M_O_l____ r!?~-
~~ - ----
0 ... 10 Slllcon1J X
'10252:i5xxxx;;;;;- 11+8
----- G 1/4
-- . o.,_1Q_____ .~c~~-----·push~!l_ ___ MOl 0,70 c---·- _
2401132 )()()()( .....
~~- G 114
- o_. c.!.Q_ _ _ Slllcon1l_ __ ... pus~ a~d !!J~k _'-:MJll_ __ _JJ-ZQ_ ___ _
~-4 xxiX-;;;-;;- A+O G 1/4 _ 0-'.:...!_0
_______ Silicon" ooml-outornntlc __ ~---- ~ ___ _
- --- ----
2401130 xxxx ..... A+B 1/4 NPT 0 ... 10 NOR _ ----~-----_Q,~ ____ X
~40i14ii xxxx ....-;-· A+O 1/4 NPT JO.lO NOR _pushonl\'_ ____ ~------ 0,70 _____ _
------------
2401136 xxxx •••••
,!.Q_____ Jl~---- pushand_I_O!:~-- MOl
A+O 1/4 NPT
'2401140 xxxx .. .-.-.- - ---
11+0 1/4 NPT ._lQ_ _ _ _ N!l_~---- ___ s~ml·automaUc ~---~----- _
0,70 ___ _
2401131
2401106
-i025226
xxxx .....
xxxx .....
xxxx ·-
II+B
11+0
II+ B
1/4 NPT ··-
1/4NPT
1/4 NPT E _l_C!_ __
-'- 10
FKM
Slllcon11 _ _
._!Q_ ___ _5!_1!c~1l_ ___ • S~'!1.1·D~Oil_1atlc
MOl
_ _ _MO~
MOl
--~!!.!!_ _____ X_
0,65
0,70 __
-~
_ - I'
Stainless steel valves {1 .4404) for aggressive environment
--l-Matorla-1---1"""""' ,;.,,,;- ''""""''-- W.iii____

- ..,..-~·
Symbol Typo Solonold ConnocUon Operating

group pressure (bar) Soat soal drawing (kg) Prufzouomsso]
IEC 61 508''
---- -- ·-
xxxx .....
~
2401186 A+B G1/4 0 ... 10 _:_:_ _N_-B_R ---~----- - __ MOl _ ~--- X
2401112 )()()()( ••••• A+B 1/4 NPT 0 '" 10 NBR ___ -_ _ MOl ___ 0,65 _ __ _ X
1--------
1 3
-- ----- --- --- -. - ----- -- - - - ---- - - - -- -.
Stainless steel valves (1.4404) for aggressive environment and aggressive fluids
SymboI Type Solenoid Connection Operating Material Manual override Dimensional Weight -- "fiili'tze.ugn1sso ·
group pressure (bar) Seat soal drawing (kg) lEG 61 508"
2401127 xxxx .•••• --
A G1/4 0 "' 10 FKM push only 0,70 M01
2
24g1170 xxxx ..... --
A G1/4 0 ... 10 FKM e~~only 0,70 M01
2401139 xxxx ..... ---- --
13
-2401145
---- xxxx .....
A G1/4 0 '" 10 ---- ~,R push and ICJ_I!__ ~-- 0,70 -----
0 ... 10 semi-automatic 0,70
24g1155 xxxx .....
A G1/4
~- MOl
------ --
A G1/4 0 '" 10 Slllcon1l MOl 0,65
--- -· -- ·-
2401156 xxxx ..... A G 1/4 0 "' 10 Silicon"
-------- semi-automatic MOl
-- ~--- --· -·- -----·-
24gl147 XXXX ..... A 1/4 NPT g __ FKM
-- -- - - - - - 1 - - - -
MOl 0,65
--
24ii1146 'XXxx .. ;;;;- P. 1/4NPT 0'' 10 __ _!~~-- semi-automatic MOl -- Q,I()__ - - - - - - - -
- 2401166
--- ·----- --
)()()()( .....
-------
A 1/4NPT 0 "' 10 Slllcon1l ______ MOl 0,65
·.When ordering please indicate solenoid, voltage and current type (frequency)
11 Approval Is not Included In delivery, part No. 0695241

Viscosity for gaseous or liquid fluids up to 40 mm 2/s
.Pnrllcutary lorvatvoa with TOV approval and attachmontln plants bosod on snfoly standards DIN V 19250, IEC 61511,
tnklng Into ncoountlo tho oporntlng and m alntanca Instructions docum ont 7603444
• The responsibility for the malntance and repair of the solenoid valves lies with the users or the supervisory authority for these process systems.
21 For ambient temperature down to -40 •c
Our poUcy Is one o! continued research and development. We therefore reserve the right
N/** 5.4.306.02 to amend, without notice, the specillcallons given In this document. 08/02
24011
With NAMUR interface

Aluminium valves anodized
Symbol Type Solenoid Connection Operating Material Manual override Variants Dimensional Weight Priifzeugnisse
group pressure (bar) Seat seal drawing (ko) lEG 61 508'1
2401116 )()()()( ..... A+B G1/4 0 ... 10 NBR add-on free of non-ferrous M02 0,55 X
l~~~l
metals
. ' 2401191xxxx ..... A+B G1/4 0 ... 10 NBR ~-dd-0!2..___ ~_?___ 0,55 X
L_____ - --- :
1025333xxxx ..... A+B G1/4 0 ... 10 NBR add-on Wiiii limit switch M02 0,70
1025254xxxx ••••• A+B 1/4 NPT 0 ... 10 NBR add-on M02 0,55 X
2401133xxxx ..... A+B G1/4 0 ... 10 Silicon21 add-on M02 0,55 X
~401109 xxxx ..... A+B G1/4 0 ... 10 NBR add-on PIn ftange interrace'' M03 0,55 X
Stainless steel valves (1.4404) for aggressive environment

i Symbol Type Solenoid
group
Connection Operating
pressure (bar)
Material
Seal seal
Manual override variants Dimensional
drawing
Weight
(kg)
Priifzeugnlsse
IEC 61 50811
2401196 xxxx ..... A+B G1/4 0 ... 10 NBR add-on M02 1,00
ltiai ---- --- I

2401142
1025212
1025328
xxxx .....
xxxx .....
xxxx .....
A+B
A+B
A+B
G1/4
G1/4
1/4NPT
0 ... 10
0 ... 10
0 ... 10
Slllcon21
NBR
NBR
add-on
add-on
add-on
M02
Pin ftange interiace31 M03
PIn ftange lntertace'' M03
1,00
1,00
1,00
X
X
XXXX ••••• When ordering please indicate solenoid, voltage and currant type (frequency).
i/
1) Approval is not included in delivery, part No. 0695241
Viscosity for gaseous or liquid fluids up to 40 mm2/s
Approval S I 3 7/01 , S IL 4 lor low de m and mode, S IL 3 for h lg h de m and m ode,
Approval S 83/96, AK 7 (request from manufactor)
e Particulary for valves with TOV approval and attachment in plants based on safety standards DIN V 19250, IEC 61511,
taking into account to the operating and maintance instructions document 7503444.
• The responsibility for the maintance and repair of the solenoid valves lies with the users or the supervisory authority for these process systems.
2) For ambient temperature down to -40 oc
3) Ace. to VDINDE 3845 port P in flange for attachment of positioners
Our policy Is one of continued research and development We therefore reserve lhe rig~t
-------~08/02-- ----- - - ---- -to-amend;wlthout-nollce;lhe-specificatlons-glven-ln-this-document._~~- - - - -- -N/** 5;4;306;03
~-==~==-~·~=-=--=---=~~~--~==~~~~~~====~~========~=====-~-=~~=·=~=-~··=~·~-=-=-=-~~~~~~~==~~·~
24011
Solenoids Group A
1 l'owor consumptiOn I ~
! Typo Current , Protection class ·1 Temperatures Eloctncal connection Dimensional Circuit Weight
?4 V DC 230 V AC 24 VDC ?30 V AC : Ambient · Fluid drawing diagram No. (kg)
(W) (VA) (rnA) (mAl ("C) ("C)
•
0800 16,9 703 IP65 > +60 +80 DIN 43650 Form A M06 SB01 0,33
3803 1B 105 IP65 '' +60 +00 DIN 43650 Form A M07 SBOG 0,34
4270 1) 8.9 315 fJx me II T4/T6 +70/+60 +70/+50 M20x1,5 31 MOO SB04 0,6
42711l 10 H:~ mo II T4/T6 +70/+50 MOB 0,6
4670 1) 8,9 369 EEx md IIC T4/T6 +701+40 M09 I o.o

EEx mo IIC T6
46711l 10 43 EE~ md IIC T4/TG +701+40 +701+40 1/2Ni'T'I M09 0,0

EEx mo IIC T6
46721) 8,9 369 EE~ md IIC T4/T6 ; 701+40 +70/+40 M20x1,6" SB04 0,8
E~mo IICT8
4673 I) 10 43 EEx md IIC T4/T6 +70/+40 +70/+40 M20X1,5 31 S807 0,0

EEx mo IIC T6
3826 13,6 NEMA Stranded wire S801 0,4

4, 4X, 6, 6P, 7, 9 460 mm long
3827 68 NEMA Stranded wire M10 0,4

4, 4X, 6, 6P, 7, 9 460 mm long
Solenoids Group B
Type Power consumption Current ~~·-Protection class Temperatures Eioctrlcol connection Dimensional Circuit Weight
24 V DC 230 V AC 24 V DC 230 V AC Ambient Fluid drawing diagram No (kg)
(W) (VA) (rnA) (mA) ("C) ("C)
~~-------
6,8 20? · IP65 '' +60 +60 DIN 43650 Form A M06 S801 0,33
10,6 46 IP65" +60 +60 DIN 43650 fonn A M07 SB06 0,34
---------~--------~-
3,9 162 EEx me II T4/TG +B0/+55 +00/+55 M20x1,5 31 MOB S604 0,6
5,3 ' 23 EEx mo II T4/T6 +80/+55 +80/+55 M20X1,5 31 MOB SB07 0,6
3,9 162 EEx md IIC T4/T6 M09 SB04 0,8

E~ me IIC T6
5,3 23 EEx md IIC T4/T6 M09 SB07 0,8

E~ me IIC T6
-+------1------1----------l~ -~------ -- ~ - ----~------!1------l---
3,9 162 EEx md IIC T4/T6 +80/+55 +80/+55 M20x1,5 31 MOS SB04 0,8
E~me IICT6
4663 I) 5,3 23 EEx md IIC T4/T6 +601+55 +80/+55 M20x1,5 31 MOS SB07 0,8
EEx me IIC TG
-------+---'-----------1---------l---------!----+---
3824 8,9 370 NEMA +60 Stranded wire M10 SB01 0,4
4, 4X, 6, 6P, 7, 9 460 mm long
3825 9,5 41 NEMA +60 Stranded wire M10 SB05 0,4

~__ ____________________________ __ __________________ :____ __:__. 4,
4X, 6, 6P, 7. 9 460 mm long
~
tl This solenoid is fitted with a fuse depending on current.

2) Required connector type 0570275
31 Cable glands see accessories
Our policy ls one of continued research and development. We therefore reserve the right
N/** 5.4.306.04 to amend, without notice, the specifications given In this document. 08/02
24011
General dimensions valves

M01
---------,
lI
I
I
---
I
"'" )
-
~--;--./
\---
Port size for eaclt type

please see data lables
30
M02 r-- 1
_,------~~
( I
I '----
1
I
I
gl
'--------:7;-;s;--H--r:'o;~r==t:-:1::! - -
'9'-i"---1-t
1 Add-on manual override 50
M03 / __ _r_-_-~
(
I
I
I
I
) '--r----- ~;=+
l,
r------~~--.
11'1. 0
~t_ ------ _Gj~ --1!-+--,!Jiln-i--!r-r-J.__-+-+
50
Add-on manual override
Add-on manual overrides for versions with NAMUR interface

without detent with detent Threaded plug
Type: 0600205 Type: 0601765 Type: 0602764
)
/'
_08/02_
24011
General dimensions solenoids

M06 63,6 M07 _ 63,6
~-l:
40
=--~-=-"l.J --
1
-~
-,
-I
"l
....
0 ~ - )-1-j :g \
-·,---'--' ~ •
---~Yic;;l
- l
I
-'
I
tll I
I_ L- -
~L
--1- --l
0
ID
~~~ I 1- I
~~~
Connactor cnn bo - t! I - Connootor onn bo
lndoxod 4 x 90'
Pg 11 -~12 _ lndoxod 4 x 00'
Pa11 -!1~2 _
~T·I
, ____T I
l."lt
~
~I
f'
I'""
- ---j "'!
I 27 I I
~-
09
- -
- 99
I
_,
MOB M09
1Q~- ·-
"l
~
Ol ,o13/o16
...JL..I
Jl-,lr -'II
-~;~-;1·.~~~~~_! 42 __ ,
M10
"l
....
0
_________
84______ ~-
63
Stranded wire AWG 18

460 mm length
Our policy Is one of continued research and development. We therefore reserve the right
N/** 5.4.306.06 to amend, without notice, the specifications given in this document. 08/02
24011
Circuit diagrams
8801 8802 SB04
8805 8806 8807
NAMUR interface 32
I .· ~10 deep)
f-®--f-.!
MS
\.
I
-- __L-
~
~1\ ..
«
~~ 02
0 Coding stud
1 Control air port B
2 Port 2(A)
3 Port 3 (R)
4 Auxiliary eo:ergy
NAMUR assembly parts

see data sheet 7502242
NAMUR quick exhaust module for a better kv-value by exhaust

see data sheet 7502144
NAMUR interlinking plates in redundancy design for .safety exhausting" and ,safety ventilating"
see data sheet 5.8.300 (7503386)
Assembly parts
Designation Type Application Weight See
(kg) data sileet
Flange pi~~- 0559857 Direct attachment to pneumatic linear actuators with NAMUR nbbing and for wall mounting, depending on the tubing positiOn, G1/4 0,50
~----
Flang~- 0612681 Direct attachment to pneumatic linear actuators with NAMUR ribbing and for wall mounting, depending on the tubing position, 1/4 NPT 0,50
Yoke 0540593 In conjunction with a flange plate for ~ttachment to pneumatic linear actuators with NAMUR pillar (round) 0,10 7502242
Adapter plate
-0603216
---- Direct attachment to older design pneumatic pivot drives. with interlace for valve Type 2401180 0,25
Filter 0545060 Threaded filter pressure port 1
Accessories/Cable glands
·----·-----,--------.-----------.-----------,-----------
Prote_c:,_ class r!~!~-~q::le:..:o:.. _____+M"'a.::te:.::rla::.I_____ +T,_Y,;Pe:_______
1
!---=::.:..: IIC ·--~.!?_:!.i.NPT 7,5 ... 11,9 mm Brass nickel plated 0588925
f--.==-:..; IIC M20x1,5--~··"_.::.·~1-'-4·.::..m.::..m~)--+-=9-=ras=s-'-n=ic:.:::ke"'lp""la:.:cte=d+-=05:.:8-=88"'5'-'1___1

I!___ ~Ox1 ,5 __ ~-'-.."·-B,_m.::..m____-'--B""ra.::..ss:..:n:.:::lc.::..ke=-l"-'pl.:cat.::..ed:cJ..:0.::;58:..;8.::..81_9___ ,
Warning
These products are intended for use in industrial compressed air systems only. Do not all component parts used in fluid power systems and to provide adequate safeguards
_________useJIJese_products..where_pressures.andJemperatures.can.exceedJhose.listed..under___to.preventpersonaLinjury.or..damage.to.equipment.in-the.event.of.such-failure.-------1
'Technical Data'. System designers must provide a warning to end users in the system
Before using tl1ese products with fluids other than those specified, for non-industrial instructional manual if protection against a failure mode cannot be adequately
applications, life-support systems, or other applications not within published provided.
specifications, consult NORGREN. System designers and end users are cautioned to review specific warnings found in
Through misuse, age, or malfunction, components used in fluid power systems can instruction sheets packed and shipped with these products where applicable.
fail in various modes. The system designer Is warned to consider the failure modes of
Our policy is one of continued research and development. We therefore reser1e the right
------08/02 --- -- - - - - - - - - -toamena:-Without notice, lhe speci!ica!lons given In this document. - - -- - -- -- ------ -N/**5':4.306:07-- -----
Filter Regulator
A W1 000 to 4000
Standard Specifications
Model AW1000 AW2000 AW3000 AW4000 AW4000-06
Y8 Y.i Y.i
Port size M5 X 0.8 v., ¥e ¥e }4
·-
Y2
Fluid Air
-------- -- ··---- ... ··-- -~~ ·---·
Proof pressure 1.5MPa

Max. operating pressure 1.0MPa
----~----- -------~--
Set pressure range 0.05 to 0.7MPa 0.05 to 0.85MPa

-·
Gauge port size V1G Ye Ye Y4 v.,
Ambient and fluid temperature -5 to 60"C (No freezing)
-
Filtration 51Jm
Drain capacity (cm 3} 2.5 8 23 45 45
Bowl material Polycarbonate
Construction Relieving style
Weight (kg) 0.09 0.36 0.53 1.09 1.15
ffixm:Ty(Scl eqjpmi) I Bowl guard - -
• • •
Accessory (option)/Part No.
Part No.
Descrip~del AW1000 AW2000 AW3000 AW4000 AW4000-06
Bracket 8120 8220 8320 8420 8420
~ 1.0MPa G27-10·R1 G36-10-001 G36·10-D01 G46·10·002 G46·10-002
0 Gaugel 1>
(J)
(J)
0.2MPa (G27-10-R1) 12 > G36-2-D01 G36-2-001 G46-2-D02 G46·2·002
Ql
()
() Auto drain N.O. - - AD43 AD44 AD44
<(
float style l3l N.C. - - AD 53 AD 54 AD 54
Auto drain pressure differential AD61 AD62 - - -
Note 1) 0 in the part number for gauge (e.g. G36·10·001) indicates threadmg. No symbol for Rc(PT) and "N" for NPT.
Note 2) A gauge for pressure 1.0MPa is used.
Note 3) Minimum operating pressure N.O.: 0.1 MPa, N.C.: 0.15MPa
• "-01, -02, -03, -04, -06," after the part numbers indicates port size. (01: 1/8, 02: 1/4, 03: 3/8, 04: 1/2, 06: 3/4).
• Gauge for "AW1 OOO·M5G·1" is "G27·1 O·R1" for the pressure at 1.0MPa.
Minimizes space and piping

due to the integration of the
filter and the regulator.
~:eel operated, relieving style
Mad• P.1.8-6
I
h®·rii
lJ 1:1~;:.;.. ...
f'•J AW3000
AW2000
AW1000
AW3000-0BG
AW2000-0BG
AW1000-0BG
1.8-1
AW1000 to 4000
\
'
How to Order
AWjO 00
Rller~:r
• Option
1!1l Set at 0.02 to 0.2MPa
2 Metal bowl
Body size Symbol Description Applicable model
6 Nylon bowl
10 M5 - - -
Metal bowl with level gauge
Thread B Bracket AW1 000 to AW4000-06 8
20 (AW3000/4000 only)
30 Metric (M5) ~ oc Auto drain float style (N.C.) AW3000 to AW4000-06
C Bowl guard (AW2000 only)
40 Rc(PT) D <(-o
-s·e
l'l.lto d'ain pressure dfferential AW1 000/2000
J!2l Drain guide (AW3000/4000 only)
Auto drain float style (N.O.) AW3000 to AW4000-06
N NPT N Non relieving
F G(PF)
"'::>0> Without limit indicator AW1000
R Flow direction: Right to left
G
"'
(9 With limit indicator AW2000 to AW4000-06
With drain cock and barb fittings
W (AW 3000/4000 only)
Port size (For nylon 06, 04)
M5 M5X0.8 •If more than one symbol is required to
01 1/s be listed when ordering, list in the
02 1/4 alphabetical order. (Ex. 2NR)
03 3fa Note 1) Only regulating spring is different
04
06
112
% P from the standard model.
Note 2) Without valve mechanism
on Combinations
~-s; ;u~ to 7e;d-b;f;;.e-h;n'dl~9. R'etert; p-:-o=26a-;:;d-o:-27for satety "instrueti;nS' i"nd' c'O~.;o;:;- - - - - - - - - - ..

1 precautions on the products mentioned in this catalog, and refer to p.1.0-1 and 1.0-2 for precautions on every
1 series. I
~---------------------------------------------------
@The adjustment handle must be operated
I Selection manually. Using a tool to turn the handle
could lead to damage.
&warning ........._ Orange mark
CDThe residual secondary pressure cannot be &Caution
released by releasing the supply pressure. (])Release the lock to adjust the pressure. After
To release the residual pressure, use a the adjustment, engage the lock.
filter regulator designed for such use. Failure to observe this procedure could
damage the handle or cause the secondary
pressure to fluctuate.
Installation and Adjustment 1) on the AW1000 and AW2000 styles, pull
the adjustment handle to release the lock
& Warning and push the handle to engage the lock. If it
does not lock easily, turn the handle slightly
Main. tenance Inspection
G)Set up the regulator while verifying the clockwise or counterclockwise before
pressure that is indicated on the supply pushing it. Warning &
and the secondary pressure gauges.
Turning the handle excessively could 2) On the AW3000 and AW4000 styles, pull the
CD Replace the filter element within 2 years of
d.ama,ge_tb.eJ.ote.m?Lp.ar::ts. adjustment handle to release the lock. (An operation or before the pressure drop
------,CD""'1The pressure gauge that_i_s_p_r-ov-i-de_d_w-it_h_ _ _--=cor"'a-=ng"'e"'c=olorea·line is proviaecranneoottom of---:::re"=a""c"he~s:c-;:o"'.1"M"P"a~·.-=F~ai"'lu"'r..,-e-ct":co_o"'b"'sc-:e-rv-e,--;;th""i"'s- - - - - ' -
the product for setting a pressure between the adjustment handle for visual checking.) precaution could damage the filter
0.02 to 0.2MPa is the 0 .2 MPa style. To Push the adjustment handle to engage the element.
prevent damage to the pressure gauge, lock. If it does not lock easily, turn the handle
make sure that pressure in excess of slightly clockwise or counterclockwise; then,
0.2MPa is not applied. push it until the orange colored line is no
longer visible.
1.8-2
Filter Regulator AW1000 to 4000
IFlow Characteristics Conditions: Supply pressure 0.7MPa]

AW1000 M5 X 0.8 AW3000 AW4000-06 Rc(PTlJ.
--- ···- ·----- -1 .....__
--- -- -- -- -
I
1 o.Sk---+--·-·- --"- -"-" ! 0.6 0.6 ........__ -·
lro
:C.. 0.5
~
l!! 0.4 ........
(iJ
~ 0.5
~ ......._
-
r-
I
-
0.4
.i
a~ o.3
-- ~
.Q.0.3 -
·i
0.2 ......, c:
0.2
-
IJ
II
i
0.1
o
o 1000
Flow (t/mln ANA)
-
·-~~M---~~·M
200ll
c<
I
8
8! 0.1
00 1000 2000 3000
Flow (t/mln ANR)
4000
AW4000 Rc(PT)'2
---------
I
0.6 -- _J
I
=-- j
I
.....__ I
-- ,_,.,_
2000
Flow ((/min ANA)
IPressure Chracteristics Conditions: Supply pressure 0.7MPa, Secondary pressure 0.2MPa, Flow 20 t/mln (ANR) I
AW1000.. M5 X 0.8 AW3000.. Rc(PT)% AW4000-06 Rc(PT)%
---·1---r--· ·-·- -- -- ··- -- r-r- "--r--r-
'"l
.....
1' r
-~ "''
I
I
0.2 6 0.25
~ I
~02
~
s-
if -~
~ -salpot nt
1
slt PJint '
1
sit pJint
-
"''k" -I
.5a>
- ,
'
~
~02
a.
?:-
"'
I
~
I'.
2 ,......;...
I
- _j
i
!
~ I
8 f' I 5
I
5 '
"'
(/} 0.1 5 I
0 ""·''
0 0.2 0.3 0.4 o..5 0.6 " 0.7 0.8 0.9 1 .
.... --~;--, 'k1
0 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
0
Jt 0.20.3 0.4 0 .b ~ .6 0.7 (.8 0.9 1
I
!
Su~pl}'"-f.e_ssure (rv\Pa) .. E;~pply pr~s~_u_re (~ Pa)
AW2000 Rc(PT) 1;. AW4000 Rc(PT) ~f
- --~- ,---, -~- ~--
-- l . T - "'
r-r- - -r-·r·· ·--
.~0.26
• (U
c.. slt J~$.
:2
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--.::;
~~~ v
det plint
v
.......
2
- ~
' .......
.2
;
-
6
5
0 Jr
0 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
I
110.2 ().3 0.4 0.5 0.8 0.7 0.8 0.9
I) 0 1
Supp1yprassur.e I.MPa) . _.................... s. up~t¥ pressure (M Pal
1.8-3
AW1000 to 4000
Construction
JIS symbol
AW1000 AW2000 AW3000/4000
·;.
!
\ Drain
+.
Dra1n
tDrain
Component Parts
No. Description Note
AW1000, 2000 AW4000, 4000·06
CD Body Painted Silver
® Bonnet Aluminum die cast Painted Black
Replacement Parts
Part No.
No. Description Material
AW1000 AW2000 AW3000 AW4000 AW4000-06
® Valve assembly Brass, NBR 134819 1349160 1315216A 1316212A 1316213A
<D Element Non-woven material 111344 1129116 111585 1116103 1116103
Indicated in 111312 11295 1315541 1316276 1316276
® Baffle (parentheses). (POM) (PBT) (POM) (POM) (POM)
® Diaphragm assembly NBR 131445A 1315215A 1316211A 1316211A
(j) Deflector PST 11133A 1129111
® Bowl assembly(11 Poly-carbonate C100F C200F C300F C400F C400F
® Valve spring Stainless steel 134824 1349158 131525 131625 131625
~r
.,.,..,
@
@
Bowl 0 ring
Valve 0 ring
NBR
NBR
111325 11297
1349247
111512
131544
111636
131645
111636
131645
@ Mini Y packing NBR MYN-10A
@ 0 rin NBR JIS B2401P5 JIS B2401P5 JIS B2401P5
Indicated in 134132 1315540 1316275 1316275
p
@
)
Valve guide (parentheses). (ZDC)
Note 1) Bowl guard (SPC) is attached to the bowl assembly of "AW3000" to "AW4000·06".
(POM) (POM) (POM)
1.8-4
i_
Filter Regulator AW1000 to 4000
Dimensions ~~
AW1 000/2000 Panel mounting hole Options (AW3000/4000}
AW1000: Mnx.3 St
AW2000 Mnx.3 5t
~ r 0 ~Fl
J~~~; i\ilj- ll~rn°0 ~I/~~fi~~~ ~
ffi\ffi~·
L
[
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I
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-
Gauge IN K .-. OU '' · 1 1I'.. ·h ·· ro

port size / in"ifnt IIl Gau~/ If911' ~?-& / J illjlr
1
(Option) 1 qaug~j 1
: (Option) j \Port sl:~:e
1
Drain
A
-t--- 2l
~ BLO
l!l ~C\J
I p t
'
' Model
With barb With drain
fittings
B
guide
B B
Molol bowl w1\h
Metal bowl lovol gnu go
B
-~ U) '\fY15 ~-o~e AW1000 - - 109.5 -
~ With pressure differential AW2000 - - 164.5 -
style auto drain AW3000 216 213.5 220.5 240.5
AW4000 267.5 265 272 292
AW4000·06 271.5 269.5 276.5 296.5
•Dimensions except forB is the same as the shown on the left.
AW3000/4000
Panel mounting hole
®-
AW3000: Max.3.5t
AW4000: Max.5t
E ---- - -F --l
---·
_p_ --- I
mr-r~--
;=t=-! l:
-- 'l -F-F-1- j
~~i·~~~
(Option) /c ~ I ~ en
~ ~·~
BI~Jl j
I
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.... A. NO
N.C.: Gray/ Applicable tube 0.0., o10
DrainJ
N.C.,N.O.
With float style auto drain
Bracket mounting dimensions With auto drain

Model Portsize A B C D E N p Float A-ess. Dff.
F G H J K L M
B B
AW1000 M5 X 0.8 25 109.5 50.5 25 26 25 28 30 4.5 6.5 40 2.0 20.5 28 - 130
AW2000 1/s, 114 40 164.5 78 40 56.8 30 34 44 5.4 15.4 55 2.3 33.5 40 - 187.5
AW3000 114. 3/s 53 207.5 92.5 53 60.8 41 40 46 6.5 8.0 53 2.3 42.5 56 248.5
AW4000 259 112 70 70.5 50 54 54 8.5 10.5 70 2.3 52.5 73 300
AW4000·06 263 114 70 70.5 50 54 56 8.5 10.5 70 2.3 52.5 73 304
UJ AW1000 SAC1000 #4 AW3000 SAC2503 #4
lEI AW2000 - - - - SAC2000, #4 AW4000 - - - - SAC4000, #4
AW4000-06 SAC4006, #4
1.8-5
Position switches 3SE3
metal enclosed (3SE31), plastic enclosed (3SE32}
Instructions Order No.: 3ZX1 012-0SE32-0BA1
Installation For changes that can be made on site, see Figure V
For dimension drawings. see Figure I (Dimensions in mm) a In the case of position switches of types 3SE31..-.J. the roller lever or rod
a Narrow housing with roller crank and pilot lamp lever can be turned through 90', while with position switches of type
b Wide housing with single plunger c Wide housing, 4-pole 3SE32.. -.G they can be turned steplessly from 10" to 10' on the drive
d Wide housing. 3-pole e Roller crank, length adjustable shaft.
f Rod actuator g Position switch with quick-release feature b The drive head can be turned in increments of 90'. To do this, undo the
h Fork lever i Roller plunger screws.
j Narrow housing (2-pole) with single plunger k Roller lever c The roller crank can be turned through 1ao• (only 90' is possible with
I Angled roller lever m Spring rod type 3SE3120-J) after undoing the filister-head screwS.
1) Clearance from the mounting surface d To alter the actuating direction of a position switch with roller fever or
rod, undo the screws. take off the head, rotate and refit (not possible
Mount on a flat surface using two M5 screws for 2-pole switches and four MS with type 3SE3230).
screws for 4-pole and 6-pole switches. <D single action (right), @ single action (left), @ double action
Always fit flat washer and spring washers.
Mounting position: any. Quick release feature with angled plug, see Figure VI
The parts are packed separately. Attach the adapter (2) to the switch (1). Fix
Connection the base plate (3) to the mounting location. Place the position switch in po-
\. Max. conductor cross-sections (screwed connection) sition and lock it with the lever (4). The connection is made via receptacle
' solid 2 x 2.5 mm2 (5) and the angled plug (6).
,,, finely-stranded with end sleeve 2 x 1.5 mm2 Securing against displacement (fixing}, see Figure VII
Terminal screws M3.5 <D Round hole
PE connection, inside housing M3.5 (2) Stop
lightening torque ·· 1 ... 1.2 Nm (;l) Longitudinal hole
Carefully seal the 20.4 ·mm (Pg 13.5) cable entry to retain the degree of protec- To secure position switches {in safety circuits) against displacement, form-
tion standard. fit methods must be employed when installing them, e.g.:
- Fixing by means of round holes
Operation - Additional use of locating pins or stops for longitudinal holes
Actuation: with straight-edge, see Figure II Protection against actuation and overriding
(applies to narrow and wide housings) Position switches should be arranged so that they will not be damaged du-
a Overtravel plunger b Roller plunger ring actuation and overriding. They must therefore not be used as a mecha·
c Fork lever nical stop. The height of the skate or the cam should be less than the entire
d Roller crank e Roller crank. length adjustable travel in the switch to avoid mechanical loading of the switch or its fixing
f Rod actuator A = Operating range arrangement.
B = Lower edge of actuator
g Single plunger h Roller lever Maintenance
Angled roller lever Replacing the contact block, see Figure VIII
j Spring rod (snap action only) Unscrew the housing cover and lift out the contact block by its upper rim,
a} Mechanical contact section of rod using a screwdriver. Push the replacement block down on the two locating
b) Minimum deflection (to ensure reliable operation) lugs in the housing.
c) Maximum deflection (to prevent damage)
It is possible for contact bounce to occur on free return. Technical data
With all types of actuators. except c,h and i, the switching elements may be Degree of protection
operated from right or left. or from right and left. metal enclosed IP 67
The actuatores, except c, are interchangeable. plastic enclosed IP65
Permissible ambient temperature
) 0 Operating point to DIN EN 50041 metal enclosed -40 to +85 ·c
· ,. Vmax. max. actuating speed plastic enclosed -30 to+ 85 "C
H Actuator travel difference Rated insulation voltage U; soov
Direction of actuation Rated operating voltage U0 ACSOO V
- - - - - - - - -!'or contact.circuit diagrams, see Figure-Ill Rated thermal current 1m lOA
6mm travel Rated operational current I,
a Snap-action contacts AC 40 to 60Hz l.fAC-12 1/AC-15
b Creep-action contacts at u. 24 v 10 A lOA
c Creep-action contacts (make-before-break) 125 v 10 A 10A
d 2 NC contacts 230/220V 10 A 6A
e 2 NO contacts 400/380 v lOA 4A
For nominal actuator travel and relevant terminals.se e Figure IV 500 v lOA 3A
0-line Reference line to DIN EN 50041 Rated operational current lcfDC- 13 10 /DC-12 1/DC-13
s Actuator travel to DIN EN 50041 at U, 24 v lOA lOA
H Actuator travel distance 4BV 6A 4A
E9 Contact closed 110V 4A 1A
c::J Contact open 220V 1A 0.4 A
Operating point for return travel 440V 0.5 A O.ZA
Enforced opening to DIN IEC 947-5-1
a in direction of travel Short circuit protection
------b--with-lateral-actuation>------------------'=---"-'-'"""'~
DIAZED fuse links 10_,1\._D
6A TDz
MCB (C characteristic) 10A
2 ----[-
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a
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II Ill IV
a b
r~. .
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Va b c
d VI
'r·
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/
Techni5che Andonmoen vorbehaltnn. Beste/1-NrJ Order No~ 3ZX1012-0SE32-0BA1
Subject to chang~_ without prior nottce. __ --- - - - - Printed-ire! he Federal Repub/ic-oFGcrmany- - -- - - ~~ --
(g Siemens AG 1995
16.06.2005 Elektrischer Anschlun / Electr1col connect1on C-30608
Y1 5_1_ A-'!! _::_o~n___ _ 52 Zu I close

-- ---,
,------,
'i
0- 0--.
I
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,- .-
I
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l Jl'~ ll_~ ---

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I I I ;! :. I , II
I
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I
I
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I ! .
Y1 3/2 Wege Magnelvenli I I 3/2 way solenord valve

51-52 Siemens Endscholler 3SE2~0~-1E I S1emens pos1 I :on sw1tch 3SE2~04-1E
X Klemmenle1sle I Plug-1n connector June I 'on Box
- Manufacturer Conlra[lrp "as
- O:mensrons 180x180x90 '1ork
Cable
- DLFLEX 110 CH "I ant NTPC BARH 2X660M'tl - STAGE I I
D:::i' It~ /11C!ct/Y'lle':l: ~~·t;;
Holler Regelarmaturen
33758 Schlafl Holle-Siukenbrock
Jc,.rq-'.c
Anschlunplan C-30608
Circuit diagram
""'
'<l'Dil.
~
Diagram
., /
~-~-·
r
Function: close and open Excelleo::e Is our standard
,I
3 1
Y1
' 1\~
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2
-'L
r--------,
I
I
61_/\1
Y I
J
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} I Y''\ I v; I
3
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1---
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1.
,,
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~- 3 2 1 X
.. -
4 Filter regulator - -
3 3/2 directional solenoid valve currentless current

2 3/2 directional valve (pneum.} - -
1 Pneum. actual or open close

open close
Pos. Designation
Function
Index Change No. Dale Nome t·licrof. Index Change No. Dale Nome t·licrol.
\
~
) Pos.: ..
-
Drmling No.
----- -- - - - ----- . Mark.: ----- --- -------------- --- -- 2005

--- Or01-m
(
-
Dale
-------- --
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--- ·-- ------- - - -- - - - - - - - - - - ------·
21~.02.Joachim
PI ant: Proofed 24.02. Seid. i
-
16.06.2005 Elektrischer AnschlurJ I Electrical connection C-30608
S2 Ze r close
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t
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I
I
I
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Y1 312 Wege Magnetventi I I 312 way so1enc1C valve ' j
S1-SZ Siemens Endschol fer 3SE2404-1E I Siemens posit ion sw1tch 3SE24C4-1= Junc t i on Box :
X Ktemmenleiste I Plug-1n connector - Honufoclurer :~ntro(r,p I I
- Oioens•or.s 1eox·scx9C
Coble
- OLFLEX 1 :o :H
~<>="1....,...1 (~ .... O;>l:r I..._ !N...r
~; [•ljf~ Ha:rer Regelormoruren

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Circuit diagram -_=J
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I ------------------------------------------~-L--------------------------------------~----
Cover
: l /•
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0
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167
120
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- Material: Polystyra!
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I .
i______ _ _ _ _ _ L__ !
_______ _! ________________________________ _ ------·-- ___________ j
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......-- 30
-- ---31
y
I I -27
-26
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Minimum Flow On/Off Valve Series C-37727

Type 68 ..,
Parts list I:C•l;ll1
REGELARMATUREN
Sectional drawing C-37727 Excellence is our standard
GB
Plant AMA
Position 1
Mark
Customer Bharat Heavy Electricals Limit
No. of order F61 OP00015 dated 26.10.2010
No. of confirmation 10208443.1 0
\~0S:ilf5h',: ,oesig ha~i or M

'~;;;;A~t~;,~~,~~:~ si:r;~['1~'t:t2rtl~~\~~~~9f¥f:~'~':· ~teria;IA~n~~t~l~tl!;:~;": .auctr:eLDams:!'.~~:\1':'< i;{i
1 Body SA217 WC9

2 Throttle bush 1.4122
3 0-ring EPDM X
I
4 Cylindrical pin 1.4305
5 Perforated cage 1.4122
"
6 Perforated disk 1.4122
12 Seat bush 1.4122 X
13 0-ring FKM-EFKM X
14 Support ring PTFE X
15 Pressurering bush 1.4122 X
16 0-ring FKM-EFKM X
17 Support ring PTFE X
18 Turcon-glyd ring T29/FKM-EFKM X
19 Piston 1.4122 X
20 Cylindrical pin High-grade steel X
21 Valve stem 1.4122 X
22 Spiral wound gasket 1.4541/Graphite X
23 Cover SA182 F22
24 Stud bolt SA193 816
25 Cap nut SA194 Gr.?
26 Bottom ring 1.4112
27 Stem packing Graphite/K80S X
28 Stuffing box 1.4057 '
29 Gland flange 1.7380
30 Stud bolt 1.7709
31 Hexagon nut 1.7258
r !
_I
1I 1 C-37727 -1 0208443_1 O.xls

------·-- --
~-
l
PART-S
SUB-DELIVERY ITEMS
SECTION-d
CONNECTING COUPLING
BETWEEN CEP & MOTOR
-
I I
'· .
--- ----~
INSTALLATION, OPERATION & MAINTENANCE
MANUAL OF CONNECTING COUPLINGS
(FOR CONDENSATE EXTRACTION PUMP)
COUPLING TYPE : BGBL-200
PROJECT : 500 MW THERMAL POWER PLANTS
CONTENTS
• GENERAL NOTES (DO'S & DON'TS)
• DESCRIPTION OF COUPLINGS/OPERATING CONDITONS
• INSTALLATION INSTRUCTIONS
• MAINTENANCE INSTRUCTIONS
• ALIGNMENT INSTRUCTIONS
• COUPLING ASSEMBLY DRAWING
INSTALLATION, OPERATION & MAINTENANCE
MANUAL
f )
\
------------ --------------- ----- -------------- -- !
GENERAL NOTES
• It is essential that all the instructions contained in the following documents be carried
out by a competent person. Should any problems be anticipated or encountered then
Euroflex Transmissions personnel are available for site visits or, alternatively, repairs
and overhauls can be undertaken in our works.
• Prior to performing any maintenance work (including inspections) it is essential that the
power supply is isolated and that no accidental movement of rotating machinery is
possible.
purpose other than that for which it is designed and supplied, and that the limits of it's
• No liability will be accepted and any other warranty, either expressed or implied, will be
null and void should any component of whatever kind, including nuts, bolts and
washers, be used in the assembly, or modifications be made to all or part of the
product which are not supplied, specified or agreed by Euroflex Transmissions.
DO'S
• Prior to filling any component, care should be taken to ensure that it is clean and free
from any dirt.
• Where hub/shaft connections require a standard interference fit the hubs may be
heated in oil at 200-250 Celsius and rapidly positioned on the shaft. It is essential that
this heat is evenly applied over the whole hub and that spot heating is avoided.
DON'TS
• Do not use any component that is not supplied or approved by Euroflex Transmissions
in the assembly of this product.
• Do not attempt, where the weight of the unit is excessive, to lift the coupling without the
use of lifting equipment.
• The inherent balance of these couplings could be disturbed if they are allowed to be
knocked either by striking or rolling. Care should be taken when transporting and fitting
to avoid such knocks. This particularly when a coupling is specifically balanced.
)
DESCRIPTION OF COUPLING
The coupling is of the dry laminated diaphragm or disc type. Flexibility is obtained by the
deformation of the disc packs, within defined limits, which are separated by a tubular
spacer.
Individual laminations are of regular polygonal profiles which are assembled into a stack of
previously designated thickness and secured by bushing. Flexibility is accomplished by
connecting through the bushed holes, on a common pitch circle diameter, by means of
bolts, alternately, to driving and driven components.
The bolts, bushes and associated holes are machined to close limits associated with "fitted
bolts". Due to the need for reasonable ease of assembly, interference fits are undesirable
and, consequently, tolerances are such as to allow for a close slide or slight transition fit.
To compensate for these clearances and to ensure the best possible concentricity
between components, the pitch circle diameter of the bolt holes in the flexible element is
made smaller that that of the mating holes in the adjacent components. On assembly, all
inherent clearances are, therefore, eliminated. Coupling bolts are sized such that they are
capable of including a load equivalent to 4 times the tensile load in the flexible element
laminations, between driving and driven bolt, when transmitting the full rated continuous
torque of the coupling. This assumes a coefficient of friction between the various
components of 0.25 but experience has shown that, due to the high loads induced, minute
compressive deformation is sufficient to raise this to about 0.3.
The reason for adopting this principle of using large, highly loaded, bolts is two-fold a (to
prevent interface slip, as already mentioned, and b) to eliminate any chance of bolt
bending due to the overhung radial loading imposed by the flexible element. Avoiding
either slip or bending helps to avoid fretting which occurs when bolts are designed only to
drive in shear.
In general, the design is identical to a large number of units already in operation.
OPERATING CONDITIONS
In operating the flexible elements are subjected to both tensile and bending stresses, each
having an influence on the allowable magnitude of the other. It is important, therefore, that
the operating limits of the various deflections for which the coupling is designed to
accommodate, are kept, as far as practicable, within those indicated on the "Allowable
Misalignment Curve" which was individually supplied with the final engineering data.
In practice, the initial alignment of the coupling should be as close as possible and within
the alignment limits given in the "Installation Instructions". This will allow for changes
during operating to remain within allowable limits.
As the Euroflex units are designed to transmit the torque in friction between the driving and
driven bolts and the flexible elements, it is essential that, should the need arise, these
bolts should be correctly tightened to the torque indicated on the assembly drawing or in
the "Installation and Maintenance instructions".
Torque and speed should remain within the originally specified conditions.
INSTALLATION INSTRUCTIONS
GENERAL
No liability will be accepted, and any warranty, either expressed or implied, will be null and
void should any components of whatsoever kind, including nuts, bolts and washers, be
used in the assembly or any modifications be made to all or part of the unit which are not
supplied, specified or agreed by Euroflex Transmissions Ltd.
For general Safety, Alignment and Maintenance Instructions see other sections of this
manual.
IMPORTANT
I
t When tightening any bolts or screws, this should be done evenly, i.e. cylinder head
fashion, to 50% torque then to 100% torque in the same sequence.
Threads should be lubricated with Molybdenum Disulphide grease or equivalent.
INSTALLATION INSTRUCTIONS
1. With the Motor Rotor in it's central axial position, check the distance between the
machinery shaft ends is xxx +1-0.1 mm (This gives a 0.7 mm pre-stretch when the
coupling is installed.
2. Check that the parallel & angular misalignment of shafts is within the limits defined on
the separate Alignment Instructions sheet.
}. 3. Fit the Hubs (items 1 & 2) to their relevant shafts, ensuring that the Motor hub (item
1) face finishes flush with the motor shaft end.
4. Check the distance between the Hub faces is xxx mm +1-0.25 mm.
5. Insert the Spacer Assembly (item 3) between the Hubs and align Match Marks (or
Serial Numbers) by rotating the Spacer or machinery shafts.
6. Insert the Element Assemblies (item 4) between the Spacer & Hub flanges (item 1,2
&3)
7. Fit Coupling Bolts, Overload Washers & Nuts (item 5/6/7) as indicated on the drawing
and torque tighten, cylinder head fashion, to the value shown on the drawing,
-------ensuring-tbreads-ar:e-cor:r:ectly-lubr:icated . - - - - - - - - - - - - - - - - - - -
}
General maintenance of the coupling consists of an annual (or other agreed period) check
of the following :
• Axial, Angular & Parallel misalignment to ensure these are still within acceptable
limits and that no major machinery movements have occurred.
Q All bolts to ensure they are correctly tightened.
• The Flexible Elements, by visual inspection, for signs of fatigue cracking local to the
washer anchor points or general signs of fretting corrosion. Slight bowing or "S" like
distortion of the laminations is not detrimental to the unit operation.
NOTE : Any requirement for spare part should be made quoting the Original Purchaser,
Original Order Number & the Coupling Serial Number (this will be etched
on the major coupling flanges as BTLxxxx and should appear on all post
production Quality documents).
ALIGNMENT INSTRUCTIONS
Euroflex Transmissions couplings will accept substantial amounts of misalignment, the

configuration of each individual unit defining the actual acceptable level. The allowable
misalignment is shown graphically on a curve produced uniquely for any unit. This curve
shows the maximum permitted level of misalignment for operation and is NOT intended to
define setup limits.
ALIGNMENT METHOD :
Each company ahs it's own method· for aligning machinery all of which well documented in
both internal and freely available documents and books. Hence it is not our intention to
describe methods for setting machines. Instead, the following gives guidelines for quick
checks for alignment suitable after initial installation and for general maintenance checks.
AXIAL:
The suggested limits for axial set-up distance between the machinery shafts will, generally,
be specified in the installation instructions unique for the coupling. However, as a general
rule, the following may be used.
4-bolt couplings:- +1- 0.4mm

These values may be exceeded in certain cases and, if no reference is made in the unique
installation instructions, reference should be made to Euroflex Transmissions.
PARALLEURADIAUANGULAR:
(_ Having basically aligned the machinery shafts using one of the established techniques, the
\... coupling may be installed as per the instructions. It is then worth performing a check to
establish that the overall alignment is correct for the particular coupling. This may be
· simply performed by one of the following two methods:
• Attach a dial indicator securely to the back of one of the coupling flanges, with the
needle in contact with the flange face the other side of the flexible element as near
the outside periphery as possible. Rotate the machinery & coupling and locate the
minimum reading position. At this position, set the dial reading to zero. Rotate the
machinery again and record the maximum reading over 360 degrees. Divide this
maximum value by the coupling flange diameter to gain a value in mm/mm, which
should be no greater than that shown in the following list. (This should be repeated at
both flexible elements in a spacer coupling).
• An alternative method is, where possible to accurately measure the distance across
the flanges which sandwich the flexible element to obtain a maximum and minimum
value. The difference between these two values should the be divided by the flange
) outside diameter to obtain a value in mm/mm, which should be no greater than that
shown in the following list. (This should be repeated at both flexible elements in a
spacer coupling).

NOTE : These values are intended as guides only and, in certain cases, may be
exceeded, IF IN DOUBT, CONTACT EUROFLEX TRANSMISSIONS.
~SSEMBLY DRAwiNG Qf/DE. S/02
U~lESS OTfiERWIS[ STATED ALL ()Jt.IENSIONS •N t.IILLIMETR£S ') DO NOT SCALE
------------------
IF •N DOUBT ASK
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(Trim Blancing Holes) (Trim Blancing Holes)
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Power 900 K.W
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Operating Torque 502 Kgm do..0a<3
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~-+---------------------·--+------~----~-~
j 14. NTPC lo!AU1lA F'7!QAQ0095 2!!.10.2()10 5
Mox.lnst Torque 1246 Kgm ~r--·
It 5.: 2<50.0 loiW JINO ...L INOlA TPS AT DERANG F711AOQ079 13.06.2011 ~
COUPLING ~APACIT_'L_; screw 12

Note:- 1. Tighlening Torque :
Continuous Torque :1061 Kgm Hem No=4 Coupling bolt Tightening Torque = 220 Nm Bush BS970 080 M40 12
Jtam No=2 Altachmerd bolt Tightening Torque = 90 Nm Hub BS970 080 M40
Peak Torque :1450 Kgm (Lubricoted threads with MOS2 grease)
7 S acer 8$970 080 M40 1
Short Circuit Torque ~21 00 Kgm 2. Gagging Screws & Bushes (Item No9&10) ore only for Tronsportotion purposes Lock Nut
2 and need to be removed prior to instaflation. Coupling not to operate with
6
;-~___;:c-+;;;;.;;.....::....:...:-.-:....=;__ BS970 817M40 12
_ _ _ _ _--t==-:-=....-=.-'-...:..
2 5 AISI 301
Inertia (WK ) :0.286 Kgm gagging screws in pos11ion. 2
6 3. For compressing transmission Unit to cleor the spigot on the hubs, 4 Cou lin BS970 817M40 12
Torsional Stiffness :0.173X1 0 Kgm/rad tighten gagging screws (wi1hout bush in position)
4. Do not disturb factory assembled Coupling bolts. 3 Ada tor M40 2
( 1/3 Shaft Penetration) ±4.5 mm 1.7 mm o.s· element Application:-MOTOR-C.E.PUMP(EN6J40/500) 2 Attachmen-t Bolt STD 12
Balclnced: G 2 _5 !SCf 1940 Axial Radial --An uiar--~-~odei.No:8GBL,-22D---W.e1 bl..:..__A_L_.K _ MOTOR Hub BS970 080 M40 I 1
MISALIGNMENT Customer:- B.H.E.L. ~---......L:..s--'-:N_;;-....c;-D=-E=-S_C_-R_-f_P...:...T.:...:IO'-"--N-'- .. -MAT[RlA-L--_~---- ;-<~HY
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~~~~~-Y-BO-F-LE_X_TR-A-NS_M_IS~SI-9~-S~[-IND~JA~l-fV-T-~~~,M~_,T_J_Q~~~~~~~~~~~-~~~~~~~~~~-~~ TITLE BGBL-220 I DRAWING NO. .
FLEXIBLE COUPLING .1 op 44_~-.0_Q

AB~~!!~ssions
,.
fl 0
ISO 9001 - REG No
10. Ensure thafall matcn marl<s are-aligned";--all-the-transit-bolts-are-removed,---all-the:---------,------+

0 U509 7
("
I
I
fastners are correctly tightened and all the coupling components are in good condition
before operating the machine.
7) REMOVAL INSTRUCTIONS
Coupling removal is the reverse of the installation process - Ensure that on reinstallation the
process is followed in careful sequence. Jacking screws may be used to facilitate removal of
transmission unit from hubs.
81 MAINTENANCE INSTRUCTIONS
General maintenance of the coupling consists of a check of the following during normal
machinery maintenance schedules.
• Axial, Angular & Parallel misalignment to ensure that these are still within the
acceptable limits and that no major movements have occurred. It is recommended
that a record of misalignment readings is maintained.
C.}
• All bolts to ensure that they are correctly tightened.
• The flexible elements, by visual inspection, for signs of fatigue cracking local to the
washer anchoring points or general signs of fretting corrosion. Slight bowing or "S"
like distortion is not detrimental to the operation of the unit. Note that any cracking will
begin at the outermost edge of the outside blade. This means that, this inspection is
still possible without disturbing the element bolting.
• Bibby Turboflex use self locking nuts. This gives a high level of performance over
many. reinstallations. It is recommended by Bibby Turboflex that these be replaced
after being re-torqued 8 to1 0 times.
Note : Any requirement for spare parts should be made quoting the original purchasers
original purchase order number and the coupling drawing number. Suggested maintenance
intervals are:-
i} 12 months
ii} At planned machine down time intervals. '
\__
9) RECOMMENDED SPARES:
Sr. No. Part Description Qtv/Coupling Recommended Qtv.

1 Shim Pack 2 Nos 2 Nos.
2 Bolts with Lock Nut 2 Sets 2 Sets
Note : COUPLING IS DESIGNED FOR VERTICAL APPLICATION.
Attra lndustmrl Motion • The Power of Experlence
Boston Gear • Warner Electric • Formsprag Clutch • Stieber Clutch • Madand Clutch • Wichita Clutch
lndustrW Clutch • Amerldrlvu Couplings • Nuftllll Gear • Delroyd Wonn Gear • KHian Manufecturing • ln8111a Dynamics
Mafrlx International • Twlffex Umited • Bibby Tmnsmisslons • Huco Dynatolk • warner Unear • Saflelr Friction
\
9
A B~!:!!!ssions 1~\
~
ISO 9001 - R£C No U U~097
5} HANDLING & STORAGE
The coupling is normally dispatched with standard commercial packing and the case should
contain a copy of required documentation. During transport the installation screws will be in a
position to ensure that the elements are not in free state. The coupling should be stored in
this condition. On receipt and also immediately before assembly, all the items should be
checked to ensure that they are all in good condition and free of damage. The coupling
should be stored horizontally. It should be protected against corrosion if stored for long
periods or outdoors.
6} INSTALLATION INSTRUCTIONS
The coupling bolts & nuts are factory tightened by Bibby Turboflex Ltd. and are not to be
disturbed since it may affect the balance of the coupling.
Following installation procedure shall be followed:-
1. Bring the shaft ends of driver and driven machinery together and check that the
distance between shaft ends Is as close as possible to the 240mm.
2. Coupling Is sent in fully assembled state. It must be dismantled at the hub faces by
removing attachment bolts between hubs and adapter plate. The coupling bolts are
factory assembled and torque tightened and should not be disturbed at site. The
portion of coupling between hubs Is called transmission unit .
3. Fit respective hubs onto driver and driven shafts and align them using your chosen
method. The hub face should be flush In line with shaft end. The misalignment shall
be less than Y..th of the maximum misalignment values given on the assembly
drawing. Bibby Turboflex do not recommended any specific alignment method as
many methods are available. The lowest values of misalignment ensure long and
trouble free operation of the coupling & connected machinery. It is recommended to
note down the Initial alignment readings.
4. At this stage before any further assembly takes place, provision shall be made to
align match marks on the coupling components.
5. Remove the installation bolts from the transmission unit and check whether the length
of the unit is as per free length mentioned on the drawing.
6. Reinstall the transit bolts and compress each element assembly such that the
transmission unit could be easily inserted between two hub faces
7. Position the coupling transmission unit between two hub faces, ensuring all relevant
match marks and attachment bolt holes are aligned. The coupling transmission unit
shall be supported to ensure that the weight is not imposed on the joint during
assembly.
8. Insert attachment bolts (bolt between coupling hub and adapter plate from the
transmission unit) In position and release the transit bolts carefully & evenly, making
sure that the spigots and recesses are properly seated. Note: Do not torque tighten
the attachment bolts before removing the transit bolts.
9. Torque tighten the attachment bolts using correct Jock nuts. The tightening torque
mentioned on Assembly drg. shall be maintained on attachment bolts.
Alfnllndu&trlal Motion • The Power of Experience

&.ton Gtn1r • W11mor Electric • Fortn8prag Clutch • SU./m' Clutch • Marland Clutch • W1chlt4 Clutch
lndustrllll Clutch • Amerldrlvn Coupllng11 • Nuttall Gt~ar • Oolroyd Wom1 Gear • Killin Manufacturing • lnort11 Dynamlc3
Matrix lnttJmBtlonDI • TWfflox Limited • Bibby Tronsmlssion:s • Huco Dyn11tolk • Wam.,. Uneer • Saftok Friction
Registered Office:- 317-319 Ampthill Road, Bedford, MK42 9RD- Registered in Enghmd- Number 158829
-A- Bibby
0
•
M. Transmissions I'
i\c
1
ISO 9001 •· REG No 0 05097
-------..:1)-GENERAL.NOTES
• It is essential that all the Instructions contained in the following documents be carried
out by a competent person. Should any problem be anticipated or encountered then
Bibby Turboflex personnel are available for site visits or, alternatively, repairs and
overhauls can be undertaken in our works. The persons responsible for selection,
handling, installation, use & maintenance shall require & understand these
instructions.
• Prior to performing any maintenance work (including inspections) it is essential that
the power supply is isolated and that no accidental movement of rotating machinery is
possible.
purpose other than that for which it is designed and supplied, and that the limits of it's
• No liability will be accepted and any other warranty, either expressed or implied, will
be null and void should any component of whatever kind, including nuts, bolts and
washers, be used in the assembly, or modifications be made to all or part of the
(~~
'-··-.../
product which are not supplied, specified or agreed by Bibby Turboflex.
2) REQUIREMENTS
• Prior to fitting any component, care should be taken to ensure that it is clean and free
from any dirt.
•
Where hub/shaft connections require a standard interference fit the hubs may be
heated in oil at 200-25o•c and rapidly positioned on the shaft. It is essential that this
heat is evenly applied over the whole hub and that spot heating is avoided.
3J CAUTIONS
• Do not use any component that is not supplied or approved by Bibby Turboflex in the
assembly of this product.
• Do not attempt to lift the coupling, or component parts, without first ascertaining their
weight from drawings or data sheets. The use of lifting equipment may be necessary.
• The inherent balance of these couplings could be disturbed if they are knocked either (
by striking or rolling. Care must be taken when transporting and frtting to avoid such \
knocks. This is particularly important when a coupling has been carefully balanced
and designed to run at high speed.
4) ATTENTIONS
• IMPORTANT: The necessity for shields & guards varies with individuals installations.
The owner or user must provide the required safety guards. Safety guards or shields
are not furnished by us with this equipments.
AltnJ Industrial Motion • The Power of Experience
Boston Gear • Warner Elactrlc • Formsprag C/utr;h • Stieber C/utr;h • Marland Clutch • Wichita C/utr;h
lndustrilll Clutch • AmerldrtvN Couplings • Nuttall Gear • Oelroyd Wo1711 Geer • l<lllan Manufacturing • Inertia Dynamics
Matrix JntemationaJ • TW/tlex Umited • Bibby Transmissions • Huco Dynatork • Werner Unear • Saftek Friction
\.
AB~~!!Xssions 0
Cannon Way,
Mill Street West,
Dews bury,
West Yorl<shire, WF13 1EH
Tel:- 01924 460801
.. Fax:- 01924 457668
Website:-www.bibbytransmissions.co.uk 'SO 9001 RL.C No 0 U5097
E-mail:- sales@blbbytransmissions.co.uk
INSTALLATION, OPERATING AND MAINTENANCE
MANUAL
Coupling : TF0750
Drg. No.: BH52
CLIENT :BHEL
PROJECT:-VIJAYWADA AND BHOPALPALLI.
CONTENTS
1) General Notes
2) Requirements
3) Cautions
4) Attention
5) Handling & Storage
6) Installation Instructions
7) Removal Instructions
8) Maintenance Instructions
9) Recommended Spares
"- Aftnllndutrtrt./ Motlon • The Power of Exporlonce

~
80#/on Goer • W11171M Eloctrlo • Fol'l'mpl'llg Clu/ch • Stlobor Clu/ch • M11rl11nd Clutch • Wichita Clutch
/ndwt>lrilll Clutch • Amorldrlvos Couplings • Nuttall Geor • Deltoyd Wonn Goar • Kilian Manufacturing • /no,.U. Dynomlcs
Mltfrlx lntemot!onel • Twin ox Umltlld • Bibby Transmissions • Huco Dynatorl< • Wl!mor Linear • Slltrek Friction
.-_,-..
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£ PROJECT:- MAITHON, KODERMA~ DURGAPUR.
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NOTE- ~~ i
• .AXIAL THRUST = 145 kg~
SPECIFICATIONS
li TIGHT.ENING TORQUE CCOUPPLING BOLT SR N017);;;225 Nl"'<oited> ~~
APPLICATION MOTOR TD CEP
RATED POVER 900 Klw'
• TIGHTENING TORQUE CATTACHMENT BOLT SR N0•9>=55 Nl"l(oite-cD rJ
"' TRANSIT BOLT S:R.N0.12 &: :BALANCING BUSH SR.N0.13 ~
RATED SPEED 1486 RPM ARE PROVIDED FOR TRANSPORTATION PURPOSE ONLY
RATED TORQUE 589.5 Kg~
S. TO BE REMOVED BEFDR OPERATION.
13 B.ALANClNG :BUSH BS 970 OBD H40 6

COUPUNG CAPACITY 12 TRANSIT BDL T GR 8.8 ... 6.
II!
CDNTINUDUS TDRQV£ 729.8 k:g!"t 11 OVER LOAD VASHER :BS 'PO 709 M40 12 !;;
P'EAK TORQUE
SHORT CIRCUIT TOROUE
1277.3 kgM
1970.6 kgf'l
If)
t.n
10 ELEMENT \oiASHER BS 970 709 M-40 12 -
'i
~
9 ATTACHMENT RDLT BS 97a 817 M40 24
MASS 525 kg. A B SELF" lDCKlNG NUT liS 970 817 M40 12
lNERTIA (\/~) 0.24 kg-n 2 A
7 CDUPUNG BDL T BS 970 817 M40 !2
GD2 • 0.96 kg-r'l2 .t..
6 0l21.t. 6 ELEMENT BLADE ASSLY SS:3Dl 2 SET
TORSIONAL STIFFNESS 0.11x10 kgl"l/ra.ol. A
~203 5 CENTER SPAC(R BS: 970 OSO M40 1
DYNAMIC BALANCING TO GR. 2.5 1S0=1940 ~
4 ADA?TDR<STD> BS 970 080 M40 l
........:<
3 ADAPTORCNSTD> BS 970 080 M40 1
MISALIGNMENTS [CEP END 2 CEP' END HUB llS 970 090 M40 1
!
~
MAX. AXIAL DEFLECTION :J:5Mr'1. BS 970 Cl8D M40
I MOTOR END KUB i ~
MAX. ANGULAR DEFLECTION {),5 • Deg./S.TACK. - .. . .. ·;::\ ..
..
SR NO DESCRIPTION MATERIAL QTY
. M'~X. RADIAL MISALiGNMENT 1.4 1''H'1,
ISSUE
DRA\JI'IIIIG NO.
TF0750 VERTICAL COUPLING BH323-2
1
PART-S
SUB-DELIVERY ITEMS
SECTION- E
SUCTION STRAINER BEFORE CEP

...
DESIGN DATA REV DATE DESCRIPTION REV BY CHO BY
350,,
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(28') Davit c lo i~
2 Tvoe of Strainer Simolex Basket l'"ilte~ 1 24/03/11 REVISED AS PER YOUR COMMENT & MARKED it . HSG BJP --
. ~/~ . - . - ~i ~1) 3 Material Code FP9760075024
4 Otv. 12 Nos. NOZZLE SCHEDULE
• • ~ . (2:fr --4 ... ~2) 6) 5 Spare Filter Element 4 Nos (~oterlal Code : FP9760075040) SYMBO SERVICE SIZE Thk. RATING ANSI STD. TYPE FACE REMARK
J.I~~~i~~~3)
5 OeQree of Fllterotion .315 Micron (50 Mesh x 0.2mm Wire Dia)) N1 [nlet 20"NB 10 150# 8-15.5 SUP ON R.F.
Y...... 7 End Conn; SOOmmNB ASA 150M ANSI 8 1 5.5
.----__ij:~U~:=:::=::~=:=:;:=~~~4) 8 Fluid to be Handle Condensate N2 Outlet 20"NB 10 150# B-16.5 SUP ON R.F.
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9
10
11
12
Flow Rote 7 Viscosltv
DesiQn Pressure
Oprt./Desiqn Temp.
Hydrotest Pressure
-Max.AIIowoble Press.Orop
970 m3lhr I 0.60 CP
8 Kg/Cm2 (g) & Full Vaccum
50"C I 7D"C
12 Kg/Cm2 (g) (For 30 Minutes)
N3 Vent
N4 Drain
NS Stub D.P .Gouge
1"NB
1"NB
1/2"NB
NS Stub D.P.Tronsmitter 1/2"NB
3000# B-16.11
3000# B-16.11
3000/1 B-16. 11
3000# B-16.11
Cplg.
Cplg.
Cplg.
Cplg.
- with Valve
- - with Valve
- with Plug
with Plug ~
lA
+---4-::l_t!~- ~Jtu._ _____ ~ ~ --4~l ----~l!!.

ot (a) Clean Cond. 0.03 kg/cm2 (g). NOTE:- 1)
- - 13
(bl 50"Ctooaed Cond. 0.05 kg/cm2 (g).
ALL DIMENSIONS ARE IM 1.41.4 UNESS OTHERWISE SPECIFIED.
(N1)
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Gross/Net filtration Area 58032 / 12352 Cm2
Rodioaroohv on B.W.Joint .100~
2} All FlANGE HOLE SHALL BE STAGGERED TO CENTRE LINE.
3} ALL FLANGE FACING FINISH SHALL BE SERRATED FINISH TO 125-250 MRH.
4) REMOVE SHARP EDGES, BURRS, &: WEtO SPATIERS.
t:r (NS) + L.z! ~

16 We·i-ht of 5t~oiner
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Em~t··: ~975 K·. (b) Flooded: _ 1360 Kg.
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5) ALL B.W. SHALL BE CHIPPED BACK D.P.TESTED & REWELDED FROM
OTHER SlOE WHEN EVER BACK CHIPPING IS NOT POSSIBLE ROOT SHALL
~ ~~i~s
17 Shipping Dimension 1.52 mtr. X 1.4 mtr. X 1.6 mtr. BE 00111£ WITH TIG WELOINC WITH ARGON PURGING.
(24 (29) -fl i 22) (24) 18 fine Mesh (50 Meshf Wire Dio. 0.2 mm
(30) "lC: . . . , ! ~ (Typ} 19 Perforated Sheet Thi.:kness 3mm Thk. 1 152062Gr8 STD.
I co 20 Ratio of Free Flow Area
to {JS Area of Inlet Pioe 6.6 : 1
1 S.S.304 STD.
(9}-- 80011 260 Nos,12 W , 17)
( 16) : Pleats
21 Paint-Outer Surface
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Element Stfffner Oetgll with PllJ9.
3 Nos, 280 Hole j 8 S.S.304 M-10 X 35 Lg.

IS2062Gr8 '10 1r.k, 900 x 8<Ji
ot 1155 PCD
NonAsbestos 3 Thk, .STD.
IS2062Gr8
S.S.316
10 Thk, x 806941
50 Mesh x 0.2mm Wire Dia.
5.5.304 3 Thk.~Hole,at 10 Tmglr.Pitch
~ Stiffner
3 SA516Gr60/70 210 X 115 X 10 Thk.
., J Thk-$.5.304
6 IS2062GrB 12 Thk.
~~ 3 IS2062GrB 180 X 20 Thk.
IN
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1
SA516G£60/70 9400 X 32 Thk.
C.S. f''NPf(F),Giobe Type STD.
{N1) (N2) 1 SA 105 1"NPT(F),3000#.STD,with Nipple
1 SA516Gr60/70 38"NB x 10 Thk., Fob.
'-<;,.... 8 In/Out Flange (N1/N2} 2 ~~1£7~/7(1 20"NB, S.O.R.F, 150f, 8-16.5,
( 11 '+--{g) 7 In/Out Nozzle(N1/N2) 2 SA516Gr60/70 20"NB x 10 Thk, Fob.
...-------~~ 6 Stud with Two Nuts 48 ~~~~g~~;7 M-22 x 130 Lg.
(1~5' ~~~
1/ 1\ 5 Shell Flange 1
SA 105/ ., 38"NB, S.O.R.F, AWWA,
SA516Gr60/h Refer Detail
(
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Gasket 1 NonAsbestos 3 Thk, 1040 0.0 x 970 I. D.
2701 Cover Fl ange SA 105/. , • 38"NB, B.LR.F, AWWA,
1"\.'I • L"\. "\. "\.'\~· .3 1 SA516Gr60t7l
1
Refer Detail
1200±15 ( 13)J I 2 Vent CPIQ.(N3) 1 SA 105 t•NPT(F).3000I,STD with Nipple
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LEG SUPPORT DEJA!L 1 Vent Valve (N3) 1 C.S. 1"NPT(F) Globe Type STD
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{Project: 4 X 600 t.IW,O P Jindal STPP,Rolgarh Chattlsgarh
ORG NO :- [REY
DATE :-09/02/2011
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DETAIL 'Z' QETAIL Of CONN. (N3) DETAIL Y -ILL.- DETAIL OF CONN, (N4) A.O.No : 8017 T DATE : 16/02/2011 8 81 0080
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0 1670271 1 - - ISSUED FOR APPROVAL -- HSG BJP
DESCRIPTION REV BY CHD. BY
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1 24 ; 03 ; 11 REVISED AS PER YOUR COMMENT
HSG BJP
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10 Snap Head Rivet 1 IS2062Gr8 Refer·- Detail~.· -- -·--
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8 Hook Bolt 1 IS2062GrB Refer Detail with Two Nuts
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7 Plate for Bush 2 IS2062GrB 63 · O.D x 30 1.0 x 12 Thk
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Gusset Plate
Support Plate
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IS2062Gr8 10 Thk. Refer Detail
IS2062Gr8 1 2 Thk x 90 W
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~ DESCRIPTION i.QI'L MATL .s.J.Z.E
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P .O.No.: F71 OA00165,
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(Project: 4 X 600 NW,O P Jindal STPP,Ralgarh Chattl59arh) DRG NO :- IBm
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DETAIL- 'A' - ~ 170 !-Y9) DETAIL OF DAVIT PIPE SCALE :- N.T.S l FILE No: 8017B20A 048581 QQ8Q 1
A.O.No.:- 8017 I DATE:-16/02/2011
----i~------------------------.-------.~-~---~-.------~--------------------------------------·----------------------~----------------I-2;-.£-~L-~r-:r-,)-F-·t_}._R~.~:~-~~-.~~-;;-~;-)V-~-i-,:-f--2~)~~
PART-S
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DRAWINGS I DOCUMENTS
INDEX
SECTION-A BOILER FEED BOOSTER PUMP
SECTION-S BOILER FEED PUMP
SECTION-C : CONDENSATE EXTRACTION PUMP
'
)
SECTION -A
LIST OF DRAWINGS
Erection & Maintenance
S.No. Description of Drawing

\
) 01. Sectional Assembly of Booster Pump
02. Outline Arrangement of MDBP
03. Outline Arrangement of TDBP
04. Key & Holding down bolts details for MDBP & TDBP
05. Spanner (Coupling Nut)

06. Hook Spanner (Var. No.9, 10, 11&12)
Informative Drawings
07. Estimated Performance Curves of MDBP
08. Estimated Performance Curves of TDBP
09. Estimated Performance Curves of BP-NPSHR

FIRST ANGLE PROJECTION (ALL DIMENSIONS ARE IN mm)
2 3 4- 5 6 7 8 9 10 11
lL.89 900 08l l
·oN ·s~o
A A
945
887 855.5
8 8
0
0
"'
4 JACKING BlOCKS FOR
1124 JACKING SCREWS D
250 595 595 250
14-4-0
1370
1710
DlSC:IiARGe: BRANCH 300 N.S.

JHSl 300lb R/F
7 E
33 lliSQoiMCE PRESSURE swm:H -TN'I'Eil 1/'1:' HPT

32 DCSai.IRGE VOLUTE DRAIN-TN'I'Eil 1/2" HPT
31 SUCl10H \IOUJlE ORHH-TN'I'Eil 1/2" HPT
F .30 PUMP CASING GINIOWEll ORAIH HOE-TN'I'Eil 1/2" HPT F
29 PUW' CASING Gt.ANOWELL. DRAIN DE-TAPPED 1/2• NPT
28 BASEPLATE DRAIN-TAPPED 1• NPT"
2:1 PUt.IP CASING VENT TN'I'Eil 1/2" HPT
26 lliSQoiMCE PRESSURE G'.UGE-TN'I'Eil 1/2" HPT
25 SUCl10H Pf<£SSURE <:AUGE-TAPPED 1/2" HPT
24 DE f!EAAING HClOSING TEMP INDICATOR TN'I'Eil 1/2" HPT
23 DE BEARING HOUSING JOURNAL. TEMP. El.EMENT-TAPPED 1/2" NPT
22 DE eEAAING OL RETURN-TN'I'Eil 3/4" NPT
21 DE eEAAING HOUSING OIL IHLEr-TAPPED 1/2" NPT
20 DE BEARING HOUSI.NG JOURtrW.. BRG. lntP. NPT -2 NOS-TH'PED G 1/2" WEtGHT OF PUWP • .34GO ~~
19 DE BEARING: HOUSING '¥18PA110H PROBE-TAPPED 3/8-2o4. UHF' WEIGHT OF BASE PlATE • 1140 KQO
18 DE f!EAAING HClOSING BRFA1HER-TN'I'Eil G 1/4"
G G
17 THRUST PAD TEWP. :rAPPED M20x1..5 B.£C1RICAL. THREAD
16 HOE f!EAAING HOUSING 1HRUST f!EAAIHG OIL IHLEr-TAPPED 3/4" NPT
15 NOE BEARING HOUSING OL RETURN-TAPPED 1" NPT
14 HOE BEARtNG HOUSING JOURNAL BEARaHO OIL INLEr-TH'P£0 1/2" t-FT 1. J.l.L L.£VELS AA£ W..R.T. POWER HOUSE GROUN:> FLOOR L£\€1... J.S ::I:O.OOM.
13 NOE BEAAtNG HOUSING JOURNAL TENP EL..Et.IENT-TJE'PED 1/2" NPT 2. GRILLAGE IS NOT SHOWN BELOW BASE PlATE IN lHlS DRAWING. 4
12 NOE BEARING HOUSING TENP. INDICATOR-TAPPED 1/2" foPT DRAINS At VENTS ARE PROVIDED 'MTH lSOLATION VN..VES.
3.
11 HOE f!EAAING HOUSING JOURNAL BRG. TEMP. HPT -2NOS-TN'I'Eil G1/2"
SUCTION BRANCH 350 N.B.
10 NOE BEARING HOUSING THRUST BRG. TEMP. NPT -4 NOS-TAPPED G1/2"
JHSl 300lb R/F
•
8
HOE f!EAAING HOUSING VIBRATION PROBE-TAPPED 3/8-24 UNF
NOE f!EAAING HOUSING BRFA1l£R-TAPPED G 1/4"
7
6
SEAL CIRCUlATION INL£.T TAPPED 1/2" NPT
SEAL CIRCUlATION OUTl.£T TN'I'Eil 1/2" NPT
CUSTOM JINDAL POWER LIMITED
5 SEAL COOUNG JACKET INL.Er-TJf'PED 1/2" NPT CONSUJANT: DEVELOPMENT CONSULTANTS PVT.LTD H
4 OOOUNG JACJ<Er AIR VEHT-TN'I'Eil 1/2" NPT & PLUGGED
3 SEAL CIRCUlATION INl.Er-TAOPEO 1/2" NPT· a: PUJGGEO
PROJECT: OP JINDAL STPP PH-ill 4X600 MW UNITS
2 SEAL CIRCULATION CUT1£T~T~ _1/2" __ NPT _a: PUJGGEO
T.AYNAR, RAIGARH CHATTISGARH
1 SEAL COCK.JHG JACKET OUTLET-T1.PPED 1/2" NPT
RA.J.C
REF. No. TAPPING POINT
N.M.RAO
B.RAJKUI.IAR
1 180 005 6871 nEW NO.Of
DATE .oLTEREO REV. DATE .o<.TEREO REV. DATE f!Al~TERED~:::._----,----!REV. DATE f!Al~TERED~:::._-__,,-------J DAlE AL.lERED DATE ALTEREO REV. DATE AllERED NO. l1tWS
CI£CKED APPO. f'CH.=ECKED::,='---.,.-APPO-.----l CHECKED APPO. C>ECKED APPO. C>ECKED APPO. C>ECKED 01 04.01.1J:'CH'::E"':CKED=-~-.,.APPO--.- - NTS NA NA NA. NA
Z<>E ZQE ZONE ZONE REV.
Z<>E REVISED INUE WITH M/S JNDAL
COMMENTS LIR OF 11.12.09 OUTLINE ARRANGEMENT OF HY-DG-1-18000-56871 01
MOTOR DRIVEN BOOSTER PUMP NO.<>
4 5 6 7 8 9 10 11
FIRST ANGLE PROJEC110N (ALL DIMENSIONS ARE IN mm)
2 3 4 5 6 7 8 9 10 11
lL99 £00 69 ~ ~
"ON "D~O
OLD
.
A
i=f~~-~
--p-------------·--------~---- ·- - - · - -
B PUMP SHAFl' END B
ISCALE>251
6J,A(J(Ir«i8LOOCS FOR
H24.JACKINGSCREWS 1108 CAS. 720 CRS. 720 CRS.
858 1189 D
2818
33 ll1SCHN<GE PRESSURE swm:tt-TAI'f'Sl 1/2 NPT

J2 ll1SCHN<GE Y01..1JTE DRAIN-TAI'f'Sl 1/2 NPT
31 SUCTlOH Y01..1JTE DRAIN-TAI'f'Sl 1/2 NPT
30 PUI*' CASING Gl.JMlWEI.l. DRMI HOE-TAPPED 1/2 toFT
F
29
28
PlAF CASING GI..NI:lWELL DRAIN DE-Tif'PEO 1/2 NPT
81& PlATE DRAIN-TAPf'Sl-1 NPT
..,. F
X
27 P1J1otP CASING le«-TAI'f'Sl 1/2 NPT
26 DISCtl.tfiGE PRESSURE GAUGE-TAPPED 1/2 NPT
,
25 SlJCTICIN PRESSURE CWJGE TAPPED 1/2 NFT
24 DE 8£AR1NG HOUS1NG TEIIP.E1.EWENT-TAI'f'Sl 1/2 NPT
23 DE 8£AR1NG HOUS1NG .IOORIW. lEliP INDICARJR-TAI'f'Sl 1/2 NPT
22 DE 8£AR1NG 011. R£TURN TAI'f'Sl 3/4 NPT
"10<"
21 DE BEIRIHQ HOUSING OIL INLEr-TAPPED 1/2 tFT
20 DE~ HOC..ISWG JOURNAL BRG TEWP NPT -2 HOS-T~ Gl/2 A "z" ")("
19 DE 8£AR1NG HOUS1NG 'IIBRA110N PROOE-TAI'f'Sl 3/8-24 UNF
18 DE 8£AR1NG HOUS1NG BA£ATHER TAI'f'Sl G1/4
17 nRUST PNJ lEt.IP-TAPPED M20x1.5 B.ECIRICAL 1tflEHl
18 NDE BE'ARlNG HCit.SHG THRUST BE'JRING OIL INLET-TAPPED .3/4 NPT
G 15 HOE BEARlNG HOUSING OL RE1'URN-TAPPEO I NPT Al.1.0WABlE EXTERtW.. NOZZlE LOADS G
14 NDE BE"AR1NG HOUS1NC .IOORNN.. 8£AR1NG 01L 11UT-TAI'f'Sl 1/2 NPT SIJCllON (350) ll1SCHN<GE (300)
13 NDE BE"AR1NC HOUS1NC JOORNN.. TEIIP IN1J1C.IJOO TAI'f'Sl 1/2 NPT Fx. (±N) 6630 2070
12 NOE BEARING HOUStNG TENP.ELaENT-TAPPEO 1/2 NPT Fy. (±N) 6630 2670
11 NOE BEARING HOUSING JOURNN... eRG TEWP NPT 2 NOS-TAI'f'Sl G1/2 Fz. (±N) 6630 2&70
10 NDE BE"AR1NC HOUS1NG THRUSr BRG TENP NPT -4 NOS-TAI'f'Sl G1/2 .... (±Nrn) 9035 2400
•a HOE B£JRING HOUSING \1BRATION PROBE TAPPED 3/8-24 UNF'

NDE 8E"AR1NG HOUSING BA£ATHER-TAI'f'Sl G1/4
Ny. (±Nm)
liz. (±Nm)
9035
11012
2400
4280
1. All. I.£\IEl.S ME. WITH RESPECr TO POWER
HOUSE GROUND FLOOR l.E'Ya 1>S ±0.0011
7 SEN.. C1RCUIA110N INI.£1' TAI'f'Sl 1/2 NPT WEIGHT OF P\J.., •
2050 Kge 2. GRl..1.AGE ts HOT SHOWN BE1.0W BASE PLATE
6 SEN.. C1RCUIA110N OUTl..Er-Tif>PED 1/2 NPT waGHT or &se: PlATE - 2260 Kge IN ltiS DRAWING.
5
4
SEN.. COOJNC JAC1<E1" l1<lEr-TAI'f'Sl 1/2 NPT
COOJNG J.IC1<Er AIR 1/ENT-TAI'f'Sl 1/2 NPT & PLUGGED
CUSTOMER JINDAL POWER LIMITED
3
2
SEAL aRCULATION INLET-TAPPED 1/2 NPT & Pl.1.JGCED
SEN.. C1RCOLA110N OUTl.£1' TAI'f'Sl 1/2 NPT & PLUGGED
FSU=L:::..:TM"lTf-::-=.D~E~VE=LO~P=-'ME~NT==~C==O~NC!:S~U=L~TAN~T~S~P~VT~.t~TD~~H
1 SEN.. C00JNG JAC1<E1" OUTt.Er-TAI'f'Sl 1/2 NPT
PROJECT: OP JINDAL STPP PH-III 4X600 MW UNITS
REF. No. TAPPlNG POINT
TAMNAR, RAIGARH CHATI'ISGARH
liEIGHT (KG REF. TO ASS'f ORG. ITEII NO.a:'

NO. ITEIIS
NA _ NA NA NA
Zot£ Zot£ 11TLE DRA'MNG NO. REV.
5. TO OUTLINE ARRANGEMENT OF HY-DG-1-18900-56872 01
6. No. OF TIJ!m~ !>B!\'EN. BOQ._!;!'I'EILP_l:1¥1' Sl·fEET NO. 1 NO- OF SHEETS .: 1
3 4 5 6 7 8 10 11
FIRST ANGLE PROJECTION
T <ALL DIMENSIONS ARE IN MM)
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8 Ag
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610
fr:
:10 I 10 7
1. LENGTH OF ITEM NO. 4 MAY BE MACHINED IF NECESSARY.
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.. ___-L.__ ==-',:.,::,-:-,:..=-:,=:=---::::-::-:--::..=-.-,.-:=-:-:.,..,{
; z
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::::;:
8 r-------------------~--------------------~--------------------~
w
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1-
0
w lJ..
I- 0
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w
(f) 0:::
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I-
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w
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1-
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> ..J
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<
0:: 0::
1-
< w
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l~ ~ EST. PERF CURVE BP SET NPSHR
'o::
>-
c... .....)
w 1-
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()
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(3%, 1%, 0% & 40,000 HRS)
lQ i5
I- ~
zw 0:::
::::;: 0
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()
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w
(f) 0:::
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=>
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CUSTDMER:JINDAL POWER LIMITED
Io .-- JOB NO. 329 CONSULTANT DEVELOPMENT CONSULTANTS PVT.LTD.
~~- , OP JINDAL SUPER THERMAL POWER PLANT
I STATUS: CONTRACT PROJECT. 4X600 MW UNITS,TAMNAR,RAIGARH CHATTISGARE
NAME SIGN DATE
It=! BHARAT HEAVY ELECTRICALS LTD. NO. OF
I~ HYDERABAD DRN. ~- 01.02.10
RAJ. C VAR.
1:I! 0 ~~r-------,_~~r---~
CKD. M.M.RAO
APPD.
~ 01.02.10
B.R.KUMAR i'J.L£ 01.02.10
NA
-
- - - -1-Dl-1---IDEPT-.-Pl:JMP-S-ENGG-:- ~--SCALE- WE:IG~::r~K.G.} -REF-./QRG,NG;{IN+mNAI=-) -I+EM- -NG,GF-
1 ~ ~ NO. ITEMS
.m CODE 410 NTS · NA FP11878 NA NA
I~ o
TITLE DRAWING NO. REV.
~~~ EST. PERF CURVE BP SET NPSHR
\
•I-
llz"<t HY-DG-4-FP11878 00
, _-/r I ~ e:- -- _______ (_3%, J%, 0% & 40,0_00 HRS) _
SFJT.NO: -ol - +roT~SHTs:- 02- -
ESTIMATED PERFORMANCE DRAWING NO: HY-DG-4-FP 11878 REV
CURVES OF BP- NPSHR (INTERNAL REF.NO. FP11878) 00
PROJECT: PUMP TYPE:
JINDAL POWER LTD
FA1875
OP JINDAL, (4X600 MW)
SHEET 2 OF2
ALL CURVES AT BP SPEED 1495 RPM
16
15
14
13
12
11
10
....-.
0
9
E
..........
0::: 8
:c
Cl)
a..
z 7
0 100 200 300 400 500 600 700 800 900 1000 11 00 1200 1300 1400 1500
- FLOW (Cu.m I Hr)
PREPARED BY: CHECKED BY: APPROVED BY: DATE:

BHEL PUMPS ENGINEERING
HYDERABAD RAJ. C M.M.R. B.RAJ KUMAR 01.02.10
• SECTION-S
BOILER FEED PUMP
CHAPTER-S
LIST OF DRAWINGS
'~ 01. Sectional Assembly of MD&TDBFP

\
I
~-
02. Foundation Arrangement of MDBFP
03. G.A. Drg. of TDBFP set
04. G.A. Drg. of MDBFP set
05. . Outline Arrangement of MDBFP
06. Outline Arrangement of TDBFP
07. Key & Holding down bolts details for TDBFP
08. Key & Holding down bolts details for MDBFP
09. Alignment Diagram of MDBFP set
10. PID of Feed Water of MDBFP set
11. PID of Sealing & Cooling water of MDBFP set
12. PID of Lube oil & Working oil system of MDBFP set
13. PID of Lube oil system of TDBFP set
-- ----- -----
14.·· · PID ofFeedWater·ofTDBFP set
- -- - ---- -- -- - --- - -- -----
15. PID of Sealing & Cooling water of TDBFP set

16. Instrument Schedule of MDBFP set
17. Instrument Schedule of TDBFP set
18. Recommended list of Annunciation & Trips for MDBFP
19. Sequential Interlocking conditions of MDBFP
20. BFP & CEP utility requirements
Z1. tuoe oil requirementof-spp-&-cEP
---~
I
22. Cartridge withdrawal arrangement

23. Method of checking coupling alignment
24. Thrust collar withdrawal plate
25. Withdrawal plates of mech seal sleeves
26. Balance drum withdrawal plate
27. Tube spanner, balance drum
28. Tube spanner, shaft
/~"
iI 29. Tube spanner, coupling nut

' ~----
INFORMATIVE DRAWINGS
30. Estimated Performance Curves of MDBFP

31. Estimated Performance Curves of TDBFP
32. Estimated performance curve of Kicker stage impeller
33. Design characteristic curves of MDBFP set at various speeds
34. Design characteristic curves of TDBFP set at various speeds
35. Design characteristic curves of BFP Kicker stage at various speeds
36. Estimated Performance Curves of BFP-NPSHR
/ '\ 37. Special Tools & Tackles for BFP set
"-- )
38. Schedule of Motors for BFP & CEP
- - - - - - - -- - ---- -- - ------- - ------- - ----- ----- - --------- - - -------- -- - ·- - ------
39. Schedule of solenoid valves of BFP&CEP

40. Schedule of Actuators for BFP&CEP
41. Technical data sheet of BFP set
42. Recommended analog input of MDBFP to DDCMIS
= # =
--------------···

- 2. 3 4 5 6 7 8 9 10 11
£L99 £00 09~ ~·oN -~~a
SUCTION BRANCH DISCHARGE BRANCH

A A
___,
{ 60 OIFnJSER IIO.RINC RING BS-25-143
..
FV52G-B
\ 59 lt.IPW.ER I'£ARING RING (NEO<) BS-25 143 (F'V520-B)
58 lt.IPEU£R \lORING RING {EYE) 85-25-143 (F\'520-B)
57 CASING Wi:ARING RING 85-25-143 (fV520-B)
55 BACX UP RING FOR POS.NO -17 as 1B06-UIB9

54 '0' RING, 0.139.1<5.359" as 1806-1989
53 '0' RING, 0.139"~4.359" as 1806-1989
52 OIL llflOII'ER- HOE LEAD TIN BRONZE SAND
8
C...STlNGS {CUSS 1'/J
51 BAQ(UP ~NG, '0' RING PClY TEJRA FLURO ETH'ItfNE (PTFE)
SO J.IEat. SEAL - NDE ROTAllt(G PARlS : SIUCCiti CARBIDE
STAllCNARY PARTS : CARBOO
49 KEY FOR OUWY Sl£E\£ (IQO<ER) S.S BARS Gr X 20 Cr 1J
-48 SPRINGOISC BS 2514.3
IN SOlUTION lREAlED CONDITI(XII
as 1806-1989
4S WASHER lHRUST COLLAR NUT AST\1 A2-40, T)Pa 321
<IS WASHER BAL. ORUt.l NUT
+4 KEY, COUPUNO S.S BAAS Or X 20 Cr 13
<13 lHRUST BEARING 'MtTE I.IETAL UNED BRG. 15:25 Gr.B+ 1
CR BS:l3J2
42 lHRUST COI.l.AR. ASSY. (C.S BARS Cr; <IOCB)
41 SUC. CUIOC BS-150+-42S-C11 c
<10 SPUT RING S.S BARS Gr X 22 Cr NoVI21
39 SH,ij='f BS: 97G-<120-529R
STaUfE25
LEAD Tlti BROOZ£ SAiiO
37 OIL'ItfiOB(DE)
CASlltiGS a.ASS 1'/.1
36 OIL GAURO (OE .!1: NOE) 15:1<158-65, Gr:Q.IV
35 0Un.£T 000£ ASSY. BS-1504-<125-CH
34 NUT OIS.COVER B<X.T CARBON SlEEl BARS Cr. 15C8 18
33 NUT COOPUNG AJ... BRONZE fORGNGS/EXTRUSICXiS
Gr.CuA11ail 5 Fe4
AL BRONZE FOO.GINGS;IXTRUSICXiS
32 NUT lHRUST COI.l..AA Gr.CuAIIai! 5 Fe<!
31 NUT BAL. DRUM
30 WETAFLEX GA!iKET (CASING/INT. STC. 1U!£) F1lL£R NATl:SUPAGRAPH

SPIRAL 'MtiOING : BS: 97G-316-S16
29 METAFlEX G,I.SKET (CASIHG/SUC. GUIDE)
D
SUPAGftAPH
28 METAR.EX GASKET (DIS. C0\9/00TlET CUDE SUPAGftAPH
27 METAFLEX GASKET (DIS. C0\9/GL.AHD HSG) SI.JPAGftAPH
26 METAFLEX G,I.SKET (CASING DiS. CO\£R) SUPACRAPH
25 t.IEOiAHICAL SEAL (OE) ROTA liNG PARTS: SIUCON CMBIOE
STA.llaiARY PARTS : CAABON
24 KEY THRUST CXXJ.AR S.S BARS Cr X 20 Cr 13
2J KEY t.IEotSEAI... 5l..fEYE 5.5 BARS Cr X 20 Cr 1J
22 KEY BA.L OftOt,l S.S BARS Gr X 20 Cr 1J
21 KEY IWPEU.ER (1st to 4th) S.S BARS Gr X 20 Cr 1J
20 KEY. COOPUNG S.S BARS GC' X 20 Cr 13
19 JOORHAL BEARI>IG (NDE) 'MtTE t.IETAL UNED BRG. 15:25 Gr.8+
18 JOORHAL BEARING (DE) 1\KTE METAL UtED BRG, 15:25 Gr.B4
17 1Nl£T GUIOE "SSf. BS-150+-425-Cil
16 OUI.It.IY SLEE\E FOR (KICKER t.IPWER) S.S BARS Cr X 20 Cr 13 E
15 lt.IPEUER ASSY,-4th STG. BS-IS0+-425-C11
1<1- II.IPEUER ASSY.-3nl STG. BS-150+-<125-CII
IJ NPEU£R ASSY.-2nd STQ.-ASSY. BS-1504-<125-CI1
12 11.1?£U.ER ASSY.-bt STC.-ASSY. BS-I!S0+-425-CI1
II Gl.NID HCOSING BS-150+-425-CII
to GASKET us;ru t.IS/ctJ
09 FLOA~G SEAL BS 1400-I.B2
OB END (XffUS(R ASSf. as 150+-425-CII
07 DIS. CO\ffi BS:97Q-150 M19
06 DIFFUSER A5S'f. BS-150+-425-CI1
OS 6£ARING HSG-DE ASS( (MY TCf'&SOTTOt.l) 851504-161-430
04 BEARING HSG-NOC ASSY (ONLY TOPdd!OlTOt.l) BS\504-161-<130
OJ BOlT DIS. CO~ CARBON STEEL BAAS Cr. 15C8 18
RECOMMENDED TORQUE 02 BALANCE OftUM BS-25-1+3 (FVS20-B)
F F
Tt I ..,.
ITEM TORQUE (NM) 01 BALANCE BUSH DRUM as-2S-t43 (FVS2o-B)
QTY.
T2 175
T6
( ) '""'
REF DIAMETRICAL CLEARANCE NOM. DIA. FLOAT NOTE :-

CRUCIAL CHARACTERISTICS. A o:s3 1 o.46 159 TOTAL AXIAL FLOAT_= 8 J. DURING CENTERING THE OIFJ'ERENCE IN
8 o.28 1 0.22 130 MIN. AXIAL FLOAT = 7
RADIAL CLEARANCE BETWEEN TOP AND
1. ENSURE THRUST COLLAR/SHAFT E o.58 1 o.so 257
F o.sa 1 o.so 172 BOTTOM SHALL NOT EXCEED 0.09 MM.
INTERFENCE 0.04-0.09 MM.
G o.ss 1 o...a 220
2. ENSURE THRUST COLLAR NUT(T6) H o.48 I o.4t 225 I"FOR INFORMATION" I
G
TORQUE TO 2850 NM K o.21 1 o.1s 110
IL IL TO THRUST BRG
3. ENSURE PERFECT MATCHING REF AXIAL CLEARANCE
BETWEEN PUMP CASING/ X 4.5 OIS.SIOE
FIRST STG.RING SECTION/CU.GASKET. XI 3.5 sue. SIDE
y J.os I 2.48 NOTE ·
z 0.50
x1 = Total float
_ O.S
2
X =Total float- X1
CUSTOMER· JINDAL POWER LIMITED
NO.OF
~AL=lE=RE:;:O~--~=----i REV. OAlE ALTERED REV. DATE f'A'=LTER=E=O:___-.,.=----\REV. DATE
( 1-'AL=lE=RE=0----.,--------1 REV. DATE f'AL=TER:.:E:::O'---.,-:--------IREV. DATE f'AL'=TER':':-'ro=----.=c:----\REV. OA lE ALTERED RAJ. CH ITEMS

CHECKED APPO. CHECKED ,6PPO, CHECKED APPD. ~C~H~E~~ro~--~~~P~D.--~ CHECKED APPO. CHECKED APPO. 01 09-03-10 CHECKED MMR APPO. BRK NA NA
ZONE ZONE ZONE ZONE ZONE ZOOE REVISED BASED ON JINDAL CQ!..IMENTS DRAWING NO. REV.
LETTER ABI2400"WIBTGI360. HY-DG-118000-56873 01
-DATED :06-03-10- --
SHEET NO. 01 NO OF SHEETS 01
3 4 5 6 7 8 11
FIRST ANGLE PROJECTION (All. OIMENSIOOS ARE IN mm)
t.l.B9SOO 091 t 11 12 13 14 15 16
__
;-
PAD
PAD
_I-FOR INFORMATION"I _I
REF DIAMETRICAL CLEARANCE NOM. DIA. CRUCIAL CHARACTERISTICS.

A 0.53 I 0.46 159
8 o.28 1 0.22 130 1. ENSURE lHRUST COLLAR/SHAFT INTERFERANCE 0.04-0.09MM
SUCTION BRANCH
E o.ea 1 o.ao 257 2. ENSURE lHRUST COLLAR NUT(T6) TORQUE TO 2650 NM
F 0.68 1 o.6o 172 3. ENSURE PERFECT MATCHING BETWEEN PUMP CASING / FIRST STAGE RING SUCTION/
P!SCHAEGE BRANCH H o.66 1 o.58 225 CU.GASKET.
K o.21 1 o.16 110
I. ll. TO 1HRUST BRG
~- VIEW-OIL CONN(DE) VIEW-OIL CONN(NDE)

REF AXIAL CLEARANCE
X
XI
4.5
3.5
SUCTION SIDE
DISCHARGE SIDE
II FLOAT ~
TOTAL AXIAL FLOAT = B
MIN. AXIAL FLOAT • 7
y 3.06 2.48
z 0.50
(
[ 12 1J 14 15 16
2 3 4 5 6 7 8 9 10 11
9999 900 09! -!- -
"ON -~~0
&
10308
A A
@NORTH
-
FOUNDATION LOADING
~
E-<z
....
<~ STATIC DYNAMIC LOADING
oo EQUIPMENT WEIGHT (Kgs) LOADING ON ROTOR WEIGHT ON EACH POINT
~~~
>-<...:o
EACH POINT
(Kgs.)
(Kgs) (Kgs)
B~LER FEED
B 1 1917 551 500 B
PUMP incl. 11500
BASE PLATE
INPUT ROTOO 1970
.,"' 2
2a
HYDRAUUC
COUPUNG
9300 (VilTHOUT OIL)
11800 (Vi1TH OIL)
3933 PRIMARY ROTOR •505
SECONDARY ROTOR =460
Pt 2
Pt 2a
1030
920
"' OUTPUT ROTOR -305
5 MOTOR 27000 3375 9000 REFER NOTE-A
6 BOOSTER PUMP 4600 1150 280 394

ci Incl. BASE PLATE
w
>--
:;; ,. 1,2,2a, COMMON
FOUNOATlON
12200 510 --- ---
::J :;; 5 & 6
FRAME
UJ
'l!0
-' ()
<{
u ~c NOTE-A c
0::
>-- :s
u
w 5 LONGITUDINAL SECTION ELEVATION 200 200
-'
w LOADING ON FOUNDATION
>-
>
~ REACTION DUE TO Wt. ON EACH SIDE (G) 135 KN
w ~
<{
MAX. SHORT CIRCUIT FORCE (MS) 517.0 KN
:c g REACTION DOWNWARD MS + G 652 KN
>--
<{
0::
<{
~z
!;!
®-- REACTION UPWARD MS - G 382 KN
.---"~ 1x0200 CONDUIT (LUBE OIL COOLER PIPES) 24 POCKETS OF 250 SQ.
OPNG 400><200 D 750 DEPTH 2
>-
G 0 OF
,J. ~0 D
1 z
< 1. BOILER FEED PUMP 14.4 KG-tJ
~ ,.
~
2. BOOSTER PUMP 8.4 KG-M
2
!f
o!
~ • BOOSTIER SUCTION
I 3. HYDRAULIC COUPLING
I 1§. • ~,-dr,-dr
2
i!J-; 1--rfh
!<! INPUT SHAFT 1508 KG-M
PLATES 4405Qx40 THICK I 8HEL. SCOPE
~ i5 EMBEDED IN B.SM FLOOR TOP ·oF PLATE 17M) OUTPUT SHAFT 41.2 KG-M
2
a i - LOAD ON EACH FOUNDATION PLATE 2100 K.G
g
i
<J>
~ i5 i g~MPOF BOOSTIER I
I'
'
0EL 8.105M FOR FIXING CARTRIDGE WITHDRAWAL GEAR 4. MOTOR 2040 KG-M
2
5 !!l
0
'
' I
z
0
'
ill E E
F
<
::!
~ I BOOSTIER DISCH.
i :;; ~
C.G. OF MOTOR
::> NOTE-B
~ "'
!:: i 0 EL 8.105M
•••
1. FOR GENERAL ARRANGEMENT OF MDBFP SET, REFER DRG.NO. HY-OG-1-18000-56868.
DIS.BRANCH
2. ALL ELEVATIONS ARE w.r.t. TO TG HALL FINISHED FLOOR LEVEL WHICH IS EL 255.25MM.&
,-dr
F
0
"'"'....
"'
1x0200 CONDUI
* 1 00
~
3. ALL GROUllNGS ARE IN THE SCOPE OF BHEL-PSWR. &
4. REF. ALL COLUMNS, ROWS & ELEVATIONS BHEL/PEM Drg.No. PE-DG-329-100-M004.
F
::!
C'i
0 0 0 0 0
0
0 0 0 SECTION I-I
"';;; l2 0()
l2 0
9 0 0
"' ~ 0()
"'"' ~
13400
~----------------~-------------------------~-------------------------~----------~--------~--~-------------------~----------~
4525
FOUNDATION PLAN
G G
TYPICAL FOUNDATION BOLT ARRANGEMENT FOR
COMMON FOUNDATION FRAME
SOLE PLATE
OPC CONCRETIE
MIXTURE GROUTING
- BLIND POCKET
QUICK SETllNG
CEMENT
- OPENING CUSTOMER: JINDAL POWER LIMITED
FCO::_:NS::::UL:.:.:TAN.:.:.Ti-~D=:E=VE::CLC::O~P':-'M!!:E~N~T~C~O:!.!N.:!!S~U~L~T'-"A~N~T'-'=S~P2
V.!cT~.L"-"T~Dc__-IH
e.G. - CENTRE OF GRAVITY
"I:!MtlAE,_EAmAE!LC_HATIIS_GAE
NAME SIGN. DATE NO.Cf'
ORN. RAJ. C 05.09.09 VAR.
BHARAT HEAVY ELECTRICALS LTD. CHO. M.M.RAO 05.09.09 NA
• HYDERABAD APPO. B.RAJKUMAR 05.09.09
WC:IGHT(KG) REF. TO ASSY. ORG. ITEM NO,OF
REV. DATE REV. DATE REV. DATE REV. DATE REV. DATE ALTERED REV. DATE NO. ITEMS
REV. DATE ALTERED ALTERED ALTERED ALTERED ALTERED ALTERED
CHECKED APPO. D-lECKED APPO. CHECKED APPD. CHECKED APPO. CHECKED APPD. CHECKED APPO. 01 02.02.1 CHKO/ APPD NA NA NA NA
5. TO
ZO«E ZONE ZOOE ZO«E ZONE ZONE NOTE. CORRECTED AS PER M/S JINDAL
LETIER OT 19.1209 TITLE FOUNDATION ARRANGEMENT DRAWING NO. REV.
[;; 6. NO.OF 568 6
0- CL_OISTANCE_CHANGEO __ B~N __
SP&MOTOR CL TO BFP DISCHARGE -oF-MOTOR-DRrvEN- BFP-UNIT-- _HY:::D_G-=l::JILO.Q.0-=. _ ___6_ Jll
~
~ 3 4 5 6 7 8 9 10
SHEET NO. 01
11
NO OF SHEETS. 01
IAU.DII1EHSIOOISARE11ool
.1.999 goo ost t .,..,.,
- A A I
_, \ 855.5 1387.35 2315 : 1628
~ ! - ---- T
887 ii' 495.3~ 450.90 ::'. 740
~~~~~~~4~53L_~-~--~79~5--~~5~90--~----~139~5----~
TURBINE
~<
~~·
I
~ (1\ ! ~ !i
..-
8
~!
u . . "'
ig
-
~~
g;;:3 r1 "'
~
~.
~I~
!al
il BOILER FEEJl PUMP 800 800
+ 1 A BOOSTER PUMP j ~ GEAR ~~ ~
(JTh -~~,~~~ j :~_:_ -~_i_ ___ j __,__: <~·~····"

hl1r llr_ J £~ • ''~
PE
.,. . - -,P_ _:_ UMP~-,....-1---,~~~ _ -r- t:: _

!;; I fJI
=> __
?1 I
j __ __ _ _
l...llllJI1111 Jl
1-r-t-------l
~' ~~\"1-/}.!_7- ~I::J---+---!0
~L--1-- ~·= ~·---j_ 'I j ~ : : ~L ~ =- i I fi-h- ~I \~~ ~
:1,;1 1-1
AlA ~ r ~ ttl~~~~~~
I '" JIL B.C.LEAKOFF '
~
~ :.__. 1 ~ ~ sL, ~~.-. ~~~~~~~,_~,__,~~~~~~ ·

f CONNECTION2"SCH40 - ...,_
HY
~~-'---- 1 \)tJ i 1-D

L~~J·~~ ~pj;~ i ~~ ~ ~-!! U~l ~ i ~
HYI
TP-1'8 I f
1
PE PE
! 9 -- I I
1'-r- ._r- I' M:=!=s=Ejs=====c::j:s==c=p=c=t=ll~~j_____l..],effo.!i!rriiboM~og_F 1080
~ ~ ~ ~~~ ~ I~ 285~ ~ ~VIEW

1 1 1 ,
1----"96"'-5--ti--96.,.,5...__--l _l L! 2922 LC-J 1-_ =BF5PGRILLAGE 'A-A' (BP)
VIEW 'B-E' (TDBFP) BDTTDMOF
BP GRILLAGE
.______.,~,r-----------''"-..'lr------------''"~~-----------'"~~------< .1~
I' ~
"' "' ~
VIEW 'X-X' I~
i: ELEVATION ~NORTH J J
ll ®---~~---------t- r---f------------ --®
HYI I !
TP-fn 1----'---------1-------' EL +14.40M
\ - -- _...iQf_TDBFP~-- --ri__ IIu__~r----Lr-1
II !
__ £.QE..l]BFP-B_ _ _ I---I--
PE
1
1
!
I
'---------------1'"'r----' i
I
~ i..__'"'+---------------'
I
0---t-----------r--_I-:_- ~~- --------------0
1000 I 21000 _11000 A
(TYPI ~
.------------~'"-•~-----------~~~~-------------~~-~----------~~~r--------~--~~~-------------~~"-r-----~ KEY PLAN OF TD BFP SETS

'l ~ ~ ~ 'l (REF. PEM.DWG.NO. PE-DG-329-100-M005 REV-00)
TERMINAL POINTS
TERitNAI.
FOR DETAILS, REFER DRIVE TURBINE CROSS SEC. DRAWING SPACE FOR C,!~ REMOVAl
POll[ DESCRIPTION OTY. ~··-··-··-··--··-··-··-··,
NOmE, sun WEl.O END,TO
TP-f7 sur m ; 406.4 x9531111
HOmE, BUTT WELD OO,TO , - - - - - - - - - - - - - . , : DRY HEHBRANE COUPLING
TP..fl lliSCHARGEOFFm!PUHP surPI'£ ;368 x,_
TP-f16 STEAM IUT TO 1UI8IHE COUIIT£R FLANGE 14",
14" 6tO WN!J1;lSS.6x19.05 1-SCH 10
I
COUIIT£R FLAHGE, 14" ANSI,
TP.f3 8165 WffiF Q300
DISOI.IAG:OFBOOSf!RPUII'
COUIIT£R FLANGE, tT ANSI,
TP-1'4 8165.~,0300
TP-1'11 W.1627xtt
TP-1'12 INTER STAGE TAPPII6
SCOPE OF
I HY BHEL, HYDERABAD SCOPE
\
I
\
SUPPLY
PE BHEL, PEM SCOPE ~ACE TO BE Q.EAR Of AMY OBSTRUCTIOK
IHO Pll'ltG SHAlL BE ROUTED II TliS AREAl
- WltiCII \Ill. R£STRICT ACCESS TO CIIAHE HOOK.
2. Arnfti'OAHIIGIOCK£RSTAGEI£AIIER,ITSH.IU.
'7 HYj ~ ~T&¥~~~~~VENT
A •• 17' CAIIIRIJGER£HOYA!..
~-~WitUI.JJ/2"
t. 700 PLAN
OMCW OUTLET. 11ii)./"
1. FOR LOADING POINTS & LOADING DETAILS, REFER EL +17.05H I IEL +17.05M
TOBFP SET FOUND. ORG. A OHCW 1Nl.EL2Jl:
2. TERMINAL POINTS SHOWN IN THE HYD. SCOPE INCLUDES
CUURIOI<' I ~·
i /EL +17.05M
TT!I.TT\ AT T
3. FOR EQUIPMENT LOCA TIDNS, REFER BHELIPEH DRG. NO,,

PE-DG-329-100-M005
1-
I
I
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855.5 887 l:l!iiDBSEl 4700

A
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A ELEVATION I 5975 :4§25

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TERMINAL POINTS
lERNINAL
POINT DESCRIPllON TERIIINATED Willi QTY.
NOZZLE, BUTT WElD END,TO
TP-F7 SUCTION OF FEED PUMP 1
SUIT PIPE ' 408.4X 9.53NM
NOZZLE, BUTT WElD END,TO
TP-F!I OISCHII!GE OF FEED PUMP 1
SUIT PIPE .368 X -48 NN
COUNTER FLANGE. 14" ANSI, 1
TP-FJ SUCllON <F BOOSTER PUll' B16.5 WNRF CL300
TP-F4 COUNTER FLANGE. 12" ANSI, 1
DISCIWlGE <F BOOSTER PUll'
~ MO~R ~
B16.5, WNRF, CL300
COUNTER FLANGE. 2.5" ANSI.
--- BP & ----1 TP-F12 INTER STAGE TAPPING B 16.5, WNRF, CL1500
1
- ______£ 0 H
.l:IQIE :
'-------' 1. TERMINAL POINTS SHOWN IN THE HYD. SCOPE
INCLUDES COUNTER FlANGES ALONG WITH
FASTENERS & GASKETS.
SCOPE OF 2. FOR LOADING POINTS & LOADS, REFER
SUPPLY MDBFP FOUND. DRG.NO.: HY-DG-1-18000-56866.
( j
---~ ~~---------

2 3 4 5 6 7 8 9 10 11
2899 900 oar ! 'ON ·s~al
38 8
,__
A A
-- 25-- ~--
26
4x 15 15
4400 A A 7500
0--------~-----_:____ I ~------' --------?---

8 8
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1 I
OIL COOLER
LUBE - - - - - - +--- DUP~ WO~;;--
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--- --- -- -~
I
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1400 _ _ _ _-l,\\
1-----....:....:.:..:.._
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~ I 1540 27 41 I 2000 A 5250

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IN FT
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STACK WI1HDRAWAL
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t...::::::....j
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4135
1540
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B 16.5 CL300
4250 FOR TUBE

F
~ I I 4nnu ~ DETAIL-A DETAIL-B
ELEVATION
NOTE: ALL ELEVATONS ARE w.r.t. TG HALL FINISHED FLOOR LEVEL WHICH IS EL. O.OOM.
REF BHEL/PEM DRG NO.PE-DG-329-100-M003 G
G
FOUNDATION LOADING DETAILS
REFERENCE DRAWINGS:- ~~ EQUIPMENT

WEIGHT STATIC LOADING
(kg) ON EACH POINT(kg)
1. MDBFP GENERAL ARRANGEMENT, DRG.NO.: HY-DG-1-18000-56868.
1 LUB OIL COOLER 1600 200
2. WORKING OIL COOLER FOR MDBFP, VOITH DRG. NO. 3067401012040-001
WORKING OIL CUSTOMER: .TTN 0 AT P U VV ~.:J-(. LIMI'T'ED
3 LUBE OIL COOLER FOR MDBFP, : VOITH DRG .. NO. 30674010 13340-001 2 COOLER 5450 682 H
4. T.G. EQUIPMENT PLAN AT O.OM : PE-DG-329-100-M003
-------------------------- -

2 3 4 5 6 7 8 9 10 11
0.!.99 900 08l l
·oN ·o~o
R.JJIGEFORIOCKER STAGE
APPNi N56S AATHi ANS12500 EDGE
A REF,NOTtOS
A
-2830
795 525
"""""-BOX
8 8
l ~~'------~93~o__ss_o__ ss_o~9~3o~----~
3500 FOR CARTRI)G£ WITIIIRAWAL
SPACE TO BE nEAR OF Niff
200 20
-4____
300 730 300
- 1950
D
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FOR EDGE PRfPARAnoH REF. NOTE OS
.... IWBED fiPAC£ RIA IMIIITII& 'MAAllCIII P.MI 80 X H M HAOtHED FACE
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PRESSURE STAGE PUMP - 11,000 kg 280 1210
BASE PLATE - 2,020 kg f.tliL£5 f4Z SPOTFACED f75

fOR HOUIIHG 00\llt 801.TSI
•
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IKTERSTACETAPPI«i(~TERI
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02. COUNTER FLANGES ARE INCORPORATED IN THE END VIEWS ONLY.
03. ALL ELEVATIONS ARE w.r.t. TG HALL FINISHED FLOOR WHICH IS EL 255.25mm . .A
04. VIBRATION PADTO BE WELDED ON BEARING HOUSING DE SIDE BY 3mm FILLET WELD.
(PAD & BEARING HOUSING MATERIAL= CARBON STEEL)
OS. EDGE PREPARATION FOR BFP SUCTION, DISCHARGE, KICKER STAGE & INTER STAGE AS PER
BHELIPIPING CENTRE DRG. NO.: 3-80-300-19825 & 4-80-300-55240.
H
OP JINDAL SUPER THERMAL POWER PLANT
-
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____4]{600_MW_UNITS,TAMNAR,RAIGARILCHA'IT1SGARH__ _ - 1 - - - - - + -
DATE HO.OF
1. J08 NO. : 329 YJII.
~ 1101.09
2. STATUS : CONTRACT
11.- 13.07.09 NA
3. DRG./REF. NO. (INTERNAL) 1:4 13.01.09
REV. DATE REV. DATE REV. DATE REV. DATE REV. DATE REV. DAlE AI..TER£0
1 180 005 6870 ITEI1
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r---
1.2TO 1.0 AT45". APPD. B.RAJKUMAF h i v'02.06.01 N.A
g_r;__RE_V. DATE ALTERED \\_..; -~--,------,r-""':::....._-i-3-._~N_i~R~~L'---~·--M_f_C_D-----'---C-O_R_N_ER_R_A_D_I_I__,_1-_:-.:-.:-·----~:~--:-P_S_----i~ _:~~:- WEIG::.-(K_G_),_R-EF_._To_A:1 ~;_o_R_G·_ _,__~~:- ~~~~~ -
REV. bD;-;:A;-;:TE..-t-AL_TE_R_E_D
~ 02 16.6.0.- CHECKED~PPD. ik 01 16.8.01 CHECKED £1~.0.
~ I 4. THE SURFACE ROUGHNESS Vv1-lEREvtR NOT SHOWN I
o ~ BETWEEN BP & MOTOR SETTING NOTE-4, TOLERANCE ON DBCF SHALL BE TAKEN FROM THE SURFACE ROUGHNESS TITLE ALIGNMENT DIAGRAM OF DRAWING NO. REV.
~ ..-
~ ~
.....
VALUE FOR RADIAL ALIGNMENT
CORRECTED TO 0.30 FROM 0.66
ADDED.
_ ..... _... ___

SHOWN OUT SIDE BACK SLASHES GIVEN AT THE
TOP_Mosr_~IGHTCORNEROF 7 QRG~----- _ __ b.{D _J3~P SET _____ .. ___

3 180 005 4907
51
SHEET_"":.;~,: ;.v~o;"E£fS ~~-Ai
51
02
_ _. ____
I
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i
2 3 4 5 6 7 8 9 10
I 9L89 goo og~ ~
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30
'ON
,£[, $!
~PlOP;!PC
AA101 ~ BFP DISCHARGE ~ ~
)-- '
0
r;: ~ r--,--- 1 -------~--r· PE-oo-~101H« 7
't I I I I I I I A
. <J.oPEpg;g~Rosl-------~ ~-------£: - - ---i. i " i - --- -
I ¢219.1X30 ~· fll!
~II ~II
8 8
'----:~~~,---- ~.£ ~ i* --- [*l ® ~~TE~/!l~ ~.

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,.-.J' HY · ·
LEGEND:
~
HY BHEL HYDERABAD SCOPE OF SUPPLY
c
I L
~ I 1\ r-; < l ;;!; I ~ o AL PC BHEL PIPING CENTRE SCOPE OF SUPPLY
~- PC ITP-F3~ r-----1 I X I (ENGINEERING BY BHEL-PEM)
H~ ~-"'-i' ~A

~*~~---~::::::::::\__j_
1/2"CL•800 CASING VENT
__ l,"'"14 (UMESTDAAIIPII) r-------L====L------l
I I ,---------------------------, QW I
i
Aiiol:il
.. ~ ~- R.C. VALVE
r-~L(Jro"""""' -t~--1--o---,r--I--i ~-lur---*J ~~1,TP-F7 ~ :~~Fe ~ -Or- SUCTION STRAINER [BASKET TYPE]
---r- -~
L--1--..J....
t- ll
LAC30A-P002 I
,..1-----' -
JW=-::m[
- L__
I
~ I
...JI
B.F.P. MOTOR
LAC30 AE001 - I 1-J I -
IL __ ...JI ----
I L-;
I I
- ---
HYDRAUUC
COUPUNG
I \
r_ili
I
I I I
\ I I_________ L,-L--,
y I I I B- SUCTION STRAINER [CONICAL TYPE] D
0 LOCAL GAUGE BOARD MOUNlEO INSTRUMENTS
l-~--r-,----j !L_______ r ! !
1
x-:::=}_ 0
L?
_ - -::r---, '"'
LAC30 AU001 .------ ; J tl
. ~~ ___ r ______ j 1 __t_{J]L_-=11JJ:L_/_ MD B.F.P. LOCAL MOUNTED INSTRUMENTS
2
1/ CL , r-:4J:>c .--. 1 -- - ~ llifl"7 LAC30AP001 I I
t CASING DRAIN t! ~ L __ ...J ! ! ---- L I .)------'
ORIFICE PLATE
I ,. __, : ~, ""' : : ~ io: -- FLOW NOZZLE
I
i
~
i
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'-----------------------------'
\ / IDD~~;
~~T-{
~ (10~~1'11)
y
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VENT VALVE NORMALLY CLOSED
GLOBE VALVE NORMALLY CLOSED

E
L-----------------------..J 'y' ~ ~ e>-<6>- INSTRUMENT ISOLA110N VALVE
<r
~6~
BALANCE DRUM
LEAK-OFF UNE
ROOT VALVE [1/2" SOCKET WELD ENDS]
NO 2 SCH 40 TO BE PROVIDED BY PIPING SUPPUER.
I><] - ROOT VALVE [1/2" SOCKET WELD ENDS]
F
l!..Lxlll-
~-----.,
L-----.J
5 VALVE MANIFOLD
F
--
PRESSURE TEMP-ANSI 2 VALVE MANIFOLD
(KG/CM 2 (g) (•c)
PDT DIFFEREN11AL PRESSURE TRANSMITTER
PDI - DIFFEREN11AL PRESSURE INDICATOR
PI PRESSURE INDICATOR
TERMINAL
PURPOSE TERMINATED WITH PT PRESSURE TRASMITTER
POINT
TP-F1 BOOSlER PUMP SUCTION STRAINER INLET COUNTER FLANGE,18",ANS1,CL150, WNRF
r---------------------------------------------,
l THIS DWG. IS DRAWN TO SHOW ONLY . 1 TI THERMOMETER
G G
TP-F2 BOOSlER PUMP sUPllON STRAINER OUlLET COUNTER FLANGE,18",ANSI,CL150,WNRF I BHEL HYD SCOPE OF INSTRUMENTS I DT DIFFEREN11AL TEMPERATURE
L------~--------------------------------------J TE RTD
TP-F3 BOOSlER PUMP SUCTION COUNlER FLANGE,14",ANSI,816.5,\'otlRF,CL3DO
FE FLOW ELEMENT
TP-F4 BOOSlER PUMP DISCHARGE COUNlER FLANGE, 12",ANSI,816.5,\'otlRF,CL3DO
TP-F5 BFP SUCTION STRAINER INLET NOZZLE, BUTT WELD, TO SUIT PIPE..roe.4x9.53mm 1) ALL DRAINS/VENTS SHALL BE ROUTED SUITABLY TO THE NEARESt DRAIN PIT.
TP-F6 BFP SUC110N STRAINER OUTLET NOZZLE. BUTT WELD, TO SUIT PIPE..roe.4x9.53mm 2) FOR INSTRUMENT SCHEDULE OF MDBFP SET, REFER DRG.NO.: HY-OG-4-FP11869.
3) ALL THE INSTRUMENTS (LGB MOUNT) EXCEPT PR.TRANSMITTERS SHOWN IN THIS SCHEME
TP-F7 BFP SUCTION NOZZLE, BUTT WELD, TO SUIT PIPE..roe.4X9.53mm
WILL BE MOUNTED IN ONE LOCAL GAUGE BOARD. PR. TRANSMITTERS WILL BE MOUN lED
TP-F8 BFP DISCHARGE NOZZLE, BUTT WELD, TO SUIT PIPEf368x48mm IN ANOTHER CABINET NECESSARY FITTINGS UKE MANIFOLDS, VALVES, DRAINS WILL BE
SUPPUED BY BHEL(HYD) ALONG WITH INSTRUMENTS. t'
TP-F9 BFP R.C.VAL\£ INLET & OUTLET NOZZLE. BUTT WELD END,TO SUIT PIPE SIZE TAMNAR, RAIGARH CHATTISGARH I
1
-F-!lj~w<. ---~===+.~~~~~~~~~~;:::=J=:!"~21~g·:!!·1X3~2m~m========ji------,<4')-REF-BHEL/PEM-PID=FEED-wATER-sYSTEM-PE=DG=329=100=N105i------------------~1.Ji)8'N0:-3:2§----~-n~~~~==~;;;;~~,;;;4~~§N~AM~r-E~~S1G~w.-~So~A~IE~~1l-t----+
"" TP F10 BFP R.C.VAL\£ AN11 FLASH ORIFICE FLANGE, WNRF, 8" ANSI CL300 1. JOB NO. 329 .I DRN. RAJ. C £oP- 16.04.09 -~~
- INLET & OUTLET 1---=2::.·__:S:.:T.:..:A~TU:.:S:....__·:..._·,--..,C=.O.:.:_:N.,:T.:..:R::,.A:.:C:...:T--J BHARAT HEAVY ELECTRICALS LTD. CHD. M.M.RAO \1..-. s.o4•09 NA
~ 3. DRG/REF. NO. (INTERNAL) HYOERABAD APPD. B.R.K i,:, 6.04.09
6
.
REV. DATE jf':,IJ.=:'TERED":"::::---r------1 REV. DAlE jf",IJ.::;;TER::,:::::ED--,--------jREV. OATEf!'
),AL::::TER:::;ED::::..___-r----1 REV. DATE -)ALTEREC REV DAlE jiJ.TERED REV. DATE IJ.TEREC REV. DATE ALTERED
1 180 0Q5 6875 DEPT. PUMPS ~8@7~1SCIJ.E 11\£1GHT (KG) REF. TO ASSf ORG. INTEMO, N1 ~<fs
'~
I !!!.- CHECKED APPD. CHECKED AI'Pil. CHECKED moo. CHECKED APPD. . r:=CH::;;ECK=EC--,.AP:::FO.::--; 02 12.04.10 CHECKED APPD. 01 4.02.10 CHECI<EC J.PPO. 4. OISTRIBU1lON CODE 410 I NTS NA NA NA NA
\ , ~ ZONE ZONE ZOI£ ZONE ZONE ZON£ DRG.REVISED As PER ZONE DRG.REVISED As PER
5
• TO
11 -1 TillLEpm oF FEED wATER DRAI'IlNG No. REV.
1 ~-- -------------- ------------- --- ------ ---- -------- - - --- - - -~~!o~~g~.~~~~~~ffi~~s-L~--~~{~~~~~~I~l~~l~L~ s.No.-OF-"!-111-l-1--1
1 1 1 1
____ UNESFORMDBFP ~:~: 1 ~~-ro~~:5 ~s:!~~ J
~ 1 3 4 5 6 7 8 9 10 11
'-------·----------·----·- ---·-·--·-·--- -----·--------·-·- - - - - - - - - - - - - - - - - - - - - - · - - - - - - - - - - · - - - - - - - - - - - - · - - ·-·-- -- - ·- ·- - --·--·---··- ------·--- --- -·---- ·-- ----- ---- -- - - - - -·--
FIRST ANGLE PROJECTION lALL DIMENSIONS ARE IN mm)
2 3 4 5 7 8 9 10 11
9.!..99 900 OBl l
·oN ·o~al
~,~--~
fr-
A A
- I Ill- m1T - - l
1
---++~rm-1~~1111-H-1-~ ~
MOTOR HYDRAUliC
- --f-tttlll,___ ll!l-1-- COUPLING
LACJO AE001 -UII 1111-
B
-r;::::-
0
LACJO NJ001
"'_UP. I B
IIIJtL~
0
£ s ~
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9
I
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10
. -- 1(1-J I
I ~ot___J ~ ~ -; ~26.7x3.91 S?(T)'I>J t,____
A~ I I
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C1l03
1 ~~r trr ~ §gr r

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ATOOO 0
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0
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THIS DWG. IS DRAWN TO SHOW ONLY - ~
I
F 8
:z
,._
"'
I
BHEL HYD SCOPE OF INSTRUMENTS d:
~
cb
PRESSURE TEMP- ANSI FLOW
2 3
~1 F
I 0
KG/CM (g) (oc) M /HR
gj J.
n SCOPE OF SUPPLY a..
- 50
I
(!)
0
:z
I
J.
a.. TERIIINAL POINT DETAIIB (COOLING _YATER) P_RESSURE DROPS ACROSS VARIOUS EQU!PIIEN'l'S ,._
"'
v '---
SERIAL I
~
EQUIPt.I£NT PfESSUR£ DROP IN NWO
NO.
BHEL BHEL
lHWJ lPEM/PCJ
0.5
cb
0
G 1-1/2'(40HB~ ANSI, tt150, SOflF 2 G
MOTOR OPERATED VALVE J.
a..
1P-C3 ON CW fiLET TO BFP 2-1/2'(65H61 ANSI, tt150, SOflF , 5
FLOW INDICATOR{VISUAL)
1P-C4 0t.1 CW OU11£T FR<* BFP 2-1jr(MiHB). NfSl, CU50, SOPF
GLOBE VALVE (NORMALLY OPENED) DUPLEX WORKING/LUBE
.HlliE : 1P-C5 : ~ TO WORKING 0'(150NB), ANSI BtO.S. a..300 5. HC wee: aL COOl.fR
GLOBE VALVE (NORMALLY CLOSED) OIL COOLERS
1. FOR GA OF MDBFP SET, REFER DRG.NO.: HY-DG-1-18000- 56868
SEAL COOLER 1P-t:e ::NO
00
a~ e'(150NB), ANSI eto.s. a..JOO 6. BfP IECH SEAL COOl£R 2
2. FOR INS1R\Jt.4ENT SCHEDULE OF MDBFP SET, REFER DRG.NO.:HY-DG-4-FP11869 ISOLATING VALVE {NORMALLY OPENED)
3. FOR P & ID O.M.C.W. SYSlEJ.I, PEt.t DRG. No. P&ID DMCW.SYS PE-DG -329 -179-N001. 1P-C7 : ~ TO UJ8E 4'(100NB), ANSI B10.S, a..300 7. BfP JACI<ET 2
ISOLATING VALVE (NORMALLY CLOSED) THERMOMETER
4. ALL THE INSTRUMENTS SHOWN IN THIS SCHEME \\ILL BE MOUNTED IN ONE LGB
EXCEPT RlllS. NECESSARY AT11NGS UKE MANIFOlDS, VALVES, DRAINS
DUPLEX RTD. I-1P--ca--r.~::::==cw01;:::~:::;~:;;:;FR'-""--I-4-·<1_00NB_>_.AN_S1_8_16_.s._a..JOO--i F-U:.:S~TO::::ME::::R'-1-:_ _,J'-"I.,.,N_,_DAL POWER LIMITED
\\ILL BE SUPPUED BY BHEL(HYD) ALONG \liTH INSlRUMENTS LOCAL I-1P_-_co-+.:::O!,::;.;~:;:L£T:=;::.T0=-:--+2--1/-r(65H6_1_ANS1_,tt__ _·SOAF-11-0N_SU_LT_AN_T+:_ _D_EVE
__L_O_P_ME_NT
__c_o_N_S_UL_TANT
__s_P_VT_.L_TD 150
_ _ _ _--IH
H LOCAL GAUGE RACK MOUNTED COOUNG WATER
SEAL WATER
---
- -
--
- -
-
-
ON cw OIJTl.£1" FRON
1P-c10 NOTOR COOl£R 2-1/2"(65H61 NISI, tt150, SOflF PROJECT: OP JINDAL STPP PH-III 4X600 MW UNITS
I
--II- -- FLANGE .. TAMNAR, RAIGARH CHATTISGARH
-&- ~-----MA_G_N_E_TI_C_A_L_TE_R
_ _ _ _ _ _ _ _ _ _ _ _ _~~~---.H~Y~B~H~E"L'H=YD~ER~AB~A~D~SCNO~P~EIO~F~SUffiP~P~LYY_ _ _ _ _r===~~~==============~~~~==~~~~~~~~~~~=~~~~~~t=s~,-,-IN~~U.E:--,sSI~~~.Tio~,~~~-i--~-
~ I!,J,f -- ~ BP-BHEL BHOPAL SCOPE OF SUPPLY 1. JOB NO. : 329 ~ DRN. RAJ. c ~ 16.04.09 N,;',.:.":
~ !i2 - PC-BHEL PC SCOPE OF SUPPLY. 2. STATUS: CONTRACT BHARAT HEAVY ELEClRICALS LlD. CHD. M.M.RAO \t;.:o.-16.04.09 NA
~ ~ 3. DRG/REF. NO. {INTERNAL) HYDERABAD APPD. B.RAJKUMAR f:.tu 16.04.09
z REV. ··~ AI.~ED 1 180 oos 6876 OEPl! PUMPs ENGG.I~I SCALE 1\IEIGHT (KG) REF. TO ORO. llEM NO. r~[ J -[
o•~ 11-"'~::.:TER:::CKED=EO'-----ri-PP-D-.---1 REV. DA~ lr.:•~;:::=:::cK::,ED,------rM':::P::-D.----1REV. DA~ r.:'~C::==::D------rAPP0::::::-.----1 REV. DA~ 1-::~::::m:=CK=:::-----,-,APP=o=-.--IREV. DA~ r.:~c=::::ED:=ED-----rAPPO::::::-.---IREV. r.:~c=::::ED:=ED-----rAP::::PO::-.---Io1 ~~~
ASS"(
L R£V. DATE 24.02.101-"c:::HE'=cKEO=:---rm-o.---+---:4-.-,0--IS_TR_I__
B_U_TI_ON--------l COOE 410 NiS NA NA NA NA
~~ !>z~oo.~-~~~-~~--tzffito~~--~~~--~~~--~zoo;.Et---~~~--~~--tZozoomE:t----~~~--~~-irozoomEr---~~~--~~--tZDN~E----~~~--~~--~w~NEfrD~R~G~.R~E~~~sfrEo~ASSFP~E~R~--i-~~~~~~l"l"l"l"lr-~ ~rrE
1 DRA~NG No ~
- -~~~- J- -- -1- --- - ---- --- - - -- -- ~--- ----- -- -- --4- ---- - --- -- -~ - - -- -- -6- - --- -- --- 7-- ~f16t~J.~~~~~~~s~;s =~- !: ~~. or: I- --1-1- +1-9- - - P~Ai:R~~~~~B~~ ~~~li{s·~:-;s~;!s ~~-
FIRST ANGLE PROJECTION (All DIMENSIONS ARE IN mm)
10 11
.!..1.. 99 900 091: ]:
'ON '<l~O
A
A
<148.3x5.08 s.s
BOOSTER PUYP MD B.F.P

LAC30 AP002 LAC30 AP001
0
I~
~
~I I
~
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~ L
~
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L -- - - <148.3x5.08 C.S
f---------- - - C I -
LEGEND 08
ADP
AUXILIARY OIL PUMP -@ VlB TRANSDUCER VERT
cc~ aRCULATION
CONTROL VALVE 0 LUBE OIL PUMP --@ VlB TRANSDUCER HOZ
cv$ CONTROL VALVE ~ THREE WAY VALVE

--e VlB MONITOR
@ LIMIT SWITCH
0 WORKING OIL PUMP
-@ TEMP IND ALARAM
NON-RETURN VALVE
-DI
--0 TEMP INDICATOR
0 FLOW INDICATOR (VlSUAL) D

-H-
REDUCER
FLANGE
--@ PR INDICATOR
LEGEND FOR BEARING G
-I><J- INSTRUMENT ROOT VALVE
ORIFICE
--@) DIFF.PR.INDICATOR @ BP 1HRUST BEARING
<>I
0 -i'l-
I
@ BP NDE JOURNAL BEARING
I
~
2 VALVE MANIFOLD
LUBE OIL LINE --@ DIFF.PR. TRANSMITER @ BP DE JOURNAL BEARING
"
-[0
CONTROL OIL LINE @ MOTOR DE JOURNAL BEARING
~~
~
:!jO
SAFETY VALVE WORKING OIL LINE --@ PR. TRANSMITER
@ MOTOR NDE JOURNAL BEARING
~a
~~
COOLING LINE --@ LEVEL INDICATOR ® BFP DE JOURNAL BEARING
cw ccw
~- 0 . LOCAL MOUNTED INSTRUMENTS ss SPEED SWITCH @ BFP NDE JOURNAL BEARING
ufr -@
- JJ
LEVEL TRANSMITER
ST SPEED TRANSDUCER @ BFP 1HRUST BEARING CUSTOMER:
0 LOCAL GAUGE RACK MOUNTED
~
INSTRUMENTS DUPLEX RTD TERt.IINA DESCRIPTION TERMINATED WITH HC BEARINGS CONSULTANT
KEY PHASER
POINT COUNTER FILANGE G)&@ RADIAL BEARING INPUT SHAFT DIRECTION ~==~-----------------=~-=---==-~~~~H
SIMPLEX RTD TP-F1 DMCW INLET TO LUBE OIL COOLER 4"(100NB), ANSI B16.5, CL300 @/@AXIAL BEARING FOR PRIMARY SHAFT OF ROTATION PROJECT:
KEY PHASER MONITOR -@
-TP-F2- OMGW-OUTlET-FROt.l-lUBEOIL-GOOlER· ·.of'(100NB);-ANSI-B16;5.--CI=300-- _@&® RAQIAL BEBRING_EB!MARY SHAFT
SCOOP TUBE STROKE INDICATOR
-@ ------u;-...,.,,....,.""'c;o=-ru=;N<T;;ni"i<iiTl-
WAlER LEAKAGE DETECTOR UNIT (Z)&@ RADIAL BEARING SEC. SHAFT 1. 'JOB NO. : 329
TP-F3 Dt.ICW INLET TO WORKING OIL COOLER 6"(150NB), ANSI B16.5, CL300 '§'•--"' AXIAL BEARING SEC. SHAFT C NTRACT
~ 2. STATUS : 0
ZON< ZONo ZOIIE ZOO<
3 4
4 9 10 11
0999 goo om: r ·oN ·<l~lO I
A
A
T&C
TP-F1 ± E;.G.
_l PUMPS
ENGG.
-~
E OIL P&l DIAGRAM
I
~~ -"'-"'~ :. ~
B
DG-329-139-0101 --
WI
G'i
,.._
L1 I ~LJ
~I ~I -fi \7
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~~
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~15
(.),_
(
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t:ji!'
VIEW
-J --~~m'l
~--=
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TD BOOSTER PUJ.IP-A
LAC10 AP002
T (Ql
l J
~II~ 111~~=1:1==~~~-:::J::;~~ GEAR
:t:g
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..... ~
COUPUNG
;!
<(
r:-:-1
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~ 0~ n LAC10AP003
TURBINE
'-
-~ ~ 0 J
;:: ,. 0
el:; ~ ~
~~
2s;!;
g: ~
w "
iE li!
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ffi
~
!5
§ fl~
Q I
~a
d # £
~ i:l
~ 5
15"
~ ~
w"'t:
E
L_ PUMPS
iE
ENGG. 1T TP-F2
~ TERMINAL
T&C
POINT
PURPOSE TERMINATED WITH
ENGG.
1P-F1 BP WBE OIL SUPPLY UNE SORF FLANGE NO 1 1/2",Cl150
L -- -- -~
OIL P&l DIAGRAM
DG-329-139-0101
lP-1'2
1P-f3
BP LUBE OIL DRAIN UNE
BFl' WBE OIL SUPPLY UNE

SORF FLANGE NO 1 1/2", Cl150
SORf FUNCE NO :t', Cl1!50

F
lP-1'4- BFl' WBE OIL CRAIN UNE SORf FUNCE NO ~· ,Cl1!50
-- -~
OIL P&l DIAGRAM
DG-329 -139-0101
'"' LEGEND
NOTE:-
K) FLOW INDICATOR
1) FOR INSTRUMENT SCHEDULE OF TDBFP SET, REFIER DRAWING.NO.
I
I
-
-i><l- HY-DG-4-FP11870 THIS DWG. IS DRAWN TO SHOW ONLY INTERNAL SCOPE

INSTRUMENT ROOT VALVE
2) ALL THE INSTRUMENTS SHOW~'~ IN THIS DRAWING ARE SUPPUED BHEL HYD/PUMPS SCOPE OF INSTRUMENTS
2 VALVE MANIFOLD OF SUPPLY
~
BY PUMPS ENGG., BHEL. HYDERABAD.
G G
~~
3) ALL PRESSURE INDICATORS HAVE INDIVIDUAL TAPPING POINTS
-
<'I
0
I
D REDUCER
WITH ROOT VALVES.
4) ALL PI & n ARE LOCAL GAUGE BOARD MOUNTED.
.
PUMPS T&C
0
ENGG.(HYD) ENGG.{HYD)
~~
-~ 0 LOCAL MOUNTED INSTRUMENTS 5) FOR ALL THE INSTRUMENTS SHOWN IN THIS SCHEME
~2
--LEGENif-FOR-BEARING_-_--_- NECESSARY FITTINGSUKEMANIFOLDS;VAtVES; DRAINS WILL BE SUPPUED BY
~&l 0 LOCAL GAUGE RACK MOUNTED BHEL(HYD) ALONG WITH INSTRUMENTS. cw ccw
INSTRUMENTS
- JJ
~:: @ BP THRUST BEARING 6) BFP AND BOOSTER PUMP OIL SUPPLY AND DRAINS TERMINATED
ufr WITH COUNTER FLANGES, BOLTS, NUTS & GASI<ETS CUSTOMER: .TTNDAT POWER T.TMI'I'I-t:D
'-- -II- FLANGE ® BP NDE JOURNAL BEARING
COOSULTANT: DEVELOPMENT CONSULTANTS PVT.LTD
7) KKS TAG NOS. INDICATED ARE FOR TDBFP-A. KKS TAG NOS. OF
d -Ill- ORIFICE @ BP DE JOURNAL BEARING
TDBFP-B MAY BE READ AS LAC02•••• LAC12••.• AND LAC20 •••• IN PLACE OF H
z I DffiECTION OP JINDAL STPP PH-ill 4X600 MW UNITS
® BFP DE JOURNAL BEARING LAC01.. .. LAC11... •• AND LAC10 ..... OF ROTATION
PROJECT:
~ -- LUBE OIL UNE
@ BFP NDE JOURNAL BEARING
TAMNAR, RAIGARH CHATTISGARH
- . ..:.-
!.__ KP KEY PHASOR @ BFP THRUST BEARING
I!!
<l
0
:;
KM - KEY PHASOR MONITOR
3. DRG/REF. NO. (INTERNAL) DEPT. PUMPS ENGG.~~
1 SCALE r\1£1GHT (KG) REF. TO ASf:f DRO. liTEMNO. NO.e<
1i REV. DATE IALTERfll REV. DATE !ALTERED
Tf"~'=~""RED:::,o----.APPO-.---lREV. DATE !ALTERED REV. DATE 11'-''AL:.::TER::.::ED=---.----rREV. DATE !ALTERED REV. DA1E !ALTERED 1 1BO 0056880 coo· l - NTS NA NA NA ITEMNAs
02 12.04.10 f!!CH::!!Ea=<ED-~-IJ'-PD-.-1 01 01.08.10 f-c~HE;;:CKED;;:;:--r.:IJ'=Po::-.---I-----:.-::D-::IS:=TR=I:::-B;-::U1l::-O:-:N-:--~:::.:::_~~=-j
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CHECKED !.PPD. " 410
0
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=·
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1 1 1
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FIRST ANGLE PROJECllON (ALL DIMENSIONS ARE IN mm)
2 3 4 5 6 7 8 9 10 11
8L89 900 08 ~ ~'ON 'Q/:Ja
A A
BALANCE DRUM
,-----,-------- ....- .... ------~ LEAK-OFF UNE

NO 2" SCH 40
@:::,.
~?~1-D<I-yM-\&-ti::Acr.o;-l
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SUCTION SIDE !:'.0?.'1<~ I/,\ LEGEND I
I --------" I r------------ -------- I /,\f ,~liW I
1 iil r----'---1....--Ll (ll> NEMESTDI!AI< Pl1)
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r--------------------, I ------- I ~~ IIElDS.
HY BHa HYDERABAD SCOPE OF SUPPLY
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B ~8 J... r----~ ---- I ENJ.C<JNN. 8
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TURBINE r _ ------------ _ _1
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L. .1_ I I.A<IIIN'OOt I
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1/2"~ r-::r~~ 1 L----~ 'i I

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- - - - - - - - ___________ JI
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II CASING DRAIN PI
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.I- VENT VALVE NORMALLY CLOSED
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INSTRUMENT ISOLAllON VALVE
\eY v v
I @ ROOT VALVE [1/2" SOCKET WELD. ENDS] :
I
~ - TO BE PROVlDED BY PIPING SUPPUER. I
f*T - ·*iT
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r-----,
ROOT VALVE [1/2" SOCKET WELD ENDS] I
I
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L-----.J5 VALVE MANIFOLD
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I ~ ~~-\!!t~V11'--21-e.83_.J..I_•_63._•--,-~I_•_•oo---ll ttf 2 VALVE MANIFOLD
1 A // ',, I 1\ OPT DIFFERENTIAL PRESSURE TRANSMITTER E
~ ~
·r
1
I ~~VA ®!~ ~~ DPI DIFFERENTIAL PRESSURE INDICATOR

I ~ ~ PI PRESSURE INDICA TOR
~ FLOW NOZZLE PC I I PT PRESSURE TRANSMITTER I
I i . I i
l'----1_
*__
I
"------~=-;5)-~=-~-A-;;;;-;~~~~~----~------------~~: ~!~~*-~~~--------------------------------;:;-" 1 c. t t-"'.'-~-r---->

PS PRESSURE SWITCH I
I
Tl THERMOMETER
DT DIFFERENTIAL TEMPERATURE
<..~~00~------J+~ I ~L-------J~ __ j I! I! TE RTD
++
'
-~-
F I L--~--J I ~
LAIIIO
MIOI
VENT UNE WITH VALVE
F
~
.....,..
I
I
I
I
I
L---~..PE-D0-329-11Xl-ft1051
.
$ DRAIN UNE WITH VALVE
<' Ill-.!;I :
L------~n~1oo-m,
FROM MD BFP 'C:
L-----------------------------------
I '-- -~ . I. _J FROM 1D BFP 'B'

TERMINAL
POINT
PURPOSE TERMINATED WITH
~ r---------------------------------------------1
i THIS DWG. IS DRAWN TO SHOW ONLY i r--------------------,
<?>
TP-F1 BOOSTER PUMP SUCllON STRAINER INLET COUNTER FLANGE,18",ANSI,CL150, WNRF
~6~
i BHEL HYD SCOPE OF INSTRUMENTS i iSCOPE OF SUPPLY!
G
TP-F2 BOOSTER PUMP SUCTION STRAINER OUltET COUNTER FLANGE,18",ANSI,CL150,WNRF
L---------------------------------------------J t--------------------i G I I
r--- I I
I I
"0 "' TP-F3 BOOSTER PUMP SUCllON COUNTER Fl.ANGE,14",ANSI,B16.5,WNRF,0..300
1) ALL DRAINS/VENTS SHALL BE ROUTED SUITABLY TO THE NEAREST DRAIN PIT.
PRESSURE TEMP-ANSI I
I
I
I
~cb 2
:l! ....
TP-F4 BOOSTER PUMP DISCHARGE COUNTER FLANGE,12",ANSI,B16.5,WNRF,Q.300
(KG/CM (g) . ("C) I BHEL BHEL I
~~ 2) FOR INSTRUMENT SCHEDULE OF TDBFP SET, REFER DRG.NO.:HY-DG-4-FP11870
I tHYDJ tPEM/PCJ :
~§ TP-F5 BFP SUCllON STRAINER INLET NOZZLE, BUTT \\Ell), TO SUIT PIPE1>406.4x9.53mm 3) KKS TAG NOS. HAVE BEEN MARKED FOR TDBFP-A. TAG NOS. FOR TDBFP-B SHALL I
L--------------------J
I
"-10 BE READ AS LAC20 .... , & LAB20•••• IN PLACE OF LAC10 ...... & LA810 ....
"-
8~ TP-F6 BFP SUCllON STRAINER OUllET NOZZLE, BUTT \\Ell), TO SUIT PIPE1>406.4x9.53mm
1
!--"=
4) ALL THE INSTRUMENTS (LGB MOUNT) EXCEPT PR.TRANSMITTERS SHOWN IN THIS SCHEME CUSTOMER: JINDAL POWER LIMn~u
WILL BE MOUNTED IN ONE LOCAL GAUGE BOARD. PR.TRANSMITTERS WILL BE MOUNTED IN CC\'lSULTANT: DEVELOPMENT CONSULTANTS PVT.LTD H
TP-F7 BFP SUCllON NOZZLE, BUTT \\Ell), TO SUIT PIPE1>406.4X9.53mm I
0 H ANOTHER CABINET NECESSARY FITllNGS UKE MANIFOLDS, VALVES, DRAINS WILL BE SUPPUED
I z
II ~ TP-FS BFP DISCHARGE NOZZLE, BUTT \\Ell), TO SUIT PIPE,36Bx48mm BY BHEL(HYD) ALONG WITH INSTRUMENTS.
TAMN.AR, RAIG.ARH CHATTISGARH
r--- - -
I
~ NOZZLE, BUTT \\Ell) ENO, TO SUIT PIPE SIZE 5) ALL CASING VENTS & DRAINS SHALL BE TAKEN TO NEAREST DRAIN PIT. NAME SIGN. DATE
I
TP F9 BFP R.C.VALVE INLET & OUllET
1. JOB NO. : 329 . I DRN. RAJ. C ~ 10.0M9 N~A.":
~
'219.1 X32mm
< BFP R.C.VALYE ANll FLASH ORIFICE 6) REF BHEL/PEM P&ID FEED WATER SYSTEM PE-DG-329-100-N105 2. STATUS : CONTRACT BHARAT HEAVY ElEClRICALS LTD. Clio. M.M.RAO ll.,. 10.04.09 NA
0
TP-F10 INLET &: OUllET FLANGE, WNRF, 8" ANSI CL300
0 3. DRG/REF. NO. (INTERNAL) HYDERABAO >PPD. B.RAJKUMAR /:tv 10.04.09
~
li
DEPT. PUMPS ENGG. L~J SCALE 1\\>JGHT (KG) REF. TO ASSY ORG. IJBM ~-Iii.,";
REV. OA'If: IALTERED
F = - - - , - - - - 1 REV. DATE lf"'Al:::::TERm=--.----IREV. OA'If: I ALTERED REV. DA'If: !ALTERED REV. OA'If: II".Al:::::TER::::ED=---.-----lREV. OA'If: !ALTERED REV. DA'If: lf"'A::.:LTER=ED'---;r---+---1_18_0_0_0_5_6_8_7_8_ _-1
(
'·
L CHECKED AP1'1), CHECKED APPD. E:'CHC:Ec='KED=---•'"=ro=.---1 r:CH=.=:E:=CI<=.:ED:-----.-_=o-.-i CHECI<ED APPD. 02 12.04.10 CHECKED API'D. 01 6.02.10 CHECI<ED AP?O. 4. DISTRIBUTION cooE 410 I~ I NTS NA NA NA NA
0 ZONE ZOOE ZONE ZOIIE ZOOE
~~~RJT~osxe tcrM~~~lS 5
LTRZOOE ~~~·~'T~o }~ cAJM~~~TS LTR 5. TO I I I I I I I PID OF FEED WATER
~, ~
Z<J<E TITLE DRAWING NO. REV. I
I P.Bf2~.9.9M~W/BIG/3!1.9. A.B/2.1()DMWL~IG/3_23_ - 6-No-OFI-1· 1--1· -~ ~~ ~~ I ' --~ -- LINEg. FOR ~'l'DBFP ~
r
I J- ----
1
~- - ~--~
3 4 5 6
DT.05.04.10
-·
7
DT.10.02.10
8
' • I I I I
9 10
HY-DG-1-18000-5687E 02 "
SHEET NO. 01 I No Of SHEETs 01
11
I
I
I
2 3 4 5 7 8 9 10 11
6.!.89 900 08l l
'ON '5!:10
r-r- A
' -~~-
1 ~
GEAR BOX TO B.F.P-A
B
L
PRESSURE TEMP-ANSI FLOW
2 3
F 50 KG/CM (g) (oc) M /HR F
:z
I
8
:z
I
"'
r--
"'
r--
I I THiS DWG. IS DRAWN TO SHOW ONLY
"'
""
!")
"'
N BHEL HYD SCOPE OF INSTRUMENTS
<.!>
I !")
I SCOPE OF SUPPLY
Cl <.!>
I Cl PRESSURE DROPS ACROSS VARIOUS EQUIPIIBNTS
...... I
......
a... SERIAL
a... EQUIPWEIIT
NO.
G
A MOTOR OPERATED VALVE
FLOW INDICATOR
1. BOOSTER PUUP JAO<ET O.S
G
GLOBE VALVE {NORMALLY OPENED) DUPLEX WORKING/LUBE J. WOTM COOLER
GLOBE VALVE {NORMALLY CLOSED) OIL COOLERS 4. HC WCftKJ.IG OIL COOl.£R
NQIE.:
-
ISOLATING VALVE {NORMALLY OPENED) SEAL COOLER S. HC WBE OL COOLER
1. FOR GA OF TDBFP SET, REFER DRG.NO.: HY-DG-1-18000-56867. TERiliNAL POINT DETAILS (COOUIIG li'ATER)
TI 6, BFP WEa-l SEAL coc:c..ER
ISOLATING VALVE {NORMALLY CLOSED) THERMOMETER
2. FOR INSTRUllENT SCHEDULE OF TDBFP SET, REFER DRG.NO.:HY-k-FP11870. TERIMNATEO 'MTH
POIHT COUNTER FLAHGE
3. FOR P & ID DliCW SYSTEii, PC DRG. No. PE-DG-329-179-NOOl. 2 TE DUPLEX RTD.
LOCAL 1P-C1 011 Cf K£T 10"""""' Pill' 1-1/2"(4CH8~ AHS1. a.tso, SORF
4. ALL THE INSTRUllENTS SHOWN IN THIS SCHEYE 1IIIL BE liOUNTED IN ONE LGB EXCEPT RTDS. CUSTOMER:
COOUNG WATER
NECESSARY FmiNGS LIKE liANIFOIDS, VALVES, DRAINS etc. 1IIIL BE SUPPLIED LOCAL GAUGE RACK MOUNTED lP-<:2 ~~ FRON
BY BHEL(HYD) ALONG lllTH INSTRUYENTS
FLANGE SEAL WATER 1P-c3 Dt.l CW N.ET TO BFP
5. KKS TAG NOS. HAVE BEEN llARKED FOR TDBFP-A. TAG NOS. FOR TDBFP-B
~ SHAU. BE READ AS PGB42... , LAC20... & PGL34... IN PLACE OF PGB41..., LAC10 ... MAGNETIC FILTER BHEL HYDERABAD SCOPE OF SUPPLY
- ;;:-- --o!.:-PGL33...
::! BHEL PC SCOPE
ALTERED REV. DATE ALTERED REV. DATE ALTERED REV. DATE ALTERED REV. DATE ALTERED
(' CHECKED APPO. CHECKED APPD. CHECKED APPO. CHEO<ED APPD. OiEO<ED APPD.
0
z ZONE Za<E ZOHE ZONE ZONE REV.
- -~--- J -- ----------- ------- - ------- -

02
-J -- - I
!l1 01
;;; 3 4 5 6 7 8 10 11 r
I
I
I
FIRST ANGLE PROJECTION ALL DIMENSIONS ARE IN mm.
~~~------~ ~~=-------~
01 9.3.10 CHECKED 02 10.4.10 f.-=Cc'::'::HE::,:C:..c.:K=:ED~-----1 CHECKED
\; ·;;..: APPROVED _ _ _ _ _ _--I----'----------l.:....::_:_;_;:..::....:..:::=__
I---1-----L:..:::__:__:_::..::....:..:::=__ APPROVED _ _ _ _-I----'------L:...::~.:::....:..==--~~~=!
APPROVED
--~/ -~
z<( REVISED AS PER JINDAL REVISED AS PER JINDAL

~ COMMENTS LETTER.AB/2400 MW COMMENTS LETTER.AB/2400 MW
8 BTG/323 DT:10.2.10 BTG/0392 DT:4.2.10
w 1----~--------------~--------------------~---------------------l
~
ci
w LL.
0
1-
~ l-
:J en
w
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~ INSTRUMENT SCHEDULE
r· Q:
w
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0
Q:
~
FOR MDBFP SET
~
0..
w (..)
~ Q:
w
!Q i5
I- ~
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::::>
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w :::;:
~ ~ r--------------------.
.----- JOB NO. 329
/' g N STATUS CONTRACT
Q:o
56C~UsiQM_~R:- ___ -J-INDA-L--POWER -LIMITED-----·-- - -----~

~ wr-------r---~==~~~~~~=-~==~--~~==~~~--------------~
~CONSULTANT:
8 ..- DEVELOPMENT CONSULTANTS PVT.LTD
~r-------r-------------------------------------------~----------~
LL..
_PROJECT: OP JINDAL STPP PH-III 4X600 MW UNITS

SIGN DATE
BHARAT HEAVY ELECTRICAL$ LTD. NAME
. HYDERABAD DRN. RAJ. C ~ 06.01.10 NO. OF
~ o:: f1 0
0 \k. _ VAR.
z ~ ~ CKD. M.M.RAO ~ 06.01.10 NA
1L_ ;o
t'l
g
..J
APPD. RAJKUMAR /lk._ 06.01.10
- - - ~ - - -~-~- DEP=f-.f'l:JM·f'3 ~ -SeAI:E- WEIGI'!T(K:-G:)- REF:jDRG:NO:(IfiJTERNAt) -ITEtvl- "1\fo-:-or
~ 0 1 - - - - - - - - - - - - - - ; l::J~ NO. ITEMS
g ::c ~ coDE 410 NTS NA FP
11869
NA NA
~ ~ 8
f2 t.: B5 TITLE DRAWING NO. REV. NO.
w>z w z
0:: ::::>
INSTRUMENT SCHEDULE HY-DG-4-FP11869 02
~
-FOR- -MDBF~ ~E'I' SHT.NO. 01 . . I NO.OF SHT. 08
INSTRUMENT SCHDULE FOR MD BFP SET DRG. NO. HY-DG-4-FP11869
BHEL
4 X600 MW. UNITS. JINDAL POWER LIMITED SHEET : 02 OF 8
HYDERABAD
LEGEND REV.NO.: 02
INSTRUMENT:
PI -PRESSURE INDICATOR Tl -TEMP. INDICATOR VTH -VIBRATION TRANSDUCER HORIZONTAL

PT - PRSSURE TRANSMITTER TIA -CONTACT TEMP. INDICATOR VTV -VIBRATION TRANSDUCER VERTICAL
PDI - DIFFL. PRESSURE INDICATOR TE - RTD, pt-100 OHMS AT o·c,4-WIRE VM -VIBRATION MONITOR
PS -PRESSURE SWITCH Ll -LEVEL INDICATOR
ST -SPEED TRANSMITTER LT - LEVEL TRNSMITTER
PDT - DIFFL. PRESSURE TRANSMITTER LD - LEVEL DETECTOR
LMS - LIMIT SWITCH
MEDIUM: PROCESS/ELEC. CONNECTION DESTINATION LOCATION
FW -FEED WATER A -1/2" NPT(M) I -INTERLOCK L -LOCAL

sw -SEAL WATER B -1/2" NPT(F) H -HIGH UCR - UNIT CONTROL ROOM
cw -COOLING WATER c - 3/4" NPT(F) H-H -HIGH HIGH LGB - LOCAL GAUGE BOARD
WNDG -WINDING D - G 3/8" L -LOW (FOR GAUGES & SWITCHES)
OIL -OIL E - 1/4" NPT(F) L-L -LOW LOW LIR - LOCAL INSTRUMENT RACK
METAL- METAL F - PLUG IN SOCKET TYPE TD -TIME DELAY (FOR TRANSMITTERS)
G - G 1/2" DT - DIFF. TEMP HC LGB - HYDRAULIC COUPLING LGB
(FOR INSTRUMENTS OF HC)
NOTE:-
-REPEATABILITY IS INDICATED IN PLACE OF ACCURACY FOR ALL THE SWITCHES.
-OPERATING CONDITIONS GIVEN FOR INSTRUMENTS ONLY FOR INFORMATIVE.
UNITS:-
PRESSURE : Kg/Sq.cm & mmwc
TEMPERATURE : Deg.C
- - --
SHEETZ OF 8
/
~ -,
I
'\
~ \ i
~-
: OPERATING CONDITION SPECIFICATION SET POINT

KKS QTY/
DESCRIPTION PMP PRE kg/ TEMP FLOW PROC. ELEC MOUNTI ACCU REMARKS'
TAG FLUID SYM RANGE ALARM TRIP /INTERLOCK
cm21 DC RATE CON. CONN NG RACY
I I
1. FEED WATER LINES, REFER DRG, HY-DG-1-18000-56875

LAB30
II DIFF.PR.ACR BP SUCT '
I
1 FW 0.1 ! 163 1100 PDT 0-6400 B F LIR ±0.1 1500(H) 2000(H-H)
CP020 STRAINER
LAB30
CP021
I DIFF.PR.ACR BFP SUCT
STRAINER
1 FW 0.1 : 163 1100 PDT 0-6400 B F LIR ±0.1 1500(H) 2000(H-H)
LAB30
CP022
I BFP SUCT PRESSURE 1 FW 26" i 163 1100 PT 0-40 B F LIR ±0.1 15 kg/cm'(L) 1Okg/cm'(T) TD-1 OSEC
LAB30
CP023
I WATER
BFP DISCHARGE FEED
PRES
1 FW 208! 163 1100 PT 0-250 B F LIR -- 40 (L) kg/em' TD-10SEC
At min speed
1 >35 kg/em• (I)

I
! (a) StartAOP.
INCASE OF BFp
LAB30 b)Solenoid valves 92&93 of the rapid
BFP SUCTION PRESSURE 1 FW 26 163 1100 PT 0-40 B F LIR ±0.1 REVERSE
CP024 start device must be switched off.
ROTATION
c)Move scooptube to 100% position
I d) Close the disch valve DV.
LAC30
CP025
I BFP-BC
PRESSURE
LEAK OF
1 FW 26 163 30 PT 0-40 .B F LIR ±0.5 30 (H) kg/em'
LAB30
CP501
I B.P. SUCTION
PRESSURE
1 FW 9.201 'I 163 1100 PI 0-16 A - LGB ±1 --
LAB30
CP502
I B.P. DISCHARGE
PRESSURE
1 FW 26 163 1100 PI 0-40 A - LGB ±1 --
LAB30
CP503
I BFP SUCTION
PRESSURE
1 FW 26 163 1100 PI 0-40 A - LGB ±1 -- !
LAB30
CP504
I BFP DISCHARGE
PRESSURE
1 FW 209 \ 163 1100 PI 0-350 A - LGB ±1 --
I
LAC30
CP505
I BFP-BC
PRESSURE
LEAK OF
1 FW 26 ', 163 30 PI 0-40 A - LGB ±1 -- !
LAB30
CP520
I DIFF.PR.ACR
STRAINER
BP SUCT
1 FW 0.1 I. 163 1100 PDI 0-5000 A - LGB ±1 -- \
I DIFF.PR.ACR
I
LAB30
CP521 STRAINER
BFP SUCT
1 FW 0.1 ·, 163 1100 PDI 0-5000 A - LGB - - I
LAB30CT
020 to 022
I
BFP SUCT.FEED WATER
TEMP.
3 FW 26
I
163 1100 TE 0-200 A c L ±1

DT>15'C-Open RC Valve(l)
DUPLEX RTDS :,
DT(DCS
I
LAB30CT
02310 025
I
BFP DISCH.FEED WATER
TEMP.
3 FW 208 163 1100 TE 0-200 A c L ±1
DT> 10'C (H) DT>15'C&Fiow less than speed
depend set point of RC Flow minus
50T/hr with TD of 30 Sec.(T)
CONTACT 2/3 :
LOGIC)
LAC30
CT101
IBFP BARREL TEMP., TOP 1 METAL - 163 -- TE 0-200 A c L ±1 DUPLEXRTDS
LAC30
CT102
IBOTTOM
BFP BARREL TEMP.,
1 METAL - 163 - TE 0-200 A c L ±1
DT22'C(H) DT(DCS
CONTACT)
LAB30 I BFP SUCT.FEED WATER
CT520 TEMP.
1 FW 26 163 1100 Tl 0-200 A - LGB ±1 --
LAB30 [ BFP DISCH.FEED WATER I
CT521 TEMP.
1 FW 208 163 1100 Tl 0-200 A - LGB ±1 --
SHEET3 OF 8 I
-~- -. ------- -----

I
OPERATING CONDITION SPECIFICATION SET POINT
KKS QTY/
DESCRIPTION PRE kg/ TEMP FLOW PROC. ELEC MOUNTI ACCU
REMARKS
TAG PMP
FLUID SYM RANGE ALARM TRIP /INTERLOCK
cm2 oc RATE CON. CONN NG RACY
2. SEAL WATER AND COOLING MATER LINES, REFER DRG. HY-DG-1-18000-56876

PGB43 BP MECH SEAL COOLER- 4 WIRE DUPLEX
CT101 NDE S.W INLET TEMP
1 sw 11 60 - TE 0-120 A c L ±1 80'C(H)
RID
PGB43
CT102
BP MECH SEAL COOLER-
NDE S.W OUTLET TEMP
1 sw 10.5 60 - TE 0-120 A c L +1 70'C(H) -do-
PGB43 BP MECH SEAL COOLER-
CT103 DE S.W INLET TEMP
1 sw 11 60 - TE 0-120 A c L ±1 80'C(H) -do-
CT104 DE S.W OUTLET TEMP
1 sw 10.5 60 - TE 0-120 A c L ±1 70'C(H) -do-
PGB43 BFP MEC SEAL COOLER-
1 sw 29 60 -- TE 0-120 A c L ±1 80'C(H) -do-
PGB43
CT106
BFP MEC SEAL COOLER-
DE S.W OUTLET TEMP
1 SW 28.5 60 - TE 0-120 A c L +1 70'C(H) -do-
1 sw 29 60 - TE 0-120 A c L +1 . 80'C(H) -do-
CT108 NDE S.W OUTLET TEMP
1 sw 28.5 60 - TE 0-120 A c L ±1 70'C(H) -do-
PGB43
CT109
BP MECH SEAL COOLER-
NDE C.W OUTLET TEMP
1 cw 4 42 - TE 0-120 A c L ±1 50'C(H) -do-
CT110 DE C.W OUTLET TEMP
1 cw 4 42 - TE 0-120 A c L ±1 50'C(H) -do-
PGB43
CT111
BFP MEC SEAL COOLER-
NDE C.W OUTLET TEMP
1 cw 4 42 - TE 0-120 A c L ±1 50'C(H) -do-
1 cw 4 42 -- TE 0-120 A c L ±1 50'C(H) -do-
1 sw 11 60 - Tl 0-120 A - LGB ±1 -
1 sw 10.5 60 - Tl 0-120 A - LGB ±1 -
1 sw 11 60 - Tl 0-120 A - LGB +1 -
1 sw 10.5 60 - Tl 0-120 A - LGB ±1 -
1 sw 28.5 60 - Tl 0-120 A - LGB ±1 -
1 sw 29 60 - Tl 0-120 A - LGB ±1 -
1 sw 29 60 - Tl 0-120 A - LGB ±1 -
1 sw 28.5 60 - Tl 0-120 A - LGB ±1 -
SHEET 4 OF 8
~
'--
I j
I
I
I,
I
I OPERATING CONDITION SPECIFICATION SET POINT

QTY/
'KKSTAG DESCRIPTION PRE kg/ TEMP PROC. ELEC MOUNTI ACCU REMARKS
PMP
FLUID FLOW RATE SYM RANGE ALARM TRIP /INTERLOCK
oc
I !cm2
- CON. CONN NG RACY
13. LUBE OIL LINES , REFER DRG.j HY-DG-1-18000-56877 (A)-

BOOSTER PUMP i .
lAC13 OILINLET PR. TO

bP301 BPTHRUST BRG· NDE
1 OIL I 2 45 - PI 0-4 A ·- LGB ±1 -
lAC13 OIL INLET PR. TO BP
bP302 JOURNAL BRG- NDE
1 OIL 2 45 - PI 0-4 A - LGB ±1 -
lAC13 OIL INLET PR. TO BP
bP303 JOURNAL BRG· DE
1 OIL ' 2 45 - PI 0-4 A - LGB ±1 -
lAC13CT BRG METAL TEMP BP SIMPLEXRTD
:101 to 104 THRUSTBRG
4 METAL - 75 - TE 0-200 - - L ±1 95'C(H) 105'C
(MINIATURE)
lAC13 BRG METAL TEMP BP 4 WIRE DUPLEX
bT105 JOURNAL BRG- NDE
1 METAL - 65 - TE 0-200 A c L ±1 85'C(H) 95'C
RTD
lAC13 BRG METAL TEMP BP
b106 JOURNAL BRG- DE
1 METAL I- 65 - TE 0-200 A c L ±1 85'C(H) 95'C -do-
lAC13 OIL DRAIL TEMP BP
b107 JOUR BRG-NDE&TH BRG
1 OIL 1 55 - TE 0-120 A c L ±1 85'C(H) -do-
lAC13 OIL DRAIL TEMP BP
bnoa JOURNAL BRG-DE
1 OIL ! 1 55 - TE 0-120 A c L ±1 85'C(H) -do-
lAC13 BRG METAL TEMP BP-
b301 NDE
1 METAL - 65 - Tl 0-120 A - LGB ±1
lAC13 BRG METAL TEMP BP-

b303 DE
1 METAL - 65 - Tl 0-120 A ·- LGB ±1
(B)-BOILER FEED PUMP

I·
lAC03 OIL INLET PR. TO BFP
bP301 JOURNAL BRG· DE
1 OIL 2 45 - PI IJ.4 A ·- LGB ±1 -
lAC03 OIL INLET PR TO BFP I
bP302 JOURNAL BRG- NDE

1 OIL 2 45 - PI 0-4 A ·- LGB ±1 -
lAC03 OIL INLET PR TO
bP303 BFPTHRUST BRG
1 OIL 2 45 - PI 0-4 A - LGB ±1 -
lAC03 BRG METAL TEMP BFP 4 WIRE DUPLEX
Cr103 JOURNAL BRG- DE
1 METAL
:
- 65 - TE 0-200 A c L ±1 85'C(H) 95'C
RTD
lAC03 BRG METAL TEMP BFP 4 WIRE DUPLEX
b1o4 JOURNAL BRG- NDE
1 METAL - 65 - TE 0-200 A c L ±1 85'C(H) 95'C
RTD
lAC03CT BRG METAL TEMP BFP ! SIMPLEXRTD
~05 to 108 THRUSTBRG
4 METAL - 75 - TE 0-200 - ·- L ±1 95'C(H) 105'C
(MINIATURE)
lAC03 OIL DRAIL TEMP BFP 4 WIRE DUPLEX
enos JOURNAL BRG-DE
1 OIL 1 55 - TE 0-120 A c L ±1 85'C(H)
RTD
lAC03 OIL DRAIL TEMP BFP 4 WIRE DUPLEX
CT110 JOUR BRG-NDE&TH BRG
1 OIL i 1 55 - TE 0-120 'A c L ±1 85'C(H)
RTD
lAC03 BRG METAL TEMP BFP-
Cr301 DE
1 METAL i- 65 - Tl 0-120 A - LGB ±1 -
lAC03 BRG METAL TEMP BFP
Cr303 NDE
1 METAL !- 65 - Tl 0-120 A ·- LGB ±1 -
b~~
I 2 PIN
VIB TRANSDUCR,HORZ
BFP DE BRG HOUSING
1 - :- - - VTH - M6X1 CONNECT
OR
L - - -
I
lAC03 VIB TRANSDUCR,VERT
CY102 BFP DE BRG HOUSING
1 - - - - VTV - M6X2 ·DO- L - - -
lAco3 VIB TRANSDUCR,HORZ I
fY103 BFP NDE BRG HOUSING

1 - i- - - VTH - - ·- L - - -
lAco3 VIB TRANSDUCR,VERT

CY104 BFP NDE BRG HOUSING
1 - I
- - - VTV - - - L - - -
I
SHEET 5 OF8
~-------------- -·----- ---- --------- --

QTY/
KKSTAG DESCRIPTION PRE kg/ TEMP ELEC
REMARKS
PMP PROC. MOUNTI ACCU
FLUID FLOW RATE SYM RANGE ALARM TRIP /INTERLOCK
cm2 oc CON. CONN NG RACY
4-20mAOIP
LAC03 0-50 MM/SEC,
CY201
VIB MONITOR BFP DE 1 - - - - VM
RMS
CUBICALE 11(H) 18(H·H) MMISEC - Signal Cubicle
Location UCR
4-20mAOIP
LAC03 0-50 MM/SEC,
CY202
VIB MONITOR BFP NDE 1 - - - - VM
RMS
CUBICALE 11(H) 18(H-H) MM/SEC - Signal Cubicle
Location UCR
LAC03
KEY PHASER FOR BFP 1 KP L
CS101
LAC03
KEY PHASER MONITOR 1 KM L
CS102
(C)-DRIVE MOTOR (SUPPLIED ALONG WITH MOTOR)

LAC03 OIL INLET PRE TO MTR
CP304 JRNL BRG. BP END
1 OIL 1 50 - PI 04.0 A - LGB ±1 -
LAC03 OIL INLET PRE TO MTR
CP305 JRNL BRG. HC END
1 OIL 1 50 - PI 04.0 A - LGB ±1 -
LAC03 ,
CT125
MTR BRG TEMP.BP END 1 METAL - 75 - TE 0-200 - - L ±1 80"C(H) so·c DUPLEXRTD
LAC03
CT126
MTR BRGTEMP.HC END 1 METAL - 75 - TE 0-200 - - L ±1 80"C(H) 9o·c -<fo-
LAC03CT STATOR WINDING TEMP.
111 to 114 R-PHASEl
4 WNDG - 120 - TE 0-200 - - L ±1 120"C(H) 130"C SIMPLEX RID
115to118 Y-PHASEl
4 WNDG - 120 - TE 0-200 - - L ±1 120"C(H) 130"C -<fo-
11910122 B-PHASEl
4 WNDG - 120 - TE 0-200 - - L ±1 120"C(H) 130"C -do-
LAC03 MTR BRG. DRAIN OIL
CT124 TEMP. HCEND
1 OIL 0.5 60 - TE 0-120 A - L ±1 80"C(H) DUPLEXRTD
LAC03 MTR BRG. DRAIN OIL
CT123 TEMP. SPEND
1 OIL 0.5 60 - TE 0-120 A - L ±1 80"C(H) DUPLEXRTD
LAC03CT MTR INLET AIR TEMP.
303 &304 HCSIDE.
2 AIR - 48 - TIA 0-120 - - L ±1 53"C(H)
LAC03CT MTR INLET AIR TEMP. BP
305 &306 SIDE.
2 AIR - 48 - TIA 0-120 - - L ±1 53"C(H)
LAC03CT
307 &308
MTR OUTLET AIR TEMP. 2 AIR - 72 - TIA 0-120 - - L ±1 77"C(H)
LAC03 BRG METAL TEMP. MTR
CT311 BRG-BPEND
1 METAL - 65 - TIA 0-120 - - L ±1 80"C(H)
LAC03 BRG METAL TEMP. MTR
CT313 BRG-HC END
1 METAL - 65 - TIA 0-120 - - L ±1 80"C(H)
LAC03 WATER LEAKAGE
CL201 DETECTOR
1 WATER - - - LD - - - L ±1 5MM
LAC03
CL201
MTR SPEED SWITCH 1 - - - - - - - - L ±1 900 rpm
-DO-
NON CONTACT
LAC03
CL202
MTR SPEED SWITCH 1 - - - - - - - - L ±1 1346 rpm -do-
1000LPM
LAC03 WATERFLOW 0.5/5A,220/240V
F1101 INDICATOR
2 WATER - 38 (FOR2 Fl - - - L - - - DC/AC
ELEMENTS)
SHEET60F8
i
' ''\ .,
I '
I
/
~- /
i
!
QT OPERATING CONDITION SPECIFICATION SET POINT

KKS REMARKS
DESCRIPTION Y/P PRE kg/ TEMP FLOW PROC. ELEC MOUNTI ACCU
TAG SYM RANGE ALARM TRIP /INTERLOCK
MP FLUID cm2 oc· RATE CON. CONN NG RACY
2 Pin
LAC03
CY105
VIB TRANSDUCR, HORZ
MOTOR DE BRG HOUSING
1 -- - - - VTH - M6X1 connect
or
L -- - -
LAC03
CY106
VIB TRANSDUCR, VERT
MOTOR DE BRG HOUSING
1 -- - - - VTV - M6X2 -DO- L - - -
VIB TRANSDUCR, HORZ
LAC03
CY107
MOTOR NDE BRG 1 -- - - - VTH - -- - L - - -
HOUSING
VIB TRANSDUCR, VERT
LAC03
CY108 MOTOR DE BRG HOUSING
1 -- - - - VTV - - - L - - -
4-20mAO/P
LAC03 0-50 MM/SEC,
CY203
VIB MONITOR MOTOR DE 1 -- - - -- VM
RMS
CUBICALE 11 (H) 18(H-H) MM/SEC -- Signal Cubicle
Location UCR
4-20mAO/P
VIB MONITOR MOTOR 0-50 MM/SEC,
LAC03
CY204 NDE
1 -- - -- - VM
RMS
CUBICALE 11 (H) 18(H-H) MM/SEC - Signal Cubicle
Location UCR
I(D)-HYDRAULIC COUPLING (SUPP~IED ALONG WITH HYDRAULIC COUPLING)

LAC23CP HC 2.2(L-L) BFP MTR STOP TIME DELAY
CONTROL OIL PRESS 3 OIL 3 - - PT 0-6 B - < 2.5 kg/em'
.
101 to 103 LGB 2/3LOGIC
> 1.2 I BFP MTR START
5.SEC
LAC23CP LUBE OIL HEADER HC > 31 AOP STOP

104 to 106 PRESSURE
3 OIL 3 50 -- PT 0-6 B
LGB
< 1.0 (L)
< 1.2 I AOP START
2/3 LOGIC
< 0.8 MTR STOP

LAC23 HC DIFF.PRE.ACROSS OIL HC
CP107 FILTER
1 OIL 3 50 - PDT 0.14-1.0 E
LGB
±1 0.6(H) kg/em'
LAC23 HC DIFF.PRE.ACROSS OIL HC

CP301 FILTER
1 OIL 3 50 - PDI 0-4 A
LGB
±1 -
LAC23 HC
CP302
LUB OIL PRE. HEADER 1 OIL 3 50 - PI 0-6 G
LGB
±1 -
LAC23 HC
CP303
WORKING OIL PRE. 1 OIL 3 - -- PI 0-6 G
LGB
±1 -
LAC23 4 WIRE DUPLEX
CT101
HC BRG- 1 TEMP. 1 METAL - 85 - TE 0-120 G L ±1 go·qH) 95•c (H-H) (T)
RTD
LAC23
CT102
HC BRG- 2 TEMP. 1 METAL - 85 ·- TE 0-120 G L ±1 so·c(Hl 95•c (H-H) (T) -do-
LAC23
CT103
HC BRG- 3/4 TEMP. 1 OIL - 85 -- TE 0-120 G L ±1 so·qH) WC (H-H) (T) -do-
LAC23
CT104
HC BRG - 5TEMP. 1 METAL - 85 - TE 0-120 G L ±1 go•c(H) 95•c (H-H) (T) -do-
LAC23
CT105
HC BRG - 6 TEMP. 1 METAL - 85 - TE 0-120 G L ±1 so·c(H) 95•c (H-H) (T) -do-
LAC23
CT106
HC BRG - 7 TEMP. 1 METAL - 85 -- TE 0-120 G L ±1 WC(H) 95•c (H-H) (T) -do-
LAC23
CT107
HC BRG- 8 TEMP. 1 METAL - 85 -- TE 0-120 G L ±1 so·c(H) 95•c (H-H) (T) -do-
LAC23
CT108
HC BRG- 9/10 TEMP. 1 OIL - 85 -- TE 0-120 G
: L ±1 so·c(H) WC (H-H) (T) -do-
LAC23
CT109
HC BRG- 11 TEMP. 1 METAL - 85 - TE 0-120 G L ±1 so·qH) 95"C (H-H) (T) -do-
LAC23
CT110
HC BRG- 12 TEMP. 1 METAL - 85 - TE 0-120 G L ±1 so·c(H) 95•c (H-H) (T) -do-
LAC23CT ,WORKING OIL TEMP. UP
111 to 113 STREAM OF COOLER
1 OIL 3.5 100 - TE 110-190 G L - 110"C(H) 13o•c (H-H) (T) 2/3 LOGIC -do-
SHEET70F8
--- --------·-------- -- --~- ~------- ------

QT OPERATING CONDITION SPECIFICATION SET POINT
KKS
DESCRIPTION Y/P PRE kg/ TEMP FLOW PROC. ELEC MOUNTI ACCU
REMARKS
TAG RANGE ALARM TRIP /INTERLOCK
MP FLUID cm2 oc RATE SYM
CON. CONN NG RACY
LAC23 WORKI. OIL TEMP DOWN 4 WIRE DUPLEX

CT114 STREAM OF COOLER
1 OIL 3.5 65 - TE 20-95 A L - 75"C(H)
RTD
LAC23 LUB OIL TEMP. UPSTREAM
CT115 OF COOLER
1 OIL 3 60 - TE 20-95 G L - 70"C(H) -do-
LAC23CT LUB OIL TEMP. DOWN

116to118 STREAM OF COOLER
3 OIL 3 50 - TE 20-95 A L - 55"C(H) 60"C (T) 2/3 LOGIC -do-
LAC23 HC
CT301
HC BRG- 1 TEMP. 1 METAL 2 85 - Tl 0-120 D
LGB
±1 - SUPPLIED WITH
LAC23 HC
CT302
HC BRG • 2 TEMP. 1 METAL 2 85 - Tl 0-120 D
LGB
±1 -
LAC23 HC
CT303
HC BRG- 3/4 TEMP. 1 OIL 2 85 - Tl 0-120 D
LGB
±1 -
LAC23 HC
CT304
HC BRG- 5TEMP. 1 METAL 2 85 - Tl 0-120 D
LGB
±1 -
LAC23 HC
CT305
LGB
±1 -
LAC23 HC
CT306
HC BRG -7 TEMP. 1 OIL 2 85 - Tl 0-120 D
LGB
±1 -
LAC23 HC
CT307
HC BRG- 8 TEMP. 1 METAL 2• 85 - Tl 0-120 D
LGB
±1 -
LAC23 HC
CT308
HC BRG- 9/10 TEMP. 1 OIL 2 85 - Tl 0-120 D
LGB
±1 -
LAC23 HC
CT309
LGB
±1 -
LAC23 HC
CT310
HC BRG- 12 TEMP. 1 METAL - 85 - Tl 0-120 D
LGB
±1
LAC23 WORKING OIL TEMP. UP HC
1 OIL 3.5 100 - Tl 0-160 G
LGB
--:!:1
LAC23 WORKI. OIL TEMP DOWN HC
C.T312 STREAM OF COOLER
1 OIL 3.5 65 - Tl 0-120 G
LGB
±1
LAC23 LUB OIL TEMP. UPSTREAM HC
CT313 OF COOLER
1 OIL 3 60 -- Tl 0-120 G
LGB
- -
LAC23 LUB OIL TEMP. DOWN HC
1 OIL 3 50 - Tl 0-120 G
LGB
- -
LAC23 MIN-90
CL101
HC TANK OIL LEVEL 1 OIL - 50 - LT L ±1
MAX-210
LAC23 HYDRAULIC COULING
CL301 TANK OIL LEVEL
1 OIL - 50 - Ll 0-232 L ±1
LAC23
CS101
BFPSPEED 1 -- - - -- ST - L - - 4-20mATO
DDCMIS(Speed)
LAC23 4-20mATO
CS102
BFPSPEED 1 -- - - - ST - L - - DDCMIS(Speed)
LAC23 HC SCOOP TUBE (I) MIN.POSITION,
CG201 POSITION
1 -- - - - LMS -- L - STARTBFP
LIMIT SWITCH
SHEET 8 OF 8
~~=----~ ~~=-------~ ~~~--------~
~- ~
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01 9.3.1 0 CHECKED
APPROVED
Revised as per Jindal
02 10.4.1 0 1-"C':':':'HE~C~KE"=:D::----~
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Revised as per Jindal
CHECKED
APPROVED
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0:: :::> HY-DG-4-FP11870 02
- F'Q R- -'1'-l) -BF'-P SE'I' - ~·-~ -
SHT.NO. 01 I NO.OF SHT. 06 ~ ~ ·r
I
INSTRUMENT SCHDULE FOR TO BFP SET DRG. NO. HY-DG-4-FP11870
BHEL 4 X600 MW, UNITS, JINDAL POWER LIMITED. SHEET : 02 OF 6

HYDERABAD
LEGEND REV.NO.: 02
INSTRUMENT:
PI -PRESSURE INDICATOR Tl -TEMP. INDICATOR VTH -VIBRATION TRANSDUCER HORIZONTAL

PT - PRSSURE TRANSMITTER TIA -CONTACT TEMP. INDICATOR VTV -VIBRATION TRANSDUCER VERTICAL
PDI - DIFFL. PRESSURE INDICATOR TE - RTD, pt-100 OHMS AT o•c,4-WIRE VM -VIBRATION MONITOR
PS - PRESSURE SWITCH Ll -LEVEL INDICATOR
ST - SPEED TRANSMITTER LT - LEVEL TRNSMITTER
PDT - DIFFL. PRESSURE TRANSMITTER LD -LEVELDETECTOR
LMS -LIMIT SWITCH
FW -FEED WATER A - 1/2" NPT{M) I -INTER LOCK L -LOCAL

sw -SEAL WATER B - 1/2" NPT{F) H -HIGH UCR - UNIT CONTROL ROOM
cw -COOLING WATER c - 3/4" NPT{F) H-H -HIGH HIGH LGB - LOCAL GAUGE BOARD
OIL -OIL D - G 3/8" L -LOW {FOR GAUGES & SWITCHES)
METAL- METAL E - 1/4" NPT{F) L-L -LOW LOW LIR - LOCAL INSTRUMENT RACK
F - PLUG IN SOCKET TYPE TD -TIME DELAY {FOR TRANSMITTERS)
G - G 1/2" DT - DIFF. TEMP
NOTE:-
-REPEATABILITY IS INDICATED IN PLACE OF ACCURACY FOR ALL THE SWITCHES.
-OPERATING CONDITIONS GIVEN FOR INSTRUMENTS ONLY FOR INFORMATIVE.
- KKS TAG NOS. FOR TDBFP-A ARE INDICATED AS LAB 1O,LAC1 O,LAC01,LAC11,PGB41.
KKS TAG NOS. FOR TDBFP-B MAY BE READ AS LAB20,LAC20,LAC02,LAC12,PGB42.
UNITS:-
PRESSURE : Kg/Sq.cm & mmwc
TEMPERATURE : Deg.C
SHEETZ OF 6
!
/,.--~\
'
.~
' '
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I' i
! /
-· 1
!
!
· OPERATING CONDITION SPECIFICATION SET POINT

KKS QTY/
DESCRIPTION PMP PRE kg/ TEMP FLOW PROC. ELEC MOUNTI ACCU REMARKS
TAG FLUID SYM RANGE ALARM TRIP /INTERLOCK
em~ oc RATE CON. CONN NG RACY
I I
1. FEED WATER LINES, REFER DRG. HY-DG-1-18000-56878

I : -
LAB10 DIFF.PR.ACR BP SUCT
1 FW 0.1 163 1100 PDT 0~6400 B F LIR ±0.1 1500(H) 2000(H-H)
CP020 STRAINER
LAB10 DIFF.PR.ACR BFP SUCT
1 FW 0.1 163 1100 PDT 0-6400 B F LIR ±0.1 1500(H) 2000(H-H)
CP021 STRAINER
LAB10
BFP SUCT PRESSURE 1 FW 26 163 1100 PT 0-40 B F LIR ±0.1 15 kg/cm'(L) 10kg/cm'(T) TD-10SEC
CP022
LAB10 BFP DISCHARGE FEED 40 (L) kg/cm'TD-10SEC
CP023 WATER PRES
1 FW 208 163 1100 PT 0-250 B F LIR - At min soeed
I
'
>35 kg/em' (I)
I (a)StartAOP.
! INCASE OF BFP
LAB10 b )Solenoid valves 92&93 of the rapid
BFP SUCTION PRESSURE 1 FW 26 163 1100 PT 0-40 B F LIR ±0.1 REVERSE
CP024 start device must be switched off.
ROTATION
c)Move scooptube to 100% position
i d) Close the disch valve DV.
LAC10 BFP-BC LEAK OF
1 FW 26, 163 30 PT 0-40 B F LIR ±0.5 30 (H) kg/cm 2
CP025 PRESSURE
LAB10 B.P. SUCTION
CP501 PRESSURE
1 FW 9.201 163 1100 PI 0-16 A - LGB ±1 -••w•
LAB10 B.P. DISCHARGE

CP502 PRESSURE
1 FW 26 163 1100 PI 0-40 A - LGB ±1 -----
LAB10 BFP SUCTION
CP503 PRESSURE
1 FW 26 163 1100 PI 0-40 A - LGB ±1 -----
LAB10 BFP DISCHARGE
CP504 PRESSURE
1 FW 209 163 1100 PI 0-350 A - LGB ±1 -----
LAC10 BFP-BC LEAK OF
CP505 PRESSURE
1 FW 26 163 30 PI 0-40 A - LGB ±1 -----
LAB10 DIFF.PR.ACR BP SUCT
CP520 STRAINER
1 FW 0.1 163 1100 PDI 0-5000 A - LGB ±1 -----
LAB10 DIFF.PR.ACR BFP SUCT
1 FW 0.1 163 1100 PDI 0-5000 A - . LGB ±1 ----
CP521 STRAINER
LAB10CT BFP SUCT.FEED WATER DT>15'C-Open RC Valve(l) DUPLEXRTDS
020to 022 TEMP.
3 FW 26, 163 1100 TE 0-200 A c L ±1
DT(DCS
DT> 10'C (H)
LAB10CT BFP DISCH.FEED WATER DT>15'C&Fiow less than speed CONTACT2/3
023 to 025 TEMP.
3 FW 208 163 1100 TE 0-200 A c L ±1
depend set point of RC Flow minus LOGIC)
LAC10
CT101
BFP BARREL TEMP., TOP 1 METAl -, 163 --- TE 0-200 A c L ±1 DUPLEXRTDS
DT22'C (H) DT(DCS
LAC10 BFP BARREL TEMP.,
CT102 BOTTOM
1 METAl ...! 163 - TE 0-200 A c L ±1 CONTACT)
LAB10 BFP SUCT.FEED WATER
CT520 TEMP.
1 FW 26 163 1100 Tl 0-200 A --- LGB ±1 -
LAB10 BFP DISCH.FEED WATER
CT521 TEMP.
1 FW 2o8 163 1100 Tl 0-200 A --- LGB ±1 -
SHEET3 OF6
--- -------· -- --- - -- -----

KKS QTY/
I
DESCRIPTION REMARKS
TAG PMP FLUID I PRE kg/ I TEMP I FLOW I PROC.I ELECII MOUNTII ACCU
SYM I RANGE ALARM TRIP /INTERLOCK
cm2 OC RATE CON. CONN NG RACY
2. SEAL WATER AND COOLING MATER LINES, REFER DRG. HY-DG-1-18000-56879

PGB41 BP MECH SEAL COOLER- 4 WIRE DUPLEX
1 sw 11 60 - TE 0-120 A c L ±1 80"C(H)
RTD
1 sw 10.5 60 - TE 0-120 A c L ±1 70"C(H) -do-

1 sw 11 60 - TE 0-120 A c L ±1 80'C(H) -do-

1 sw 10.5 60 - TE 0-120 A c L ±1 70'C(H) -do-
PGB41 BFP MEG SEAL COOLER-

1 sw 29 60 - TE 0-120 A c L ±1 80'C(H) -do-

1 sw 28.5 60 - TE 0-120 A c L ±1 70'C(H) -do-
1 sw 29 60 - TE 0-120 A c L ±1 80'C(H) -do-

1 sw 28.5 60 - TE 0-120 A c L ±1 70'C(H) -do-
CT109 NDE C.W OUTLET TEMP
1 cw 4 42 - TE 0-120 A c L ±1 50'C(H) -do-
PGB41 . BP MECH SEAL COOLER-
1 cw 4 42 - TE 0-120 A c L ±1 50'C(H) -do-
CT111 NDE C.W OUTLET TEMP
1 cw 4 42 - TE 0-120 A c L ±1 50'C(H) -do-
1 cw 4 42 - TE 0-120 A c L ±1 50'C(H) -do-
1 sw 11 60 -- Tl 0-120 A --- LGB ±1 -
1 sw 10.5 60 - Tl 0-120 A --- LGB ±1 -
1 SW 11 60 - Tl 0-120 A --- LGB ±1 -
1 sw 10.5 60 - Tl 0-120 A --- LGB ±1 -
1 sw 28.5 60 - Tl 0-120 A --- LGB ±1 -
1 sw 29 60 - Tl 0-120 A --- LGB ±1 -
1 sw 29 60 - Tl 0-120 A --- LGB ±1 -
1 sw 28.5 60 - Tl 0-120 A --- LGB ±1 -
SHEET4 OF6
/,-----..\
I ' )
\, \ j ' J )
-- ' .. _ ~
--
-
KKS QTY/
REMARKS
TAG PMP
3. LUB:E OIL LINES, REFER DRG. HY-DG-1-18000-56880

(A)-B09STER PUMP '
LAC11
CP301
I OIL INLET PR. TO
i BPTHRUST BRG- NDE
1 OIL z: 45 -- PI 0-4 A --- LGB ±1 ---
LAC11 OIL INLET PR. TO BP
CP302
j
I JOURNAL BRG- NDE

1 OIL 2 45 -- PI 0-4 A --- LGB ±1 ---
LAC11 IOIL INLET PR. TO BP 1 OIL 2: 45 - PI 0-4 A --- LGB ±1 ---
CP303 JOURNAL BRG- DE
I
LAC11CT I BRG METAL TEMP BP 4 METAL -- 75 -- TE 0-200 --- --- L ±1 s5·ccHl 1o5·c
SIMPLEX RTD
101 to 104 THRUST BRG (MINIATURE)
LAC11 I BRG METAL TEMP BP 1 METAL ' 65 -- TE 0-200 A c L ±1 a5·ccHl 95•c
4 WIRE DUPLEX
CT105 JOURNAL BRG- NDE RTD
LAC11 I BRG METAL TEMP BP 1 METAL -- 65 -- TE 0-200 A c L ±1 a5·ccHl 95•c -do-
CT106 JOURNAL BRG --DE
LAC11 I OIL DRAIL TEMP BP JOUR 1 OIL 1! 55 - TE 0-120 A c L ±1 a5·c(H) -do-
CT107 BRG-NDE&TH BRG I
LAC11 I OIL DRAIL TEMP BP 1 OIL 1i 55 - TE 0-120 A c L ±1 a5·c(H) -do-

CT108 JOURNAL BRG-DE
LAC11 I BRG METAL TEMP BP- 1 METAL
:
65 - Tl 0-120 A --- LGB ±1
CT301 1NDE
LAC11 I
CT303
I BRG METAL TEMP BP-DE 1 METAL 65 - Tl 0-120 A --- LGB ±1
:
I (B)-BOILER FEED PUMP :
LAC01 OIL INLET PR. TO BFP
CP301
!
I JOURNAL BRG- DE 1 OIL 2i 45 - PI 0-4 A --- LGB ±1 --

I OIL INLET PR. TO BFP I
LAC01
CP302 JOURNALBRG-NDE
1 OIL z: -45 -- PI 0-4 A --- LGB ±1 -
LAC01 I OIL INLET PR. TO
'
CP303 1BFPTHRUST BRG
1 OIL 2
I
45 - PI 0-4 A --- LGB ±1 --
LAC01 i BRG METAL TEMP BFP 1 METAL -- 65 - TE 0-200 A c L ±1 s5•c
4 WIRE DUPLEX
CT103 JOURNAL BRG - DE a5·ccHl RTD
LAC01 I BRG METAL TEMP BFP 1 METAL -- 65 - TE 0-200 A c L ±1 as·ccHl ss•c 4 WIRE DUPLEX
CT104 JOURNAL BRG - NDE RTD
LAC01CT I BRG METAL TEMP BFP I
SIMPLEXRTD
105 to 108 I THRUST BRG
4 METAL ..l. 75 - TE 0-200 --- --- L ±1 a5·cr10 1os·c
(MINIATURE)
LAC01 I OIL DRAIL TEMP BFP 1 OIL 1! 55 - TE 0-120 A c L ±1 a5•c(H)
4 WIRE DUPLEX
CT109 JOURNALBRG-DE RTD
LAC01 II OIL DRAIL TEMP BFP 1 OIL 1! 55 - TE 0-120 A c L ±1 a5·c(H)
4 WIRE DUPLEX
CT110 JOUR BRG-NDE&TH BRG RTD
'
I
'
I
I
I
SHEET50F6
I
I
---~--------- -·--------- --- -·--- . - -------- ------- -- ---- -------
KKS QTY/
REMARKS
TAG PMP
LAC01 BRG METAL TEMP BFP-
CT301 DE
1 METAL - 65 - Tl 0-120 A -- LGB ±1 -
LAC01 BRG METAL TEMP BFP-
CT303 NDE
1 METAL - 65 - Tl 0-120 A - LGB ±1 -
2 Pin
LAC01 VIB TRANSDUCR, HORZ
1 - - - - VTH - M6X1 connec L - - -
tor
LAC01 VIB TRANSDUCR, VERT
1 - - - - VTV - M6X2 -DO- L - - -
LAC01 VIB TRANSDUCR, HORZ
CY103 BFP NDE BRG HOUSING
1 - - - - VTH --- --- -- L - - ---
LAC01 VIB TRANSDUCR, VERT
1 - - - - VTV - -- -- L - - -
0-50 4-20rnAO/P
LAC01
CY201
VIB MONITOR BFP DE 1 - - - - VM MM/SEC, CUBICALE 11 (H) 18(H-H) MMISEC - Signal Cubicle
RMS Location UCR
0-50 4-20rnA 0/P
LAC01
CY202
VIB MONITOR BFP NDE 1 - - - - VM MM/SEC, CUBICALE 11(H) 18(H-H) MMISEC - Signal Cubicle
RMS Location UCR
LAC01
CS101
KEY PHASER FOR BFP 1 - --- - -·- KP L
LAC01
CS201
KEY PHASER MONITOR 1 - -- - -·- KM L
SHEET6 OF6
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02 10.04.10 CHECKED
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Page 2 of4
LIST OF RECOMMENDED ANALOG INPUT TO DDCMIS

MOTOR DRIVEN BOILER FEED PUMP SET
---------------------------------------------------------------------------------------------------------------------------
SLNO DESCRIPTION OF INPUT INITIATING KKSTAGNO.
DEVICE
6 ---------------------------------------------------------------------------------------------------------------------------
~;>., 1. BFP & BOOSTER PUMPS.
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18. BP MECH. SEAL COOLER DE, S.W OUTLET TEMP. RTDPT 100 PGB43 CT 104
19. BFP MECH. SEAL COOLER DE, S.W INLET TEMP. RTDPT 100 PGB43 CT 105
20. BFP MECH. SEAL COOLER DE, S.W OUTLET TEMP. RTDPT 100 PGB43 CT 106
21. BFP MECH. SEAL COOLER NDE, S.W INLET TEMP. RTDPT 100 PGB43 CT 107
22. BFP MECH. SEAL COOLER NDE, S.W OUTLET TEMP. RTDPT 100 PGB43 CT 108
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DEVICE
26. BFP MECH. SEAL COOLER DE, C.W OUTLET TEMP. RTDPT 100 PGB43 CT 112
27. DIFF. PR. ACROSS BP SUC. STRAINER DIFF.PR. TRANSMITTER LAB30CP020
DIFF. PR. ACROSS BFP SUC. STRAINER DIFF. PR. TRANSMITTER LAB30CP021 I
28.
29. BFP DISCHARGE PRESSURE PR. TRANSMITTER LAB30CP023 i
30. BFP SUCTION PRESSURE PR. TRANSMITTER LAB30CP022
31. BFP VIBRATIONS VIBRATION TRANSDUCER LAC03CY101 TO 104
32. BFP SUCTION PRESSURE PR. TRANSMITTER LAB30CP024
33. BFP BC LEAK OFF PRESSURE PR. TRANSMITTER LACS30CP025
2. MOTOR.
1. MOTOR BEARING (BP END) METAL TEMP. RTDPT 100 LAC03 CT 125
2. MOTOR BEARING (HC END) METAL TEMP. RTDPT 100 LAC03 CT 126
3. MOTOR STATOR WINDING TEMP. RTDPT 100 LAC03 CT 111 TO 122
4. MOTOR BEARING (BP END) DRAIN OIL TEMP. RTDPT 100 LAC03 CT 123
5. MOTOR BEARING(HC END) DRAIN OIL TEMP. RTDPT 100 LAC03 CT 124
i
6. MOTOR VIBRATIONS VIBRATION TRANSDUCER LAC03CY105 TO 108
7. MOTOR INLET AIR TEMP. HC SIDE CONT. TEMP. IND LAC03 CT 303 & 304
8. MOTOR INLET AIR TEMP. BP SIDE CONT. TEMP. IND LAC03 CT 305 & 306
9. MOTOR OUTLET AIR TEMP. CONT. TEMP. IND LAC03 CT 307 & 308
3. HYDRAULIC COUPLING.
1. H.C BEARING N0.1 METAL TEMP. RTDPT 100 LAC23 CT 101

---- ------ ------ ------- ------ -- - - - -- --- ------------· - - -------- ---- ------ ---- ---- -- --- -- --- -- -------
3. H.C BEARING N0.3/4 OIL TEMP. RTDPT 100 LAC23 CT 103
8. H.C BEARING N0.9/10 OIL TEMP. RTDPT 100 LAC23 CT 108
9. H.C BEARINGNO.ll METAL TEMP. RTDPT 100 LAC23 CT 109
10. H.C BEARINGNO.l2 METAL TEMP. RTDPT 100 LAC23 CT 110
11. BFP SPEED (4- 20ma SIGNAL) SPEED TRANSDUCER LAC23 CS 101
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Page 4 of4
12. BFP SPEED (4- 20ma SIGNAL) SPEED TRANSDUCER LAC23 CS 102
13. H.C WORKING OIL TEMP.UP RTDPT 100 LAC23 CT Ill TO 113
UP STEAM OF COOLER

DEVICE
14. H.C WORKING OIL TEMP. RTDPT 100 LAC23 CT 114

DOWN STEAM OF COOLER
15. LUBE OIL TEMP. UP STEAM OF COOLER RTDPT 100 LAC23 CT 115
16. LUBE OIL TEMP. DOWN STEAM OF COOLER RTDPT 100 LAC23 CT 116 TO 118
17. CONTROL OIL PRESSURE PRESSURE

TRANSMITTER LAC23 CP 101 TO 103
18. LUBE OIL PRESSURE PRESSURE

TRANSMITTER LAC23 CP 104 TO 106
19. HC DIFF. PR. ACROSS OIL FILTER DIFF. PRESSURE LAC23 CP 107
TRANSMITTER
20. HC TANK OIL LEVEL LEVEL LAC23 CL 101

TRANSMITTER
02 0.04.10 CHECKED CHECKED
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10a::: JOB NO. 329

CUSTOMER: JINDAL POWER LIMITED
I~
u. CONSULTANT
DEVELOPMENT CONSULTANTS PVT.LTD
~- OP JINDAL STPP PH-III 4X600 MW UNITS
STATUS '' CONTRACT PROJECT:
I TAMNAR, RAIGARH CHATTISGARH
SIGN DATE
I!=! ~ BHARAT HEAVY ELECTRICALS LID.
NAME
NO.OF
IC5 HYDERABAD DRN. RAJ. C w- 09.06.09 VAR.
1: ~
0
CKD. M.M.RAO 09.06.09 NA
~- APPD. B.R.KUMAR /!Jk. 09.06.09
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~
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o. NO. ITEMS
I .0> CODE 410 NTS NA FP411885 NA NA
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il g..-- SEQUENTIAL INTERLOCKING CONDITIONS HY-DG-4-FP11885 02
[-~ ~- ~-- --F0R--M0TOR---DRIVEN-B0ILER--FEED PUMP--
SHT.NO: 01 TTOT.SHTS: 06
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HY-DG-4-FP11885
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Sheet 2 of 6

FOR
MOTOR DRIVEN BOILER FEED PUMPS
LEGEND:
BP - BOILER FEED BOOSTER PUMP

HM - DRIVE MOTOR OF FEED PUMP
HC - HYDRAULIC COUPLING
BFP - BOILER FEED PUMP
RV - RECIRCULATION VALVE
sv - SUCTION VALVE
DV - DISCHARGE VALVE WITH MOTOR DRIVE
cwv - ELECTRICALLY OPERATED COOLING WATER VALVE
(for supplying water to air cooler to HM and working oil cooler of HC)
AOP - AUXILIARY LUBE OIL PUMP IN HC, DRIVEN BY ITS OWN MOTOR
SP - SHAFT DRIVEN LUBE OIL PUMP IN HC
FRV - FEED REGULATING VALVE
DPT - DIFFERENTIAL PRESSURE TRANSMITTER
REFERENCE DRAWINGS :
1. Instrumentation schedule of MDBFP Drg. no. HY-DG -4-FP11869.

2. Design characteristic curves of MDBFP set at various speeds Drg. No. HY- DG- 4 -FP11875.
1.0 LUBRICATION SYSTEM OF BOILER FEED PUMP SET :
a) Start up of BFP through hydraulic coupling :
The hydraulic coupling has an auxiliary oil pump AOP driven by its own 415v, 3-phase, 50Hz
motor. In addition, the hydraulic coupling has a shaft driven lube oil pump (SP). On auto, the AOP
shall start automatically with start command given to HM to pre-lubricate the step up gears and
bearings of hydraulic coupling, boiler feed pump, booster pump and motor. When a pressure of
1.2 Kg./Cm 2 is established, HM starts by"the maximum contact from pressure transmitters
tag.nos. LAC23CP104, LAC23CP105 & LAC23CP106 with 2/3 selection after a time delay of 3
sec. When the HM starts, lube pressure increases due to AOP and also SP. When the lube oil
pressure increases approximately to 3.0 Kg./Cm 2 , AOP shall be cut off through pressure
transmitters tag nos .. LAC23CP104, LAC23CP105 & LAC23CP106 with 2/3 selection.
b) Normal running:
During normal running of pump set, the lube oil will be supplied by the shaft driven lube oil pump
(SP) in the hydraulic coupling. If due to excessive leakage or any other reasons, the lube oil
pressure drops down to 1.2 Kg./Cm 2 , the AOP shall be started with an impulse from pressure
transmitters tag nos. LAC23CP104, LAC23CP105 & LAC23CP106 with 2/3 selection. When the
pressure increased to 3.0 Kg./Cm 2 , the AOP may be automatically cut off. This support from
AOP does not amount to normal working condition and hence the operator has to investigate the
fault and rectify the same. If the pressure falls to 1.0 Kg./Cm 2 , an optical and accoustic signal for
low pressure alarm shall be initiated in tag nos. LAC23CP104, LAC23CP105 & LAC23CP106
with 2/3 selection. In case the lube oil pressure further falls down to 0.8 Kg./Cm 2 , the BFP motor
shall be immediately tripped by the minimum contact in pressure transmitters tag nos.
LAC23CP104, LAC23CP105 & LAC23CP106 with 2/3 selection.
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Sheet 3 of 6
c) Tripping and run down of BFP :
Whenever the BFP motor HM is tripped, the AOP shall be automatically switched ON to supply
lube oil during the running down of the BFP set including hydraulic coupling and shall be kept
running for the specified period. The AOP may be manually stopped after the bearing
temperatures come down to normal values.
The AOP and SP are gear type pumps. An adjustable relief valve is provided in the common
discharge line. By adjusting the relief valve, the lube oil pressure at the discharge of AOP/SP is
normally set to about 3.0-4.0 Kg./Cm 2 •
The pressure setting values given above for pressure transmitters in lube oil header after lube oil
cooler and filter are tentative values. These settings may be adjusted as required at the time of
commissioning at site depending on site requirement.
-
'\
2.0 PUTTING THE BFP INTO OPERATION :
The feed pump chosen for operation shall have the following conditions satisfied.(To be
ensured manually.
a) AOP in hydraulic coupling shall be running condition.
b) The isolating valve in cooling water out let line of motor coolers and in inlet & outlet of working oil
coolers and lube oil coolers shall be kept open.
c) The discharge valve (Tag.no 'LAB30 AA011 ') of the BFP shall be kept in closed condition.
'
d) Oil level (Level indicator tag no.LAC23CL301) in the Hydraulic coupling shall be above normal
level.
2.1 The feed pump chosen for operation shall have the following permissive conditions are
satisfied.
a) The BFP motor HM shall be started provided the following permissive conditions are satisfied.
i. Suction valve of BFP (SV) is open (limit switch in SV shall be used)
ii. Lube oil pressure minimum 1.2 Kg./Cm 2 (setting from LAC23CP104, LAC23CP105 &
LAC23CP106 with 213 selection)
iii. Deaerator level shall be above minimum permissive level. ( Not applicable for pump kept in
auto stand by condition )
iv. Recirculation valve shall be in full open condition.
v. Hydraulic coupling scoop tube shall be at minimum position, tag no. LAC23CG?01 (when
scoop tube is driven to 0 % position either by Rapid Start Device or by Normal action)
. b) Simultaneous with the starting of BFP motor HM, impulse shall be given to valve Tag no. E>GB 39. . . .... . . .. . _ ..
AA201 to open for supply of cooling water to air cooler of HM and working oil cooler of HC.
c) Differential temperature across BFP casing top & bottom is not exceeding 22•c (DCS contact
from tag nos. LAC03CT101 & 102)
3.0 CONDITIONS DURING NORMAL OPERATION OF THE FEED PUMP :

At low loads, (approximately 0-33% unit load), the scoop tube shall be controlled by electric
actuator, to vary the speed of the feed pump according to load requirement automatically from
DPT across the feed regulating valve. At higher loads the speed of the feed pumps will be directly
controlled by drum level controller.
4.0 CONDITIONS FOR TRIPPING THE FEED PUMP :

The operating feed pump shall be tripped when any of the following abnormal conditions exist,
with an audio visual signal.
i. Lube oil pressure in~co=-=m~m~o~n.::h-=-ea=-:d:.:e=-=r~v~e=-:ry:ol:::ow-:-:-;,O"."B."K'=g-;;/C=-::m::-:2"fc:-:ro=-=m~tr=a-=-ns:::m=itt=e=rs~(~ta=-=g:-:n::-:o:-:s-.- - - - I - - - - - - +
LAC23CP104, LAC23CP105 & LAC23CP106 with 213 selection)
ii. Working oil temperature high 13o•c from RTDS (tag no.LAC23CT111 to CT113 with 213
selection).
DRG.NO.
HY-DG-4-FP11885
"'"'
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' 0.
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~~ STPP PH- III 4X600 MW UNITS RevNo. 02

]~ Sheet 4 of 6
iii. Working oil pressure low, low, 2.2 Kg./Cm 2 , with time delay 5 sec. from transmitters tag no.
LAC23CP101 to CP103 with 2/3 section.
iv. Deareator level very low. Level switches Tag.nos (LAA01 CL 101/102/103)
v. Suction valve not open.
vi. Differential temperature between BFP discharge and suction feed water very high,(+)15·c.
and Flow Less than "speed dependent set point of RC flow MINUS 50 tlhr with a time delay
of 30 sec.(differential temperature between tag nos. LAC30CT023 to CT025 and
LAC30 CT020 to CT022, DCS contact).
vii. Lube oil temperature down stream of lube oil cooler very high, 6o•c from RTDS tag no.
LAC23CT116 to CT118 with 2/3 selection.
viii. BFP & Booster Pump journal bearings and Hyd.Coupling brgs temp. very high, 95•c from
RTDs( tag nos. LAC03CT103, CT104 & LAC13CT105, CT106 & LAC23CT101 to CT110)
ix. BFP Drive Motor journal bearings temperature very high, 9o•c.
(tag nos. LAC03CT125 & CT126)
x. BFP & Booster Pump thrust bearings temperature very high, 1os•c
(tag nos. LAC03CT105 to CT108 & LAC13CT101 to CT104)
xi. BFP Drive Motor winding temp. very high, 13o•c (tag nos. LAC03CT111 to CT122).
xiii. BFP Suction pressure low 10Kg/cm2 with a time delay of 10sec from Tag no. LAB30 CP022
5.0 WHENEVER THE OPERATING PUMP TRIPS, THE FOLLOWING SHALL OCCUR FOR ITS
OWN AUXILIARIES :
a) AOP shall be started automatically and run for a period of 5 to 10 minutes ( to be set during
commissioning)
b) CVW may be closed with a time delay of 0-5 minutes (to be set during commissioning)
6.0 CONDITIONS FOR PUTTING MDBFP INTO OPERATION WHEN IT IS KEPT AS STAND-BY:
a) DV of the stand-by pump shall be in open condition.(Common Discharge header pressure >50
Kg./Cm 2 from pressure Transmitters tag No. LAB30CP011&012 (MVN).
b) RC valve shall be kept open condition.
c) AOP shall be started with Auto Start command to BFP Drive Motor.
d) The isolating valves in cooling water outlet of motor and in inlet &outlet of lube oil coolers and
working oil coolers shall be kept open.
e) The other permissive conditions for HM starting at cl.no. 2.1 a(i),a(ii),(v) are satisfied.
f) When first pump is running Dearator level adequate permissive not applicable for remote
manually starting of second BFP.
g) Stand by BFP on 'auto' shall not come into operation, whenever running pump trips due to
dearator level very low.
7.0 RAPID START REGULATION OF HYDRAULIC COUPLING:

(Cam control bypass using solenoid valves, refer typical scheme Drg.no. 306 74010 11790 is
enclosed as sheet no.6)
Using this arrangement, the scoop tube is moved from any position towards zero output speed
and back to the direction of full output speed more rapidly than is possible with the actuator.
i. QUICK RUN-UP OF DRIVE MOTOR AND DRIVEN MACHINE BY RAPID DRAINING OF THE
GEARED VARIABLE SPEED TURBO COUPLING (DURING NORMAL START-UP AND AUTO
START-UP OF STAND-BY PUMP):
The two solenoid valves (92 & 93) are energised for rapid runup of main motor under no load.
The energised solenoid valve (92) lets pressure oil flow into the chamber (36) of the scoop tube
positioning cylinder irrespective of the position of the control valve (35). At the same time solenoid
DRG.NO.
HY-DG-4-FP 11885
"'"'
' . PROJECT:
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OP JINDAL STPP PH- III 4 X 600 MW UNITS Rev No. 02
§
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Sheet 5 of 6
I
valve (93) stops the supply of oil and allows the oil into chamber (38) to flow unhindered into the
oil sump. The scoop tube moves to the position of 0% filling.
After run up of drive motor (with approx. 95% of normal speed), the solenoid valves are de-
energised and the scoop tube moves at once to the position fixed by the actuator. The coupling
fills within the specified time and the driven machine runs up to the corresponding speed
(acceleration time 15 sec.).
I
ii. QUICK RUN-DOWN OF DRIVE MOTOR AND DRIVEN MACHINE BY RAPID DRAINING OF
Cl THE GEARED VARIABLE SPEED COUPLING (DURING BFP TRIP I STOP): I
~
~ ~
0..
The two solenoid valves {92 & 93) are energised for rapid drain of the coupling. The scoop tube
:::5 e0 moves in the position of 0% filling as described above. The coupling drains and power
' ·- \ Cl) <) transmission from drive motor to driven machine is interrupted.
I ~]
u4:: 8.0 CONDITIONS DURING REVERSE ROTATION OF STAND-BY PUMP:
1:2 0
~
r-oti
u ~
~:I:) Q) Whenever the stand-by BFP rotates in reverse direction ( BFP Suction Pressure more than 35
o-l'E
~:I:)·- kg/cmsq from transmitter tag no. LAB 30 CP 024 due to passing of discharge NRV, following
Q)
...::~>--:5 interlocks shall occur for its own auxiliaries immediately .

~~B
zf-o~«i'E
~f-oCI)
a) StartAOP.
b) Solenoid valves 92 & 93 of the rapid start device must be switched off (not energized).
~ ~ .§...
.... c) Move the scoop tube to 100% position.
~<as d) Close the discharge valve DV. I
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8~ ......co ~
~ 9.0 SUMMARY OF THE CONDITIONS GIVEN ABOVE :
I
z 0 ;>,
a) Auxiliary oil pump :
<£ §
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following conditions :
~
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0 'Ei ... - For duration of 5 to 10 minutes (to be set during commissioning) subsequent to tripping I
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-----
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i. CVW shall open simultaneously with the starting of HM.
ii. CVW shall close with a time delay of 0-5 minutes (to be set during commissioning) after stopping/
15 tripping of HM.
c) R.C.Valve:
i. During normal start-up of BFP, its RC valve shall be kept open.

ii. For the BFP selected as Auto Stand-by, its RC valve shall be kept open.
iii. RC valve shall automatically open when BFP flow falls to speed dependent set point, with
minimum setting of 250 tlhr.
iv. RC valve shall also open whenever the feed water differential temperature across BFP suction
and discharge rises to 15°C. I
v. RC valve shall open with BFP trip I stop.
<) V'l
0 V'l vi. RC valve shall close when BFP flow increases to (twice speed dependent set point + 50 tlhr), or
Cl 0\
o·
...... (250+50 tlhr), whichever is higher.
......
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Ver.No 1 RDDD173.. 182
VDITH TURBO FUNCTION Qnd MEASURING POINTS DIAGRAM for RlBKGS 14-API Cocle 1 BHEL
79
73 25 s:5
171
84
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'------~~~969
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B<urc~ru>gm .m HusrnstnNnw srmr Lrsto-Hr. 306 74010 naoo CUSTa.tER:I JINDAL POWER LIMITED
FIR ln!GNATIOO AND I£AStRINi INSTRU£111S, SEE LIST Nl 306 74010 11800 OOW.TAHTI DEVELOPMENT CONSULTANTS PVT.LTD
PRO.ECT:I OP JINDAL STPP PH-ill 4X600 MW UNITS
TA11NAR. RAIGARH CHATI'ISGARH
VDITH TURBO PRIVATE LIMITED 306 74010 11790

- TrQnSM I ssons Qncl EngIneer 1ng-
P. 0. INDUSTRIAL ESTATE, NACHARAH, HYDERABAD-500076
PHONEr 27173561. 27173592. fQX No. 27171141 Rev - ' Sheet I of I
CHECKED CHECKED CHECKED
1. APPROVED APPROVED APPROVED ----
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REGD OFFICE: PLOT NO. 12 LOCAL SHOPPING COMPLEX,
10-1'- - - ------- -- -- -- --- ---- - -- --- -- -- -- ------ -- -SECTOR B-I,VASANTKUNJ, NEWDELHI-110070- ---- - ------
I g; LD PHONE: 011-26139256-65 FAX: 011-26121734

I.N WEBSITE : jindalgroup.com
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JOB NO. 324 •
TATA
PROJECT:
CONSULTANT: TATA CONSULTING ENGINEERS LIMITED
2X600MW THERMAL POWER PROJECT

MUMBAI
I AT DERANG, ANGUL, ORISSA

I NAME SIGN DATE NO. OF
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-REQUIR-EMEN'I'g,--BFF&GER - --- ----
I~ SHT.NO. 1 I NO.OF SHT. 5

COMPUTER FILE NAME :-FP12257 COPYRIGHT AND CONFIDENTIAL
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED. TD-106-2
It must not be directly of indirectly in any way detrimental to the intrest of the company REV NO 1
SUMMARY OF COOLING WATER REQUIREMENT FOR MOTOR DRNEN BFP,

D
TURBINE DRIVEN BFP SET(Including BFP Drive Turbine Requirement) & ti:J
1-:!:j
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CONDENSATE EXTRACTION PUMP R"
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A. WHEN 2 NOS OF TO BFPs ARE IN OPERATION AND MD BFP IS IN STAND BY CONDITION. I t-'
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C.W. REQUIREMENT = 392 Cu.m/hr (INCLUDING 90 Cu.m/hr FOR STANDBY MD BFP SET) I
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B. WHEN 1 NO. OF TO BFP & 1 NO. OF MD BFP ARE RUNNING AND 1 NO. OF TO BFP IS N c::
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IN STAND BY. CONDITION. '-1 iS::
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C.W. REQUIREMENT = 526 Cu.m/hr (INCLUDING 31 Cu.m/hr FOR STANDBY TD BFP) U2
C. WHEN 2 NOS OF CEPs ARE IN OPERATION. "U ::u I

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C.W REQUIREMENT FOR 1 !NO. TD BFP SET I '":l:j
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01 I B00STER PUMP JACKET DE & NDE 2 1 2 10 0.5 3 6 NO CONTINUOUS ~

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DUPLEX €DOUBLE) COOLER=2Nos 100% COOLERS, WITH ONE WORKING & ONE STAND BY ()1
COMPUTER FILE NAME:- FP12257 COPYRIGHT AND CONFIDENTIAL
C.W REQUIREMENT FOR 1 NO. MD BFP SET.
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NOS. PER ECW QTY PER
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05 HC WORKING OIL COOLER 1 182 182 15 5 8 10 NO MD BFP ONLY
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QUALITY OF COOLING WATER : OM WATER -'
COOLING WATER INLET TEMP. : 38·c N
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COMPUTER FILE NAM~ :- FP12257 COPYRIGHT AND CONFIDENTIAL

INSTRUMENT AIR ·REQUIREMENT FOR BFP PACKAGE, FOR EACH UNIT

l1
SL EQUIPMENT REQUIRING INSTRUME~T AIR NOS AIR PER VALVE AIR PR ( Kgs/Sq.cm TOTAL INSTRUMENT AIR
NO.
BFE RECIRCULATION VALVE PNEU:MATIC tJ:1
01 3 66,000 Cu.cm 6 1,98,000 Cu.cm 1-:!:j
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. o.. CONSULTANT: DEVELOPMENT CONSULTANTS PVT.LTD
~ ~~------+---------------------------1
~STATUS: CONTRACT PROJECT: OP JINDAL STPP PH-III 4X600 MW UNITS
NAME SIGN DATE NO.OF
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!!liS PREPARATION FOR CARTRIDGE REMOVAL CENTRALISE lHE CRADLE. USING lHE JACKING SCREWS ITEM NO. 19. (WITH CARTRIDGE WITHDRAWN)
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1. ISOLATE PUMP SUCTION AND DISCHARGE. UNTIL lHE RUNNERS MAKE CONTACT WllH lHE ROLLERS.
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;;:; ~ WllH THE CARTRIDGE REMOVAL DO~ BOLTS ITEM N0.18 AND LOCKNUTS ITEM NO. 28.
~!:: 4. REMOVE INSTRUMENTATION CABLES AND CABLE TRAYS 17. POSITION THE HINGED \\1-!Ea STOPS ACROSS lHE CRADLE RUNNERS.
CARffiiDGE WITHDRAWAL
OBSTRUCTING THE CARlRIDGE WllHDRAWAL
5. REMOVE lHE SUCTION BEARING HSG VENT CAP. CARTRIDGE WITHDRAWAL 25. POSITION lHE SUPPORT PLATE ITEM NO. 8 ON lHE PUMP CASING
6. REMOVE lHE COUPLING GUARD AND COUPUNG SPACER. STUDS AND DISTANCE ITEM NO. 9
7. REMOVE lHE PULL UP RING. 18. INSERT JACKING SCREWS ITEM NO. 25 INTO lHE DISCHARGE 26. lHEN USE COVER NUTS TO LOCK TUBE FlT lHE UFTING PLATE
8. REMOVE SPOOL PIECE FOR INTERSTAGE TAPPING. REMOVE COVER. EVENLY TIGHTEN lHE SCREWS TO JACKOUT lHE CARTRIDGE ITEM NO. 21 TO THE SUCTION GUIDE USING SCREWS ITEM NO. 22
INTERSTAGE TAPPING TUBE FROM PUMP CASING. 19. THE JACKING SCREW ITEM NO. 17 AND JACK ITEM NO. 7 MAY REQUIRE AND FIT EYE BOLT ITEM NO. 20 AT DISCHARGE CARTRIDGE.
F INDIVIDUAL ADJUSlMENT TO ENSURE SMOOTH REMOVAL OF THE CARTRIDGE F
27. FIT UFTING SUNGS, TAKE UP SLACK AND SUPPORT lHE CARTRIDGE.
20. MOVE lHE CARlRIDGE TO lHE FlRST STOP POSITION AND
ASSEMBLY OF WITHDRAWAL GEAR AT SUCTION END FlT lHE SECOND EXTENSION SLEEVE ITEM N0.6 USING 28. UNBOLT THE SECOND EXTENSION SLEEVE ITEM NO. 6 FROM THE
SCREWS ITEM N0.29, 30 FlRST EXTENS10N SLEEVE ITEM NO. 5 AND JACK OFF AT
21. MOVE lHE CARTRIDGE TO lHE SECOND STOP POSITION SPIGOT LOCATION.
9. SECURE THE FIRST EXTENSION SLEEVE ITEM N0.5 TO lHE SUCTION
END BEARING HOUSING WllH SCREWS ITEM N0.12 AND NO 24 AND FIT THE THIRD EXTENSION SLEEVE ITEM N0.6 29. THE CARTRIDGE CAN BE UFTED AWAY.
10. FIT THE CARTRIDGE TENSIONING SCREW ITEM N0.1 0 AND USING SCREWS ITEM NO. 29. 30
TIGHTEN NUT ITEM NO. 11 UNIT, ALL CARTRIDGE MOVEMENT IS 22. MOVE lHE CARTRIDGE TO lHE lHIRD STOP POSITION AND
TAKEN UP FIT THE FOURTH EXTENSION SLEEVE ITEM N0.6
USING ITEM NO. 29,30. JiQIE__;_
11. LOCATE lHE SUCTION END JACK ITEM NO. 7 ON lHE BASEPLATE
THE CARTRIDGE TENSIONING SCREW ITEM NO. 10 AND NUT
PAO. CENTRALISE THE ROLLER USING lHE SLOTS PROVIDED ON 23. MOVE lHE CARTRIDGE TO lHE FOURlH STOP POSITION AND
G ITEM NO. 11 MUST NOT BE REMOVED DURING TRANSIT. G
lHE JACK BASE. JACK UP THE ROLLER UN11L GOOD CONTACT IS FlT lHE FlFTH EXTENSION SLEEVE ITEM N0.6 USING
r-- MADE WITH lHE FlRST EXTENSION SLEEVE. TIGHTEN SCREWS ITEM N0.13 SCREWS ITEM NO. 29,30.
.. o 24. lHE CATRIDGE MAY NOW BE FULLY WllHDRA~.
VALID FOR AP GENCO, VUAYAWADA SOOYW & KAKATHIYA 500YW•
~~ ASSEMBLY OF WITHDRAWAL GEAR AT DISCHARGE END

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12. USING lHE HYDRAUUC TENSIONING GEAR PROVIDED SLACKEN OFF
SUCTION END ROLLER JACK WHEN FlTllNG EXTENSION I"FOR INFORMATION" I
AND REMOVE THE DISCHARGE COVER TO PUMP CASING NUTS.
13. BOLT lHE TOOLS ITEM NO. 15 (FOR MD) I 16(FOR lD) TO lHE FLOOR SLEEVES. USE lHE HINGED STOPS PROVIDED TO PREVENT
~ MOVEMENT ON CRADLE.
WITH BOLTS ITEM NO. 23,26 & 30. AND FOUNDATION PLATE N1PC DRG.NO. 4230-4231-110-04HY-PVY-K-005, REV.-01
ITEM NO. 27(FOR MD) I 31(FOR lD). NATIONAL lHERMAL PO~ CORPORATION LlD.
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KNiALGOAN SUPER lHERMAL. POY£R PRO..ECT
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14. LOCATE THE WllHDRAWAL CRADLE ITEM NO. 1. lHE BASE PLATE AND
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STAGE-I. PHASE-I {2X!500 WW)
TOOLS ITEM NO. 15{FOR MD) I 16(FOR TD) FIT THE ROLLER S'T'EAW 1UR9t£ COERATOI't PACKAGE
-~ ASSEMBUES ITEM NO. 2,3(FOR MD) / -4-(FOR lD) WllH ITEM NO. 14 -- ---------~~~------------ ---------------------.-------. ......==::=====--,-tle~~Z~~~F=====:;;;;:;,;;::;:::;~~-~-~N-"'~E::f-~s~oo:~-~~D"~•TEg::;;!=1
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FIRST A,NGLE PROJECTION
(All DIMENSIONS ARE IN mm)
806"7 SOO 08~ E
METHOD FOR DETECTING THIS TYPE METHOD FOR DETECTING THIS TYPE PARALLEL ALIGNMENT
OF ERROR - PARALLEL OF ERROR - ANGULAR
1. Clamp a dial gauge to the coupling halves or hubs as shown in Sketch-1 or 2
- - as applic.able and zero the gauge.
2. Link the coulping halves so that both shafts can be rotated together.
Mark each coupling half or hub with a coincident line.
3. Rotate both shafts and take readings at each quarter revolution. If the
shafts are not linked together, move first one shaft through a quarter
revolution then move the other shaft until the lines marked in Para-2 cohlCide.
Take a reading and repeat at each quarter revolution.
ANGULAR ALIGNMENT :
~- Clamp a dial gauge to one coupling hub (Sketch-3) or two gauges to coupling
halves (Skecth-~1 as applicable and zero the gauge.
5. Mark or link the coupling halves or hubs as described in Para 2, Parallel alignment.
6. Rotate both shafts through 180° and note the gauge readings.
The angular alignment is correct, if :-
Sketch-3 : The gauge reading is the same.
Sketch-4 : The gauge readings are the ,same. (but not necessarily zero)
7. Rotate both shafts through a further 90° and check the gauge reading as
explained in Para 6 above.
SKETCH-1 SKETCH-3
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DATA SHEET FOR BOILER FEED PUMP SET
7.0 BOILER FEED PUMPS & ACCESSORIES
7.1 General
7.1.1 Model Number No FK4E36(BFP) &

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FA I B75(BP)
1- ;>, 7.1.2 Manufacturer BHELIHYDERABAD
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7. 1.3 Number of BFP sets per STG Unit Nos. 3 (2TD +I MD)
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7.1.4 Liquid handled FEED WATER
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Design And Performance Data (Capability
7.2 Main BFP Booster pump
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m /hr 1240 1240
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1-~C. 5805(MDBFP) 1495(MDBP)
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5805(TDBFP) 1495(TDBP)
1- C.·- 7.2.6 Suction pressure of BP at rated capacity Kg/cm 7.874
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2
25.23
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217
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7.2.9 Total dynamic head at rated speed and capacity Mlc 23 I 5 mlc (BFP+BP)
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7.2.10 Maximum shut off head Mlc

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7.2.11 NPSH required
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(a) At design flow mlc 68.7 5.9
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7.2.12 Efficiency at design point % 80.0 82.2
..<:: Power input to pump set (main pump, booster
1- 7.2.13 kW 10231
pump & hydraulic coupling) at rated flow &
head
7.2.14 Suction specific speed US Units 7374 8465
7.2.15 Bearing Housing Vibrations mm/sec NORMAL -7
HIGH - 11
RMS
V. HIGH - 18
Revisions: Prepared: Approved: Date:

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7.3.1 Power required by pump kw 8097/MD 713 MDBP

8097/MD 713 TDBP
7.3.2 Power loss in hydraulic coupling kw 1420
7.3.3 Power input to motor kw 10547
7.3.4 Max.noise level at 1.5m from pump outline dB A 85
7.4 Construction Features of Boiler Feed Pumr;1 Main Pumr;1 Booster r;1ump
7.4.1 Casing type BARRAL SPLIT
7.4.2 Impeller arrangement Horizontal series Horizontal
7.4.3 Number of stages 4
7.4.4 Journal bearing ,type THICK WALL BABIT LINED
(SLEEVE TYPE)
7.4.5 Thrust Bearing ,type TILTING PAD
7.4.6 Type of axial balancing device DRUM -NA-
7.4.7 BFP suction strainer
(a) Type Conical Type Basket type
(b) Strainer mesh size, fine mm 195microns 315microns
7.5 Materials of Construction Main Pumr;1 Booster Pump

(Indicated to which standard it confirms to)
(a) Inner casing BS: 1504-425-Cll NA
(b) Outer casing BS:970-150-MI9 BSI504161 Gr.430
(c ) impellers BS:I504-425-CII ~81504425 Cll
(d) DiffusereN olute BS: 1504-425-Cll NA
(e)Casing wearing rings material/hardness

FV520B/363-40 I FV520B (363-401)
(BHN)
(f)Impeller wearing rings material/hardness
FV520B/363-401 BSI504425CII
(BHN)
(g) shaft BS:970-420-529R BS970420S29 'R'
(h) Shaft nuts BS:2872,CAI04 NA

(AI Bronze)
(i) Shaft sleeves
G) Shaft sleeve nuts NA
(k) stuffing box NA
(1) Stuffing box bushing
(m) Balancing device BS:970-431-S29
- -------- - - - - - --------- - - - - - - - - -- - - -
--- ----------~---------
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(n) Pressure bolting studs DIN EN I 0083/CrMo4 (Alloy

St. Bar)
(o) Nuts -do-
(p) Base plate IS:2062
(q) Suction and Discharge nozzle BS1504-161-430
(Suction) BS 1504161 Gr 430
BS970-150-M 19 Sue.& D1s
(Discharge)
0 (r) Hydraulic coupling
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§ (i) Coupling wheels
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U""" 7.6 Lubrication Oil System for each BFP Shaft A.C D.C
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Driven Emergency Standby
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7.6.2 Number of pumps Nos I I
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7.6.6
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(a) Shell material DIN1626, DIN2458
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(b) Channel material DINENI561
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7.8 Hydraulic Coupling for each BFP I No.
7.8.1 Type Rl8KGS
7.8.2 Manufacturer M/s. VOITH, INDIA
7.8.3 Input motor speed 1495 rpm
7.8.4 Gear ratio LATER
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7.8.5 Primary start-up speed LATER

7.8.6 Full load slip LATER
7.8.7 Secondary speed(maximum) 6010 rpm
7.8.8 Number of bearing I type JRNL-8
THRUST-2
7.8.9 Performance
(a) Slip between impeller and runner at normal
§,_ >. load
~ (b) Maximum possible slip between impeller
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and runner at design ratings of driven
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7.8.12 Working oil cooler

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(b) Shell material DIN1626, DIN2458
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7.11.4 Any other codes I standards NA
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JOB NO. 324
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STATUS CONTRACT
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CUSTOMER: JINDAL INDIA THERMAL POWER LIMITED
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REGD OFFICE: PLOT NO. 12 LOCAL SHOPPING COMPLEX,
...-- SECTOR B-1,VASANT KUNJ, NEW DELHI-110 070
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CONSULTANT: TATA CONSULTING ENGINEERS LIMITED
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ATDERANG, ANGUL, ORISSA
NAME SIGN DATE
NO.OF
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LIST OF RECOMMENDED ANALOG INPUT TO DDCMIS

MOTOR DRIVEN BOILER FEED PUMP SET
---------------------------------------------------------------------------------------------------------------------------
SLNO DESCRIPTION OF INPUT INITIATING KKS TAG NO.
DEVICE
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[::: ;.,:, I. BFP & BOOSTER PUMPS.
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:J E I. BFP BEARING (DE) METAL TEMP. IUD PT 100 LAC03 CT 103
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(.) (.) 13. BFP BARREL TEMP. TOP RTD PT 100 LAC03 CT 101
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..s:: 18 . BP MECH. SEAL COOLER DE, S.W OUTLET TEMP. RTD PT 100 PGB43 CT 104
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19. BFP MECH. SEAL COOLER DE, S.W INLET TEMP. RTDPT 100 PGB43 CT 105
20. BFP MECH. SEAL COOLER DE, S.W OUTLET TEMP. RTD PT 100 PGB43 CT 106
21. BFP MECH. SEAL COOLER NDE, S.W INLET TEMP. RTD PT 100 PGB43 CT 107
22. BFP MECH. SEAL COOLER NDE, S.W OUTLET TEMP. RTD PT 100 PGB43 CT 108
23. BP MECH. SEAL COOLER NDE, C.W OUTLET TEMP. RTD PT 100 PGB43 CT 109
24 . BP MECH. SEAL COOLER DE, C.W OUTLET TEMP. RTD PT 100 PGB43 CT 110
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SECTION-C
LIST OF DRAWINGS
01. Sectional Assembly of CEP

, ..
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) 02. General Arrangement of CEP
03. Schematic diagram of Sealing and Cooling water for CEP

04. Instrumentation Scheme for CEP
05. Instrumentation Schedule for CEP
06. Recommended list of analog inputs to owner's DDCMIS for CEP

07. Sequential Interlocking conditions of CEP
08. Thrust bearing withdrawal & assy tools
09. Impeller withdrawal & assy tools
10. 'C' Spanner (Var.no. 12 & 13)
Informative Drawings
( I
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11. Estimated Performance Curves of CEP NPSHR
12. Estimated Performance Curves of CEP
13. Design characteristic curves of 2 CEPs in operation
14. Technical Data of CEP
I
'---
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FIRST ANGLE PROJECTION ALL DIMENSIONS ARE IN mm
2 3 4 5 6 7 8 9 10 11
8889 900 l8l l
t
'ON 'Sl:IO
A . A
UP TO MOTOR STOOL TOP (23361 I 7565
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3606 3167 2607

TOP SHAFT INTERMEDIATE SHAFT BOTTOM SHAFT
ITEM DESCRIPTION MATERIAL REF. DIAMETRAL CLEARANCE(MINIMAX) NQTE FOR ROTQR WEIGHTS
1 CANISTER IS : 2062 GR.B A 0.1310.23mm 1. CEP.
2 SUCTION BELL MOUTH BS 1452 Gr260 B 0.4 710.64mm RUNOUT OF ROTOR 0.75MM MAX. (INCLUDING FOUNDATION RING &
3 1St STAGE LOWER BRG. BRASS/RUBBER LINED (BS:2872 Alloy CZ 126 EUNT) c 0.1310.23mm OR AT 0.125MM PER METER LENGTH. CANISTER) =9150Kgs.
4 1St STAGE UPPER BRG. BRASS/RUIIBER LINED (BS:2872 Alloy CZ 126 EQNTl D 0.4710.64mm ' 2. FOUNDATION RING. = 580Kgs.
BS 1504 1,25 C11 E 0.3010.35mm E
5 1St STAGE IMPELLER ASSY
i
3. CANISTER. =2682Kgs.
6 1St STAGE CASING ASSY BS 1452 Gr260 F 0.3010.35mm
7 IN TERMED IA TE STAGE CASING BS 2789 Gr420112 H 3 TO 5mm AXIAL 4.MOTOR =5500 Kgs
8 DELIVERY CASING BS 2789 Gr420112
9 INTERMEDIATE STAGE IMPELLER ASSY BS 1504 425 C11
10 FOUNDATION RING ASME SA 106 GR.B
11 ELEMENT I ASSY ASHE SA 106 GR.B
17 Fl FMFNT II A<;SY ASME SA 106 GR.B
NOTE TO ERECTION
13 ELEMENT Ill ASSY ASHE SA 106 GR.B 1. CEPs ARE SUPPLIED AGAINST DES NO. F1501 1\tiiCH INC1.UDES MOTOR STOOL. HEAD GEAR
WITH DISCH. COUNTER FLANGES AND WITH OUT CANNISTER, FOUNDATION RING &: COUPLINGS
14 ELEMENT IV ASSY ASHE SA 106 GR.B
BRASS/RUBBER LINEO(BS:2872 Alloy CZ 126 EQNT) 2. BEFORE CHARGING THE PUMP/DISCHARGE PIPE UNE REPLACE THE DUMMY PLATE AVAILABUE
15 INTERMEDIATE BRGS
BETWEEN DISCHARGE FLANGE/COUNTER FLANGE WITH CAF GASKET SUPPLIED AGAINST DES NO. F1510
F 16 HEAD PIECE ASSY IS : 2062 GR.B F
3. THE ADAPTER PLATE LOCATED BETWEEN THRUST BEARING BASE PLATE (HOUSING) AND HEAD PIECE
17 SHAFT BOTTOM BS 970 420 S37R
DETERMINES THE POSITION OF ROTATING ASSEMBLY WIHEN THE THRUST BEARING AND THRUST NUT ARE
18 SHAFT INTERMEDIATE BS 970 420 S37R
ASSEMBUED. DURING MANUFACTURE OF THE PUMP SET, THE ADOPTER PLATE IS MACHINED TO SPECIFIC
19 SHAFT TOP BS 970 420 S37R
THICKNESS, FOR SETTING THE ROTOR POSITION. LOOSENING OF THRUST NUT OR REt.IOVAL / REPLACEMENT
20 SHAFT SLEEVE BS 970 420 S37R
OF ADOPTER PLATE WILL RESULT IN DISTURBANCE .OF ROTATING ASSEMBLY POSITION, THEREBY LEADING TO
21 SHAFT COUPLINGS BS 970 420 S37R DAMAGE OF PUMP. HENCE, IT IS NOT RECOMMENDED TO CHECK OR ADJUST 'FLOAT AT SITE DURING ERECTION.
22 MECHANICAL SEAL -- -4-. IN CASE OF LOOSENING/REMOVAL OF THRUST NUT FOR MAINTENANCE ON PUMP, THE THRUST NUT SHALL BE
23 THRUST BRG. -- TIGHTENED FULLY AFTER LIFTING THE ROTOR ASSEt.IBLY TO THE TOP MOST POSITION.
24 MOTOR STOOL IS : 2062 GR.B 5. THRUST COI..l.ER NUT IS PRO'<lDED WITH ADDillONAL UENGTH FOR MACHINING AT SITE DEPENDING ON THE
25 CONNECTING COUPLING HUB -- UENGTH OF THE PUMP SIDE COUPLING HUB IN SHAFT EXTENSION OVER THE THRUST COLLIER NUT.
26 RAISING MAIN BS1501161 Gr430
THRUST BEARING CW CONNECTIQNS
G 27 SNUBBER IS :1570 GR 15C8 G
1. DO NOT LOOSEN THE BOTTOI.I NUT(ABUTllNG TH.BRG TOP COVER) 1\tiiUE CONNECTING CW LINES TO
28 WEARING RINGS FV520B (B52S143)
CW INUET &: OUTUET CONNECTIONS OF THRUST BEARING. ENSURE THAT THE BOTTOM NUT IS FULLY TIGHTENED
29 SLEEVE(MECH. SEEL) 316 ss (AT CW INUET &: OUTUET CONNECTION OF THRUST BEARING) BEFORE CHARGING TO CW WATER LINES •
30 INSERT(ST ATIDNARY I MECH. SEAL! # 5 CARBON INTO BEARING HOUSING)
31 SEAL RING 9ROTERY I MECH. SEAL) 316 SSI DURCHROME (LOOSENING OF BOTTOI.I NUT UEADS TO FAILURE OF SEAJUNG INSIDE THRUST BEARING AND WATER INGRESS
32 GLAND RING 316 ss
SEALING WATER !sEALING WATER ~~~_ _ _r_o_s_u_c_n_oN_ CUSTot.!ER JINDAL POWER LIMITED
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DETAIL OF MECH.SEAL (TYPICAL) FSU:::L:::..:TAN"-1Tf---::--!::D:!::E=:VE::::L:;::07P::=M~E~N::,:T~C~O~N~Sc::U=-LT~ANT~~S~P:-:,VT~.!.!::L:=TD==,..,.---I H
PROJECT: OP JINDAL STPP PH-ITI 4X600 MW UNITS
TAYN.AR RAIGARH CHATTISGARH
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1. JOB NO. : 329 li!Vl~~~ HANE DAlE
~ CAll. LAKSHt.ll 1a.oa09 H~_:'
2.. STATUS : CONTRACT BHARAT HEAVY ELECTRICAI.S llD. aiD. M.t.I.RAO 1B.oa09 NA
3. DRG./REF. NO. (INllERNAL) HYDERABAD APPO. B.RAJKUt.IAR 1B.oa09
l'TEll NO.OF
HO. ITEJ.IS
f:N-::::1EI<£D;:,::::------,-=::-----1REV DAlE I"N-:::1EI<£D=:.._----,-----IREV DAlE ~N-:::1ER£ll=:.._----,-=::----IREV OAlE ~N-:::1EI<£D=:..____,_ _ _--IREV DAlE N.lERED REV DATE AlTER£D
CHECO<ED APPD. CHECO<ED APPD. CHECO<ED APPD. CHECKID APPO. f'-CHE::c.=.a<ED::::,--...,.,.,APPDc:::-.- - J t::CHE:"'CKED=---.APPD-:-.---i NA NA
2
'17889 90D !8! !
·oN -~~ai''x~,~~~~~~~~~~:---~3~--------~---------r4======~~~~~~~~5~~::~--L---------~6~--------~--------~7 __________l __ _ _ _ _ _ _ _ ~s~~~~~~~~~~~g~--------L---~~~~~:o~~~~~~~~~~~~~~~~---------
• HYDRAULIC TEST PRESSURE THE REACTIONS DUE TO MOTOR ARE AS FOLLOWS
A 1) CANNISllER= 12KG/CM' FOR 30 MINUllES A
DRIVE MOTOR 2240 1) NORMAL RUNNING REACTION (PER SOLT)
2) HEAD GEAR= 55KG/CM' FOR 30 MINUllES
(A) VERTICALLY DOWN WARD 963 kg DUE TO WEIGHT OF MOTOR.
3) OTHER CASINGS=45KG/CM' FOR 30 MINUllES
(B) SHEAR FORCE 4.95 kN TANGENTIAL IN BOTH DIRECTION IN
4) 1ST STAGE CASING=12KG/CM' FOR 30 .MINUTES
HORIZONTAL PLANE.
2) SHORT CIRCUIT REACTION (PER BOLT)
(A) SAME AS ABOVE 1A
(B) SAME AS ABOVE 18 BUT MAGNITUDE 49.5 kN.
0
B 5;; IRRESPECTIVE OF THE DIRECTION OF ROTATION.
N
TERMINAL llERMINATED
SERVICE SIZE OTY.
POINT \11TH
COUNTER FLANGE,ANSI
TP1 PUMP SUCTION 20"' 1
B16.5,CLASS 150,\\1NRF
COUNTER FLANGE,ANSI
TP2 PUMP DISCHARGE 12" 1
DMCW INLET & 816.5,CLASS 300,WNRF
EL 2.034M OUTLET TIP7&8 COUNTER FLANGE,ANSI
TP3 CANISllER VENT 2" 1
B16.5,CLASS 150,SORF
:J<i 1 t0.8 ALLOWABLE FORCES & MOMENTS TP4 DISCHARGE VENT 3/4"
SOCKET TYPE GLOBE
VALVE NO 3/4"SW
1 c
-H
SUCTION DISCHARGE SOCKET TYPE GLOBE
TP5 SEAL SUPPLY 3/4" 1
VALVE NO 3/4"SW
Fx ±13500N ±7500N
. Fy ±13500N ±7500N TP6 STUFFING BOX DRAIN 3/4" SCREWED Rc 3/4" (F) 1
....,
... ~
Fz ±13500N
Mx ±10200Nm
±7500N
±6100Nm TP7 BEARING C. W. INLET 1/2" SCRE\\1ED Rc 1/2" (F) 1
DETAIL - D My ±10200Nm ±6100Nm
TPB BEARING C. W. OUTILET 1/2" SCRE\\1ED Rc 1/2" (F) 1
Mz ±10200Nm ±6100Nm
HY TP1 PE
".)<1 1 tD.B THERMAL MOVEMENTS OF SUCTION &
DISCHARGE NOZZLES ARE NEGLIGIBLE.
TP9 TH. BRG. OIL llEMP 3/4" NPT 3/4" (F) 1 D
TP10 TH. PADS llEMPERATURE 1/2" BSP 1/2" (F) 2

...
0>
TP11 JOURNAL PADS llEMP. 1/2" BSP 1/2" (F) 1
......co TECH. DATA
DETAIL - S NOTE :
COND. EXTRN. PUMP ASSLY. WT. = 9150 KGS 1. FOUNDATION BOLTS & NUTS ARE SUPPLIED BY BHEL, HYDERABAD.
(INCLUDES PUMP ROTOR)
2. NUTS, BOLTS & GASKETS FOR ALL FLANGE JOINTS (TIP1, TIP2 &
c Q) WT. OF CEP ROTOR 670 KGS
0 ..c TIP3) ARE SUPPLIED BY BHEL, HYDERABAD.
:;;; WT. OF PUMP \11TH WATER 9250 KGS
0 0 E
WT. OF MOTOR 5500 KGS 3. GROUTING OF CANISTER IS NOT RECOMMENDED. GROUTING OF
] c
DIRECTION OF ROTATION CLOCK\\1SE FOUNDATION FRAME SHALL BE DONE BY QUICK SETIING CEMENT.
-0
(/) J:: (VIEW FROM MOTOR TOP)
§ (/) NO.OF . PUMPS 3 *•t. ALL ELEVATIONS IN THE DRAWING ARE WITH RESPECT TO TG BUILDING
·en 0'1 (STATION BUILDING) GROUND FLOOR LEVEL OF EL 0.00 M (FFL) WHICH
c c
Q)
E 2
"§:
::;
NO OF STAGES
CASING TIEST PRESSURE
6
55KG/CM
CORRESPONDS TO RL( +) 255.250 M. A
0
:.0-a CD CANNISTIER TIEST PRESSURE 12KG/CM'
5. GROUTING MATERIAL SUPPLIED BY BHEL(PSER)/AS PER CONTIRACT
0 DYNAMIC MOMENT AT FOUNDATION
0 -~ . 2 FLANGE 158802 Nm (M1) 6. REF BHEL/PEM DRG PE-DG-329-100-M003 TG EQUIPMENT PLAN
Q):SC: g
(/) Q)
o ui E "'I ~ AT O.OM FOR CEP ELEVATION
e- -g .e- "'
F
a. ..2 .,g.
., o.,_
"2
UJ
~
EL 0.6M -------,-------ffi F
:S
c
a.
A 12100 I 2500 I 2500 I 3400 I
t+-+-t--t
~ 0
.2 c B
0
"0 ."2 "'
UJ
(!) '1.~ TP5 SUCTION
TECHNICAL DATA OF PUMP
~
.2
., :J
"0
~
U1
FLOW BOO Cu.mtr/Hr.
f--
U1
VIEW ON ARROW "A" (MOTOR AND STOOL REMOVED) TOTAL DYNAMIC HEAD 265 mlc
"'"-G: "'cc
C1' N 0. OF STAGES 6 (SIX)
0 Lf1
NPSH (r) 3.10(M)
..."'z
UJ
DISCHARGE ~-------------BT MOTOR P0\\1ER
UJ 900 KW
G u ~ EL(-)2.0M G
0
!::.
0
"'"'
&h
"' KEY PLAN FOR 4 UNITS
16 Nos M24 CANISTER HOLDING

DOWN BOLTS EQUI-SPACED OFF
CENTRES ON 1110 PCO
-! HY IOHfl. ""'· SOOPO
CUSTOMER: JINDAL POWER LIMITED H
SCOPE OF SUPPLY
ONSULTANT DEVELOPMENT CONSULTANTS PVT.LTD
PE (BHa., PEM SCOPE)
SUCTION
FOUNDATION DETAILS AT SECTION "F-F"

(PLAN VIEW OF FOUNDATION RING)
I I 5 I I 8
II 2 3 4 I 6 7
.1..909 900 lSl G 'ON'~CJO
OPERATING PARAMETERS ORIFICE TABLE
FLOW RATE PIPE NB NO. DIA mm
r=z Q LPM MM R1 6.8
~ ;. QT 283 25 R2 9.04 )
:::2:
0 Q1 98 20 R3 5.36
u
Q2 92.5 20 R4 8.43
w
I Q3 55.6 R5 8.43
.l-
OLL Q4 104 20
f:!o Q5 44 15
PRESSURE (KGS/SQ.CM)
:::2: 1-r- 1-
::J(f) ) ( RS f y P1 39
w Q6 12.5
(f)Cl::: 20 P2 12
...JW ) ( R4 Q7 47.5
<(1-
uz HY '? VA-9 Q8 38 15 P3 9
~~ ~OPEN Q9 25 15 P4 0.4
UI
~1-B TP4 HY -----r-- PE B
wo PE --!----... IC.WO\i_TIJ:T I :.J(fMA(V
>-1- TERMINAL POINT DETAILS
>...J (THRUST \TPB v " I P6-llJ.Jl!.-.~
<(<(
wl-
+-....:..:C.C:,:..::.-'---1--
~EA~ING )TP7 a9~ :.J(fMA(V I T.P. SERVICE NB TERMINATED
:r:r;J ~~~~LET v ~P6-Ili-Jl!.._~ ~R~E~F~----------------4---+----~~~~~----~
1-:::2: COUNTER FLANGE
<(- TP3 CANISTER VENT 2" ANSI CL 150, SORF
e:::g: 1----1---------------4---+---------------1 1-
<C wl-
:r:o TP4 DISCHARGE VENT 3/4" SOCKET WELD
( CD VALVE
>-
\c_ LL<(
o:;;::
COMMON
DISCHARGE
CD-52 C~-53QT
TP5 MECH. SEAL WATER INLET 3/4" SOCKET WELD
HEADER v '-' v P1 VALVE
>-r- PE
~z az
P:EH7
Li.fD-57
PE
,_II'It_
STUFFING BOX
(MECH. SEAL)
STUFFING
a'!MECH. SEAL
98~}1~ CD-58 TP6 STUFFING BOX DRAIN 3/4" SCREWED RC 3/4"
w<Cc PE HY TP9 ..---- PE HY TP9 c
g;~ HY y ~~~" " T f 0 /PE6 ~ HY TP7 BEARING C.W INLET 1/2" PIPE
0:::>-
o.....J ~ P2 A ,V L "\ l I "-A~ P2
wl- '---,T~PS.-1;vl><!-=,........_::=:--..~.._..:...::..___::f---(v--]~ ~ HY TPS~;,..--...
:r:U TP8 BEARING C.W OUTLET 1/2" PIPE
~--~
Cflo ~~~ ALTERNATE SEAUNG
~~
TP9 FROM COND.STORAGE TANK 3/4" PIPE
-z
f---1--
ze:::r-
)(R3 - -f--
)(Rz
~o SEAL WATER SEAL WATER
::J>-
U...J
FLOW GLASS INDICATOR
V RETURN
VSEAL WATER RETURN
V RETURN
Ol- LEAK IN TO LEAK IN TO LEAK OUT FROM
ot;3 SOLENOID VALVE STUFFING BOX STUFFING BOX STUFFING BOX VALVE SCHEDULE(HYDERABAD SCOPE)
(f)O:::
:co VA-1~:PE VA-2 ~
'lH:E VA-3_ ~HE
fi.
-v
TP~':::: TP3 SL. D
-vv--
1-oD ISOLATING VALVE TP~ ::',:: TYPE OF VALVE VALVE SIZE QTY. REMARKS
=i= -.- HY NO. (TOTAL)
zw HY
HY
0~ a3 a4 as a3 a4 as Q6 a7 as
Zw
Qm
I-
<(I-
ORIFICE
NON RETURN VALVE /v P1

:::-GLAND UNLOADING I v - - - r - P - 1 - - v : : : - GLAND UNLOADING
CANISTER
/
v--- P4
~C~A~NI~ST~E~R+----
1\ GLAND
UNLOADING VA-7
V1
VA- 8
GLOBE VALVE
SOLENOID VALVE
NO 3/4" I
NO 3/4", NPT(F)
CL 800
L~V~A=9~~(~NO=R=M~A=LL~Y~C~LO=S=E~D)~--~~=R=E~AD~IN=G~_L____L ______
3
::::;::0 CANISTER
~~---~'---~- ~~-----~-~------~ ~---~-~-----~

e:::z FLANGE
0 1-f-- 1-
l.L.(f)
~::J __jHY SHE~ HYDERABAD SCOPE P4 Pt.
w::2:
f!:t:
,--- tPE SHE~ PEM SCOPE
1 E \PUMP RUNNING- A I IPUMP RUNNING- B\ \PUMP oN STAND-BY-e I 1 - - - - - - , - - - - - - - - - - - - - - - - - - - - E

lw ~
J:::i!f".
~~ i3
NOTE :
(1) ORIFICES R4 & R5 TO BE LOCATED IN VERTICAL LINE AND ABOVE THE WATER LEVEL IN THE CONDENCER THE DOWN
:w l{) STREAM ELBOW SHOULD BE AT LEAST 10 PIPE DIAMETERS AWAY FROM THE DISCHARGE OF ORIFICES. CONSULTANT DEVELOPMENT CONSULTANTS PVT.LTD
!~ ~ (2) SOLENOID VALVE SHALL BE LOCATED IN A VERTICAL LINE AND ABOVE THE WATER LEVEL IN THE CONDENSER VALVE
'I~ s TO BE OPEN WHEN PUMP IS STATIONARY AND CLOSED WHEN PUMP IS RUNNING VALVE TO BE ARRANGED TO FAIL. PROJECT: OP JINDAL STPP PH- III 4X600 MW UNITS
g ~I- SAFE IN THE OPEN POSITION. TAMNAR, RAIGARH CHATTISGARH
-~ (3) THE DISCHARGE CANISTER VENT LINES SHELL BE LED IN A GRADUAL UPWARDS SLOPE AND CONNECTED TO THE • NAME SIGN. DATE I-
I fr: CONDENSER ABOVE THE CONDENSER WATER LEVEL INDIVIDUALLY.
1· JOB NO. : 329
o.IMI. NO.OF
21 08 09
! (4) REFERANCE DRAWINGS:
2. STATUs
CONTRACT BHARAT HEAVY ELECTRICALS LTO.
DRN.
CHD.
RAJ.
M.M.RAO
c l"'F ' '
\\.-,_ 2 08 0
VAR.
'
I ~) ~ :g g~~~E~~~~M~Y~~~·Ng~~E~gG~~2g~16 5~Ncig1~-N '
)
: 3 106
3. DRG/REF. NO. (INTERNAL) HYDERABAD APPD. s.RAJKUMAR tLu 2~:o8:o: NA
rF-= -F ---c~-INSTRidMEN'FATIGN-SGHEME-FGR-GEP,-QRG,-NG,-H~-QG-2--18lOQ-55068----------------------I-------,--,.--,-,--=-----IF.0~E~PT~.=======r-==:::::;:=J::::;;;;;:;:;;:::==r:;:;;;;::;;:;:;~:j:::;;;:,;;=;;~~::;;:.:~=f-=;;~=t-:;;:N0;;:.:;,0 F:::l- _c - - 1 - - - - - - ' -
1! 2 181 005 5067 I---.:....PU.::...cc..:M.:....P..:..S_----1lC::J~ SCALE ~-WEfGRT(I<gr REF. TO ASSY DRG. ITE!;I r
I r-- REV. DATE IALTERED REV. DATE IALTERED REV. DATE :.:..A::.LTE:.::R=E::.D_ _,....----IREV. DATE ALTERED l~ NO. ITEMS
lg i3 lcHECKEo IAPPD. !cHEcKED IAPPo. cHEcKED IAPPo. ~c~HE~c~K==ED:..__TI·A-PP_o_.----..jr-;4-.-=oiS::T:::R:::IB::::U-:-T=I::O::-N:-----------1 coDE 410 NTS NA NA NA NA
I ZONE ZONE ZONE ZONE TITLE DRAWING NO. REV.
jii: l{)
,.... 5. TO SCHEMATIC DIAGRAM OF
I~ ~ SEALING AND COOLING WATER HY-DG-2-18100-55067 00
, :~ "' 6. No. OF FOR CEP (EN6J40/500) SHEET NO. 01 NO OF SHEETS 01
!~ - -lo - - - 1 - :2.- - - " I - a- I -- - 4 - 5 1- -6 -- --1 - -- -7 8 --
I
FIRST ANGLE PROJECTION \ (ALL DIMENSIONS ARE IN mm)
QJ) SlRAINER
./V\1\.. COOUNG COIL
,.r~--------+--------r~~J -D LOCAL MOUNTED INSlRUMENT
-o
TIA H
1-----< A
'""
1/r----I..LCB01
CT202 LOCAL GAUGE BOARD MOUNTED
INSlRUMENT
MOTOR --1><1- GLOBE VALVE

___...__ GLOBE VALVE NORMALLY CLOSED.
TE
LCB01 D
H
A,T ~ 11-IREE WAY ISOLA11NG VALVE
CT102
--8 TEMPERATURE ELEMENT SIMPLEX
B
IPE-DG-329-179-N001
TO CEP-A PE-DG-329-179-N001
~
--<>-
TEMPERATURE ELEMENT DUPUEX
FLOW INDICATOR
tro CEP-8 PI PRESSURE INDICATOR 1-

PT PRESSURE lRANSMITTER
!
ITo CEP-e
(~}
4
I c,<S ~c,~ H'>[~E DPI DIFFEREN11AL PR. INDICATOR
IPE-DG-329-100-N106 '>--~GLAN~!!:!.D..:SE:!A~U~NG~INLET!:!::.!..._ _ _ _~
_ __ _ _l-t.r:r::r-....1.f--l~~c,X'-~ r-- IE DISCHARGE I OPT DIFFEREN11AL PR. lRANSMITTER
'---i==~----+--t-IJ--JI-.J---+,----r--:.:..::_:;..:.:....::...:..:..=----JI PE-DG-329-100-N1 06 11 TEMPERATURE INDICATOR

11A
c
SUCTION P ' 1-- 1-- A. CONTACT TEMP. INDICATOR
STRAINER P~HY ~ I ' ~'* ~'* LQ.1.

TE
u
TEMPERATURE ELEMENT (RTD)
P~~~y. ~. H~~E ~l
LEVEL GAUGE (VISUAL)
1-- L,l L,l J}- -4>-H ALARM ~H : HIGH(c

ALARM H-H : H GH HIGH)
FROM HOT WELL ~ I II I.~ II~
rv 1 SUCTION ___r.l~ ~~ ~7
1
PE-DG-329-1 00-N106 )---------~--'=+-lr-rli~J,....,~f-+=-
1 --l+--l+--.-~-i---I-HHI-I----I------l -,..,,..
~ ,i1~ ;fi,l~
-,..,,.. --,_.,
--v ALARM & lRIP
'-- 1--
------0 INTERLOa< & lRIP
I* * y~~ NOTE: ~+ ANALOG INPUT TO DDCMIS
~iJ
1. FOR INSlRUMENT SCHEDULE OF CEP, REFER DRG.NO.: HY-DG-4-FP11893.
2. FOR SEAUNG & COOLING WATER SCHEME OF CEP, REFER DRG.NO.: HY-DG-2-18100-55067 D
J> 3. INSlRUMENTS TAG.NOS. OF CEP-A ARE INDICATED. INSlRUMENT TAG NOS. OF CEP-B & CEP-C MAY BE READ AS
1
1 *~ ~
LCA20•••. , LCB02 AND LCA30•• , LCB03 RESPEC11VELY IN PLACE OF LCA 10.••• , LCB01.
4. FOR SCOPE OF SUPPLY AND TERMINAL POINTS OF CW, SEAUNG AND VENT UNES REFER DRG. NO.
HY-DG-2-18100-55067 & CEP GA DRG. NO. HY-DG-1-18100-56884
CEP 5. tk ) - 1/2" SOCKET WELD VALVE TO BE PROVIDED ON DISCHARGE PIPE BY BHEL-PEM. 1\

2 6. FOR C.W. INLET & OU11LET INTER FACE DETAILES, REF. DMCW DRG NO. PE-DG-329-179-NOOL ~
A -H LCA10/20/30 AND FOR GLAND SEAUNG INTERFACE CONNECTION REF. BHEL/PEM ORG. PE-DG-329-100-N106 (P & 10 CONO. SYSTEM). 1-
AP001
7. INSlRUMENTS LOCATION INDICATED AS LGB (BHEL/HYD SCOPE) WILL BE MOUNTED IN ONE LOCAL GAUGE BOARD
A AS PER INSTAULATION SCHEME ALONG Will-I NECESSARY FITTINGS UKE MANIFOLDS, VALVES, DRAINS & IMPULSE PIPE, ETC.
8. 11-IIS SCHEME IS APPUCABLE FOR 011-IER CONDENSATE EX1RAC110N PUMPS ALSO
E
CONSULTANT: DEVELOPMENT CONSULTANTS PVT.LTD
PROJECT: OP JINDAL STPP PH- III 4X600 MW UNITS
DRAWING NO. REV.

INSTRUMENTATION SCHEME HY-DG-2-18100-55068 02
FOR CEP (EN6J40/500) SHEET NO. 1 I NO. OF SHEETS 1
I Fi I I 8
I TD-150/REV.N0.03 SIZE A2
REV. DATE ALTERED RAJ. CH REV. DATE ALTERED REV. DATE ALTERED
~C-HE-C-KE-D----~ ~C-HE-CK_E_D------~
01 01-03-10 CHECKED M M RAO
APPROVED 8 R K APPROVED APPROVED
~ REVISED AS PER JINDAL COMMENTS
~ LETTER AB/2400MW/BTG/323
~ DATED 10-02-2010
u
w
ci
i:!:
~ ~
~ 1-
::J Vl
w
...J
Vl a::
w
<( 1-
u z
~ ~
G3 i:!:
...J
w 0
>- 1-
> ...J
~ ~
J: r5
1- ::::;;
~ ~
<(w
J: 0
CD
>-
u...
0 ~
>- >-
~
. w z
<(
; g, ~
a:: >-
0..
w u
~ w
a::
~
INSTRUMENT SCHEDULE
!:2 0
1-
r5 a::
::::;;
~
0
FOR CEP SET
::> >-
g ~
0 ~
Vl a::
~ 0
0
z !7!
0 ::>
z w
~ !D
<( 1-
::::;: 0
a:: z
~ 1-
z
-
Vl
::>
w ::::;;
~ !::: f - - - - - - - - - - - - - . ,
r-
11--------t
JOB NO. 329
'~/ ' Ig
a::
sTATus CONTRACT
I~ ~1--CU_ST_OM_ER:-1------=:J:...=I:!::....!N-=D--=..:A=L~P_.:::O~W~E=-=R~L=-=I~M~I~T~E~D~------l
::::;; I"')
18 ~ CONSULTANT: DEVELOPMENT CONSULTANTS PVT.LTD

.-
I 8:: PROJECT: OP JINDAL STPP PH-III 4X600 MW UNITS
r- TAMNAR, RAIGARH CHATTISGARH
I wl-
NAME SIGN DATE
NO. OF
I
~ U'l. HYDERABAD DRN. RAJ. C ~ 06.01.10 VAR.
~ a::w o
z ~ u
z
° CKD. M.M.RAO ~ 06.01.10 NA
g
(.!)
l!i
N ...J
APPD. B.RAJKUMAR ik_ 06.01.10
-~ ~ -§-:-DEP~-. Pt:JMP-S-ENGG~ ~ -SGAbE--WEIGH::r~K.G}--~EE..IO_ASSX.DB_G_. _ _ _ ~3~-~~~t
o 0cn ~ gu CODE 410

0 NTS NA FP
11893
NA NA
z 0
fi:
. ,I ~ ~ ~ 5
~ ~ ~ TITLE INSTRUMENT SCHEDULE DRAWING NO.
HY-DG-4-FP11893 01
REV.
---- I~ ·"<j-·- ----- ------------FOR--C-EFc.-~Err'----~---- ·sRT.-No:--{)1---1 NO~ -oF-sRrCJ4-----

INSTRUMENT SCHDULE FOR CEP SET DRG. NO. HY-DG-4-11893
BHEL 4 X600 MW, UNITS, JINDAL POWER LIMITED SHEET: 02 OF 4

HYDERABAD
LEGEND REV.NO.: 01
INSTRUMENT:
PI -PRESSURE INDICATOR Tl -TEMP. INDICATOR

PT - PRSSURE TRANSMITTER TIA -CONTACT TEMP. INDICATOR
PDI - DIFFL. PRESSURE INDICATOR TE - RTD, pt-100 Ohms AT 0°C,4-WIRE
PDT - DIFFL. PRESSURE TRANSMITTER Ll -LEVEL INDICATOR
COND -FEED WATER A - 1/2" NPT(M) I -INTER LOCK L -LOCAL

WDG -WINDING B - 1/2" NPT{F) H -HIGH UCR - UNIT CONTROL ROOM
MTL -METAL c - 3/4" NPT{F) H-H -HIGH HIGH LGB - LOCAL GAUGE BOARD
F - PLUG IN SOCKET TYPE L -LOW (FOR GAUGES & SWITCHES)
L-L -LOW LOW LIR - LOCAL INSTRUMENT RACK
TD -TIME DELAY (FOR TRANSMITTERS)
AL -ALARM
NOTE:
-OPERATING CONDITIONS GIVEN FOR INSTRUMENTS ONLY FOR INFORMATIVE. UNITS:-
- KKS TAG NOS. FOR CEP-A ARE INDICATED AS LCA10 .... ,& LCB 01. PRESSURE : Kg/ sq.cm /mm.wc
- KKS TAG NOS. FOR CEP-B MAY BE READ AS LCA20 ..... & LCB 02. FLOW : CUB.M I HR
- KKS TAG NOS. FOR CEP-C MAY BE READ AS LCA30 ..... & LCB 03. TEMPERATURE Deg.C
-ACCURACY OF TRANSMITTERS : ±0.1% OF SPAN FOR >1/1 Oth URL VIBRATIONS : mm/Sec
-ACCURACY OF GAUGES :±I% FSL
-ACCURACY FOR RTDS :±I DEG.C.
SHEET 2 OF 4
,--- ,_
r~ /"'~
I I
I I
i
' ___ ..-
I
~
- --~
I
'
I OPERATING CONDITION SPECIFICATION SET POINT

I I QTY/
KKSTAG DES<i;RIPTION PRE kg/ TEMP FLOW PROC. ELEC ACCURACY REMARKS
I PMP
I FLUID SYM
oc RANGE MOUNTING ALARM TRIP /INTERLOCK
I cm2 RATE CON. CONN (%OF SPAN)
I
: INSTRUME~TATION SCHEME FOR CEP, REFER DEG. NO.: HY-DG-2-181 00-55068
. I (A-CON~ENSATE EXTRACTION PUMP)
LCA10
I
CP022
DISCHAR~E PRESSURE 1 COND 28 49.2 800 PT 0-40 B F LIR ±0.1
>18 (I) OPEN DV TD-5 SEC
<20(T) TD-10 SEC
LCA10
CP023
DISCHAR~E PRESSURE 1 -do- 28 49.2 800 PT 0-40 B F LIR ±0.1
I
DIFFL. PRESSURE
LCf-10 0-1500 500 (H)
cPp21
ACROSS CEP SUCTION 1 -do- 0.025 49.2 800 PDT
mm.wc
A F LIR ±0.1
750 (H-H) mm.wc
-
STRAINER I
DIFFL. PRESSURE
LCA10 0-1500
CPS21
ACROSS 1EP SUCTION 1 -do- 0.025 49.2 800 PDI
mm.wc
B - LGB ±I - -
I STRAINER
LCA10 I -1.0 TO
CP522
SUCTION ~RESSURE 1 COND (-)0.15 49.2 800 PI
+1.0
A - LGB ±1 - -
LCA10
CP523
DISCHAR~E PRESSURE 1 -do- 28 49.2 800 PI 0-40 B - LGB ±1 - -
LAC10 SEALING V}'ATER INLET
I
CP524 PRESSURE
1 COND 12 49 6 PI 0-16 A - LGB ±1 - -
LC!=J01, I
THRUST BEARING TH.PAD
cT:101 &
TEMP
2 MTL - 80 - TE 0-200 A - L ±1 95(H) 105(H-H) DUPLEX RTD
CTi102 I
LCB 01 THRUST BEARING JRNL.
I
CT1103 PAD TEMPI
1 MTL - 80 - TE 0-200 A -- L ±1 95(H) 105(H-H) DUPLEX RTD
LCB 01 THRUST BEARING OIL
cT:118 TEMP. I
1 OIL - 65 - TE 0-200 A -- L ±1 90(H) -- DUPLEX RTD
LCB 01 THRUST BEARING OIL
CT301 TEMP. I
1 OIL - 65 - Tl 0-120 A - LGB ±1 - - ---
LCB 01 THRUST BEARING OIL PART OF THRUST
CL301 LEVEL. I
1 OIL - - - Ll - B - L VISUAL - - BRG
I
I
SHEET3 OF 4
-- -·-- ---·----------- --- --- -

QTY/
KKSTAG DESCRIPTION PRE kg/ TEMP FLOW PROC. ELEC
REMARKS
PMP
FLUID oc RATE SYM RANGE MOUNTING ACCURACY ALARM TRIP /INTERLOCK
cm 2 CON. CONN
(8- MOTOR INSTRUMENTS SUPPLIED ALONG WITH MOTOR)

SUPPLID ALONG WITH
LCB 01 MOTOR BEARING METAL
CT104 TEMP. DE
1 MTL - 70 - TE 0-200 - - L - 80 90 MOTOR
DUPLEX RTD
LCB 01 MOTOR BEARING METAL
CT105 TEMP, NDE
1 MTL - 70 - TE 0-200 - - L - 80 90 do
LCB01 SUPPLID ALONG WITH
MOTOR WINDING TEMP. R
CT106 to
PHASE
4 WDG - 100 - TE 0-200 - - L - 110 130 MOTOR
SIMPLEX RTD
CT109
LCB01
MOTOR WINDING TEMP. Y
CT110to
CT113
PHASE
4 WDG - 100 - TE 0-200 - - L - 110 130 do
LCB01
MOTOR WINDING TEMP. B
CT114 to
PHASE .
4 WDG - 100 - TE 0-200 - - L - 110 130 do
CT117
2SPDT CONTACTS
LCB01 MOTOR BEARING TEMP.
CT202 DE
1 MTL - 70 - TIA 0-120 - - L - 85 5A.220V.AC/
0.2A.220V,DC
LCB01 MOTOR BEARING TEMP.
CT203 NDE
1 MTL - 70 - TIA 0-120 - - L - 85 do
SHEET 4 OF 4
~
z<(
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0
()
w
~ LIST OF RECOMMENDED ANALOG
c:i
w t...
1-
SE
0
1-
INPUTS TO DDCMIS OF CEP SET
::J (f)
w
(f) ~
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<( ~ SL. DESCRIPTION OF INPUT INITIATING KKS
()
~
~ w NO. DEVICE TAG NO.
()
w
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--
w
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>-
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TRANSMITTERS LCA10 CP023
w ~
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~
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t...
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~
z
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0
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w :::;:
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r-
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II """I
.
DRG. NO.: HY-DG-4-FP11893
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CUSTOMER:
ltJ.:w JOB NO. 329 CONSULTANT: DEVELOPMENT CONSULTANTS PVT.LTD.
L__
PROJECT: OP JINDAL SUPER THERMAL POWER PLANT
I STATUS: CONTRACT 4X600 MW UNITS,TAMNAR,RAIGARH CHATTISGARFl
I~ ~ BHARAT HEAVY ELECTRICAL$ LTD.
NAME SIGN DATE
NO.OF
I~ HYDERABAD DRN. RAJ. C ~ 09.05.0S VAR.
1: ~- 09.05.09
0
CKD. M.M.RAO
ili-..: APPD. B.RAJKUMAR ik 09.05.09 NA
-I PtJtv1rs-I:"N<3<3-:- -SGAI.::~- W~l GH:rEK-;G;-)- REL/"QR_G_._hi_Q:_(INTERNAL.) ITEM NO.OF
~
DEPT. NO. ITEMS
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I z,...,
o m CODE
((J)
,~ TITLE LIST OF RECOMMENDED ANALOG
DRAWING NO. REV.
. I w~ ..-OCi HY- DG-4- FP11894 00

- _>- _lNI?JIT~LifO ___ DDCMI~LQE_ CEP_____
-sHT.No:-o1----j-----ToT~SHTs:--01---
----~ -~-----
l ~ "<F
l
REV. DATE ALTERED CH RAJ REV. DATE
ALTERED ADDITIONAL
_ _ o CHECKED MMR 1-::C::-:-H=-:EC:-:-:K=ED::---------J INFORMATION
01 9 7 1
~~-~A~P~P~RO~V=ED~B~RK~-~-~-~AP~P~R~OV=E~D_ _ _~S~TUSOF _ _ _ _ _ _ _
'.
~ 1. CL.N0.5.2.4, 6.5.0, 7.4.0 & 9.1.5 DRAWING
~ DELETED IN VIEW OF COMMOM RE- I-DISTRIBUTION- - - - - - -
8 CIRCULATION LINE FOR 3 CEPS. OF PRINTS
w 2. CL.N0.5.1.1.2 & 7.0.0 DORRECTED
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FOR CONDENSATE EXTRACTION PUMP
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1: ~ JOB NO. 329 CONSULTANT DEVELOPMENT CONSULTANTS PVT.LTD.
lliL ~ . OP JINDAL SUPER THERMAL POWER PLANT
I STATUS: CONTRACT PROJECT. 4X600 MW UNITS,TAMNAR,RAIGARH CHATTISGARfl
Iw 1- BHARAT HEAVY ELECTRICALS LTD.
NAME SIGN DATE
I~ HYDERABAD DRN. RAJ.C ~ ~0.04.10

NO.OF
IZ
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CKD. M.M.RAO ~ J30.04.10 NA
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NO. ITEMS
0 0\ CODE 410 NTS NA FP41810059021 NA NA
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~SS TITLE DRAWING NO. REV.
\II ~.q SEQUENTIAL INTERLOCKING CONDITIONS IHY-DC-4-18100-59021 01
~D....
---- -- [ r~ G...- - --- - - - -F'GR --GO ND EN SATE -EX'I'RAGT-I QN---P-lJMP-- -si-11-:-N CJ:-o1-- -1--f(JT-:-Sr!IS: -e4----- --- ---
DRG.NO
HY-DC-4-181 00-59021
PROJECT:
OP JINDAL STPP PI-I-III 4 X 600 MW UNITS Rev No. 01
Page 2 of 4

FOR
CONDENSATE EXTRACTION PUMPS
"n n
J.u.u LEGEt..lD:
CEP CONDENSATE EXTRACTION PUMP

HM DRIVE MOTOR OF CEP
RV RECIRCULATION VALVE
DV DISCHARGE VALVE
sv SUCTION VALVE
2.0.0 REFERENCE DRAWINGS :
Instrumentation scheme of CEP HY-DG-2-181 00-55068

Sealing & Cooling water scheme of CEP HY -DG-2-181 00-55067
Schedule of Instruments of CEP HY-DG-4-FP11893
3.0.0 3 x 50 % duty Condensate Extraction Pumps are provided for this project. These pumps are
meant to draw condensate from the condenser hot-well and pump it to deaerator through LP
heaters. Conditions for safe operation of these pumps are specified below. These shall be kept in
view while designing the control circuits and during operation of the pumps.
4.0.0 CONDITIONS WHEN CEPs OF THE UNIT ARE AT REST :
4.1.0 The circuit breakers of the drive motor (HM) of the CEPs shall be in OFF position.
4.2.0 The suction valve (SV) and re-circulation valve (RV) shall be kept OPEN for all pumps.
4.3.0 The discharge valve (DV) shall be kept CLOSED.
5.0.0 PERMISSIVE CONDITIONS FOR CEP START-UP:
5.1.0 The CEP chosen for operation shall have the following conditions satisfied. (To be ensured
manually)
5.1.0.1 Oil level in thrust bearing gauge glass is above normal level.
5.1.0.2 Cooling water is available to thrust bearing.
5.1.0.3 Sealing water is available to the mechanical seal (initially sealing water is to be taken from
emergency source and subsequently from the pump discharge header when the pump comes
into operation).
5.1.0.4 The valve in canister vent line to condenser is OPEN. The valve should be locked in OPEN
position.
5.1.1 The CEP chosen for operation shall have the following conditions satisfied (through logics.)
5.1.1.1 Power supply is available to the drive motor.

DRG.NO
HY -DC-4-181 00-59021
PROJECT:
~ OP JINDAL STPP PH-III 4 X 600 MW UNITS RevNo. 01
§
....0 Page 3 of 4
-5.1.1.2 The solenoid valve in discharge vent line to the FLASH TANK 'A' shall be in OPEN condition (KKS
tag no.are LCB1 0/20/30/AA201 ). &

5.2 The drive motor (HM) shall be started provided the following permissive conditions are fulfilled.
5.2.1 Suction valve (SV) to be kept fully open. (Limit switch in SV shall be used).
5.2.2 Condenser hot-well level NORMAL (from level Transmitters with 2/3 selection provided on the hot
well).
5.2.3 CEP discharge valve (DV) to be in closed condition.
5.2.4 Re circulation valve kept in open, it modulates •,vhen measured flow is varying between 0 tph to
300 tph and it is closed fully when measured flow exceeds 300 tph. DELETED
5.3 START-UP :
5.3.2 If all the conditions envisaged above are fulfilled, the pump can be started. When the pump is
started and attained a pre-set pressure of more than 18 kg./Cm 2 sensed by a pressure transmitter
Tag no. LCA10/20/30CP022&023 (one out of 2 selections) (provided at the pump discharge
before NRV), discharge valve (DV) of the CEP shall OPEN automatically.
5.3.3 Discharge line vent solenoid valve shall CLOSE after starting of pump with time delay of 2
minutes.
6.0.0 CONDITIONS FOR TRIPPING THE OPERATING CEP:
The operating CEP shall be tripped when any of the following abnormal conditions exists with an
audio-visual signal.
6.1.0 If the hot-well level falls to LOW-LOW level.
6.2.0 If discharge pressure before NRV is less than the pre-set valve of 20 kg./Cm 2 , sensed by a
pressure transmitter tag no. LCA10/20/30CP022&023 (one out of 2 selections) provided at the
: I pump discharge. (with a time delay of 10 sec. after CEP drive motor starting)
\._/}
6.3.0 If the drive motor (HM) protections are actuated.
6.4.0 Whenever the pump trips or stopped from manual I remote, the associated discharge valve (DV)
shall be closed and the discharge vent line solenoid valve shall be opened.
9.5.0 Flow through pump less than 300 m3 /hr, '>'lith a time delay of 5 sec. DELETED
6.6.0 CEP thrust bearing metal temp very high, set at 105°C (derived from tag no. LCB01 CT1 01 &
LCB01 CT1 02).
6.7.0 Motor bearing temperature very high, set at 90°C (derived from tag no. LCB01CT104 &
LCB01 CT1 05).
6.8.0 Motor winding temperature very high, set at 130°C (derived from tag no. LCB01CT106 to
LCB01 CT117).
6.9.0 Suction valve not open.
0 0\
0 I'
\ 0 s:l
'->-< ......
------ -~ - -~- ------ - ---- ----------- ------
DRG.NO
HY-DC-4-181 00-59021
PROJECT:
_g OP JINDAL STPP PH-III 4 X 600 MW UNITS RevNo. 01
§
If • Page 4 of 4
7.0.0 STAND-BY PUMP:
When one I two CEPs are operating, third CEP can be kept as stand-by. When a pump is kept
as stand-by, its selector switch shall be in AUTO position and its discharge valve shall OPEN
only when the discharge header pressure after NRV is not less than 18.0 kg/ Cm 2 and
/'\ sustained for 5 seconds sensed by pressure transmitters in discharge header after NRV tag. no.
~ LCA40CP011 &012 (One out of 2 selection). All other conditions envisaged in 5.0.0 shall be
fulfilled before starting the Stand-by pump. When the stand-by pump is kept on AUTO, it shall
come into operation when any of the following conditions occur.
7.1.1 Running pump trips.
7.2.0 Discharge header pressure less than a pre-set value of 20 kg/ Cm 2 for more than 10 sec.
7.3.0 Whenever the running pump trips due to LOW-LOW level in condenser hot-well, it should not be
possible to start the STAND-BY pump.
+.4-:-1--R-:G-veEitllates-wAeFl-ffieas~:~-reel-flew-is--vafytA@-Getwee~B-W~AEI-ikleses-fully
-wl:lefl-ffieawreel-flew-e-x-eeeels--WG+A=If:. DELETED
8.0.0 RECOMMENDED ANNUNCIATIONS FOR EACH PUMP :
8.1. 0 Condenser hot-welllevel LOW
8.3.0 Diffl. Pr. across suction strainer, HIGH 500 mm we (Tag no. LCA10CP021)
8.4.0 Diffl. Pr. across suction strainer, HIGH-HIGH 750 mm we (Tag no. LCA10CP021)
8.5.0 Stand-by pump started
8.7.0 Thrust bearing metal temp. high 95°C
8.8.0 Thrust bearing oil temp. high 90°C
8.9.0 Motor brg. DE metal temp. high 80°C
8.1 0.0 Motor brg. NDE metal temp. high 80°C
8.11.0 Motor winding temp. R,Y,B phase high 11 0°C
9.0.0 RECOMMENDED TRIPPINGS FOR EACH PUMP :
9.1.1 Condenser hot well level "Low-Low"

9.1.2 Pump thrust Brg. Metal temp. very high : 105°C
9.1.3 Motor bearing temp very high : 90°C
9.1.4 Motor winding temp. very high :130°C
9.1.5 Flmv tl:lreugl:l pump, very lew : 300 m3 /Hr. ('NitA time elelay ef 5 sec.) DELETED
9.1.6 Discharge pressure low : 20 Kg/cm 2 (With time delay of 10 sec.)
9.1. 7 Drive motor protections actuated
f-----r--1 9.1.8 Suction valve not open.
==#==
2 3 4 5
999£ l £Z 191 l 1 6 7 8 9 10 11
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APPROVED BY:
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I DATE:
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HYDERABAD
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lt:i t_ JOB NO. 329 CONSULTANT:DEVELOPMENT CONSULTANTS PVT.LTD.
L~ . OP JINDAL SUPER THERMAL POWER PLANT
I STATUS: CONTRACT PROJECT. 4X600 MW UNITS,TAMNAR,RAIGARH CHATTISGARH
Iw NAME SIGN DATE
t- BHARAT HEAVY ELECTRICALS LTD. ~ NO.OF
I~ HYDERABAD DRN. RAJ. C 30.04.1 0 VAR.
I Z~ 0
CKD. M.M.RAO
.~
~- 30.04.10
I!- APPD. B.RAJKUMAR fk 30.04.10 NA
- - - 1 - - t - - - t - -E
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__ _
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--'==ill~-- _____ TE_CH_NIC_A_L__ D~~A_S_H_E_E!_o_F-~~~--- ~~:0~~;-~-~~T~~~T;:5 0 ~0

DRG NO. : HY -DG-4-FP11895
TECHNICAL DATA SHEET OF CEP
INTL. NO. : FP411895
Rev No. 00
Page 2 of 5
CLAUSE
DESCRIPTION UNITS
NO.
1.01.00 Design flow rate kg/hr 790.5 (800 m 3 /hr)
1.02.00 Design inlet condition :
1.02.01 Inlet temperature Deg.C 46.1
1.02.02 Specific gravity 0.9881
1.02.03 NPSH required at pump mounting flange for
a) 3% head breakdown m 3.1
b) I% head breakdown m 4.2
c) 0% head breakdown m 4.4
d) 40,000 hrs. erosiOn life of first stage m 4 .8

impeller
1.03.00 Design discharge conditions :

2
1.03.0 I Discharge pressure ata 24 (Kg/ c.m )
1.03.02 TDH m 265 MLC
1.04.03 Shut off head m 333 + (1 0)* = 343

( )* indicates(+) 3% tolerance as per HIS
1.04.00 Pump speed rpm 1485
1.05.00 Power Consumption at design condition :
1.05.01 Power input to motor at 50 Hz kw 740
1.05.02 Loss in motor at 50 Hz kw 34
1.05.03 Power input to pump at 50 Hz kw 706
1.05.04 Efficiency of pump alone % 80.8

DRG NO.: HY-DG-4-FP11895
INTL. NO.: FP411895
RevNo. 00
Page 3 of5
CLAUSE
DESCRIPTION UNITS
NO.
1.05.05 Overall efficiency of pump set % 77.08
1.06.00 Suction Specific speed for first stage (US units) 10943
1.07.00 Canister losses mwc 0.4
1.08.00 External seal water requirment from alternate

m 3/hr 6 per pump
sealing (When three pumps are not running).
) 1.09.00 Minimum flow for continuous stable operation m 3/hr 300
1.10.00 On set recirculation low (if any) m 3/hr N.A
1.11.00 Peripheral speed at the eye of first stage impeller, m/sec 19.21
1.12.00 Maximum residual thrust

kg ~.?.~.~· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·
1.13.00 Manufacturer BHEL I Hyderabad
1.14.00 EN6J40/500, 3 Nos PER

Model Number and No. of pumps UNIT.
1.15.00 Number of stages 6 (Six)
l ) 1.16.00 Type of first stage impeller Double suction, radial

'" . /
1.17.00 Impeller diameter, mm 388 (OD)
1.18.00 Suction specific speeds (US Units) 10943
1.19.00 Design pressure of bowl and discharge kg-m2 39

components (g)
1.20.00 Outer casing (canister) :
1.20.01 Minimum wall thickness mm 12
1.20.02 Design pressure ata 2 I
I
1.20.03 Depth below pump mounting flange mm 5892 ....................................................................................
--I
I
1-----....._-_ _ _ _ _ _ _ _ _-_----_·---_ _ _ _ _ ____J
t
DRG NO. : HY -DG-4-FP11895
!Jifj TECHNICAL DATA SHEET OF CEP

INTL. NO.: FP411895
Rev No. 00
Page 4 of 5
CLAUSE
DESCRIPTION UNITS
NO.
1.21.00 Suction connection :
1.21.0 I Size I schedule 20", ANSI 816.5, CL-150
1.21.02 Type of connection with piping Flanged, WNRF
1.21.03 Height of centerline above pump mounting flange mm 1320
1.22.00 Discharge connection :
1.22.0 I Size I schedule 12", ANSI B 16.5, CL-300
1.22.02 Type of connection with piping Flanged, WNRF
1.22.03 Height of centerline above pump mounting flange mm 2020
1.23.00 Critical speeds :
1.23.01 First critical speed in water rpm 3380
1.23.02 Second critical speed in water rpm 5798
1.24.00 GD 2 of rotor including coupling kg-m 2 32
1.25.00 Top shaft:
1.25.01 Length mm 3606
1.25.02 Diameter mm IOO (max)
1.25.03 Span between bearings mm 1350
I .26.00 Intermediate shaft :
1.26.0 I Length mm 3I67
1.26.02 Diameter mm 87
1.26.03 Span between bearings mm 1350

DRG NO. : HY-DG-4-FP11895
INTL. NO. : FP411895
RevNo. 00
Page 5 of 5
CLAUSE
DESCRIPTION UNITS
NO.
1.27.00 Bottom shaft :
1.27.01 Length mm 2607
1.27.02 Diameter mm 88 (max)
1.27.03 Span between bearings (max) mm 1350
1.28.00 Method of coupling with adjacent shafting Muff Coupling

'j
1.29.00 Radial bearings :
1.29.01 Type & Number Cutless Rubber, 8 Nos
1.29.02 Size mm 100
1.30.00 Thrust bearing :
1.30.01 Located in pump I motor In pump
1.30.02 Type & number Tilting pad, 1 no.
1.30.03 Design load kg 2732
./ )
\_____ 1.30.04 Maximum load kg 6038
1.31.00 Bearing lubrication type :
1.31.01 Radial bearing Condensate
1.31.02 Thrust bearing Sump oil
1.32.00 Recommended hole size of suction strainer 400 microns
1.33.00 Shaft sealing :
~.11.D_O___M_eJh_.p_d_Q(s_h_aft__sealing _ _ _ _ _ _ _ _ _ _ _ _ _ _ _.£M"-"e~c±!'ha:!±n~ic~a~l-'!:se~a~l_ _ _ _ 1_ 1_ _ __,_

1 1
1.33.00 Make of seal As per approved vender
From CEP common
1.33.01 Mechanical seal cooling discharge..................................................................

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BHARAT HEAVY ELECTRICALS LIMITED

OPERATING AND MAIN'TENANCE INSTRUCTIONS

OP JINDAL STPP PH-III, RAIGARH - 4x600. MW

JINDAL POWER LIMITED

PART~ 1 SAFETY STANDARDS

PART~ 2 SYSTEM INFORMATION

PART -3 PRESERVATION & STORAGE

A. BOILER FEED BOOSTER PUMP

PART-5 SUB-DELIVERY ITEMS

A. CONNECTING COUPLINGS, BFP SET

PART-6 DRAWINGS I DOCUMENTS

A. BOILER FEED BOOSTER PUMP

HYDRAULIC COUPLING FOR BFP

WARNING : A WARNING CALLS ATTENTION TO INSTRUCTIONS WHICH

CAUTION : A caution calls attention to instructions which must be

NOTE : A note gives supplementary information where considered necessary.

1 General System Description

3 List of Sub-vendors for Bought-out Items

1.0 GENERAL SYSTEM DESCRIPTION

1 .1 Chandrapur Thermal Power Station Expansion, Unit-8&9, of Maharashtra State

"-~- 2.0 EQUIPMENT SCHEDULE:

3.1 Mechanical Seals : (a) M/s.Burgmann India Pvt. Ltd

(b) M/s.Fiowserve Sanmar Limited

(c) M/s.Eagle Seals&Systems India Ltd

3.2 Journal Bearings : (a) M/s. Waukesha Bearings

(b) M/s.Michell Bearings

(c) M/s.Michell Bearings India Pvt Ltd.

(d) M/s.Colherne Ltd.

3.3 Thrust Bearings : (a) M/s.Michell Bearings

(c) M/s. Kingsbury Inc.

1/A: M/s.Voith India Pvt. Ltd.

3.5. BFP RC Valve (a) M/s. Dresser Produits lndustriels, France

(b) M/s. Control Components Inc.,

(b) M/s. Otoklin Global Business

(c) M/s. Multitex Filteration Engineers (P) Ltd.

(b) M/s. Bibby Transmissions Limited.

IIA : M/s. Rathi Transpower Pvt. Ltd.

(c) M/s. Panam Controls

(d) M/s. Instrumentation Limited

3.10 Reverse Rotation Monitoring (a) M/s.Bently Nevada Corporation

PRESERVATION & STORAGE

HY0490563 TRP Application on Ferrous components of different

HY0490564 Code of practice for storage of different products and

TRP APPLICATION ON FERROUS COMPONENTS OF DIFFERENT PRODUCTS

The effectiveness ofTRP depends on the following aspects:

2.1 Selection of proper TRP.

2.3 Application of TRP - Under normal atmospheric conditions, corrosion of machined

2.4 TRP - Reference on manufacturing & erection instructions/drgs. wherever necessary by

4. SURFACE PREPARATION: (For details refer plant std HY0674166)

Revisions: Cl. Nos. 1.2, 2.2 modified. Issued:

Dt.FEB. 98 Dt. Year: STDS.ENGG. SR.MANAGER MAY, '83

6. PRECAUTIONS FOR APPLICATION:

8. DETAILS OF REPRESERVA TION TECHNIQUES:

8. I The earlier coating shall be removed by using white spirit.

8.3 Surfaces prepared for re-preservation shall not be touched by hand.

9. DEPRESERVATION BEFORE ASSEMBLY I ERECTION:

Preservative Instruction to Site:

1. This standard on preservation of different products and components shall be followed.

5. Represervation shall be followed as per the Tag attached to the component.

RECOMMENDED TYPES OF TRPs

Rust preventive 6 months HE 1709

deposited Rust solution, Steam 3 months HE 1712

TRP APPLICATION CATEGORIES