DOCUMENT SUBMISSION STATUS: FF

NOTE:

0 07.08.2015 FOR FINAL D.H.LEE J.W.SHIN T.H.JUNG

REV. DATE DESCRIPTION DRAWN CHECKED APPROVED APPROVED

OWNER OWNER’S CONSULTANT

VIETNAM OIL AND GAS GROUP (PVN) FICHTNER PVPOWER PCC

EPC CONTRACTOR EPC CONSTRACTOR’S CONSULTANT

PETROVIETNAM CONSTRUCTION JOINT

WORLEYPARSONS
STOCK CORPORATION (PVC)
POWER ISLAND PACKAGE SUPPLIER

SOJITZ CORPORATION DAELIM INDUSTRIAL CO., LTD.

PROJECT TITLE

THAI BINH 2 THERMAL POWER PLANT 2 x 600MW

DRAWING / DOCUMENT TITLE

INSTALLATION MANUAL FOR BFP

Vendor's Logo: FUNCTION NAME SIGN DATE
DRWN D.H.LEE 07.08.2015
CHKD J.W.SHIN 07.08.2015
APPD T.H.JUNG 07.08.2015

DOCUMENT NO: TB2-SDC.VP103-00LAC-M-M1B-MAN-0001 No of page: Scale Rev.0

Cover page 1 / 2
P.O NO. 110180-18-101-001

11LAC10AP001/002/003/004/005,
ITEM NO.
21LAC10AP001/002/003/004/005

ITEM DESCRIPTION BOILER FEEDWATER PUMP

DOCUMENT NO. TB2-SDC.VP103-00LAC-M-M1B-MAN-0001

DOCUMENT TITLE INSTALLATION MANUAL FOR BFP

REV NO. Rev.0

Daelim's Approval Status

Daelim Industrial Co., Ltd.

Job No. 110180

A - APPROVED

B - APPROVED WITH COMMENTS

C - RETURNED FOR CORRECTION

D - REJECTED

N - NOT APPLICABLE(REFERENCE ONLY)

SIGNED BY : DATE :

DIC'S PERMISSION TO PROCEED OR REVIEW TAKEN ON VENDOR

PRINTS SHALL NOT RELIEVE VENDOR FROM ITS RESPONSIBILITIES
OR LIABILITIES UNDER THE PURCHASE ORDER.

VENDOR'S LOGO:

Cover page 2 / 2
 INSTALLATION MANUAL
FOR MBFP, BFBP & SBFP

FOREWORD

This Installation Manual provides instructions for the installation of the MBFP, BFBP & SBFP. It
covers our standard products.

For the special options, the supplemental instructions are supplied as follows.

Before installing and erecting the pump, carefully read this manual and examine all related data,
such as the attached drawings and data until they are understood sufficiently. If the questions
arise, please contact our company.

However, where there are differences, they are called out separately within the manual. The life
and satisfactory service of any mechanical unit is enhanced and extended by the correct
application, proper installation, and periodic inspection, monitoring conditions and careful
maintenance. It was prepared to assist operators in understanding the construction and the correct
methods for installing and erecting these pumps.

Our company, “Hyundai Heavy Industries Co., Ltd. / Engine & Machinery Division” (hereinafter the
“HHI-EMD”) shall not be liable for the physical injury, damage or delay caused by the failure to
observe the instructions described in this Installation Manual.

Warranty shall be valid only when the genuine parts are used only.

Use of the equipment on a service other than stated in the order will nullify the warranty, unless the
written approval is obtained from the HHI-EMD in advance.

The supervision by the qualified HHI-EMD representative is recommended to assure the proper
installation.

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 INSTALLATION MANUAL
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SAFETY INSTRUCTIONS

These safety instructions must be followed to this installation manual additionally.

In case that the safety instructions are not followed, it can be resulted in serious damage such as
the death, serious personal injury or property damage, etc. Therefore, it is essential that all of the
instructions in this manual should be adhered to strictly.

The successful operation of pumps shall be dependent on the proper handling, maintenance and
installation. Failure to follow the certain fundamental installation requirements may incur personal
injury and the failure or loss of pumps as well as damage to other property.

The qualified personnel should work on or around this equipment after becoming thoroughly
familiar with all warning, safety notices contained herein. And, they should be involved in inspection,
maintenance and repair procedures and all plant safety procedures must be observed.

These safety instructions contain the specific safety markings where non-observance of an
instruction would result in hazards. The specific safety markings are:

DANGER: This indicates safety instruction which, if non-compliance, would result in

personnel safety.
CAUTION: This indicates safety instruction which, if non-compliance, would affect the safe
operation, protection of pump or cause the damage of pump or associated
equipment.

Do not operate this equipment in excess of the values given on the nameplate or contrary to the
instructions contained in this manual. The equipment has been tested at the factory and found
satisfactory for the conditions on which it was supplied. The operation in excess of these conditions
can cause stresses and strains beyond the design limitations. Failure to head this warning may
result in equipment damage and possible personal injury.

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Warranty & Guarantee

Precondition of warranty

The following instructions must be strictly followed to maintain the system in good working condition and to
maintain the validity of the warranty. The warranty is limited to the product(s) HHI supplies. HHI shall not be
liable for any injury, loss, damage or delays and any incidental or consequential loss or damage which is
caused by a failure to observe the instruction of installation and the operation & maintenance manual.

 Observation of the instruction in installation, operation and maintenance manual.

 Acceptable oil & grease quality and type according to the lubricant list to be used.
 Before starting operation, make sure that all air is vented, if applicable.
 Alarm and trip function according to the set point list to be set firstly and to be check regularly. (at
least, once a year)
 Abnormal leakage to be repaired as quickly as possible.
 Excessive operation is not allowed without HHI’s instructions.
 Genuine spare parts shall be used to ensure the quality level of the equipment.

Terms of guarantee

The warranty period shall be as per the warranty term contained in the contract.

 Wear and tear parts are excluded from the warranty.

- All wear rings.
- All sealing part. (O-ring, rubber ring, gland packing etc.)

If a warranty period is not defined in the commercial or technical agreement, HHI will cover the products for
a period of 12 months from the date of installation and commissioning.

HHI shall make good any defect through repair or replacement at HHI’s cost. In the event a defect occurs
which triggers HHI’s warranty obligation, HHI shall be notified within seven (7) days of discovery. In the
event that such notice is not sent within seven (7) days, the claim shall be waived.

Except for the express warranties contained herein, any and all other warranties, whether express or implied,
are hereby disclaimed.

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Loss of guarantee

Warranty claims shall be rejected if they are generated from the following causes.

 Improper transportation and storage.

 Defects caused by incorrect installation, insufficient foundation condition, improper construction work
 Unsuitable use and faulty operation.
 Damages resulting from improper commissioning, incorrect operation, improper use & handling,
chemical or mechanical attack.
 Abnormal wear due to improper maintenance and operation.
 Maintenance not according to the manuals
 Defects caused by the lack of execution of regular overhaul.
 Faulty assembly and repairing with unsuitable spare parts and tools.

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 INSTALLATION MANUAL
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CONTENTS

SECTION No. TITLE

SECTION 1 General Description

SECTION 2 Cautions During Transportation and Storage

SECTION 3 Installation

SECTION 4 Oil Flushing

SECTION 5 Reference Drawings & Documents LIST

SECTION 6 ATTACHEMENTS

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SECTION 1 GENERAL DESCRIPTION

1.1 The supplied pumps are the horizontal, multi-stage, double casing type of MBFP, SBFP
and horizontal, radial split, double suction type of BFBP. For the details of dimension,
arrangement, structure, etc., please refer to the Section 5. Reference Drawings &
Documents.

1.2 This manual describes the storage and installation. Also, please refer to the “Operation
and Maintenance Manual” for the details of construction, operation and maintenance.

1.3 Before installing the pumps, read carefully this manual and examine all of the related
drawings until they are fully understood. If you have any question, please contact the HHI-
EMD qualified personnel immediately. Also, please read carefully the instruction manual of
driver and become thoroughly familiar with it.

1.4 Safety action

This is a description of conditions and actions to prevent injury to the personnel and
damage to the equipment. It contains the instructions for installation of the HHI-EMD
centrifugal feed water pump. It has been designed to provide safe and reliable operation.

As it is also both the high pressure equipment and speed rotating machine, the personnel
must have enough the exercises and proper safety practices to prevent damage to the
equipment and to personal injury.

It is recommended that the safety program established be reviewed by the maintenance

and operating personnel prior to the installation, operation or maintenance on the
proposed pump and associated equipment.

DANGER: Proper installation and protective guards, emergency shutdown equipment

etc. shall be considered an essential part of safety program.

DANGER: During the maintenance work, special preventive measures to prevent

applying power to the equipment at any time.

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CAUTION: Do not apply excessive external piping load to pump and use pump as a
support for piping.

CAUTION: Ensure correct and proper lubrication of pump and motor.

CAUTION: Never run the pump at dry condition.

CAUTION: Let pump start with discharge valve partial open or minimum flow line valve
full open. (Unless otherwise specified in the user instructions)
It is recommended to minimize the risk of overload and damage the pump
motor at full or zero flow.

CAUTION: Suction valve to be fully open while pump is running and start-up.
Start-up or running the pump at zero flow or below the recommended
minimum flow continuously will result in damage to the seal and/or bearing.

CAUTION: Do not run pump at abnormally high or low flow rates.

Operating at a flow rate higher than flow normal may overload the motor.
Operating at a flow rate lower than the recommended minimum flow may
cause a reduction in pump seal/bearing life, overheating of the pump,
cavitation and vibration.

CAUTION: Drain the pump fully and isolate piping before starting dismantle of the pump.

DANGER: As pump parts may have sharp edges, the wearing of safety glass, gloves
and equipment shall be recommended.

DANGER: Safety guard shall be installed before running the pump and while the pump
in running. If not, this could cause personnel injury.

CAUTION: Conduct proper pre-warming and do not operate with the rapid change in
the temperature of the feed water inside the pump. The rapid temperature
change can cause thermal shock and this might result in damage of pump
components.

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SECTION 2 CAUTIONS DURING TRANSPORTATION AND STORAGE

Please observe the following items during the transportation period.

2.1 Caution during the transportation period

2.1.1 Care Marks

The care marks are put on the packages.

Please pay attention to these marks when you are handling the packages.

2.1.2 Pay attention to the following items when unloading and hoisting the packages.

- Tie up the lifting wires securely so that the packages do not slip and become
damaged.
- Tie securely the lifting wires at the position for slings shown on the packages
and adjust the wires so that the load is balanced.
- Do not raise and set down the packages too rapidly in order to avoid damage.
※ Note: The pump and motor shall be lifted by using 4-lifting lugs.

2.1.3 The package shall be fixed with bolts or a suitable manner to avoid damage due
to shocks, impacts and vibration during transportation.

2.2 Receipt of package and unpacking

When the equipment is arrived at the site, carefully unpack and immediately check the
followings.

2.2.1 Packing contents and quantity of the delivered goods should be checked in
accordance with Packing List/Shipping documents. If any shortage and/or
damage found, it must be reported immediately to HHI/EMD and must be
received in written within one month of receipt of the equipment. Later claims
cannot be accepted.

2.2.2 Check the nameplate and confirm that it is the ordered pump.

2.2.3 Check the shipping mark & care marks, packing & painting conditions.
If necessary, renew the preservative or touch up in rubbed off or scraped area to
Installation Manual 8
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restore the parts to the “as shipped” conditions. Paint and preservatives used shall
be accordance with the contract specification.

2.2.4 Check that the equipment is not damaged and the fixing bolts / nuts have not been
loosened during transportation. The condition of the skid and covering is indicative
as to the way the shipment was handled. Broken skids, torn coverings, bent fixing
bolts, broken straps, etc. indicate improper handling in transportation.

2.2.5 Inspect all covers over pump openings and piping connections. The protective
covers should be in place and undamaged. If covers for openings are damaged or
loosen, they should be removed, and a visual inspection shall be made of the
interior areas for any foreign materials or water. Install or replace covers and
fasten securely.

2.3 Handling

Boxes, skids, crates or cartons may be unloaded using the fork-lift vehicles or slings
dependent on their size, weight and features. Be careful in handling them not to be
damaged and consult local regulations for the details.

2.4 Lifting

DANGER: Careful attention must be paid to lifting the equipments. Improper lifting can
cause serious injury to personnel and/or damage to the equipments.

CAUTION: When lifting the pump and common bed, sling common bed from all of the
lifting holes supplied. Failure to do this may result in permanent deformation
of the common bed.

CAUTION: Assure that any equipment used for lifting the pump or its components is
capable of supporting the total weight (Refer to the General Arrangement
Drawing).

CAUTION: Ensure that the coupling is disconnected before lifting equipment.

CAUTION: Suction casing and discharge casing flanges, and/or auxiliary equipment or
piping should not be used to support the weight of the pump-motor unit.

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2.5 Cautions during storage

If it is necessary to store the equipment during the period from its delivery to the start of
installation (including transportation), the following treatment is necessary to minimize
damage of equipment during long periods of storage. It is recommended that pump be
stored as the complete assembly.

The guarantee of the equipment will remain valid for the entire guarantee period only as
long as the equipment is stored faithfully according to the following storage instruction.

However, the replacement of parts which become defective due to failure to follow these
instructions will be made at some charge.

CAUTION: Motor should not be stored in a damp atmosphere without special protection.
Refer to motor instruction manual for storage.

CAUTION: Pump flanges and piping connection covers provided with the pump should
be left in place during storage.

2.5.1 All packages shall be stored as packed and shall not be unpacked unless a
complete repacking shall be conducted after unpacking.

2.5.2 If pump is equipped with mechanical seals and is stored or has not been run for 1
year or more, the mechanical seal must be removed before start-up and faces re-
lapped to guard against the possibility of seal leakage. Refer to Mechanical Seal
Instruction Manual for the details.

2.5.3 Storage conditions

If possible, all crates and cases shall be stored in a warehouse with a floor. If all
crates are not kept in a warehouse, please store them outdoors according to “2.5.3
4) Storage Method”. The maximum period of storage for equipment in the crating
is 6 months after arrival at the site. If the period is over the above specified term,
please consult with the supplier and originate a better method of storing.

CAUTION: During the storage, turn the pump rotor 1 and 1/4 revolution once a
week.

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1) Environment of storage place

a. Clean, low humidity, good ventilation and temperature lower than 50℃
b. No dust and no generation of corrosive or harmful gas
c. No damage by small animals and insects
d. Good drainage and few weeds in case of outdoor storage
e. Storage floor or ground shall be level horizontally.

2) Storage of mechanical equipment

Many of the machines are furnished with finished painting.
These should not be exposed to direct sunshine and humidity.
Ferrous materials should be protected from humidity for the purpose of anti-
corrosion.

3) Storage of electrical equipment

Keep indoors and strictly observe the environment of 2.5.3 1) above.

4) Storage method

a. For cases: Indoor storage is required.

b. For crates: Indoor storage is desirable. If indoor storage is not practicable

and the storage period is more than 20 days, all surfaces of packages shall
be covered by vinyl sheets to prevent entrance of water and direct
exposure to the sun.

2.5.4 Care marks

For packing which must be handled carefully during transportation and storage,
care marks shall be written where clearly visible on the outside of the packing.

2.5.5 A pallet or similar material shall be put under the package to prevent direct contact
with the ground.

2.5.6 A vinyl sheet covers each package from the top to the ground level.

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2.5.7 Pay attention to the weight limitation for stacking of the packages.
Sleepers shall be put between each case in order to make the weight distribution
as even as possible.

2.5.8 Inspection and maintenance during storage

1) Visual inspection of packages

Each package shall be checked for damage or distortion every three (3) months,
and it shall be repaired if there is anything wrong.

2) Inspection for equipment

Twelve (12) months after shipment and every six months after that, each package
shall be unpacked and the exposed machined surfaces including screw threads
must be inspected visually. If there is rust on parts, or if paint has peeled off from
some parts, those parts shall be repaired in conformity with “Painting and Coating
Procedure. During this repair, care shall be taken not to loose the flat surface of the
machined surface.

3) During the above 1) & 2), the equipment shall be handled carefully and care taken
not to cause deformation of the equipment or damage to the paint. When repacking,
the package shall have the same structure or manner as before, and all of the
necessary care marks shall be printed on the package.

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SECTION 3 INSTALLATION

3.1 Cautions before installation

3.1.1 When unpacking the packing, be careful not to damage the goods and accessories.

3.1.2 Before the commencement of installation after long-term storage, the following
inspections shall be made of each part to confirm that it can be used. If any
unsatisfactory parts are found, they shall be replaced with new ones or they may
be used only after consulting with HHI/EMD supervisory personnel.

1) Check the contents and quantity in the package, while referring to the Packing List.
2) Check that the equipment has not been damaged during storage.
3) Check the painting condition of equipment.

3.1.3 Rust prevention

After unpacking, be thoroughly careful to prevent rust in the period from

installation to operation start.

3.1.4 In advance of starting the installation, study carefully the drawings and documents
which are attached herewith to understand the construction of the subject pump
and determine the preliminary arrangement.

3.2 Provisions for installation

The following shall be prepared before installation.

3.2.1 Non-shrinkage grouting (In case of initial installation only)

3.2.2 Flat and taper liners (in case of initial installation only)

Outline and recommended dimensions are shown in the “Foundation Drawing”.

Liners shall be machined accurately with a level surface to prevent partial contact
with the common bed or other liner.

3.2.3 Regular tools

Example: Spanner, Screw driver, Hammer, Pipe wrench, etc.
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3.2.4 Shackles

3.2.5 Pads which are required when lifting and laying down the parts.
Example: Wooden supports, Soft pads, etc.

3.2.6 Measuring instrument

Example: Level gauge, Theodolite, Plumb bobs, Dial gauge, etc.

3.2.7 Washing oil, waste cloth

3.2.8 Compressed air

3.2.9 Anti-galling compound (see Table 4.1 Details of Never Seez)

3.2.10 Lifting devices

Example: Crane, Chain block, Lifting rope, etc.

3.2.11 Welding equipment including the electrode

3.2.12 Others

3.3 Installation procedure

3.3.1 Installation preparation

1) Make the bench lines or bench marks, which will be the reference for installation,
at a place which shall not shift or sink.

2) Check that the floor level and the location of foundation holes of the pump floor
confirmed with the requirements shown in the "Foundation Drawing".

3) Mark the pump center lines and foundation height, etc. in accordance with the
"Foundation Drawing".

4) Chip the concrete surface of pump floor on which the common bed will be
installed, so that the grouting will adhere to the concrete tightly.

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5) The concrete surface and foundation bolt holes shall be cleaned by the
compressed air, and all of the foreign particles removed.

CAUTION: The design of foundations is not the responsibility of the HHI-EMD.

Therefore, it is recommended that the customer consult a competent
specialist in the field of foundations in order to insure proper design and
installation of the foundation.

CAUTION: There are many methods to install the pump unit to its foundation. The
correct and proper method depends on the size of pump unit, location
and vibration limitations. Non-compliance with the provision of correction
foundation and installation may result in failure of the pump. The
followings are satisfied at least.

 Foundation should be sufficiently rigid to prevent pump vibration and support

the pump unit at all points permanently.
 The reinforced concrete may be recommended for the satisfactory foundation.
This should be poured in advance of the installation to allow enough time for
drying and curing.
 The foundation mass ratio should be at least three to five times the total weight
of the pump unit.
 The foundation drawing will provide the details for anchor bolt size, numbers
and locations etc.
 Foundation should be designed so that structural resonance is outside of the
operating speed range of pump and motor.

3.3.2 Setting of the liners temporarily

1) Prepare the liners which consist of one (1) flat liner and two (2) taper liners.
These liners are the same as the final ones described later, and are used for the
purpose of installing the common bed temporarily and fixing the foundation bolts
at the proper position in the foundation bolt holes by non-shrinkage grouting.

2) Set the flat and taper liners temporarily at near position of the foundation bolts.

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3.3.3 First adjustment

CAUTION: Motor (and hydraulic fluid coupling for variable speed, if supplied) must
be removed before lifting common bed.

1) As the pump and common bed have been bolted together at the HHI-EMD shop
after centering and delivered to the site as one unit, do not disassemble them
after unpacking.

2) Place the common bed with the pump on the taper liners put temporarily, and
center it according to the bench lines or bench marks by using the upper
machined surfaces of the common bed which are the mounting feet for pump
and motor installation. Before placing the common bed on the liners, set the
foundation bolts that the thread shall be protected with grease, suspending them
from the holes in the common bed.

3) Adjust the level of the upper surface of the pump base (the height of the pump
elevation) to a tolerance of less than 0.5mm/m by using the taper liner as shown
in the following figure.

Fig. 6

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And, the level datum point of pump base, please refer to the following Figure 3.1 & 3.2.

Figure 3.1 Level Datum Point of Pump Base for MBFP

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Figure 3.2 Level Datum Point of Pump Base for MBFBP

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Figure 3.3 Level Datum Point of Pump Base for SBFP

3.3.4 Foundation bolt fitting

1) Pour the non-shrinkage mortar into the foundation bolt holes.

At this time, take care that the foundation bolts are set vertically and that the
grouting is pushed sufficiently in all corners with the help of vibrator or similar
device, so that no air pockets are left. Also, be careful not to permit extreme
temperature change and vibration or impact during mortar hardening.

2) After hardening the mortar, remove the pump base and then, remove the liners
placed temporarily.

3.3.5 Setting of final liners

The setting procedure for final liners is as follows.

These liners shall be fully buried into the finishing grouting when the installation
work has been completed. The weight of pump, driver including lube oil unit and
water in pump must be supported by these liners.

1) Chip the concrete surface of the pump floor where the final liners will be placed,
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as shown in the Figure 3.4, so that the grout will adhere tightly to the concrete.
After that, clean the floor and properly wet it.

TAPER LINER

10 mm
FLAT LINER

NON-SHRINKAGE MORTAR

Figure 3.4

2) Spread non-shrinkage mortar thinly on the chipped surface of the concrete.

3) Set the flat liners which are wide enough to support the weight of the driver, lube
oil unit, pump and water in the pump, near the foundation bolts.

Then, push the flat liners against the mortar and adjust the level of the upper
surface of the each liner with a tolerance of less than 0.1mm/ m.

The elevation of liners should be as accurate as possible, with the difference of

height of each flat liner being less than 0.5mm.

4) After hardening the mortar, put a pair of taper liners on the flat liners.

3.3.6 Common bed installation and secondary adjustments

1) Mount the common bed only with the pump on the taper liners.

2) Center the pump in reference to the bench liners or bench marks.

3) Level crosswise and lengthwise on every machined surfaces of common bed,

which are the mounting feet for the pump and motor (Figure 3.1 & 3.2) so that it
has a tolerance of less than 0.1mm per 1000mm by using the taper liners.
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4) Tighten the foundation bolts loosely and check the level in both crosswise and
lengthwise direction. If the level is disturbed by tightening, adjust leveling till
levelness is achieved when anchor bolts are tight.

5) Mount all equipment and proceed to alignment.

3.3.7 Shaft alignment (centering) of pump and driver

In order to keep the operation of the pump and driver continuously in satisfactory
condition, the centering of the coupling is very important.

For the axial alignment of the proposed pumps, refer to the following figure.

Carry out the following procedure, and the axial alignment shown in the figure can
be attained.

The pump and driver normally have to be aligned at ambient temperature.

Therefore, they should be corrected to allow for thermal expansion at operating
temperature.

Hot alignment can only be made after the unit has been in operation a sufficient
length of time.

Illustration of Axial Alignment for BFP

 Check that the total end play of the motor is at least 12 ± 4 mm.
 Place the rotor of the motor into the magnetic center position.

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Illustration of Axial Alignment for MAIN BFP TRAIN

Fig 3.5
Fig 3.6 Fig 3.7

VERTICAL DIRECTION

R/G (Input) C/L R/G (Output) C/L

0.07

0.21
TURBINE C/L
BP C/L
0.2

MBFP C/L

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HORIZONTAL DIRECTION
TURBINE C/L BP C/L

0.16
BFBP C/L 0
R/G (Output) C/L

0.01
R/G (Input) C/L

D.B.S.E 600 ±0.1

Fig 3.5 Flexible Coupling for TURBINE & MBFP

D.B.S.E : Distance Between Shaft Ends
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D.B.S.E 400 ±0.1

Fig 3.6 Flexible Coupling for TURBINE & REDUCTION GEAR

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D.B.S.E 250.6 ±0.1

Fig 3.7 Flexible Coupling for MBFBP & REDUCTION GEAR

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Illustration of Axial Alignment for START-UP BFP TRAIN

Fig 3.9

Fig 3.8

VERTICAL DIRECTION

SBFP C/L
MOTOR C/L

0.13
F/C (Input) C/L F/C (Output) C/L
0

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HORIZONTAL DIRECTION
SBFP C/L
MOTOR C/L

0
F/C (Input) C/L F/C (Output) C/L

0
D.B.S.E 351.96 ±0.1

Fig 3.8 Flexible Coupling for FLUID COUPLING & MOTOR

D.B.S.E : Distance Between Shaft Ends

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D.B.S.E 250.72 ±0.1

Fig 3.9 Flexible Coupling for SBFP & FLUID COUPLING

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 INSTALLATION INSTRUCTION
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Alignment Criteria for MBFP & MBFBP & SBFP(Allowable Tolerance ± 0.05mm)

Procedure to align shafts at ambient temperature

1. Confirm the shaft movement (End Play) of the motor.
2. Check the difference distance between the magnetic center on the shaft and
the magnetic pointer installed on motor frame.
3. Decide the revised DBSE considering the above difference distance.
4. Keep the revised DBSE by controlling the push bolts.

CAUTION: Shaft alignment must be corrected for successful operation.

Shaft misalignment might cause noise, vibration, abnormal
wear and actual damage to the equipment.
1) Before taking shaft alignment measurements it is recommended that
the pump mounting bolts which are assembled at the pedestal of
pump be tight. This considers the driver as the movable equipment.
But the bolts at pin block and key block of BFP be loosened for axial
alignment. Motor with sleeve bearings is to be aligned with rotor at
magnetic center.

CAUTION: If the motor does not run in its magnetic center the resultant
additional axial force may overload the pump thrust bearing.

2) The first step in pump and driver shaft alignment is to bring the pump
and driver shafts into their proper axial position. The distance
between shaft ends must be in accordance with the specified value
on General Arrangement Drawing.

To check the alignment of the shaft, remove the shaft coupling

spacer and completely remove the rust preventive on the outside of
the shaft coupling with solvent such as thinner.

DANGER: Ensure that pump and motor are isolated electrically.

CAUTION: Ensure that the bearings are to be pre-lubricated before
starting alignment.

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3) Horizontal Direction
Move the pump or driver by using the alignment jack screws or
hammering with soft hammer.

4) Vertical Direction
It is very important that the vertical thermal expansion be taken into
consideration before moving the pump or driver vertically.

The stainless steel shims between the motor feet and mounting
surface of common bed should be clean and dry. This is especially
critical for pumps that have been in service for some time and
needed to be realigned.

Dirt, rust, etc. may change the height of the shim pack over a period
of service. Do not use many thin shims because this may cause a
sponge mounting effect.

Move the pump or driver vertically by adding or removing the

calculated thickness of shims. Tight the pump or driver holding bolts
to required values.

5) Checking coupling alignment

The offset and angular coupling alignment must be rechecked.

 Offset Misalignment: coupling outside diameters are to be aligned

within 0.050 mm TIR (0.002 inch TIR) at the least four (4) points
around the circumference of the shaft coupling, as shown in Fig 3.7.
 Angular Misalignment: coupling faces are to be parallel within 0.050
mm (0.002 inch) at the least four (4) points around the coupling
circumference, as shown in Fig 3.10

If some misalignment is observed at the alignment of the pump and

driver, the common bed may be bent or distorted because it is

unevenly supported. Re-check the centering of pump and driver.

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Correct differences of level and gap clearance by gradually adjusting

pump and driver by using shim plate.

Offset Misalignment Angular Misalignment

Fig. 3.10

NOTE: It is recommended that the completed coupling alignment

data sheet be retained as part of your permanent
maintenance file and the coupling alignment data sheet be
prepared by your own format.

3.3.8 Fasten the foundation bolts tightly

3.3.9 Spot welding of liners

As shown in the Figure 3.11, conduct the spot welding on the flat and
taper liners so that the liners do not slip.

SPOT WELDING

Figure 3.11

3.3.10 After conducting the spot welding, the alignment of pump and motor

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shall be re-checked and install the coupling and coupling guard.

3.3.11 Finish grouting

1) Assemble the mould (wooden frame) in order to fill the concrete

around the common bed.

2) Grout below, around and inside the common bed in accordance with
the Foundation Drawing. The grouting should be spread sufficiently
to all of the corners by using the vibrator or similar device, so that no
air pockets are formed in the grouting.

3.3.12 Pipe strain check

In order to keep accurate assembly of pump with the Suction &

Discharge pipe, the following procedure shall be performed.

1) For MBFBP Suction Nozzle

(1) Put two dial gauge on the R/G coupling - 1 for vertical movement,
1 for horizontal movement check - and set the indicator on BP
coupling (Refer to illustration below)
(2) Assembly the suction pipe and pump suction nozzle.
(3) Check the displacement.※
(4) Disassembly the suction pipe and pump suction nozzle.

2) For MBFBP Discharge Nozzle

(1) Put two dial gauge on the R/G coupling - 1 for vertical movement,
1 for horizontal movement check - and set the indicator on BP
coupling (Refer to illustration below)
(2) Assembly the cross-over pipe and pump discharge nozzle.
(3) Check the displacement.※
(4) Disassembly the cross-over pipe and pump discharge nozzle.

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<BP Coupling> <R/G Coupling> <View from right side>

3) For SBFP Discharge Nozzle

(1) Put two dial gauge on the F/C coupling - 1 for vertical movement,
1 for horizontal movement check - and set the indicator on SBFP
coupling (Refer to illustration below)
(2) Assembly the discharge pipe and pump discharge nozzle.
(3) Check the displacement.※
(4) Disassembly the suction pipe and pump suction nozzle.

<View from left side> <F/C Coupling> <SBFP Coupling>

※ Acceptance Criteria of Displacement: ≤ 0.02mm

If displacement exceed above criteria, constructor should follow
HHI’s instruction.

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3.3.13 Discharge and suction pipe connection

CAUTION: Do not use the pump as a support for piping.

CAUTION: Ensure the piping and fittings are flushed before use.

Install the discharge and suction pipes to the pump discharge and
suction nozzle carefully so as not to cause the pipe weight or
unreasonable force to act on the pump, and also to prevent
disturbance of the leveling. Suction and discharge piping should be
installed in direct runs and have a minimum of bends.

Suction pipe is at least one size larger than the pump suction nozzle.
Keep the suction pipe free of all of the air pockets.

Install a check valve and a gate valve in the discharge piping of the
pump.

The check valve will prevent the pump from running backward when
the pump is stopped. The check valve should be installed between the
pump discharge nozzle and the gate valve. The gate valve is useful in
priming and starting the pump.

Ensure all piping is installed in accordance with design which should

result in nozzle loads below the acceptable limits. All piping supports
and hangers must be set properly before operating equipment. When
the suction and discharge piping is installed, do not force piping to fit
up to pump nozzles. Piping should not be strained in the cold static
condition.

The excessive forces and moments may result in misalignment, hot

bearings, worn couplings, vibration and the possible failure of the pump
casing. To minimize the forces and moments, the followings should be
followed:

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 Prevent excessive external pipe load

 Do not draw piping into place by applying force to pump nozzle
connections
 Do not mount expansion joints so that their force due to internal
pressure acts on the pump nozzle

3.3.13 Suction Strainer

In a new installation, the great care should be taken to prevent dirt,

scale and welding beads etc. from entering the pump. Even though the
piping has been flushed previously, it is difficult to remove the oxides
and mill scale which will become free when the pipe heats and cools
several times. Foreign particles may be large enough to jam a pump
which may cause damage the pump. Smaller material passing through
the pump can cause rapid wear and premature failure.

The pump is provided with the expectation that it will be pumping clean
feedwater. If a suction strainer is provided it is not intended to be used
for cleaning the entire piping system.

Particle of this size will normally pass through the pump without
causing damage. However, such particles can become trapped in the
running clearances during on pump shut-down. The HHI-EMD cannot
recommend a procedure that will totally prevent such binding but we
strongly suggest that systems be cleaned and flushed prior to
connecting the pump to the piping to minimize particles entering the
pump.

CAUTION: Minimize the pump starting and stopping as pumps are

most susceptible to dirt during starts and stops.

When the binding is occurred, it is not likely that the binding can be
remedied by hand turning the rotor and partial disassembly may be
required to clean the affected parts.

CAUTION: Excessive force applied to try to free a bound rotor may

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result in damage and repair of rotor parts.

Generally, a pump should be installed with the suction strainer

protection. The suction system should be thoroughly flushed before
installing the suction strainer and setting up the suction piping to the
pump. The suction strainer should be installed in the inlet piping of the
pump. Ensure that the installed suction strainer will not distort the flow
to the pump suction.

CAUTION: Never install the suction strainer directly on the pump

suction nozzle. The suction strainer should be located at
least 6 or 10 pipe diameters upstream of the suction
nozzle.

At all times when using the suction strainers, it is critical that the
pressure drop across the strainer be continuously monitored to ensure
that the pump suction pressure does not fall below that required to

prevent the pump cavitation.

An increase in the differential pressure indicates that the strainer or

screen is becoming clogged with dirt and scale. Before the pressure
drop becomes so severe that cavitation occurs, the pump should be
shut down and the strainer cleaned. Alarm settings to protect the pump
from damage due to cavitation need to be supplied by the plant
engineer or system designer before operating the pump. Typically
alarm settings would be 0.3 bar differential pressure across the strainer.

When the strainer is installed, 80 mesh or higher mesh screen is

typically used for the pump start-up at reduced flow rates. For normal
operation, 40 mesh screen is used for permanent strainer.

CAUTION: The pressure drop across the suction strainer is a direct

reduction in NPSH available to the pump. NPSH available
must always exceed NPSH required by the pump. This
requirement may limit the pump flow rate during pump

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start-up. Alarms or pump trip devices should be installed to

minimize the possibility of pump damage. It is the
responsibility of the pump operator to obtain the allowable
pressure drop across the strainer of safe pump operation
from the plant engineer or system designer prior to
operation of the pump.

3.3.14 Auxiliary piping

All of the auxiliary piping is assembled on the pump according to the

“Aux. Piping Arrangement Drawing”. Be careful not to trample the
auxiliary piping under foot and not to damage these piping by falling
objects, etc.

Do not install piping until alignment, grouting and final field welding
have been completed.

3.3.15 By-pass line for minimum flow

A suitable minimum flow by-pass system connected to pump discharge

prior to the first valve should be provided by the Customer. The by-
pass flow should be directed to the source of the pump suction and
designed to control the minimum flow required by the pump.

Note that a back pressure device located downstream of the minimum

flow valve may be required to suppress valve cavitation or downstream
line flashing.

3.3.16 Flushing or acid washing

Pumps subjected to flushing or acid washing intended to clear the

piping system must be by-passed to prevent debris from entering the
pump or disassembled internal cartridge part from casing.

Failure to do so will cause the corrosion damage to critical parts and

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deterioration of non metallic parts.

3.3.17 Reamer pin and key-block assembly

1) After completion of final alignment of MBFP&SBFP and MBFBP, the

holes of reamer pin shall be drilled to the pump foot and base
simultaneously and then, assembled with reamer pins in order to
minimize thermal expansion.

CL. OF DISCHARGE
CL. OF SUCTION

55 2-? 28 SPOT FACE DP. 1

2-? 16 TAPER REAMER DP. 100
(TAPER:1/50)
PROCESSING WITH BASE
AFTER SHAFT ALIGNMENT

55

Reamer Pin Location of BFBP

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2) For MBFP & SBFP, also key-block which is located to below outer
casing shall be firmly assembled.

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3.3.18 In case that the driver is a motor,

1) Especially be careful about the wiring of the power supply cables for
the motor rotating direction.

2) The details of subsequent steps for checking the motor rotating

direction of trial operation shall be described in “Operation &
Maintenance Manual”. Also, refer to the “Instructions for Three Phase
Induction Motor” for motor pre-commissioning.

3) If the motor pre-commissioning is not performed immediately after

installation, coat temporary rust preventive on the shaft coupling.

3.3.19 In case that the driver is a hydraulic coupling,

The details of subsequent steps for installation and commissioning of

hydraulic coupling shall be described in the “Instruction Manual of
Variable-speed turbo coupling 562 SVTL 12.1”. Please refer to
“Instruction Manual of Variable-speed turbo coupling 562 SVTL 12.1”.

3.4 Cautions for installation

3.4.1 The pump foundation and installation works shall be performed to

provide smooth pump operation and to prevent transmission of vibration
and impact caused by operation to other objects.

3.4.2 Cautions for unloading products

1) In hoisting common bed with pump and driver, pay attention to attach
the wire rope so that the load will be balanced and the wire rope will
not slip.

2) When lifting heavy parts, use soft pad under the wire to protect the
coated and machined surface from the wire. And do not raise lower

parts to rapid with the crane.

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3.4.3 Remove and clean the cloth cover and rust preventive which are
performed for rust prevention and protection during transportation by
washing with oil before assembling. Remove foreign matter in the
tapped holes by compressed air.

3.4.4 When assembling each part, check that there is no flash,

protuberances or dust on the flange surface and fitting surface.

3.4.5 When tightening the coupling bolts and other fixing bolts, spray or coat
anti-galling compound (“Never Seez” or equivalent) on the fitting
surface, thread and reamer surface to prevent seizing.

3.4.6 Details of “Never Seez” are shown as below.

Table 4.1 Details of Never Seez

Brand Name Material Maker Prevention
Hydro Carbon Never Seez
Never Seez Compound, Compound Seezing
etc. Corp.

3.4.7 Refer to “Technical product manual for Mechanical Seal”, ”Installation

instructions for seal cooler” in “Operation & Maintenance Manual” for
handling the seal & cooler equipment.

3.4.8 Repeatedly check to make sure that all bolts of each flange and other
parts are completely and evenly tightened.

3.4.9 Consideration must be given to external forces and shocks resulting

from operation of other devices.

3.4.10 Care must be taken to protect each part from rust during the period until
operation begins.

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3.4.11 Touch-up the coated surface with paint which has been damaged
during assembling or installing. Refer to “Painting Procedure”.

3.4.12 The auxiliary piping should be free from the foreign particles.

3.4.13 During and after installation, it is desirable to enclose and cover the
pumps with a protecting fence as necessary if the pumps may be
damaged by falling objects or impact in conveyance of other
construction works, etc.

3.4.14 If the pump is idle for a long-term time,

1) Blind the openings of the pump (at the suction and the discharge
flange to prevent entering foreign matters).

2) The pumps shall be adequately treated for rust prevention. If there is

rust, it should be removed immediately and anti-rust treatment re-
applied. Also, attention should be paid to the effective periods of rust
preventive measures.

SECITION 4 OIL FLUSHING

4.1 Purpose

The boiler feed pump and other equipment have several bearings, therefore,
the flushing of the lube oil system for boiler feed water pump train shall be
carried out completely in accordance with this procedure after installation or
storage, prior to the site test & operating the pump.

The purpose of oil flushing shall be to remove the dirt which is related with the
site installation works including welding and to increase the anti-dust capability
for safety of equipment bearing.

DANGER: The equipment is not filled up with lubricating oil at the time
of delivery. So before operating, fill the lubrication oil in

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accordance with the specification indicated in this document. If

operated with the insufficient lubricant, the equipment could be
damaged.
CAUTION: During flushing work or operating the equipment, be careful
about oil leakage. If any leakage are found, clean it away,
stop the equipment(if necessary), and correct the leakage.

4.2 Equipment and Materials to be prepared

4.2.1 Flushing Oil
Flushing oil or regular operating oil must be used for oil flushing.
Required quantity of flushing oil is the same as that for normal operation.
Flushing oil must be charged into oil tank through #100 mesh strainer.

4.2.2 Temporary Strainer

Install some mesh strainers at proper points in order to inspect flushing
effect and to collect foreign materials in the circulating system. #100 or
#200 mesh strainers must be installed at the inlets to each bearing, etc.

4.2.3 Oil pump to be used for Oil Flushing

Auxiliary oil pump equipped with the unit can be used for oil flushing.
Auxiliary oil pump must be operated with the relief valve adjusted to
higher pressure in order to raise the line pressure so that maximum oil
flow can be obtained through the circulating system.(Do not allow the
lubricating oil pressure to fall below 0.05MPag during oil flushing.)

4.2.4 Sponge Pad

Sponge pad can be used to clean the interior of oil tank. Do not use any
fabric materials such as cotton rag, cloth, etc.

4.2.5 Plastic Hammer

During oil flushing, hammering can be done with the plastic hammer to
increase the effect of oil flushing.

4.3 First Oil Flushing

The temporary piping or hose must be installed in order to bypass the bearing

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boxes, and the first flushing must be carried out. The purpose of this first
flushing is to eliminate the foreign materials and scales in the piping system,
increasing the flow rate by bypassing the bearing boxes.

4.3.1 Preparation
Following preparation works must be done prior to flushin operation;
① Prepare the record sheets for oil flushing.
② Install temporary strainers (#100 or #200 mesh).
③ Clean and inspect the oil tank interior.
④ Charge flushing oil (record a charged quantity).
⑤ Start the auxiliary oil pump (A.O.P.) and check for oil leakage on all
system

4.3.2 Start oil flushing

Following preparation works must be done prior to flushing operation;
① Start Oil Circulation
Do not operate the A.O.P at overload condition due to the clogging
of strainers, and make sure of the oil tank level during oil
flushing.(Replenish oil if required).
② Hammering
During the oil flushing, hammering must be done properly to
increase the effect of flushing. After that, inspect the strainers and
collect the foreign materials caught at any strainers. Hammering
must be done at every one (1) hour. Hammering on bending parts,
flanges and welding seams must be carefully done. Do not continue
hammering until just before circulation is suspended. And do not
use any rigid hammers or tools which will cause deformation of
pipie.
③ Inspection, Cleaning and Change of Strainer
Inspection, cleaning and change of the strainer must be done after
stopping the A.O.P. First inspection of the strainer must be done 10
minutes after the circulation is started. At this time, if collected
foreign materials are in large amount, then the strainers inserted at
the oil inlets must be changed with new ones at every 10 to 15
minutes so that no strainer is broken during oil circulation.
Subsequent inspections of the strainers must be done every 1 to 2

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hours and the strainers must be cleaned thoroughly.

④ Recording
Take the flushing records at every inspection of strainers so as to
make sure of progress of oil flushing clearly and easily.

4.3.3 Judgement
① Method of Judgement
Most simple and reliable method of judgement for flushing effect is
to judge the condition of strainers by visual inspection, as referring
to the actual progress of oil flushing with record sheets.

② Criteria of judgement
Criterial of judgement for the first oil flushing are as follows.
1) Collected foreign materials at the strainers in the oil tank and the
temporary strainers installed in each line must be reduced to a
certain minimum amount and must be saturated in amount.
2) Flushing must be continued until the following quantitative and
qualitative criteria are satisfied.
(i) Quantitative Criteria
Total accumulation of foreign materials collected at every
temporary strainer must be less than 1 gram per 8 hours.
(ii) Qualitative Criteria
No hard particles larger than 0.25mm such as slag, spatter,
metal piece and sand. Hard particle is defined as one not to
be crushed by finger.

4.4 Second Oil Flushing

The second flushing must be carried out with the complete oil piping line
including the bearing boxes. This second flushing is the final oil flushing for
operating pump.

4.4.1 Preparation
① Prepare the record sheets for oil flushing.
② Install temporary strainers right in front of each bearing box.
③ If necessary, clean the tank and charge flushing oil (record quantity
charged).

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④ Start auxiliary oil pump (A.O.P.) and check for oil leakage on all
system.

4.4.2 Start oil flushing

Do the same procedure as the first flushing.

4.4.3 Judgement
Criteria of judgement for second oil flushing are as follows.
① Collected foreign materials at the strainers in the oil tank and the
temporary strainers installed in the each line must be reduced to a
certain minimum amount and must be saturated in amount.
② Flushing must be continued until the following quantitative and
qualitative criteria are satisfied.
(i) Quantitative Criteria
Total accumulation of foreign materials collected at every
temporary strainer must be less than 0.5 gram per 24 hours.
(ii) Qualitative Criteria
No hard particles larger than 0.25mm such as slag, spatter, metal
piece and sand. Hard particle is defined as one not to be crushed
by finger.

※ Standard Specification: NAS 1638 Class 11

4.5 Restoration
4.5.1 Drain Flushing Oil
After the oil flushing is completed, drain the all flushing oil. Oil remained
in the strainers, coolers and piping where the oil cannot be drained
naturally, must be drained by loosening the flanges. Maximum allowable
percentage of remaining flushing oil in the system is five percent (5%) on
the total.
4.5.2 Cleaning
After flushing oil is drained from the system, carry out the following
cleaning operations.
① Oil Tank Interior
Clean the interior of oil tank with sponge pads. Do not use normal
waste rag.

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② Duplex Strainer
Dismantle and clean the inside, and then re-assemble.
③ Oil Cooler
Drain oil thoroughly, if possible, by blowing air.
④ Mesh Strainer
Make sure that the strainer is not broken. Remove all mesh strainers
installed temporarily for oil flushing.
4.5.3 Charge Regular Operating Oil
Charge the regular operating oil into the oil tank through #100 to #200
mesh strainer.
Continue to charge the oil with the operation of the A.O.P., until normal
oil level of the oil tank is reached.

SECTION 5 REFERENCE DRAWINGS & DOCUMENTS LIST

DRAWING No. DRWAING TITLE

TB2-SDC.VP103-00LAC-M-
Foundation Drawing for Main BFP & BFBP
M1B-DFN-0001
TB2-SDC.VP103-00LAC-M-
Foundation Drawing for Start-up BFP
M1B-DFN-0002
TB2-SDC.VP103-00LAC-M-
Outline Drawing for Main BFP & BFBP
M1B-DGA-0001
TB2-SDC.VP103-00LAC-M-
Outline Drawing for Start-up BFP
M1B-DGA-0002
TB2-SDC.VP103-00LAC-M-
P & I Diagram for Main BFP & BFBP
M1B-PID-0001
TB2-SDC.VP103-00LAC-M-
P & I Diagram for Start-up BFP
M1B-PID-0002
TB2-SDC.VP103-00LAC-M-
Sectional Drawing for Main BFP
M1B-DSE-0001
TB2-SDC.VP103-00LAC-M-
Sectional Drawing for Main BFBP
M1B-DSE-0002
TB2-SDC.VP103-00LAC-M-
Sectional Drawing for Start-up BFP
M1B-DSE-0003
TB2-SDC.VP103-00LAC-M- Cross-over Piping Arrangement Drawing for Main BFP
M1B-DSE-0015 & BFBP
TB2-SDC.VP103-00LAC-M- Cross-over piping Support Drawing for Main BFP &
M1B-DPS-0001 BFBP

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TB2-SDC.VP103-00LAC-M-
Mechanical Seal Drawing for Main BFP
M1B-DSE-0004
TB2-SDC.VP103-00LAC-M-
Mechanical Seal Drawing for Main BFBP
M1B-DSE-0005
TB2-SDC.VP103-00LAC-M-
Mechanical Seal Drawing for Start-up BFP
M1B-DSE-0006
TB2-SDC.VP103-00LAC-M-
Mechanical Seal Cooler Drawing for Main BFP
M1B-DSE-0007
TB2-SDC.VP103-00LAC-M-
Mechanical Seal Cooler Drawing for Main BFBP
M1B-DSE-0008
TB2-SDC.VP103-00LAC-M-
Mechanical Seal Cooler Drawing for Start-up BFP
M1B-DSE-0009
TB2-SDC.VP103-00LAC-M-
Flexible Coupling Drawing for Main BFP & Turbine
M1B-DSE-0010
TB2-SDC.VP103-00LAC-M- Flexible Coupling Drawing for Turbine & Reduction
M1B-DSE-0011 Gear
TB2-SDC.VP103-00LAC-M-
Flexible Coupling Drawing for Reduction Gear & BFBP
M1B-DSE-0012
TB2-SDC.VP103-00LAC-M- Flexible Coupling Drawing for Start-up BFP & Fluid
M1B-DSE-0013 Coupling
TB2-SDC.VP103-00LAC-M-
Flexible Coupling Drawing for Fluid Coupling & Motor
M1B-DSE-0014
TB2-SDC.VP103-00LAC-M- Aux. Piping Arrangement Drawing (1/2 & 2/2) for Main
M1B-DGA-0005 BFP & BFBP
TB2-SDC.VP103-00LAC-M- Aux. Piping Arrangement Drawing (1/2 & 2/2) for Start-
M1B-DGA-0006 up BFP
TB2-SDC.VP103-00LAC-M-
Sound Enclosure Drawing for Main BFP train
M1B-DGA-0014
TB2-SDC.VP103-00LAC-M-
Sound Enclosure Drawing for Start-up BFP train
M1B-DGA-0015
TB2-SDC.VP103-00LAC-M- General Arrangement Drawing of Suction Strainer for
M1B-DGA-0004 Main BFP & Start-up BFP
TB2-SDC.VP103-00LAC-M-
Assembly Disassembly Drawing for Main BFP
M1B-DGA-0007
TB2-SDC.VP103-00LAC-M-
Assembly Disassembly Drawing for Main BFBP
M1B-DGA-0008
TB2-SDC.VP103-00LAC-M-
Assembly Disassembly Drawing for Start-up BFP
M1B-DGA-0009

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SECTION 6 ATTACHMENTS

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 INSTALLATION INSTRUCTION
OF BFP

6. Instruction Manuals
6.1 Instruction Manual for Sound Enclosure

Installation Manual 45
 TOTAL SHEET : 14 SHEET

(INCLUDING COVER)

INSTALLATION MANUAL
for
SOUND ENCLOSURE
===================================

Project No. : KA1549

Project name : THAI BINH 2 TPP Project

Item name : Sound enclosure for Main BFP

Document title : Installation manual

Manufacturer : Hanil noise and vibration Co.,Ltd.

A 2015. 4, 30 installation manual you d y joe s h kim y g

Rev. Date Description Prep'd Check'd App'd

Hanil Noise & Vibration Co.,Ltd
 CONTENTS

1. GENERAL PRECAUTIONS

2. SOUND ENCLOSURE INSTALLATION PROCEDURE

1) Guide Rail & Corner Panel installation
2) Front Panel & Right Panel installation
3) Back Panel & Left Panel installation
4) Upper Guide, Roof Panel & ETC installation
5) Electric Equipment #1 piping & lighting
6) Electric Equipment #2 vent fan & contron box
7) Electric Equipment #3 control box
8) Electric Equipment #4 switch & others

3. CLOSING & INSPECTION

 Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Main BFP

1. GENERAL PRECAUTIONS

1-1. CAUTION (on moving)

A) The assembly of enclosure frame and acoustic panels including accessories should
be installed according to this installation manuals.
B) If there is question in installation processing, refer to this manual for installation, or ask to
maker's designer or supervisor and comply with his order.

C) The site manager confer with supervisor's proposal of drawings at the beginning and
at the end of the installation about process, some cooperated work with other department,
and take the instructions.
D) During the installation, a damaged parts should be repaired before installation.
E) Any damage or deformation should be repaired immediately.
F) Handle with care, to prevent the product's corner's bending, paint separation and
scratching.
G) Enclosure was painted by owner's color or contractor's choice, be careful not to be shocked

1-2. CAUTION (on installation)

A) Every parts should be prepared according to form, quality, usage and material and
treated appropriated with the characteristic of the material.
B) The acoustic panels and accessories should be transported without any deformity and
damage due to itself weight.
C) All acoustic panel and accessories should be transported without deformity or twist.
D) All products should be transported without any pollution which like mud or contaminant
E) Every worker must be well acquainted with the installation procedure and handling
methods.
 Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Main BFP

2. SOUND ENCLOSURE INSTALLATION PROCEDURE

A) The guide rails are to be installed without modifications robust and horizontally with a set anchor
B) Connected and assembled parts is in accordance with the approved drawings and the
use of bolts, nuts representation by drawings.
D) The panel is installed above the horizontal guide rails caught the frame interval is a
clearance within 2mm as possible.
E) Panels installed on the horizontal guide rails, height allowance within 0~-5mm.
F) When product decomposition from skid, carefully handle a particular attention to
avoid the paint work. (to avoid painted surface)
G) Panel installation can be installed to change the order in accordance with the site conditions.

Packing Sticker (for example)

 Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Main BFP

2. SOUND ENCLOSURE INSTALLATION PROCEDURE

SOUND ENCLOSURE ASSEMBLY PROCEDURE

1) Guide Rail & Corner Panel installation

2) Front Panel & Right Panel installation
3) Back Panel & Left Panel installation
4) Upper Guide, Roof Panel & ETC installation
5) Electric Equipment #1 piping & lighting
6) Electric Equipment #2 vent fan & control box
7) Electric Equipment #3 control box
8) Electric Equipment #4 switch & others

(CAUTION)

A) Assemble a upper guide rail at wall panel installation.

B) All products have part No. and assemble according to drawing.

C) Wall panel loading with rope fasten to attached screw tapping hole of upper side
center use eye bolt and shackle by crane.

D) Roof panel loading rope fasten to upper I-bolt, as a lifting lug by crane
 Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Main BFP

1) Guide Rail & Corner Panel installation

LOWER GUIDE

INSTALL LOWER GUIDE RAIL WITH SET ANCHOR BOLT

CORNER PANEL

C06

C05

C01 C04

C02 C03

LOWER GUIDE

INSTALLED THE CORNER PANEL ON THE LOWER GUIDE.

CORNER PANEL ASSEMBLY & PROCEDURE : C01 - C03 - C05 - C06 - C03 - C04
 Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Main BFP

2) Front Panel & Right Panel installation

F01

F01 FR1

REINFORCEMENT
CHANNEL

C01
C02 LOWER GUIDE

FRONT PANEL ASSEMBLY & PROCEDURE : F01 - FR1

THE UPPER GUIDE ASSEMBLY AFTER THE WALL PANEL INSTALLATION AT THE SAME TIME.
REASSEMBLE REINFORCEMENT CHANNEL OF F01 AFTER WALL PANEL INSTALLATION. (CHECK POINT)

R01

RR1
R01
C04
C03
REINFORCEMENT
CHANNEL

LOWER GUIDE

RIGHT PANEL ASSEMBLY & PROCEDURE : R01 - RR1

REASSEMBLE REINFORCEMENT CHANNEL OF R01 AFTER WALL PANEL INSTALLATION. (CHECK POINT)
 Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Main BFP

3) Back Panel & Left Panel installation

DOOR PANEL

BR1 C06
B01
C05

LOWER GUIDE

BACK PANEL ASSEMBLY & PROCEDURE : B01 - BR1

C06 LR1
L02
L01
C01

LOWER GUIDE

LEFT PANEL ASSEMBLY & PROCEDURE : L01 - L02 - LR1

 Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Main BFP

4) Upper Guide, Roof Panel & ETC installation

UPPER GUIDE
RF02
RF03 RF01
RF04

ROOF PANEL ASSEMBLY & PROCEDURE : UPPER GUIDE - RF05 - RF04 - RF03 - RF02 - RF01

RIGHT VIEW

FRONT VIEW LEFT VIEW
BACK VIEW

ASSEMBLY THE OUTSIDE & INSIDE FLASHING BAR, COVER, SILENCER, ATTACHMENTS & ETC
SHALL BE SILICONIZED AFTER ASSMEBLY FOR PROTECTION OF LEAK.
 Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Main BFP

5) Electric Equipment #1 piping & lighting

ELECTRIC  LIGHTING 
CONNECTION

ELECTRIC 
CONDUIT PIPE LIGHTING

INSTALL THE ELECTRIC STEEL PIPING, LIGHTING & CONNECTION BRANCH

INSTALL  THE  3‐
WAY SWITCH 

INSTALL THE ELECTRIC LIGHT SWITCH

Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Main BFP

6) Electric Equipment #2 vent fan & contron box

FLEXIBLE HOSE 
& CONDUIT PIPE
VENT FAN ,0.75KW, Φ3, 
400VAC, 50Hz, 

INSTALL THE VENT FAN AND ELECTRICAL WIRING

CONDUIT PIPE

CONTROL BOX 

INSTALL THE CONTROL BOX TO PANEL & CONNECT PIPING

Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Main BFP

7) Electric Equipment #3 control box

CONTROL BOX 
INNER VIEW

CONNECTION THE CONTROL BOX INNER WIRING

CONTROL BOX  CONTROL BOX 
CONTROL BOX  INSTALLAED  VIEW DOOR OPEN   

CHECK THE CONTROL BOX S/W AND WIRE CONNECTION

Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Main BFP

8) Electric Equipment #4 switch & others

ENCLOSURE INSIDE  
VIEW

CHECK THE FAN AND LIGHT OPERATION

ENCLOSURE INSIDE  
VIEW

ELECTRIC PIPING & CONTROL SWITCH INSTALLATION PHOTO

 Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Main BFP

3. CLOSING & INSPECTION

3.1 Cleaning & finishing

A) Installed wall panel and roof panel should be clean the pollution material and mud,
contaminant.

B) Product should be handled carefully for prevent damag by shocking after repairing
& re-painting

C) After the installation is complete (including all attachments inside and outside)
All panel joint region by sealing with silicone to prevent water intrusion

3.2 Inspection

A) When every parts are installed complete, the supervisor have to submit the complete
report after solve aproblems as missing material for zero defect.

B) After completing the assembly, missing fasteners, to investigate the occurrence

of the relaxation area, exterior paint and etc.

C) Expected noise level when driving in noise as the average noise level, when noise
measurement by measuring the internal noise and the background noise is considered.

D) The joint area of outdoor equipment shall be sealed with silicone to prevent water penetration,
properly.
 TOTAL SHEET : 14 SHEET

(INCLUDING COVER)

INSTALLATION MANUAL
for
SOUND ENCLOSURE
===================================

Project No. : KA1549

Project name : THAI BINH 2 TPP Project

Item name : Sound enclosure for Start-up BFP

Document title : Installation manual

Manufacturer : Hanil noise and vibration Co.,Ltd.

A 2015. 4, 30 installation manual you d y joe s h kim y g

Rev. Date Description Prep'd Check'd App'd

Hanil Noise & Vibration Co.,Ltd
 CONTENTS

1. GENERAL PRECAUTIONS

2. SOUND ENCLOSURE INSTALLATION PROCEDURE

1) Guide Rail & Corner Panel installation
2) Front Panel & Right Panel installation
3) Back Panel & Left Panel installation
4) Upper Guide, Roof Panel & ETC installation
5) Electric Equipment #1 piping & lighting
6) Electric Equipment #2 vent fan & contron box
7) Electric Equipment #3 control box
8) Electric Equipment #4 switch & others

3. CLOSING & INSPECTION

 Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Start-Up BFP

1. GENERAL PRECAUTIONS

1-1. CAUTION (on moving)

A) The assembly of enclosure frame and acoustic panels including accessories should
be installed according to this installation manuals.
B) If there is question in installation processing, refer to this manual for installation, or ask to
maker's designer or supervisor and comply with his order.

C) The site manager confer with supervisor's proposal of drawings at the beginning and
at the end of the installation about process, some cooperated work with other department,
and take the instructions.
D) During the installation, a damaged parts should be repaired before installation.
E) Any damage or deformation should be repaired immediately.
F) Handle with care, to prevent the product's corner's bending, paint separation and
scratching.
G) Enclosure was painted by owner's color or contractor's choice, be careful not to be shocked

1-2. CAUTION (on installation)

A) Every parts should be prepared according to form, quality, usage and material and
treated appropriated with the characteristic of the material.
B) The acoustic panels and accessories should be transported without any deformity and
damage due to itself weight.
C) All acoustic panel and accessories should be transported without deformity or twist.
D) All products should be transported without any pollution which like mud or contaminant
E) Every worker must be well acquainted with the installation procedure and handling
methods.
 Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Start-Up BFP

2. SOUND ENCLOSURE INSTALLATION PROCEDURE

A) The guide rails are to be installed without modifications robust and horizontally with a set anchor
B) Connected and assembled parts is in accordance with the approved drawings and the
use of bolts, nuts representation by drawings.
D) The panel is installed above the horizontal guide rails caught the frame interval is a
clearance within 2mm as possible.
E) Panels installed on the horizontal guide rails, height allowance within 0~-5mm.
F) When product decomposition from skid, carefully handle a particular attention to
avoid the paint work. (to avoid painted surface)
G) Panel installation can be installed to change the order in accordance with the site conditions.

Packing Sticker (for example)

 Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Start-Up BFP

2. SOUND ENCLOSURE INSTALLATION PROCEDURE

SOUND ENCLOSURE ASSEMBLY PROCEDURE

1) Guide Rail & Corner Panel installation

2) Front Panel & Right Panel installation
3) Back Panel & Left Panel installation
4) Upper Guide, Roof Panel & ETC installation
5) Electric Equipment #1 piping & lighting
6) Electric Equipment #2 vent fan & control box
7) Electric Equipment #3 control box
8) Electric Equipment #4 switch & others

(CAUTION)

A) Assemble a upper guide rail at wall panel installation.

B) All products have part No. and assemble according to drawing.

C) Wall panel loading with rope fasten to attached screw tapping hole of upper side
center use eye bolt and shackle by crane.

D) Roof panel loading rope fasten to upper I-bolt, as a lifting lug by crane
 Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Start-Up BFP

1) Guide Rail & Corner Panel installation

LOWER GUIDE

INSTALL LOWER GUIDE RAIL WITH SET ANCHOR BOLT

CORNER PANEL

C03

C04

C01

C02

LOWER GUIDE

INSTALLED THE CORNER PANEL ON THE LOWER GUIDE.

CORNER PANEL ASSEMBLY & PROCEDURE : C01 - C03 - C02 - C04
 Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Start-Up BFP

2) Front Panel & Right Panel installation

DOOR PANEL
FR1

F01
C01
F03
F02
C02

LOWER GUIDE

FRONT PANEL ASSEMBLY & PROCEDURE : F01 - F02 - F03 - FR1

THE UPPER GUIDE ASSEMBLY AFTER THE WALL PANEL INSTALLATION AT THE SAME TIME.

RR1

R01 C04
R02
C02

LOWER GUIDE

RIGHT PANEL ASSEMBLY & PROCEDURE : R02 - R01 - RR1

 Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Start-Up BFP

3) Back Panel & Left Panel installation

DOOR PANEL
BR1

B03 C02
B02
C04 B01

LOWER GUIDE

BACK PANEL ASSEMBLY & PROCEDURE : B01 - B02 - B03 - BR1

L02 L01

LR1‐1

L01 C01
C03 L02

LOWER GUIDE
LR1‐2

LEFT PANEL ASSEMBLY & PROCEDURE : L01 - L02 - [LR1-1] - [LR1-2]

★ BOLT HOLE PITCH = 266 mm (BETWEEN L02 AND L01) : CHECK POINT
 Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Start-Up BFP

4) Upper Guide, Roof Panel & ETC installation

RF02
UPPER GUIDE
RF01

RF03
RF04

RF05

ROOF PANEL ASSEMBLY & PROCEDURE : UPPER GUIDE - RF05 - RF04 - RF03 - RF02 - RF01

RIGHT VIEW

FRONT VIEW
LEFT VIEW BACK VIEW

ASSEMBLY THE OUTSIDE & INSIDE FLASHING BAR, COVER, SILENCER, ATTACHMENTS & ETC
SHALL BE SILICONIZED AFTER ASSMEBLY FOR PROTECTION OF LEAK.
 Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Start-Up BFP

5) Electric Equipment #1 piping & lighting

ELECTRIC  LIGHTING 
CONNECTION

ELECTRIC 
CONDUIT PIPE LIGHTING

INSTALL THE ELECTRIC STEEL PIPING, LIGHTING & CONNECTION BRANCH

INSTALL  THE  3‐
WAY SWITCH 

INSTALL THE ELECTRIC LIGHT SWITCH

Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Start-Up BFP

6) Electric Equipment #2 vent fan & contron box

FLEXIBLE HOSE 
& CONDUIT PIPE
VENT FAN ,0.75KW, Φ3, 
400VAC, 50Hz, 

INSTALL THE VENT FAN AND ELECTRICAL WIRING

CONDUIT PIPE

CONTROL BOX 

INSTALL THE CONTROL BOX TO PANEL & CONNECT PIPING

Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Start-Up BFP

7) Electric Equipment #3 control box

CONTROL BOX 
INNER VIEW

CONNECTION THE CONTROL BOX INNER WIRING

CONTROL BOX  CONTROL BOX 
CONTROL BOX  INSTALLAED  VIEW DOOR OPEN   

CHECK THE CONTROL BOX S/W AND WIRE CONNECTION

Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Start-Up BFP

8) Electric Equipment #4 switch & others

ENCLOSURE INSIDE  
VIEW

CHECK THE FAN AND LIGHT OPERATION

ENCLOSURE INSIDE  
VIEW

ELECTRIC PIPING & CONTROL SWITCH INSTALLATION PHOTO

 Project Name THAI BINH 2 TPP Project Project No. KA1549

Sound Enclosure
Item Name Manufacturer Hanilnv Co.,Ltd
for Start-Up BFP

3. CLOSING & INSPECTION

3.1 Cleaning & finishing

A) Installed wall panel and roof panel should be clean the pollution material and mud,
contaminant.

B) Product should be handled carefully for prevent damag by shocking after repairing
& re-painting

C) After the installation is complete (including all attachments inside and outside)
All panel joint region by sealing with silicone to prevent water intrusion

3.2 Inspection

A) When every parts are installed complete, the supervisor have to submit the complete
report after solve aproblems as missing material for zero defect.

B) After completing the assembly, missing fasteners, to investigate the occurrence

of the relaxation area, exterior paint and etc.

C) Expected noise level when driving in noise as the average noise level, when noise
measurement by measuring the internal noise and the background noise is considered.

D) The joint area of outdoor equipment shall be sealed with silicone to prevent water penetration,
properly.
 INSTALLATION INSTRUCTION
OF BFP

6.2 Instruction Manual for Mechanical Seal & Cooler

Installation Manual 46
 PROPRIETARY MATERIAL
This John Crane Inc. Proprietary Information is Supplied in Confidence and is not
to be Disclosed. All Rights are Reserved. Do Not Duplicate; Shred Before
Discarding

TECHNICAL PRODUCT
MANUAL
TYPE 57B/58B/58U

Document: TPM-1032

Issue: B
 Type 57B/58B/58U
TECHNICAL PRODUCT MANUAL
TPM-1032

2010 - John Crane Inc.

All rights reserved. This publication is fully protected and no part of the
publication can be reproduced without the expressed written consent of John
Crane International.

John Crane International specifically excludes warranties, expressed or implied,

as to the accuracy of the data and other information set forth in this publication
and does not assume liability for any damage resulting from the use of the
materials or application of the data discussed in this publication.

John Crane Inc.

 TABLE OF CONTENTS
SECTION 1: PREFACE ........................................................................................ 1
1.1 Preface ................................................................................................... 1
SECTION 2: INTRODUCTION ............................................................................. 2
2.1 Introduction ............................................................................................. 2
2.2 Working Principle .................................................................................... 2
SECTION 3: SEAL DESCRIPTION ...................................................................... 4
3.1 Seal Description ..................................................................................... 4
3.2 Component Description and Design Features ........................................ 4
SECTION 4: STANDARD SIZE RANGE .............................................................. 6
4.1 Standard Size Range ............................................................................. 6
4.2 Typical Installation .................................................................................. 6
4.3 Tabulated Component Drawing List ....................................................... 6
SECTION 5: OPERATING LIMITS ..................................................................... 10
5.1 Dynamic sealing pressure rating .......................................................... 10
5.2 Hydrostatic Sealing pressure ................................................................ 12
5.3 Static Sealing pressure ......................................................................... 12
5.4 Reverse pressure/ vacuum operation: .................................................. 12
5.5 Temperature: ........................................................................................ 13
5.6 Speed: .................................................................................................. 13
5.7 Viscosity: .............................................................................................. 13
5.8 Solids handling: .................................................................................... 13
5.9 Power consumption / heat generation: ................................................. 14
5.10 Flush requirements: .............................................................................. 14
5.11 Quench requirements ........................................................................... 14
5.12 Dry running: .......................................................................................... 14
5.13 Axial flexibility: ...................................................................................... 15
SECTION 6: STANDARD MATERIALS ............................................................. 16
6.1 Standard Materials ............................................................................... 16
SECTION 7: DESIGN ......................................................................................... 17
7.1 Introduction ........................................................................................... 17
7.2 Seal Face Components ........................................................................ 17
7.3 CSTEDY ............................................................................................. 17
SECTION 8: CONSUMPTION ............................................................................ 18
8.1 Consumption ........................................................................................ 18
SECTION 9: ASSEMBLY & RECONDITIONING ............................................... 19
9.1 Assembly Instructions ........................................................................... 19
9.2 Pressure Test ....................................................................................... 19
9.3 Reconditioning Policy ........................................................................... 19

i
 LIST OF FIGURES
Figure 1: 57B section view .................................................................................... 4

LIST OF TABLES
Table 1: 57B Drawing List ..................................................................................... 7
Table 2: 58B Drawing List ..................................................................................... 8
Table 3: 58U Drawing List ..................................................................................... 9
Table 4: Dynamic seal pressure rating 57B & 58B.............................................. 10
Table 5: Dynamic & Hydrostatic sealing pressure rating for 58U………………...11
Table 6: Hydrostatic seal pressure rating 57B & 58B……………………………...12
Table 7: Dynamic pressure rating 58B RP in reverse pressure operation …...…13

ii
 Issue Page
Type 57B/58B/58U TPM-1032
Technical Product B 1
Proprietary Material Manual Section 1
Do Not Copy
Preface
Type 57B/58B/58U

SECTION 1: PREFACE
1.1 Preface

This product handbook was written to provide necessary information for

application of Type 57B/58B/58U seals. The handbook will be updated as it
becomes necessary and additional data will be added as it becomes available.
 Issue Page
Type 57B/58B/58U TPM-1032
Technical Product B 2
Proprietary Material Manual Section 2
Do Not Copy
Introduction
Type 57B/58B/58U

SECTION 2: INTRODUCTION
2.1 Introduction

The type 58U is an unbalanced multi spring DIN 24960 seal with a compact
design that fits on to a straight through shaft. The Type 57B and 58B are
hydraulically balanced, multi-spring DIN 24960/EN 12756 seals. They are
versatile designs using components common to other o-ring and wedge type
seals. They allow easy repair, reduce inventory, and represent a simple
conversion.

o For use in general and high pressure sealing duties, including chemical
processing, refinery and petrochemical plants.
o Complies with International Standard ISO 3069, European Standards EN
12756, DIN 24960, and BS 5257: 1975. Also comply with API 610
specifications.

The preferred standard Type ‘BO’ and ‘BP’ Mating Rings should be used. If a
retained seat is required then use a ‘BD’ type seat.

There is also available a 58BRP seal design that permits reverse pressure when
used in conjunction with a suitable retained seat. Overall dimensions are identical
to the 58B seal.

2.2 Working Principle

The 58U (unbalanced design) is considered to be a lower duty seal that the
balanced design. The simple design has eliminated the need for a stepped shaft
reducing potential cost. The need for a machined step increases potential
machining costs however a balanced face design hydraulically offloads the face
promoting longer seal life, reduced temperature generation and higher pressure
capabilities. The unbalanced design is a contacting seal used only for low duty
applications to avoid high temperature generation. The simple design has
eliminated the need for a stepped shaft reducing potential cost. Pressures must
to be kept low to reduce face heat generation.

The 57B and 58B (balanced design) is a higher duty seal than the 58U. The seal
design requires a stepped shaft to accommodate the seal faces being at a
smaller diameter than the sealing diameter of the secondary seal when
compared to the 58U. The need for a machined step increases potential
machining costs however a balanced face design hydraulically offloads the face
 Issue Page
Type 57B/58B/58U TPM-1032
Technical Product B 3
Proprietary Material Manual Section 2
Do Not Copy
Introduction
Type 57B/58B/58U

promoting longer seal life, reduced temperature generation and higher pressure
capabilities.

The 57B seal offers axial flexibility of +/- 3mm across the full size range.
 Issue Page
Type 57B/58B/58U TPM-1032
Technical Product B 4
Proprietary Material Manual Section 3
Do Not Copy
Seal Description
Type 57B/58B/58U

SECTION 3: SEAL DESCRIPTION

3.1 Seal Description

The type 58U is an unbalanced multi spring DIN 24960 seal with a compact
design that fits on to a straight through shaft. The Type 57B and 58B are
hydraulically balanced, multi-spring DIN 24960/EN 12756 seals. They are
versatile designs using components common to other o-ring seals. They allow
easy repair, reduce inventory, and permit a simple conversion to unbalanced or
wedge seals.

o For use in general and high pressure sealing duties, including chemical
processing, refinery and petrochemical plants.
o Complies with International Standard ISO 3069, European Standards EN
12756, DIN 24960, and BS 5257: 1975. Also comply with API 610
specifications.

3.2 Component Description and Design Features

Figure 1: 57B section view

 Issue Page
Type 57B/58B/58U TPM-1032
Technical Product B 5
Proprietary Material Manual Section 3
Do Not Copy
Seal Description
Type 57B/58B/58U

Figure 1 shows a section of a standard assembly. The following descriptions

detail the function and design of each component:

A –Face/Primary Ring: is housed within the outer gland plate. Drive to the
mating ring is through dog point screws located I the gland plate. The face is
sealed by a PTFE wedge which also holds the face in place.

B – Seat/ Mating Ring: Is sealed with an ‘O’ ring at the back of the face between
the disc and the face.

C – O-ring: The o-ring is the secondary seal of the cartridge preventing leakage
traveling behind the face. This o-ring is a sliding seal.

D – Anti X-Ring: As the o-ring is a dynamic o-ring a larger shaft clearance is

used to prevent hang up. To ensure the o-ring is not able to enter the large
extrusion gap an X-ring made of PTFE is in place. This ring is a close clearance
but low friction.

E – Snap Ring: This clip holds the seal face in place during transit and fitting.

F – Springs: Multi spring design applies even loading behind the face.

G – Disc: This disc transmits the force from the springs to the face, evenly
distributing the force and protecting the back of the face from the sharp edges of
the springs.

H – Retainer: Houses the spring pockets while also retaining the Primary ring
axially.
 Issue Page
Type 57B/58B/58U TPM-1032
Technical Product B 6
Proprietary Material Manual Section 4
Do Not Copy
Standard Size
Type 57B/58B/58U
Range

SECTION 4: STANDARD SIZE RANGE

4.1 Standard Size Range
57B/58B/58U sizes: 14mm to 100mm Shaft Diameter

4.2 Typical Installation

57B
TYPICAL INSTALLATION OF A TYPE 57B WITH A 'BP' SEAT – S/35364

58B
STD. INST. WITH 'BP' SEAT - S/32338
STD. INST. WITH 'BO' SEAT - S/32340
STD. INST. WITH 'BD' SEAT - S/37916

58U
STD. INST. WITH 'BP' SEAT - S/32337
STD. INST. WITH 'BO' SEAT - S/32339
STD. INST. WITH 'BD' SEAT - S/37917

4.3 Tabulated Component Drawing List

Parts Matrix

57B EAA/D0466
58B EAA/D0634
58U EAA/D0635
 Issue Page
Type 57B/58B/58U TPM-1032
Technical Product B 7
Proprietary Material Manual Section 4
Do Not Copy
Standard Size
Type 57B/58B/58U
Range

Table 1: 57B Drawing List

 Issue Page
Type 57B/58B/58U TPM-1032
Technical Product B 8
Proprietary Material Manual Section 4
Do Not Copy
Standard Size
Type 57B/58B/58U
Range

Table 2: 58B Drawing List

 Issue Page
Type 57B/58B/58U TPM-1032
Technical Product B 9
Proprietary Material Manual Section 4
Do Not Copy
Standard Size
Type 57B/58B/58U
Range

Table 3: 58U Drawing List

 Issue Page
Type 57B/58B/58U TPM-1032
Technical Product B 10
Proprietary Material Manual Section 5
Do Not Copy
Operating Limits
Type 57B/58B/58U

SECTION 5: OPERATING LIMITS

5.1 Dynamic sealing pressure rating

Table 4: Dynamic seal pressure rating 57B & 58B

 Issue Page
Type 57B/58B/58U TPM-1032
Technical Product B 11
Proprietary Material Manual Section 5
Do Not Copy
Operating Limits
Type 57B/58B/58U

Table 5: Dynamic & Hydrostatic sealing pressure rating for 58U

To determine the maximum pressure for the size of seal required, multiply the
pressure obtained from the charts above by the appropriate factors from table
below. For Silicon Carbide vs Silicon Carbide limits contact Engineering.

Multiplier
Selection Considerations
Factor
Sealed Fluid Petrol/Gasoline, Kerosene or Better x 1.00
Lubricity Water and Aqueous Solutions (<80°C/176°F) x 0.75
Flashing Hydrocarbons* x 0.60
Sealed Fluid Up to 80°C/175°F x 1.00
Temperature From 80°C to 120°C/175°F to 250°F x 0.90
(for carbon
From 120°C to 180°C/250°F to 355°F x 0.80
only)
From 180°C to 260°C/355°F to 500°F x 0.60
 Issue Page
Type 57B/58B/58U TPM-1032
Technical Product B 12
Proprietary Material Manual Section 5
Do Not Copy
Operating Limits
Type 57B/58B/58U

Speed From 400 to 1800 x 1.00

From 1800 to 3600 rpm x1800rpm/
new speed
Above 3600 or <400rpm **

*The ratio of sealed pressure to vapor pressure must be greater than 1.5,
otherwise consult engineering. If the SG is less than 0.6 consult engineering.
** consult engineering

5.2 Hydrostatic Sealing pressure

Table 6: Hydrostatic seal pressure rating 57B & 58B. For 58U see table 5.

5.3 Static Sealing pressure

This is the same as the dynamic sealing pressure.

5.4 Reverse pressure/ vacuum operation:

The seals will take full vacuum pressure in static operation but a retained seat
should be used. For high potential reverse pressure use 58BRP with retained
seat. See pressure capability below.
 Issue Page
Type 57B/58B/58U TPM-1032
Technical Product B 13
Proprietary Material Manual Section 5
Do Not Copy
Operating Limits
Type 57B/58B/58U

Table 7: Dynamic pressure rating 58B RP in reverse pressure operation, ie ID pressure,

(Carbon Primary ring).

5.5 Temperature:

-40°C to 260°C/ -40°F to 500°F (depending on materials used)

5.6 Speed:
The seal is designed for use from 400 to 3600 RPM
up to a maximum velocity of 25 m/s/5000 fpm

5.7 Viscosity:

Fluid Kinematic Viscosity ν Seal Face Materials Seal Arrangement

Centistokes (cSt.)
UP TO 750 Standard Single seal
Carbon vs. SiC
> 750 Consult EAA Engineering Consult EAA
Engineering

5.8 Solids handling:

The T57 & T58 seals are not specifically designed to handle solids. However as
a general recommendation for applications involving solids it can be used in
 Issue Page
Type 57B/58B/58U TPM-1032
Technical Product B 14
Proprietary Material Manual Section 5
Do Not Copy
Operating Limits
Type 57B/58B/58U

applications up to 0.1 % by weight or 1000 ppmw (parts per million by weight)

maximum with Carbon vs Silicon. For hard faces please refer to TB060_UK.

5.9 Power consumption / heat generation:

Please see web calculations

5.10 Flush requirements:

‘Webcalcs’ is the preferred method to calculate the seal flush requirements.

Alternatively, the flush flow rate can be calculated manually from the following equation.
SI (Metric) Units:

Q = 60 H / (SG . Cp . T)

Where;
Q = Flow rate (l/min)
H = Heat Load (kW)
SG = Specific Gravity ( )
Cp = Specific Heat (kJ / kg °C)
Δ T = Temperature Rise = T flush out – T flush in (°C)

Imperial Units:
Q = H / (500 . SG . Cp . T)

Where;
Q = Flow rate (g/min)
H = Heat Load (Btu / Hr)
SG = Specific Gravity ( )
Cp = Specific Heat (Btu / lb °F)
ΔT = Temperature Rise = T flush out – T flush in (°F)

Note 1. For Temperature Rise, assume 8 °C (15 °F) for aqueous solutions, 16 °C (30 °F) for
Lube oils, and 2.5 °C (5 °F) for light hydrocarbons.
Note 2. The flow rate from the above formulae should be compared with the rule-of-thumb
value of 0.16 l/min per mm (1 GPM per inch) of seal size for lubricating fluids and twice this
for light hydrocarbons (SG<0.6), and the highest value used.

5.11 Quench requirements

See document ‘Circulation Systems for Single and Multiple Seal Arrangements’
on the intranet where applicable.

5.12 Dry running:

 Issue Page
Type 57B/58B/58U TPM-1032
Technical Product B 15
Proprietary Material Manual Section 5
Do Not Copy
Operating Limits
Type 57B/58B/58U

Not designed for dry running

5.13 Axial flexibility:

The maximum allowable axial movement is as follows:-

SEAL SIZE RANGE AXIAL FLEXIBILITY

57B 14 to 100mm ± 3mm

58B/58U 14 to 58mm ± 2mm

58B/58U 58mm to 100mm ± 3mm

Note: This is not a setting tolerance.

 Issue Page
Type 57B/58B/58U TPM-1032
Technical Product B 16
Proprietary Material Manual Section 6
Do Not Copy
Standard
Type 57B/58B/58U
Materials

SECTION 6: STANDARD MATERIALS

Description Standard Options

Primary Ring/Face Resin Impregnated Carbon Sintered Silicon Carbide (9221)
Graphite (9055) Antimony Impregnated Carbon
(9048)
Mating Ring/Seat Sintered Silicon Carbide (9221) Alumina Ceramic (9101)
Tungsten Carbide (9205)
Retainer 316 Stainless Steel(0550) Alloy 400 (Monel) (1800)
Disc Alloy C-276 (UNS N10276) (0690)
Spring
Set Screw
Snap Ring
Secondary Seal O- Nitrile (9501) Perfluoroelastomer (9579)
ring Fluorocarbon (9549)
Ethylene Propylene (9561)
Seat O-ring/ Mating Nitrile (9501) Perfluoroelastomer (9579)
Ring Fluorocarbon (9549)
Ethylene Propylene (9561)
Anti-X Ring PTFE (7500)

6.1 Standard Materials

 Issue Page
Type 57B/58B/58U TPM-1032
Technical Product B 17
Proprietary Material Manual Section 7
Do Not Copy
Design
Type 57B/58B/58U

SECTION 7: DESIGN
7.1 Introduction
The following sections provide some detailed information on the design of the
Type 57 and Type 58 component parts.

7.2 Seal Face Components

7.2.1 Primary Ring

The standard design of primary ring can be found on drawing S/68066 for the
58U, S/68067 for 58B and S/75423 for 57B.

7.3 CSTEDY
N/A
 Issue Page
Type 57B/58B/58U TPM-1032
Technical Product B 18
Proprietary Material Manual Section 8
Do Not Copy
Consumption
Type 57B/58B/58U

SECTION 8: CONSUMPTION
8.1 Consumption
For leakage requirements refer to ‘Webcalcs’ on the intranet.
 Issue Page
Type 57B/58B/58U TPM-1032
Technical Product B 19
Proprietary Material Manual Section 9
Do Not Copy
Assembly &
Type 57B/58B/58U
Reconditioning

SECTION 9: ASSEMBLY & RECONDITIONING

9.1 Assembly Instructions

Refer to Product pages

9.2 Pressure Test

Refer to pressure test instructions on the intranet.

9.3 Reconditioning Policy

Reconditioning and repair should only be carried out at a John Crane Service
Centre.

Refer to drawing S/69756 for details of minimum primary ring length after
reconditioning.

For seal faces that are re-lapped, refer to lapping specification IS-107
 Issue Page
Type 57B/58B/58U TPM-1032
Technical Product B 20
Proprietary Material Manual Appendix 1
Do Not Copy
Revision List
Type 57B/58B/58U

Revision Date Description

Rev. A 30-07-2010 Original issue

Rev. B 24-06-2014 Wording for Mating ring and Primary ring reversed
 1. FOREWORD
John Crane Italia SpA
External seal flush coolers mounted in the seal flush piping may be considered as a viable means of
Via Giotto, 3 creating the required margin between the flushing fluid vapour pressure at the seal chamber temperature
20053 Muggiò (MI) and seal chamber pressure.
Different seal flush plans may be used and they are described as follows.
Tel. 039-2714.1
Fax 039-2714.300 1.1 API PLAN 21
In this flush plan product is routed from the pump discharge to the cooler, lowering its temperature, and
then to the seal chamber, to provide cooling for the seal and to vent air or vapours from the seal
chamber. Calculations are required to determine the proper orifice dimensions to assure adequate seal
COOLER PLAN 21 & 23 flush flow.
The industry has considerable negative experiences with this plan, because of cooler plugging, due to
pumped fluid.

1.3 API PLAN 23

Plan 23 is the plan of choice for all hot water services and many hydrocarbon services.
Installation instructions Hot water has very low lubricity above 80°C, resulting in high seal face wear.
This plan is also desiderable in many hydrocarbon and chemical services where it is necessary to cool
the fluid to establish the required margin between the flushing fluid vapour pressure at the seal chamber
temperature and seal chamber pressure.
In Plan 23 the cooler only removes the seal face generated heat plus the heat soak from the process.
This duty is usually much less than that of Plan 21.
In Plan 23 product in the seal chamber is isolated from that in the impeller area of the pump by a throat
. bushing and is circulated through the cooler and back to the seal chamber.
Attention must de paid with high freeze point and viscous products, since the cooler may cool the fluid
below the point of circulation. In these applications consider using steam as a cooling medium or use a
Plan 21 System.

2. PRODUCT CIRCULATION
4. INSTALLATION

For tubing, use smooth, long-radius bends. For piping, minimize the use of 90° elbows, although 45°
This is obtained through :
elbows may be used.
a) A thermal siphon system which, by exploiting the difference of temperature between the cooler
Use pipes with an inside diameter of not less than ½”.
connection pipes, causes sealed fluid re-circulation between seal chamber and cooler.
All lines shall slope up from the gland to the heat exchanger at a minimum of 40 millimeters per meter.
b) A pumping ring positioned on the seal rotary element which produces circulation in the circuit.
The cooler should be located as close as possible to the pump while leaving sufficient room for operation
This needs to be looked at very carefully for low pump speeds and those equipped with variable
and maintenance. It should not be located directly above the pump.
speed drivers.
Hot lines should be insulated as necessary for safety.
c) A circulation pump included, in some special cases, in pressurised circuits.
Attention must be paid during piping connections to avoid errors on heat exchanger performances and
possible seal damages. Always refer to the relevant drawing , where IN & OUT connections for process
3. FITTINGS
liquid and cooling water are clearly indicated.
Heat exchanger can be usually mounted on any convenient mounting leg, with the necessary number of
The cooler is usually delivered with the following fittings :
bolts. It can be mounted according to all mounting positions indicated on the relevant drawing.
During installation, drain and vent connections must be positioned in bottom and top position
-CONNECTIONS TO PIPINGS (delivery and return)
respectively.
-FITTING FOR VENTING LINE
Be sure that any airlock is removed.
-WATER COOLING COIL
and, if required, with :
-VALVED DRAIN

5. START UP 7.2 MAINTENANCE

Before starting the machine (pump or mixers) carry out the following operations :
Flange joint tightness shall be verified, gaskets substituted if necessary with ones provided by John
- Open all existing vents on process lines, including removal of the casing vent plug
Crane only and linkwork shall be tightened. If needed by the plant, the inside shall be cleaned and the
- Close each vent and/or replace the plug when fluid begins to flow from its opening, indicating that all
filling liquid shall be substituted.
air has been expelled
Pressured thickness shall be periodically verified, especially if aggressive fluids are used.
- Tighten fixing nuts after about four hours of continuous service at operating temperature and check
their tightness after about 24 hours.
7.3 RE-ASSEMBLY

6. RUNNING - Be sure that manifold and all gaskets / O-rings are in good conditions and in place
- Re-assemble the shell assembly on to coil assembly and tighten the nuts
The equipment shall be kept efficient and clean to allow the reading of the instrumentation, shall not - Vent the casing when re-admitting the fluid, using the relevant plug
be exposed to knocks, heat sources or fire. Disconnection shall be made after plant person in charge - Tighten locking nuts after about four hours of continuous service at operating temperature
authorisation and after complete pressure discharge and cooling of the equipment. After that, and check their tightness after about 24 hours.
disconnection shall be plugged off.
8. DISMISSING
7. MAINTENANCE
Maintenance shall be made periodically by specialised personnel only.
In case of dismissing, dangers due to pressure and temperature shall be removed and confinement of
Before any operation internal pressure shall be discharged, equipment cooled to ambient temperature
internal fluids shall be made.
and a receiving tank provided.
At the end of the cleaning the cooler may be dismantled and used as scrap steel.

7.1 DISASSEMBLY
9. NAME AND DATA PLATE
- Remove all locking nuts
- Withdraw the shell assembly with end cover, being carefully not to damage the gasket / O-ring. A name and data plate is supplied with each cooler, reporting cooler identification data, calculation and
- Remove the coil, if necessary, as follows : design standards used.
- Disconnect process piping and cooling water piping from cover Please consult the closest JOHN CRANE office or JOHN CRANE ITALIA for any further information,
- Remove coil assembly for suitable inspection and cleanliness quoting the cooler code number.
10. LONG TERM STORAGE, CONSERVATION AND INSPECTION

It is necessary to protect and to preserve the integrity of the equipment arrived on the job site and
before start-up on plant, when storage for a longer period is contemplated. • The cases shall be wrappe d with water proof tarpaulin which should extend under the same and over
both ends.
Usually mechanical Seal Coolers are shipped directly installed on skid together with the main rotating • Loose components not ins talled in the sealing systems or accessories that should be removed from
equipment (pump, mixer, etc.), with auxiliary piping and relevant components properly mounted. the package, shall be stored as above, after proper itemization.
• In the sealing system are i nstalled various type of instrumentation such as Pressure Gauges, Pressure
Mechanical Seal coolers and generally all auxiliary sealing systems installed on rotating equipment skid Transmitters, Level Indicators and so on. Take care that during the storage no damages can be
shall be packed in suitable crates in accordance with Customer’s Packing Specification. caused
• It is suggested to make a w eekly visual external inspection of the protection and preservation ; any
deficiencies shall be corrected.
At arrival at site and before unloading for storage, a visual inspection shall be done to observe whether
the package has been damaged. In this case the cover shall be removed and the conditions all the If water, condense, sand or dirt has entered the equipment, through package damages or improperly
contents shall be controlled with accuracy. positioned covers, the equipment shall be dried and cleaned before restoring the needed storing
conditions
If the parts are considered acceptable and no damages are detected, the package shall be closed
again and than can be stored.

To maintain their integrity, it is important that mechanical seal systems shall be stored correctly also for
a long time between receipt and plant installation.

Following recommendations are given sealing system protection scope, such that they can avoid any
deterioration arising from long term storage.

• Sealing systems should re main in their original packaging and if possible the cases should be stored
indoors, away from direct sunlight, inside well ventilated buildings with hard floor.
• No temperature control is r equired, but large temperature fluctuation shall be avoided.
• If stored outdoors, it is adv isable to put the cases on square timber resting on concrete or other hard
surfaces.

ATTENTION

• All safety requirements must be strictly adhered to.

• Ensure all precautions are taken to avoid personnel hazards.
• Full machinery protection is ensured.
• Use protective clothes.

• In the event of an operating problem the machinery must be switched off immediately and
made safe. promptly.

• Fitting, operating and maintenance operations should be carried out by qualified, experienced
and competent people, for whom these instructions have been written.

• During normal operation of a double unpressurised seals, working on toxic products like H2S,
due to the physical inboard seal leakage towards the outboard seal or if accidental leakage
occurs at the inboard seal due to vibrations or mechanical problems, the barrier fluid inside
the reservoir may be contaminated.
In this case the reservoir must be considered as dangerous and contaminated area by such a
product.
During the maintenance operation the operators have to be informed about the dangerous
area; for safety reasons the operators must be protected wearing gloves and respirators and
suitable osmoscope.
Pay attention the reservoir has not to be vented or drained to atmosphere but to a safe area
due to the high H2S toxicology, the buffer fluid has to be periodically checked and replaced
when contamination exceeds acceptability limits provided by local laws on safety and
environment pollution.
• All above according to the local legislation.

For further information and safe operating limits contact John Crane
.
 INSTALLATION INSTRUCTION
OF BFP

6.3 Instruction Manual for Flexible Coupling

Installation Manual 47
 Doc. No. NRT070215-A
Disc Coupling
Date 2010. 09. 17.
Installation Manual Page 1 / 6

DISC COUPLING

INSTALLATION MANUAL

NARA CORPORATION
http : //ww.naracorp.com E-mail : nara@naracorp.com
Tel. : 82-51-264-3100, Fax : 82-51-264-3107
 Doc. No. NRT070215-A
Disc Coupling
Date 2010. 09. 17.
Installation Manual Page ２ / 6

1. STRUCTURE
 Doc. No. NRT070215-A
Disc Coupling
Date 2010. 09. 17.
Installation Manual Page ３ / 6

2. INSTALLATION
(1) Initial Assembly

1) As the distance between shaft ends is less than dimension "D" of the coupling used,
adjust shaft to required dimension "D" by making the shaft project(Fig.1). When the shaft
diameter is larger than the element bore, adjust shaft project within the range "S" as shown
on below table.

Fig. 1

Size No. 405 410 415 420 425 430 435 440 445 450 455
Element
25 30 32 40 45 51 69 76 89 101 108
4 bolts Bore(mm)
S(mm) 2 2 2 3 3 3 4 4 5 5 6
Size No. - 610 615 620 625 630 635 640 645 - -
Element
- 142 163 184 200 216 231 253 280 - -
6 bolts Bore(mm)
S(mm) - 3 3 3 3 5 5 5 5 - -
Size No. - 810 815 820 825 830 835 840 845 - -
Element
- 155 178 201 218 235 252 275 304 - -
8 bolts Bore(mm)
S(mm) - 4 4 4 4 6 6 6 6 - -

S: Allowable length of shaft projection when shaft diameter is smaller than element
bore. (But, shaft diameter should be smaller 2.0mm at least than element bore)

2) When the hub has been fabricated by interference fit, heat in a 90~120℃ oil bath and
fit it to the shaft. Never apply heat locally, It may cause distortion.
 Doc. No. NRT070215-A
Disc Coupling
Date 2010. 09. 17.
Installation Manual Page ４ / 6
3) Move equipment units to permit coupling in the correct position.
Set both flange faces(G dimensions) within ± 0.25mm except special cases. (Fig A)

(Fig. A)
(2) Angular Misalignment

1) Fix a dial gauge on one side of hub, rotate hub, find minimum reading on dial
gauge, and set gauge at zero.

2) Rotate coupling side with dial gauge 360° and readjust dial gauge so it shows
smallest deflection reading. Peripheral face deflection for an angular misalignment
is as shown in the table below.

3) Peripheral section of dial gauge may show abnormal deflection at through-hole

area of hub. This is due to flaring of flange during working. Avoid this area when
reading gauge.

Fig. 2
 Doc. No. NRT070215-A
Disc Coupling
Date 2010. 09. 17.
Installation Manual Page ５ / 6

Angular
Type Gauge Reading(TIR mm)
Misalignment
Size No. 405 410 415 420 425 430 435 440 445 450 455
4 Bolts 0.1° Value
0.12 0.15 0.16 0.20 0.22 0.25 0.29 0.34 0.37 0.43 0.48
(mm)
Size No. - 610 615 620 625 630 635 640 645 - -
6 Bolts 0.07° Value
- 0.33 0.37 0.42 0.45 0.50 0.54 0.57 0.62 - -
(mm)
Size No. - 810 815 820 825 830 835 840 845 - -
8 Bolts 0.05° Value
- 0.23 0.26 0.30 0.32 0.35 0.38 0.41 0.44 - -
(mm)

(3) Parallel Misalignment

1) To measure parallel misalignment of shafts, fix a dial gauge on the driving side hub
and, while rotating the driving shaft, read the dial gauge at the periphery of the driven
hub. A parallel misalignment of 2 mm per 1,000 mm distance between flange
faces(BE) results in an angular misalignment of 0.1°

2) Recheck angular misalignment and verify that it is small sufficiently.

Fig. 3
 Doc. No. NRT070215-A
Disc Coupling
Date 2010. 09. 17.
Installation Manual Page 6 / 6

(4) Bolt Fastening Torque

When fastening bolt, do not force, or the thick washer may intrude into the large hole
on the flange. Fasten all nylon nuts using the rated torque as shown in table below. Bolts
may be inserted in the direction which makes the job easiest.

Size No. 405 410 415 420 425 430 435 440 445 450 455
Bolt Head
10 10 13 13 17 19 19 24 24 27 36
Diameter(mm)
4 Bolts
Fastening
0.9 0.9 2.2 2.2 4.2 7.3 7.3 15.9 15.9 22.1 58
Torque(kgf?m)
Size No. - 610 615 620 625 630 635 640 645 - -
Bolt Head
- 27 32 36 46 50 55 55 60
Diameter(mm)
6 Bolts
Fastening
- 22.1 45 58 110 150 170 170 170 - -
Torque(kgf?m)
Size No. - 810 815 820 825 830 835 840 845 - -
Bolt Head
- 27 32 36 46 50 55 55 60
Diameter(mm)
8 Bolts
Fastening
- 22.1 45 58 110 150 170 170 170 - -
Torque(kgf?m)
 Installation and Maintenance Manual
MAXIMUM PERFORMANCE Document No: IAM-0190
CONTOURED DIAPHRAGM COUPLING Revision: 02

INTRODUCTION:
This Installation and Maintenance Manual is generic to the EKK Contoured Diaphragm Couplings. Please read all of these instructions in
this document with the EKK assembly drawing of the specific coupling to be installed.
This Installation and Maintenance Manual is a supplementary document for the equipment manufacturer’s Assembly Manual. There are
numerous methods that may be applied for installing the EKK Contoured Diaphragm Couplings. This document covers one of them so, if
the assembler/installer knows an easier manner, it is also viable. When there is a contradiction between these Manuals, follow the
equipment manufacturer’s Assembly Manual.

W
WAAR
RNNIIN
NGG
Be sure to follow basic safety precautions, including the following:
 Use a crane to move and assemble.
 All couplings must be covered with a guard in operation.
 Turn off power to install or service.
 Rotating parts may cause serious or fatal injury.

1.0 EKK CONTOURED DIAPHRAGM COUPLING

The EKK Contoured Diaphragm Couplings are designed to provide the maximum transmission of power between the rotating shafts
of two machines. The principal component of the coupling is the flex unit and two hubs. The flex unit has diaphragms located at
each end of the center tube. They are made of elastic metal flexure of the thin web and can accommodate both axial and angular
(parallel offset) misalignments and transmit torque simultaneously.
The coupling provides two basic assembly configurations, Bolt Fitted and Piloted Guard Type Coupling. They are defined by
Figure 1 and 2 each. It should be noted that each depicts the basic components of the coupling assembly, not peculiar to the
specific coupling – always use together with the EKK assembly drawing which shows a dimensional information of the complete
coupling.

1.1 BOLT FITTED COUPLING

This is the standard assembly configuration of the bolt fitted coupling and is categorized into Model 66, 67 and 99 couplings of
the EKK Contoured Diaphragm Couplings.
Be aware that shims and field balance holes are not necessarily included as the standard components of the coupling.
 Shims are provided when a tapered bore or integral flange is specified for one or both ends of the coupling.
 Field balance holes are provided only if required.

【 FIGURE 1 】

Page 1 of 10
 Installation and Maintenance Manual
MAXIMUM PERFORMANCE Document No: IAM-0190
CONTOURED DIAPHRAGM COUPLING Revision: 02

1.2 PILOTED GUARD COUPLING

This is the standard assembly configuration of the piloted guard coupling and is categorized into Model 74 and 100 couplings
of the EKK Contoured Diaphragm Couplings. This is the same as the standard guard (Model 66/67/99) except the outer rim
is extended to form a retractable pilot, which slides on the outside diameter of the diaphragm and the shaft or hubs.

Jacking holes are provided in the guard to disengage the piloted guard.

PILOTED GUARD
JACKING SCREW HOLES

【 FIGURE 2 】

1.3 ELECTRICALLY INSULATED COUPLING

If specified, this coupling incorporates electrical insulation to prevent stray electric current from traveling across the coupling
interface on generator and some motor applications. The insulating sheet and sleeve, a fiberglass epoxy compound
(EL-GEM), is usually used only for one end of the coupling.

Insulating Sheet Insulating Sheet

Insulating Sleeve Insulating Sleeve
Washer Washer

Model 66/67/99 Fitted Bolt Model 74/100 Piloted Guard

Electrically Insulated Coupling Electrically Insulated Coupling

【 FIGURE 3 】

2.0 GENERAL INSTRUCTIONS

The coupling generally includes the flex unit, hubs, reamer bolts, self lock nuts and shims in a shipping container. For the
electrically insulated coupling, insulating sleeves, washers, insulating sheet are also provided.
Prior to installation, check for missing components with the EKK assembly drawing supplied with the coupling. Inspect the
coupling/components for any signs of damage during shipment. Components should be supported during handling not to be
damaged and be wrapped for its protection.
Shims are not always included in the standard coupling. Check the specific drawing for shims.

2.1 Diaphragm
The Diaphragm is shipped with its profile (thinner web part) unprotected. Extra care should be taken during handling to
prevent damaging the diaphragm profile.

CAUTION: DO NOT DAMAGE UNGUARDED DIAPHRAM PROFILES. AVOID DENTS OR SCRATCHES.

Page 2 of 10
 Installation and Maintenance Manual
MAXIMUM PERFORMANCE Document No: IAM-0190
CONTOURED DIAPHRAGM COUPLING Revision: 02

2.2 Reamer Bolts and Nuts

Bolting between the flex unit and the hubs is designed to transmit the required torque by shearing resistance of the
reamer bolts. For interfacing between them, the reamer holes are precisely machined to insure a close fit, which
achieves the maximum transmitting torque and the repeatability of the dynamic balance. The nuts used with the reamer
bolts have a self-locking feature to avoid loosening during operation.

CAUTION: ONLY USE BOLTS AND NUTS PROVIDED BY EKK ARE TO BE USED.

2.3 Rivets
Do not loosen the rivets to position and retain the guard to the diaphragm (Model 66/67/99).

2.4 Insulating Materials

The insulating materials are composed of insulating sleeves and sheets and made of glass fiber epoxy compound
(EL-GEM). They are so fragile and require careful handling.

2.5 Storage of Parts

Ideally store parts in their original shipping containers. If this is not possible, components should be protected to avoid
scratches and dents.

2.6 Coating
The flex unit is given a baking finish and hubs are coated only with a black oxide. For a long-term storage, periodically
check the components for rust and coat any area where no coating is applied with rust preventive oil as needed. Store in
sheltered environment.

3.0 GENERAL PROCEDURE FOR MOUNTING TO EQUIPMENT

Always reference the EKK assembly drawing when installing the EKK Contoured Diaphragm coupling.

3.1 Check Distance Between Shaft Ends (DBSE)

The initial check must be performed with the shafting set in the continuous operating conditions. Position the machinery
rotors in their running position to determine the DBSE dimension. Thrust bearings must be set on active faces, double
helical (herringbone) gears in the axial center of their mesh and motor rotors at their magnetic center.

3.2 Install Hubs

Check the hub bore and shaft for nicks and burrs. Ensure that the bore and shaft ends are clean. Install hubs on the
driving and driven machinery shafts as per instructions below. A proper fit is important to successful coupling operation.

3.2.1 Straight Bore For Keyed Hub

Heat hubs evenly and thoroughly in an oil bath or oven until bores are larger than shaft diameter. Insert the keys
in the shaft to assist the hub in proper relative positioning. There should be no key extension or recess.

CAUTION: DO NOT EXCEED 240℃ WHEN HEATING THE HUB.

3.2.2 Tapered Bore For Keyed Hub

Use mechanics blue to check the fit of the bore to the shaft. At least a 70% blued fit (surface contact) to the taper
gauge is necessary.

For the installation of tapered hubs, record the position of the hub on the shaft as the start position to advance up
the hubs. This is generally referred to as pull up. Place the cold hub in the proper position on the shaft. Using
a position plate and stop is recommended for proper positioning of the hub on the shaft. The hub must be
advanced the correct pull up as specified by the machine manufacturer or as given on the EKK assembly drawing.
Using a stop plate is recommended for proper positioning of the hub on the shaft.

Heat hubs gently and placed on the shaft end in a hot condition. Push the hub up the shaft until the position stop
contacts the shaft end.

CAUTION: DO NOT EXCEED 240℃ WHEN HEATING THE HUB.

NOTE: MAKE CERTAIN TO MAINTAIN A CORRECT HUB PULLUP.

Page 3 of 10
 Installation and Maintenance Manual
MAXIMUM PERFORMANCE Document No: IAM-0190
CONTOURED DIAPHRAGM COUPLING Revision: 02

【 FIGURE 4 】

3.2.3 Tapered Bore For Keyless Hydraulically Fitted Hub

There are a number of methods to hydraulically mount hubs on the shaft ends. Specific instructions on mounting
are given by the equipment manufacturers. The following general instructions are given for reference.
Check the hub bore and shaft for burrs. Ensure that the bore and shaft are clean. Check the fit of the bore to
the shaft using mechanics blue. At least a 85% blued fit is required.
Record the position of the hub on the shaft as the start for advancing. Place the hub in the start position. Set up
hub without O-rings or backup rings in the oil seal grooves. Measure the distance between the end of the hub
and some stationary reference point on the machinery housing and set an axial position stop at a gap distance that
corresponds to the correct pull-up. Remove hub and install the O-rings and backup rings. Spread hydraulic oil
on the shaft, hub bore, and o-rings. Place the hub back on shaft. Install the necessary hydraulic mounting
equipment. Inject oil to pressurize the bore and expand the hub using the high-pressure pump. Using the
low-pressure axial hydraulic pushers, push the hub onto the shaft to the specified advance. Maintain the proper
radial pressure in the bore. It should not be necessary to exceed 260 MPa. Release the radial bore pressure
slowly and allow some time for the oil to drop the bore. After the radial high pressure has been dropped to zero,
leave the axial pusher in place to hold the hub in position. Wait the recommended interval. Remove the hub
pusher after the bore oil has drained and verify the correct advance of the hub on the shaft.

CAUTION: FOR INSTALLATION OF ELECTRICALLY INSULATED COUPLING, SET UP HUB ON THE SHAFT
WIHTOUT THE INSULATING SLEEVE.

3.3 Check Hub Runout

To check for proper flange fit, measure the runout of both
the bolting face and external flange using a dial indicator.
Attach the dial indicator base to one flange and set the
indicator needle in contact with the outside diameter of
opposite flange. Relocate the dial indicator base to the
opposite flange and repeat the procedure.

【 FIGURE 5 】

Page 4 of 10
 Installation and Maintenance Manual
MAXIMUM PERFORMANCE Document No: IAM-0190
CONTOURED DIAPHRAGM COUPLING Revision: 02

4.0 COUPLING INSTALLATION

4.1 Check Distance Between Flanges

After installing the driving and load hubs, the distance between the two bolting faces on the hubs must be recorded. Take
the average of 4 measurements at 90 degrees apart and establish a mean dimension. This dimension should be equal
to the flex unit dimension given on the EKK assembly drawing with tolerances of ＋0.1 ~＋0.4 mm.

DISTANCE BETWEEN FLANGES SET AT INSTALLATION

DISTANCE IS SUM OF;
- ACTUAL FLEX UNIT LENGTH
- PRESTRETCH GAP
- SHIM THICKNESS INSTALLED
○○○.○ REFERENCE DISTANCE

FLEX UNIT LENGTH ○○○.○ REF.

ACTUAL FLEX UNIT
INSTALLED LENGTH SCRIBED PRESTRETCH
SHIM GAP

DISTANCE BETWEEN SHAFT ENDS (DBSE)

【 FIGURE 6 】
4.2 Shims
Shims are intended to provide a means of making axial adjustments within the coupling assembly, primarily required after
the machines are in place. They are provided with couplings involving one or more tapered bore flanges and integral
shafts to accommodate variations in flange-to-flange distance.

Shims are split into 180°segments for ease of installation and match marked for proper location. Always include all
shims either actively or inactively as part of the coupling assembly. Shims directly relate to bolt grip length and to the
tightness of the bolted joint.

CAUTION: DO NOT DISCARD SHIMS. STORE THE UNUSED SHIM FOR POSSIBLE USE IN SUBSEQUENT
COUPLING REMOVAL/RE-INSTALLATIONS.

EKK standard shim set installation is comprised of:

a) For the shaft diameter with less than 4 inch (101.6mm): One 1.6mm thick shim and two 0.8mm thick shims
b) For the shaft diameter with more than 4 inch: One 3.2mm thick shim and two 1.6mm thick shims
Figure below depicts a typical shim set.
ACTIVE SHIM STORED SHIMS
1 each 1.6mm 2 each 0.8mm
or 3.2mm Thick or 1.6mm Thick

FLANGE-TO-FLANGE DISTANCE
PER EKK ASSEMBLY DRAWING
【 FIGURE 7 】

Page 5 of 10
 Installation and Maintenance Manual
MAXIMUM PERFORMANCE Document No: IAM-0190
CONTOURED DIAPHRAGM COUPLING Revision: 02

4.2.1 SHIM ARRANGEMENT

There are two typical examples of arranging shims. One is a situation where the mounted flanges for the coupling
flex unit are too close together, the other is where the mounted flanges are too far apart to maintain the prestretch
gap shown on the coupling drawing.

Make every effort on initial installations to leave shims installed as they are shown on drawing.

4.2.1.1 The actual distance between flanges set at installation was greater than the value stated on the
coupling drawing. 【 FIGURE 8 】
(a) Decrease original flange to flange distance (b) Further decrease by 1.6 or 3.2 mm.
by 0.8 or 1.6mm.
Actual Distance Between Flange Ends Actual Distance Between Flange Ends
One 0.8 or 1.6mm
One 1.6 or 3.2mm Shim Active One 1.6 or 3.2mm
Shim Stored Shim Stored

One 0.8 or 1.6mm Two 0.8 or 1.6mm

Shim Stored Shim Stored

4.2.1.2 The actual distance between flanges set at installation was less than the value stated on the
coupling drawing. 【 FIGURE 9 】
(c) Increase original flange to flange distance (d) Further increase by 1.6 or 3.2 mm.
by 0.8 or 1.6mm.
Actual Distance Between Flange Ends Actual Distance Between Flange Ends
One 1.6 or 3.2mm One 1.6 or 3.2mm
Shim Active Shim Active
One 0.8 or 1.6mm Two 0.8 or 1.6mm
Shim Active Shim Active

One 0.8 or 1.6mm

Shim Stored

5.0 PERFORM MACHINE ALIGNMENT

Align the machinery shafts using the flange outside diameter and faces as shown below in accordance with the machinery
manufacturers’ instruction or your own standard practice to provide the best possible alignment at the continuous operating
condition. The alignment compensations can be made to accommodate expected movements such as thermal expansions
when machines heat up. The EKK assembly drawing shows actual misalignment capabilities for each coupling. It should not
exceed in any operating conditions. An alignment check should be performed as per the machinery manufacturer’s instruction
or your own standard practice.

【 FIGURE 10 】

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 Installation and Maintenance Manual
MAXIMUM PERFORMANCE Document No: IAM-0190
CONTOURED DIAPHRAGM COUPLING Revision: 02

6.0 FLEX UNIT INSTALLATION

With the machinery set in the proper location, the flex unit can be installed.
Matchmarks are lines scribed across each flanged joint (flange to flex unit) and are in the same circumferential position.
Assemble the flanges and the flex unit in this match-marked orientation.

6.1 Prestretch
Prestretch is the difference between the flex unit length plus active shim thickness and the distance between flanges.
This is set to accommodate the thermal growth that occurs during steady state continuous operation. Refer to contract
specific drawing for the prestretch gap dimensions. With the coupling properly in place, check the final machine
alignment using a dial indicator.

If there is a difference in gap dimension, use the provided shims or move the machinery axially to adjust.

NOTE: ENSURE THAT THE MATCHMARKS ARE ALIGNED.

NOTE: VERIFY THAT PRESTRETCH REQUIREMENTS ARE BEING MET.

6.2 Model 66/67/99 Bolt Fitted Coupling

Ensure that the matchmarks are aligned. Bolt up one end of the coupling using the provided hardware. The remaining
bolts should be used to position the other end of the coupling. Check the prestretch gap.

6.3 Model 74/100 Piloted Guard Coupling

Align the matchmarks of the coupling and bolt up one end of the flex unit using the provided hardware. To engage the
pilot over the hub of the coupling, it may be necessary to use longer slave bolts in a minimum of six equally spaced
positions around the rim of the coupling hub or hit by a soft hammer.

By making a couple of turns at a time on each slave bolt in sequence, the piloted guard will become engaged on the hub.
The remaining standard hardware should now engage the piloted guard. The standard bolts should be used in the same
manner, to draw the piloted guard to its final position. Once the standard hardware is utilized the slave bolts should be
removed and replaced by the provided coupling bolts. The remaining bolts should be used to position the other end of
the coupling.
Once the bolts are fully tightened, check the pre-stretch gap.

6.4 Bolt Installation

Generally install bolts from the flange side of the assembly for the bolt fitted coupling.
All external fasteners should be torque tightened to the figures given on the EKK assembly drawing.
NOTE: A COMMERCIAL SOCKET WRENCH (INCH SIZE) IS AVAILABLE FOR TIGHTENING THE NUTS.

7.0 FINAL ALIGNMENT CHECK

Actual relative position of driving and driven machine can be measured on the coupling as installed. It is recommended to
check the machine alignment when the machines shut down for a periodical inspection. The alignment of the machines may
be checked with a dial indicator clamped to the center tube.

7.1 Fix a dial indicator on the center tube and place the indicator probe on the face of the guard near the OD.
7.2 Zero the indicator at 12 o’clock position.
7.3 Rotate the machinery shaft, the coupling and a dial gauge concurrently.
7.4 Measure the runout of the guard end face taking readings at 3, 6, 9 and 12 o’clock position. When the reading doesn’t
repeat zero, rezero the indicator and retake three readings.
7.5 Take the second set of readings at the other end of the coupling. Record the readings on the data sheet.

EKK Contoured Diaphragm Coupling can accommodate misalignment by angular deflection of both end diaphragms. Using
the following expression, make sure that misalignment is within acceptable level. The allowable angular deflection used on this
equation is specified on the coupling drawing.

T.I.R ＜ D x tan θ
Where: D (mm) is a coupling outside diameter (indicator tipped position)
θ(deg) is an allowable angular misalignment

Page 7 of 10
 Installation and Maintenance Manual
MAXIMUM PERFORMANCE Document No: IAM-0190
CONTOURED DIAPHRAGM COUPLING Revision: 02

This alignment check are done under static conditions. Misalignment varies with temperature. The proper alignment
compensations may be made to accommodate the difference between the cold state position and the stabilized position following
thermal shift.

【 FIGURE 11 】

8.0 REMOVAL
When heat is used for hub removal, allow hubs and shaft to cool to ambient temperature. Match-mark hubs to their respective
machinery shafts and record the location of all shims installed. Leave two bolts from each end of coupling. Make sure that
flex unit is securely supported. Be careful not to damage unguarded diaphragm profiles.

8.1 Removal of Straight and Tapered Bore Hubs with Keyways

Install a puller on the hub utilizing the puller holes that are provided in the face of the hub; pull the hub off the shaft. The
flange rim is so thin and easy to be elastically deformed.

NOTE: DO NOT EXTRACT THE FLANGE FROM SHAFT WITH A PULLER, OTHERWISE, IT WILL DEFORM AND
DAMAGE HUBS.

PULLER

【 FIGURE 12 】

Page 8 of 10
 Installation and Maintenance Manual
MAXIMUM PERFORMANCE Document No: IAM-0190
CONTOURED DIAPHRAGM COUPLING Revision: 02

8.2 Removal of Straight and Tapered Bore Hubs with Keyways

Install the hydraulic equipment and remove the hub from the shaft.

8.3 Removal of a Piloted Guard Coupling

Remove all nuts and bolts. The pilots will hold flex unit in place, and jacking bolts must be used to disengage these
pilots.

CAUTION: NEVER TURN JACKING BOLTS MORE THAN ONE HALF REVOLUTION AT A TIME.

Insert six jacking bolts into the jacking screw holes in the face of the
piloted guard. By making a couple of turns at a time on each jacking
bolt in sequence, disengage the piloted guard from the hub.

【 FIGURE 13 】

CAUTION: MAKE SURE THAT THE FLEX UNIT IS SECURELY SUPPORTED DURING REMOVAL.

9.0 INSPECTION AND MAINTENANCE

The EKK Contoured Diaphragm Coupling has no moving parts to wear out so they will operate in longer life if the coupling
is operated within the misalignment ratings.
However, high overload torques and over misalignments can cause permanent damage. Abusive handling, especially
scratches and dents in the profile area can deminish service life. These types of damage can be detected visually.
Therefore, the coupling should be inspected during equipment overhauls and any other periodical shut-down. It should
be noted that shutdown for a routine maintenance is not required for the EKK Contoured Diaphragm Coupling.

9.1 In-Place Inspection

Remove the coupling housing to expose the coupling.
 Check all bolts and nuts for tightness of fit.
 Check for center tube for looseness or side-play in all directions. The presence of looseness will require coupling
removal for further inspection.
 Using a soft probe(piece of wood), make sure that all drain holes are free of sludge build-up.

NOTE: WHENEVER TIME PERMITS, PERFORM AN ALIGNMENT CHECK AND VERIFICATION OF PRESTRETCH
GAP.

9.2 Removal Inspection

Disassembly will provide a more detailed inspection of the coupling and permit the accomplishment of any required
maintenance.
 With the flex unit removed check for : serious chipping, crazing, blistering, scratches or dents in the contoured
profile area of the diaphragm.
 Check all bolts for excessive scoring of shank bodies.
 Check all nuts and bolts for thread deterioration
 Check all bolt holes in diaphragms and hubs for serious scoring or elongation.

NOTE: IF ANY SIGNS OF OBVIOUS DAMAGE ARE PRESENT, THE COUPLING MUST BE RETURNED TO EKK
FOR EVALUATION.

9.3 Replacement
When serious chipping, crazing, discoloration or blistering of paint, scratches or dents are observed on the diaphragm
profile, the coupling must be returned to EKK for evaluation.
For electrically insulated coupling, any cracks are found on Isolate sheet and sleeve, they should be replaced. EKK
recommnends that as a minimum a spare insulating sheet and sleeve be ordered since they are not available
off-the-shelf.
The nut self-locking feature will be deteriorated with assemblies and disassemblies. The bolts and nuts should be
replaced after they have been assembled and disassembled ten times.

The weight-matched bolt and nut replacement sets must be replaced in complete sets.

Page 9 of 10
 Installation and Maintenance Manual
MAXIMUM PERFORMANCE Document No: IAM-0190
CONTOURED DIAPHRAGM COUPLING Revision: 02

REVISION HISTORY
Rev DESCRIPTION DATE CHECKED

00 Initial release Aug 5,'10 H.K/K.I

01 Correction 4.3.1.2 May 18,’12 H.K/M.S

Correct numbering.
02 Feb 25, ‘13 H.K/M.S
Addition ‘replacement instruction’ to 4.3

Page 10 of 10
 INSTALLATION INSTRUCTION
OF BFP

6.4 Instruction Manual for Fluid Coupling

Installation Manual 48
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 4 Transport and Storage

4 Transport and Storage

4.1 Safety information

The following safety information applies to the entire chapter. It must be observed in
addition to the various specific instructions.

Hazard from loss of stability and danger arising from masses

As the result of inadequate packaging and securing, the coupling may have
WARNING
become unstable and could shift unintentionally, causing serious injury.

Maintain a safe distance! Allow only knowledgeable personnel to handle transport!

Hazard from loss of stability and danger arising from masses

Unqualified personnel could misjudge the weight of the coupling. This could (for in-
WARNING
stance, as the result of selecting unsuitable lifting equipment) allow the load to
drop on someone underneath, resulting in serious injury or death and/or cause
severe damage to the coupling.

 For weight data, see Chapter 1 „Technical Data“ and „Assembly Plan - variable-
speed turbo coupling 91500734810“.

Allow only knowledgeable personnel to handle transport!

Hazard of crushing of upper and lower body limbs

Improper handling of the coupling, especially during transport by a crane, poses

WARNING
the risk of crushing and serious injury.

Maintain a safe distance! Allow only knowledgeable personnel to handle transport!

Impact hazard
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe

The suspended and swinging coupling could strike someone and cause serious injury.
WARNING
Maintain a safe distance! Allow only knowledgeable personnel to handle transport!

Friction and abrasion hazard

The suspended and swinging coupling could rub against someone and cause friction
CAUTION
or abrasion wounds.

Maintain a safe distance! Allow only knowledgeable personnel to handle transport!

Impact hazard during transport

Serial No. 8210546 to 8210547

While being transported, the coupling could strike a person or object, resulting in se-
CAUTION
rious injury or damage.

Allow only knowledgeable personnel to handle transport!

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 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 4 Transport and Storage

4.2 As-delivered condition

4.2.1 State of assembly and test run

The variable-speed turbo coupling cannot be used on its own in the as-delivered con-
dition.

• The variable-speed turbo coupling is fully assembled and ready for installation. State of assembly
• All internal piping for the working oil and lube oil is in place.
• All external piping connections are provided in the form of welding neck flanges
with gaskets, and are sealed for protection during transport.
• If connecting couplings are being supplied by Voith or have been provided by
the customer, their hubs have been mounted on the input and secondary shafts
of the variable-speed turbo coupling.
• All instruments (indicating instruments, switchgears etc.) are attached to or
mounted on an instrument gauge board. The panel is attached to the housing by
means of vibration-absorbing mounts.
• Electrical indicating instruments and switches are wired to a terminal strip in a
junction box.
• The instruments installed are identified.
• The scoop tube actuator is installed.

Prior to shipment, the variable-speed turbo coupling underwent a trial run at the Voith Operation check
test facility or was subjected to an extensive final inspection.

The following items were checked:

• Attachments (such as duplex oil filter, electric motor etc.)

• Operation of the actuator

The following items were adjusted:

• Actuator
• Oil flow rates
• Oil pressures
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe

• Operating points of the instruments installed

Serial No. 8210546 to 8210547

29
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 4 Transport and Storage

4.2.2 Preservation/corrosion prevention and packing

The variable-speed turbo coupling and all attached components have been treated
(preserved) and packed in a manner that provides protection for 12 months.

4.3 Storage and preservation

The internal surfaces of the variable-speed turbo coupling have a light film of oil in the Corrosion
as-delivered condition (either from the oil used during the trial run or from having had protection for
solvent-free corrosion-inhibiting oil sprayed on as corrosion protection1). This film of shipment within
oil provides 12 months of protection within Europe, provided that the coupling is Europe
stored in a dry location.

For shipment overseas, the variable-speed turbo coupling is additionally sealed in Corrosion
plastic film. Bags of desiccant inside the packaging absorb some of the humidity. protection for
Equipment packaged in this way can also be stored for 12 months in a dry location, shipment overseas
provided that the plastic film is not punctured or damaged.

 (see Section 4.5 „Preservation specification“ on page 33).

For variable-speed turbo couplings that are to be stored for periods of longer than Preservation/
12 months, Voith Turbo GmbH & Co. KG Crailsheim offers special long-term corrosion
corrosion prevention with storage instructions after delivery. prevention after
delivery
 Appendix _A_ (see „Preservation Method and Instructions for Storage after Delivery
3625-006714“)
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe
Serial No. 8210546 to 8210547

1. used by the factory as well as recommended (see Section 4.5.1 „Internal corrosion-inhibiting oils“ on
page 35)

30
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 4 Transport and Storage

4.4 Unpacking, transportation

The variable-speed turbo coupling is delivered ready for installation. If necessary, it is

also protected by a crate. Both the coupling and the crate have specified lifting points.

1. If necessary, remove the crate.

WARNING

Risk of injury

Improper lifting of the variable-speed turbo coupling

can result in equipment damage and personal injury.

The variable-speed turbo coupling is to be suspended

only from the specified lifting points.

Use only appropriate lifting appliances that conform

to safety requirements!

CAUTION

Equipment damage

Transporting and setting the variable-speed turbo

coupling down improperly can results in damage
to the coupling.

The variable-speed turbo coupling is to be

transported only when it is properly secured and
with the transport rails attached!

Set it down only on a firm and appropriate surface!

Rest it only on the feet attached to the housing or

Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe

the feet attached to the oil reservoir!

NOTE

The lifting points provided on the variable-speed turbo coupling are intended
only for the weight of the coupling itself.

Do not lift any other equipment at the same time! The variable-speed turbo
coupling is to be lifted only without oil in it!
Serial No. 8210546 to 8210547

1. Check lifting points (1) for cracks, deformation and corrosion before using.

31
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 4 Transport and Storage

2. The variable-speed turbo coupling is to be suspended only from the specified lift-
ing points (1) (see Ilustration 4-3 „Lifting points“).

Illustration 4-3:
Lifting points

1) Lifting points
1 2) Sticker

1
1

1 1
1
1 1

3. Unscrew the machine from the transport framework and pull the frame from under
the machine.

4. Set the variable-speed turbo coupling down on the feet attached to the oil reser-
voir.
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe
Serial No. 8210546 to 8210547

32
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 4 Transport and Storage

4.5 Preservation specification

Source: Sheet 3625-006212 de, date of issue 2002- 11- 20

These specifications apply to protection of internal and external surfaces (insofar as

the surfaces are not treated and/or corrosion-resistant or made of cast aluminum), as
well as the packing of shipments.

Overview

Preservation

Transport, storage and dura- Internal with Internal without

Packaging No. External
tion of storage test run test run

• Overland/air transport for imme- Packaging External preserva- Internal preserva- Internal preserva-
diate installation at the destina- No. 1 tion No. 1 tion No. 1 tion No. 2
tion (or storage in a closed build-
ing for up to 6 months)

• Sea transport and / or storage for Packaging

up to 12 months after the date of No. 2
packaging

• Sea transport and / or storage for Packaging

up to 24 months after the date of No. 3
packaging

• Extended protection (after expira- Replace plastic film External preserva- Internal preservation No. 3
tion of the initial protection) and reseal tion No. 2

• Painting as specified in order documents. External preser-

• Bright iron parts sprayed with “Shell Ensis Fluid S”1). vation No. 1
• See note.

• Painting as specified in order documents. External preser-

• If necessary, reapply depending on the condition of preservation No. 1. vation No. 2
• Replace desiccant.
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe

NOTE

If use of VCI preservation products for an order is ensured throughout the

entire packaging chain, corrosion protection based on this preservation
method is permissible if agreed upon.
Serial No. 8210546 to 8210547

1. Before installing the coupling or parts, clean sprayed surfaces with solvent (white spirits or petro-
leum).

33
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 4 Transport and Storage

• Internal preservation from oil used during test run. Internal preser-
• If the order documents call for "Inspection" after the test run, spray with solvent- vation No. 1
free corrosion-inhibiting oil ("Shell Ensis Engine Oil 20" used at the factory) to the
extent possible. For alternatives to "Shell Ensis Engine Oil 20" see 3625-006237).

• All surfaces of iron parts (including holes, cavities and internal surfaces of pipes) Internal preser-
sprayed, immersed or flushed with solvent-free corrosion-inhibiting oil during as- vation No. 2
sembly (with Shell Ensis Engine Oil 20 at the factory) based on installation prog-
ress. All assemblies sprayed during assembly to the extent possible.
For alternatives to "Shell Ensis Engine Oil 20" see 3625-006237).

• Inspect the preservation. Internal preser-

• Spray all rotating parts and wall surfaces with solvent-free corrosion-inhibiting oil vation No. 3
(e.g. “Shell Ensis Engine Oil 20”), turn rotating parts while spraying. For alterna-
tives to "Shell Ensis Engine Oil 20" see 3625-006237).
• Spray the inside of piping with solvent-free corrosion-inhibiting oil (see above).
As an alternative, fill the interior of the coupling with dry air, relative humidity
max. 10%.

• Means suitable for transport (e. g. transport frame, holder, support) Packaging No. 11
• Transport means provides protection from the weather.

• Means suitable for transport (e. g. transport frame, holder, support) Packaging No. 21
• Sharp edges and supporting surfaces covered with elastic materials.
• Sealed in PE film.
• Desiccant in acc. with DIN 55 473 / 55 474.
• Water-resistant carton or wooden crate.
• Inside of crate lid covered with closed ribbed PE sheets (Akylux). With PVC film
underneath at butt joints.

Identical to packaging No. 2. Difference: sealed in aluminized plastic film instead of Packaging No. 3
PE film.
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe
Serial No. 8210546 to 8210547

1. The unit is packaged in accordance with the latest version of the packaging guidelines issued by the German Association for
Wooden Packaging -Pallets - Export Packaging (HPE) e. V.

34
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 4 Transport and Storage

4.5.1 Internal corrosion-inhibiting oils

NOTE

The variable-speed turbo coupling is not filled with working oil!

Source: Sheet 3625-006237 de, date of issue: June 1996

HD engine oils with especially pronounced anti-corrosion properties are recom-

mended as internal corrosion-inhibiting oils. Special ingredients in these solvent-free
corrosion-inhibiting oils promote the formation of strongly adhering protective films
that protect vertical surfaces effectively.

(Shell Ensis Engine Oil 20 used at the factory)

Recommended
Supplier Designation grades:
AGIP AGIP RUSTICA 10W-20
ARAL ARAL Oil KONIT SAE 20 W 20
DEA DEA DEAMOT EKM 162 N (SAE 20 W-20)
ESSO ESSO MKZ Engine Oil HD 20W-20
FINA FINA RUSAN MOTOR OIL SAE 20 W-20
MOBIL MOBILARMA 524 (SAE 30)
SHELL SHELL Ensis Engine Oil 20
WINTERSHALL WINTERSHALL Antikorrol 20 W-20

(This list makes no claim regarding completeness.)

Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe
Serial No. 8210546 to 8210547

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 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 4 Transport and Storage

4.5.2 To be ensured on the jobsite:

Special attention should be paid to the effectiveness of the preservation applied to Installed units or
these units, since it often subjected to additional hazards such as water, accumulation units ready for
of large amounts of dirt and physical damage. installation

This includes measures that provide supplemental internal protection when idle times Complete systems
of up to about 12 months are to be expected and when the original corrosion preven- installed on a
tion coating has been disturbed. foundation

Fill units with water-free working oil. The following can be performed at intervals of
1-2 months, depending on the state of installation:

• System that is ready to operate:

– Start and operate only briefly (approx. 5 minutes) to coat the surface of internal
parts with oil; do not run until warm.

• System that is not ready to operate:

– Units with a ready-to-operate electric auxiliary lube oil pump or oil pump and
oil reservoir:
– Switch on pump; allow system to operate, if possible. Move operating compo-
nents (e. g. joints).
– Units without a ready-to-operate electric auxiliary lube oil pump or oil pump:
– Remove oil from the sump, spray inside through openings in the housing and
circulate oil through the piping with the aid of a separate oil pump, run for ap-
prox 5 minutes: allow system to operate, if possible. Move operating compo-
nents (e. g. joints).

NOTE

Before filling with the operating fluids, contact the suppliers to confirm
compatibility with the internal corrosion preventative.
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe
Serial No. 8210546 to 8210547

36
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

5 Assembly

5.1 Safety information

The following safety information applies to the entire chapter. It must be observed in
addition to the various specific instructions.

Hazard from improper installation

Improperly installed or assembled components could loosen, electrical lines could

WARNING
be incorrectly connected or routed, the insulation on poorly routed cables could be
abraded and, as a result, cause serious personal injury or equipment damage.

Only a qualified electrician who is knowledgeable about rules that apply to electronic
equipment in the country of installation is allowed to perform work involving the elec-
trical equipment on the variable-speed turbo coupling.
Use only cables with insulation that can withstand the ambient operating conditions!

Danger in areas that cannot be fully viewed

A person could be severely injured while working on the machine when starting it up.
WARNING
Attach suitable protective covers that cannot be removed without the respective tool,
between the coupling and the shaft!
Only work on the machine when the system is shut down (no power)!
Operation is only permitted after visually ensuring that no persons are in the hazard
areas!

Hazard from maximum pressures, pressure shocks, pressure rise or pressure

loss

An unsuitable or poorly maintained heat exchanger, improperly sized oil lines, the ab-
WARNING
sence of shutoff valves, incorrectly set pressure relief valves or an improperly installed
check valve could result in high pressures that might destroy the equipment, causing
serious personal injury due to flying objects as well as damage to the environment.
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe

A severe pressure drop could damage bearings.

– Allow only trained personnel to perform installation, maintenance and service

work on the equipment and to operate it!
– Confirm that check valves are installed correctly!
– Observe maintenance intervals!
– Comply with limits!
– Do not install shutoff valves in the oil circuit; make sure that the oil circuit con-
forms to the schematic provided!
Serial No. 8210546 to 8210547

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 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

Equipment damage

Creepage or stray electric currents can reach the variable-speed turbo coupling via
CAUTION
the drive shaft, leading to spark erosion damage on bearing surfaces and the surfaces
of teeth on the drive gears in the pump drive.

Provide appropriate grounding / insulation for the driving machine (e.g. between the
connecting coupling) and take the necessary measures to interrupt the flow of electric
current!

Equipment damage

Dirt caused by construction, flying sparks, grinding and water can get into the vari-
CAUTION
able-speed turbo coupling and cause the equipment to malfunction.

Cover the variable-speed turbo coupling with a tarpaulin completely during construc-
tion work at the installation site!

Protect instruments, electrical cables and cable trays particularly well!

Use only appropriate sealants that are oil resistant up to 130°C and do not contain sil-
icone. Failure to comply with the above will have an adverse effect on oil quality and
can cause damage to the variable-speed turbo coupling.

Equipment damage

Improper installation can result in malfunctions and premature wear in the equipment.
CAUTION
Setup and initial commissioning should be performed by a Voith technician!
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe
Serial No. 8210546 to 8210547

38
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

5.2 Tools and auxiliary means

• Metric tools
• Torque wrench
• Sealant (must not contain silicone) (see „Sealant“ on page 108)
• Lifting appliances
• Device for mounting the coupling hubs
• Shims
• Brackets and adjusting bolts for horizontal alignment on the concrete foundation
• Adjusting bolts for vertical alignment
• Alignment device

5.2.1 Sealing the keyway

How to seal the keyway in the case of an oil-filled or grease-filled connecting coupling.

• Connecting coupling hub provided or still to be provided with a taphole above the
keyway.
• Mount the hub on the shaft.
• Fill the taphole 2/3 with the sealing compound1.
• Insert and tighten set screw. Remove any sealing compound squeezed
out of the face side.
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe
Serial No. 8210546 to 8210547

1. LOCTITE 5910; When applying, please follow the instructions on the tube.
Supplier: Loctite Deutschland, Arabellastrasse 17, D-81925 Munich

39
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

5.3 Mounting the connecting couplings at the shaft

NOTE

Gear couplings or all-metal couplings with low radial restoring forces are
suitable. Connecting couplings with a flexible compensating element
(flexible element) are to be agreed upon only in individual cases.

If the connecting couplings are being supplied by Voith or have been provided by Factory mounting
the customer, the input- and output-side connecting coupling halves will have
been mounted at the factory:

• The end cover (2) and coupling hub (3) have been mounted on the shaft ends (1)
• The coupling sleeves are packaged separately.

Illustration 5-4:
2 Coupling hub on shaft
3
4 1) Shaft end
1 2) End cover
5 3) Coupling hub
6
Mounting device
4) Plate
5) Bolt
6) Threaded spindle
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe
Serial No. 8210546 to 8210547

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 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

If the connecting couplings are not yet mounted: On-site mounting

 Manufacturer's specification for connecting coupling

NOTE

Check the connecting coupling for existence of the puller thread at the face end
and taphole above the keyway.

1. Clean the shaft (1) and hub (3) from preservation agents using gasoline or cellu- Gear couplings with
lose thinner (not petroleum) and degrease. key

2. Check the bore, shaft, key and keyway for dimensional accuracy.

3. Remove the key from the shaft keyway and fit it into the hub keyway. Then fit the
key into the shaft keyway again. Check the height of the key: the back clearance
between the keyway and key must be 0.2 – 0.3 mm.

4. Apply a thin coat of Molykote D Paste1 or an equivalent lubricant to the shaft.

5. Slide the end cover (2) and O-rings over the shaft end.

6. Mount the coupling hub using a mounting device (4, 5, 6).

7. Seal the keyway of the connecting coupling hub

(see Section 5.2.1 „Sealing the keyway“).

8. Connecting couplings without an intermediate piece: slide the sleeve over the hub.

9. Connecting couplings with an intermediate piece: mount the sleeve only after
alignment.

10.Protect the connecting couplings against corrosion and cover them.

Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe
Serial No. 8210546 to 8210547

1. Molykote D Paste; When applying, please follow the instructions on the tube / can.
Manufacturer Dow Corning Europe Rue General de Gaulle 62 B-1310 La Hulpe

41
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

5.4 Setting the variable-speed turbo coupling down on

a concrete foundation

Checks: Prior to setting

down
• Are the foundations for all machines in the system properly sized? (height, center
position, flatness)
• Is the height of the concrete foundation measured so that there is free space of
10 mm for putting shims beneath the variable-speed turbo coupling and foundation
rails?
• Does the space provided for installation match that stated on the assembly plan
for variable-speed turbo couplings?
• Are the connecting coupling sleeves mounted or has a sufficient distance been
provided between the shafts for connecting couplings with an intermediate piece,
in order to mount the sleeve later?
• Can the oil lines be installed after positioning the variable-speed turbo coupling?
• Is the driven machine fixed axially?
• Is the axial clearance of the driving machine within tolerances?
Is the rotor of the driving machine in operating position?
• Are the shims present?

5.4.1 Setting down on a concrete foundation

To set the variable-speed turbo coupling down on a concrete foundation either Prerequisites

• 2 foundation rails or
• 4 strong foundation plates

with holes for the anchor bolts are required.

NOTE

Paint the foundation with oil-resistant paint so that oil cannot seep into the
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe

foundation and damage the concrete.

1. Set the variable-speed turbo coupling down on the concrete foundation with the aid Setting down
of suitable lifting appliances once the anchor bolts are inserted and the 2-mm sup-
port shims and foundation rails or plates are in place. Maintain the specified axial
clearance between the connecting couplings in this case.

2. Place the support shims under the foundation rails or plates for the variable-speed
turbo coupling align approximately.
Serial No. 8210546 to 8210547

3. Grout the anchor bolts and foundation rails or plates with concrete and allow
it to set.

42
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

Illustration 5-5:
Grouting the concrete
1 2
foundation

3 1) Shim
(10mm)
2) Adjusting screw
3) Grout
4) Shim
5) Compressed con-
crete
6) Foundation rail
4 or
5 foundation plate
7) Concrete grout
1

4. Use the adjusting screws provided to adjust the height of the coupling.
 For measurements, see Section 5.5 „Machine alignment“ on page 44.

NOTE

All machines involved (driving machine, variable-speed turbo coupling,

driven machine) should be set in position prior to performing the alignment.
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe

5.4.2 Setting down on a steel foundation

1. Set the variable-speed turbo coupling down on the steel foundation with the aid of Setting down
suitable lifting appliances. Maintain the specified axial clearance between the con-
necting couplings in this case.

2. Use the adjusting screws to adjust the height of the coupling.

3. Place the greased support shims provided under the coupling. Align the coupling
laterally by moving the coupling on the support shims with the aid of the adjusting
screws.
Serial No. 8210546 to 8210547

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 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

5.5 Machine alignment

The system components must be aligned with one another. All machines must be
at the standstill temperature. At operating temperature, the shafts must be optimally
aligned.

Normal alignment sequence:

1. Align the Variable-speed turbo coupling with the driven machine

2. Align the driving machine with the variable-speed turbo coupling

NOTE

The machine alignment procedure described here is based on a measuring

method using dial gauges.

It is also possible to use equivalent systems such as “electronic / optical

measuring methods”, for example, the electronic CTC measuring method,
Optalin measuring system or Indikon measuring system as well as others.

Additional information regarding alignment can be found in:

– VDI Directive VDI 2726 “Alignment of Gearboxes”

– Manual for practical use “Alignment of Shafts in Machine Sets”, VDI
Publishers
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe
Serial No. 8210546 to 8210547

44
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

5.5.1 Shaft misalignment and alignment tolerance

When aligning the variable-speed turbo coupling, dimensional changes arising Shaft misalignment
from the following must be taken into account:

• Warming and expansion of the housing during operation

Illustration 5-6:
Radial and
axial displacement
L1 L2
Radial displacement
vertical  H

H
Axial displacement  L1
Axial displacement  L2

Radial displacement, vertical1 H 0.53 mm

Axial displacement1
• input side (driving side) L1 0.42 mm
• output side (driven side) L2 0.42 mm
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe

1. assumed housing temperature: at installation 20°C (68°F), during operation 80°C (176°F)
Values represent the greatest possible shaft displacement, including bearing clearance.

This means that the shafts connected by means of connecting couplings should not
be aligned at standstill, but rather must have a radial/angular/axial offset. This offset
compensates for the displacement arising at startup and during operation.
Serial No. 8210546 to 8210547

45
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

When rotating both shafts by 360°: Alignment tolerance

at operating temper-
• Radial measurement A: radial offset ± 0.03 mm
ature
• Angular measurements B and C:
Angular misalignment ± 0.03 mm/100 mm Radius Rm

Illustration 5-7:
ah bh Angular displacement
and radial offset

1) Machine
aligned
2) Machine still to be
1
2 aligned

Radial offset
av horizontally ah and verti-
bv cally av

Angular misalignment
horizontally bh and verti-
A cally bv
Radius Rm
B

Rm
22

11 Rm
C
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe
Serial No. 8210546 to 8210547

46
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

5.5.2 Connecting couplings with an intermediate piece

In most cases, a connecting coupling with an intermediate piece is placed between

the driven machine and the variable-speed turbo coupling, I.e. there is a space be-
tween the shaft ends.

NOTE

Gear couplings or all-metal couplings with low radial restoring forces are
suitable. Connecting couplings with a flexible compensating element are
to be agreed upon only in individual cases.

A Illustration 5-8:
3 Alignment using the
alignment device for
B
connecting couplings
with an intermediate
piece
1 2 1) Machine
aligned
2) Machine still to be
C aligned
3) Alignment device with
dial gauge

1. Fabricate a solid alignment device out of flat stock, round bar stock and steel pro-
files (3) and bolt to the shaft end of the machine to be aligned (2).

NOTE

The initial value or reading on the dial gauge can be 5.00 as assumed
in the following examples.
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe

2. Insert the dial gauges so that they are free from play and secure them.

3. Check the radial run-out of the already aligned machine (1): rotate the shaft (1) Radial run out check
by 360°.

Value to be aimed at: dial gauge deflection  0.02 mm;

permissible value: see instruction manual of driven machine.
Serial No. 8210546 to 8210547

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 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

4. Reset the dial gauges to the initial value. Precision alignment

in vertical plane
5. Rotate shaft (2) by 180°.

6. Enter the dial gauge deflection in the coordinate system of the installation
check form.

Illustration 5-9:
B = 5.00 Example of radial
A = 5.00 C = 6.55 B = 5.00 measurement A and
C = 6.55
angular measurements
B and C in the vertical
plane

A = 4.66 B = 5.45 C = 5.00 B = 5.45

C = 5.00

Evaluation:

Radial measurement A:
Radial offset, vertical = (5,00 - 4,66) : 2 = 0,17 mm

Angle measurement B+C:

Angular misalignment, vertical = (6,55 - 5,45) : 2 = 0,55 mm

For the angular measurements: half of the difference between two angular mea-
surements is the amount of the angular misalignment.

7. Correct the vertical radial offset and the vertical angular misalignment by means
of the adjusting bolts.

8. Place the alignment device (3) in the horizontal position (rotate 90° with respect Precision alignment
to the original position). in the horizontal
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe

plane
9. Repeat the measurement.
Serial No. 8210546 to 8210547

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 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

Illustration 5-10:
Example of radial
B = 5.00 C = 5.00 measurement and
A = 5.28 A = 5.00
C = 4.55 B = 4.65 angular measurement in
the horizontal plane

Evaluation:

Radial measurement A:
Radial offset, horizontal = (5,28 - 5,00) : 2 = 0,14 mm

Angle measurement B+C:

Angular misalignment, horizontal = (4,65 - 4,55) : 2 = 0,05 mm

10.Move the variable-speed turbo coupling horizontally using the adjusting bolts and
in this way correct the horizontal radial offset and the horizontal angular misalign-
ment.

5.5.3 Connecting couplings without an intermediate piece

In most cases, a connecting coupling without an intermediate piece is placed between

the driving machine and the variable-speed turbo coupling, I.e. there is no space be-
tween the shaft ends.

Prior to performing the precision alignment, it is advisable to first align the machines Rough alignment
roughly use a feeler gauge and straightedge.

NOTE

Gear couplings or all-metal couplings with low radial restoring forces are
suitable. Connecting couplings with a flexible compensating element are
to be agreed upon only in individual cases.
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe
Serial No. 8210546 to 8210547

49
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

Illustration 5-11:
Rough alignment of
1
connecting couplings
without an intermediate
piece

1) Straightedge
2) Feeler gauge
3) Coupling sleeve
4) Coupling hub
5) End cover

5 4 3 2

1. Check the shaft spacing using the thickness gauge (2).

2. Check the radial and axial misalignment with a short straightedge (1).
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe
Serial No. 8210546 to 8210547

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 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

Following this, align the machine precisely using an alignment device with Precision alignment
dial gauges. in vertical plane

Illustration 5-12:
Rough alignment of
connecting couplings
without an intermediate
1 piece

1) Alignment device with

dial gauge
2) Coupling hub
3) End cover
4) Coupling sleeve
2 5) Bolt
3 6) Spacer
4

3. Fabricate an alignment device out of flat bar steel (1) and attach it to the shafts.

NOTE

The initial value or reading on the dial gauge can be 5.00 as assumed
in the following examples.

4. Insert the dial gauges so that they are free from play and secure them.

5. Connect the sleeves of the connecting couplings (4) with each other using
2 bolts (5) and 2 spacers (6) of about 20 mm.
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe

6. Slide the flat steel between the two sleeves and rotate the two shafts by 180°.

7. Continue measuring in the vertical and horizontal planes as outlined in

Section 5.5.2 „Connecting couplings with an intermediate piece“ on page 47.
Serial No. 8210546 to 8210547

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 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

5.6 Securing the machine to the foundation

Illustration 5-13:
1 Securing to the
foundation
2
1) variable speed turbo
3 coupling
2) Fastening
bolts
4 3) Adjusting screws
4) Shims
5) Foundation
5

1. Place shims under each fastening bolt of the coupling housing. Ensure that all
shims support equally (see Ilustration 5-13 „Securing to the foundation“ on
page 52).

2. Unscrew the adjusting screws slightly.

The machine is seated completely on the shims.

3. Tighten the fastening bolts.

4. Check the alignment.

5. Record the final measurements in the coordinate system of the installation

check form.

5.6.1 Realigning the entire system at a future date

If the entire system is to be realigned after a long period of operation, the variable-
speed turbo coupling will have to be shifted on the shims. With the fastening bolts cen-
tered in the base plate, they will have enough clearance for movement in the holes
(see Ilustration 5-13 „Securing to the foundation“ on page 52).
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe

After the realignment, secure the fastening bolts to the shims to prevent them
from turning.
Serial No. 8210546 to 8210547

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 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

5.7 Plumbing the machine to the heat exchanger

For installation dimensions for the heat exchanger:

 Heat exchanger installation diagram (see Chapter 14 „Attaching Parts (descrip-

tions)“) in this documentation.

5.7.1 Installing the heat exchanger

NOTE

If possible, install heat exchanger below the oil level and close to the machine!

For an arrangement above the oil level, heat exchangers and pipes may drain into the
oil reservoir when the system is at standstill, causing overfilling, leaks and malfunc-
tions on start-up.

If the heat exchanger is installed above the oil level, observe the measures described
in this document.

Draining of the heat exchanger and/or pipes is permissible only if the oil reservoir was
designed sufficiently for a corresponding spare (rundown) volume.

In case of long pipes (> 8 m single length), the nominal width and assembly of pipes
might have to be optimized. Please consult Voith Turbo in this respect.

Applications in case of extreme low ambient and / or low cooling water temper-
atures.

Here an exact matching of heat exchanger design, installation, control system and
logic is necessary.

In case of extreme ambient temperatures, you may ask for to make available the in-
stallation and piping plan, the pressure loss calculation, the dimensions of the pipes
and the oil volumes for checking.

For pressure losses on cold start, see section 'Pressure losses'

Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe

In case of cooling water temperatures < 5 °C, add antifreezer.

Antifreeze (glycols) reduces the heat transfer which has to be considered when de-
signing the heat exchanger.
Serial No. 8210546 to 8210547

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 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

5.7.2 Arrangement of heat exchangers

The following figures show horizontally arranged heat exchangers. When planning the
arrangement, please observe the dimension required to remove the tube bundle.

Illustration 5-14: Dimen

sion for removing the
1 2 tube bundle

A) Heat exchanger
without optional temper-
ature control valve on
the oil side
A B) Heat exchanger with
optional temperature
control valve on the oil
side
1) Tube bundle length
2) Dimension for remov-
1 2 ing the tube bundle
3) Optional temperature
control valve on the oil
3 side

B
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe
Serial No. 8210546 to 8210547

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 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

5.7.3 Horizontal installation below the oil level

The heat exchanger is arranged below the machine. Pipes and heat exchanger cannot
run empty.

Usually, the nominal widths of connecting lines are to be provided as on the machine.

Illustration 5-15:
Horizontal heat
1 exchangers

1) Variable speed turbo

coupling
2
2) Oil level
3) Heat exchanger be-
low the oil level
4) Oil "supply"
5) Oil "return"
6) Cooling water
"supply and drain"
7) Draining

5
4

7
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe
Serial No. 8210546 to 8210547

55
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

5.7.4 Horizontal installation above the oil level

Oil supply and return pipes must be laid in a way to prevent the oil of the heat ex-
changer and, as far as possible, from the pipes from returning into the oil reservoir at
standstill.

To do so, the pipes must be run upwards gooseneck-shaped from the heat exchanger.

Connect the supply and return pipe at the highest point by a compensating pipe (e.g.
DN 15 mm) with an orifice ø 3 - 6 mm, dependent on the system size to prevent drain-
ing of the heat exchanger at standstill.

For long pipelines, the horizontal sections must be run below the oil level of the ma-
chine.

Where not possible, lay the gooseneck in the vicinity of the machine.

Illustration 5-16:
4 Horizontal heat
exchangers

1) Variable speed turbo

coupling
2) Oil level
3) Heat exchanger
above the oil level
4) Compensating pipe
7 with orifice ø 3 - 6 mm
5) Oil "supply"
6) Oil "return"
7) Cooling water
6
"supply and drain"
3
5 8) Draining
9) Run longer pipelines
1 below the oil level
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe

8 8
Serial No. 8210546 to 8210547

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 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

5.7.5 Vent and drain connections

Vent connections on the oil and/or water side are required at the heath exchanger if
otherwise no complete ventilation would be possible via the connected oil pipes, e.g.
for lateral oil connections or a vertical cooler position.

Drain connections must be available at the heat exchanger and the pipes at suitable
points.

Pressure losses
The entire pressure loss in the pipes, the temperature control valve (if any) and the
heat exchangers shall be below the following standard values:

< 1.3 bar at operating temperature (heat exchanger alone up to 0.8 bar)

< 2.0 bar at start-up temperature (heat exchanger alone up to 1.5 bar)

Temperature control
A temperature control shall be provided for the following conditions:

Temperature controller

Moderate variations of the water temperature Not required

Major variations of the water temperature (e.g. seasonally ex-

Required
tremely varying cooling water temperatures)

Cleanliness of system and connection of pipes

It is imperative to carefully flush the heat exchangers. We recommend meeting at
least the cleanliness grade stated in API 614.

Pipes made on the jobsite must be cleaned on their inside. For de-scaling, we recom-
mend pickling the pipes and flushing them in addition. After pickling it is mandatory to
neutralize and preserve the pipes. Ensure to mount the pipes free of stress.
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe

Pickling of oil pipes: (see Section 5.7.7 „Pickling of oil lines“ on page 59).
Serial No. 8210546 to 8210547

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 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

5.7.6 Installing the oil lines

NOTE

It is preferable to run the oil lines below the oil level in the variable-speed turbo
coupling.

The oil lines should be as short as possible (< 8 m). If possible, the oil lines should be
run below the oil level, while keeping the installation instructions for heat exchangers
in mind (see Ilustration 5-15 „Horizontal heat exchangers“ on page 55 and
Ilustration 5-16 „Horizontal heat exchangers“ on page 56).

Size the oil lines upstream and downstream of the heat exchanger to allow the lube
oil and working oil to flow at a velocity between 1.0 m/s and 4.0 m/s.

Maintain a constant oil line diameter over the entire length. In the case of larger con-
nections on the cooler, increase the line size directly at the cooler.

 Heat exchanger assembly plan (see Chapter 14 „Attaching Parts (descriptions)“)

in this Instruction Manual.

The machine is aligned exactly. Requirement

1. Remove the weld-neck flanges from the machine. Installing the oil
lines
2. Plumb the heat exchanger to the variable-speed turbo coupling as shown in
(see Ilustration 5-15 „Horizontal heat exchangers“ on page 55 and Ilustration 5-16
„Horizontal heat exchangers“ on page 56). Ensure that the installed piping is free
from stress.

3. Support the lines.

4. Horizontal heat exchangers H1–H2:

– If a venting connection is provided on the heat exchanger shell, attach a collec-
tion line to the vent connection on the working oil heat exchanger.
– For the purpose of draining the oil, attach a drain line with shutoff valve
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe

to the drain connection on the working oil heat exchanger.

5. Install the external lube oil lines (e.g. for the driving machine, driven machine
and /or the connecting couplings.

6. Switch on the auxiliary lube oil pump. Pilot bore orifices at the lube oil outlets from Drilling of orifices
the variable-speed turbo coupling to the driving machine and driven machine or in- for lube oil supplied
stall already pilot-bored orifices. to external units

The lube oil flow rate and lube oil pressure for external units depend on the diam-
eter of these orifices and possibly on additional orifices upstream of bearing loca-
Serial No. 8210546 to 8210547

tions on the driving and driven machines.

 For required lube oil flow rates, please refer to Section 1.2 „Operating data“ on
page 4.

58
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

5.7.7 Pickling of oil lines

NOTE

Before preparing this or another pickle, be sure to read and understand the
specifications, safety information (data sheets) and application information.

WARNING

Hazard from dangerous substances

Hazardous substances (pickling solutions) can

cause injuries or burns.

Wear personal protective equipment, especially

safety goggles, when cleaning and pickling oil lines!

Oil lines assembled and welded on site must be disassembled and pickled in an im- Pickling oil lines
mersion bath to ensure that they are free from scale and rust. Only then can they be made of steel
reassembled and flushed. (neither rust-proof
nor acid-proof)

1. Unscrew the oil lines.

2. Degrease heavily oiled or greased workpieces prior to pickling, e.g. by means

of steam cleaning or immersion in a degreasing bath.

3. Mix the pickle1 with water.

4. To remove dirt, light oil films, graphite or carbon deposits: add pickling degreaser2
to the pickle.

5. Heat the solution to 40°C.

Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe

6. Place parts into the pickle.

7. Remove the parts from the pickle. After pickling, they should be bright and free
from scale and rust.

Pickling period

Rust film approx. 5–10 min.

Rust approx. 15–30 min.

Rolling skin approx. 50 min.

Serial No. 8210546 to 8210547

1. Recommendation: product BETONA, manufacturer Karowa Co., Memmingerstr. 39A, Neu-Ulm,

Germany, or equivalent pickle. Mixture: 1 part pickle to 10 parts water
2. Recommendation: product S13, manufacturer Karowa Co., Memmingerstr. 39A, Neu-Ulm, Ger-
many, or equivalent pickle. Mixture: 1–3 l to 100 l of pickling solution.

59
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

Pickling period

Descaling of annealed steel parts approx. 120 min.

8. Allow the parts to dry protected from dripping water (24–48 hours at 20°C).
Do not wash off! If the drying time cannot be observed, rinse again with clean water.

9. Spray parts internally with the working oil and externally with paint.

Oil lines assembled and welded on site must be disassembled and pickled in an im- Pickling of oil lines
mersion bath to ensure that they are free from scale, temper colors and rust. made of rust-proof
Only then can they be reassembled and flushed. and acid-proof steel
(stainless steel)

NOTE

Before preparing this or another pickle, be sure to read and understand the
specifications, safety information (data sheets) and application information.

1. Unscrew the oil lines.

2. Degrease heavily oiled or greased workpieces prior to pickling, e.g. by means

of steam cleaning or immersion in a degreasing bath1.

3. Prepare the pickle2.

4. Place parts into the pickle.

5. Remove the parts from the pickle. After pickling, they should be bright
and free from scale and rust.

The pickling period depends on the

– temperature and
– life (age of the pickle)

and the influence of the pickling fluid

Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe

Pickling procedure for materials with the

material nos.1.4541, 1.4550, 1.4571

Age of pickle Pickling period

New pickle up to 1 week old 20 to 30 min.

1 to 4 weeks 40 to 60 min.

4 weeks and older up to 120 min.

Serial No. 8210546 to 8210547

1. Recommendation: product DERUSTIT 1622, manufacturer Deutsche Derustit GmbH • Emil von
Behringstrasse 4 • Dietzenbach/Germany • or equivalent degreaser.
2. Recommendation: product DERUSTIT pickle 1234, manufacturer Deutsche Derustit GmbH • Emil
von Behringstrasse 4 • Dietzenbach/Germany • or equivalent pickle.

60
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

Pickling procedure for materials with the

material nos. 1.4301, 1.4306, 1.4401

Age of pickle Pickling period

New pickle up to 1 week old 10 to 15 min.

1 to 4 weeks 20 to 30 min.

4 weeks and older 60 to 120 min.

CAUTION

Environmental damage

Pickle that escapes into the sewers or ground

can cause damage to the environment.

Dispose of used pickle in a proper manner that

complies with national statutory regulations.

6. Flush the part with water1, making sure to comply with protection regulations.

7. Spray the wet parts with a passivation solution2.

8. For final cleaning of the parts, flush them with water3.

9. Let the parts dry in clean rooms. Allow parts with cavities to dry in pure nitrogen.

10.Spray parts internally with the working oil and externally with paint.
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe
Serial No. 8210546 to 8210547

1. High pressure 160 bar

2. DERUSTIT passivation solution 2016, contact time 5-10 minutes
3. Fully demineralized water with a conductivity of 10 m

61
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

5.8 Connecting electrical instruments

WARNING

Risk of injury

Dangerous electric currents and voltages on the

variable-speed turbo coupling can injure or kill
individuals.

Only a qualified electrician who is knowledgeable

about rules that apply to electronic equipment in
the country of installation is allowed to perform work
involving the electrical equipment on the variable-
speed turbo coupling.

WARNING

Risk of injury

Hazard resulting from improper insulation.

As the result of improper insulation, an individual

could come into contact with electrical components
and be seriously injured.

Use only cables with insulation that can withstand

the ambient operating conditions!

CAUTION

Risk of injury / equipment damage

Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe

Stray currents in the variable-speed turbo coupling

can cause personal injury or damage gear teeth
and bearings.

Take suitable grounding measures on all components

of the drive line!

1. Connect all power consuming equipment.

2. Connect all control units.

Serial No. 8210546 to 8210547

3. Check motors for their direction of rotation, current draw and protection by fuses.
 Terminal diagram for wiring in the junction box.

62
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

 (see Chapter 14 „Attaching Parts (descriptions)“) of this Instruction Manual for de-
tailed information on the instruments installed.

5.9 Attaching guards

• Guarding to prevent accidental contact with rotating and hot components (connect- Types of guarding
ing couplings, oil lines) and other recognizable source of danger and protection
• Protection from noise
• Protection from the weather in the event of outdoor installation (roof or enclosure)

5.9.1 Attaching guarding to prevent contact

WARNING

Risk of injury

Entanglement or trapping hazard in the vicinity

of rotating shafts and in the vicinity of the rotating
connecting couplings.

Clothing, long hair or loose objects (lines, cords and

ropes/cables) could become entangled in the danger
zone and cause serious injury / damage.

Attach suitable guarding over the connecting

couplings that can only be removed by using tools!

CAUTION

Burn hazard
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe

The housing, oil lines, connecting couplings and

working oil may be very hot - in extreme cases,
up to 130°C. Contact can cause burns on the skin.

The variable-speed turbo coupling must be allowed

to cool prior to maintenance or repair work!
Serial No. 8210546 to 8210547

63
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

Attach guarding to prevent contact with rotating and hot components and other recog-
nizable sources of danger in compliance with the safety regulations of the operator
and/or the country where the equipment is being installed.

Attach the guarding to the connecting couplings using size 80 holes (Ø 8 mm)
for air exchange.

Illustration 5-17:
Ventilation holes on the
guarding for the
connecting couplings

5.9.2 Attaching sound-absorbing covers

Attach sound-absorbing covers in such a way as to not impede continued perfor- Unimpeded work
mance of the following activities.1

• Reading instruments on the instrument panel and on piping

• Reading the oil level from the oil level indicator
• Cleaning the duplex oil filter
• Actuating shutoff valves
• Installing and removing instruments
• Performing service work (topping up lubricant, e.g. in connecting couplings
and the like)
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe
Serial No. 8210546 to 8210547

1. Instructions based on VDI Directive 2711 "Sound Protection by Encapsulation"

64
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

WARNING

Poisoning hazard

Use of sound-absorbing covers without openings

can result in poisoning.

Poisoning and suffocation can result from gas

leaks when compressors are operating.

Always provide sound-absorbing covers with

vent holes to exchange the air!!

CAUTION

Explosion hazard

Heat may accumulate when using sound-absorbing

covers without openings.

Always provide sound-absorbing covers with vent

holes to dissipate the heat and exchange the air!

• Avoid exposing instruments, control units, electrical insulation and equipment Heat dissipation and
to excessive operating temperatures. ventilation
• Provide separate ventilation for electric motors. The cooling air for an air-cooled
electric motor can be used for ventilation, if necessary (consider the characteristic
curve of the cooling fan and the required motor cooling).
• Regulate the air flow in the cover to ensure heat dissipation (determine the flow
rate for a cooling air temperature increase of 10°C).
• Route the vented air from the housing and coverings (closed connecting coupling
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe

covers) through the sound-absorbing covers via ducts.

• Provide openings and seals for shaft passages, windows for viewing of instru-
ments, pipe and cable entry points and vents.
Serial No. 8210546 to 8210547

65
 Voith Turbo | Variable-speed turbo coupling | HHI S 34 Thai Binh 2 | 562 SVTL 12.1 5 Assembly

5.10 Attaching the scoop tube actuator

Prior to attaching the scoop tube actuator, check the orientation of the scoop tube.
The side of the scoop tube stamped “OBEN” (UP) must face upwards.

Attach the scoop tube actuator such that the scoop tube can be brought to any de-
sired position. Secure it to prevent rotation (use universal joints, not ball joints).

NOTE

Measures to limit the scoop tube stroke must be provided on the actuator,
not on the scoop tube itself!

Connect the scoop tube and scoop tube actuator in such a way that neither play nor
vibration can arise. Then, slight irregularities in operation of the scoop tube (e.g. due
to oil pressure fluctuations) will have no noticeable effect.
Techn. Documentation No. 215001029-0400-00-EN, Version 1.00, aevpd / Kapp-PRe
Serial No. 8210546 to 8210547

66
 INSTALLATION INSTRUCTION
OF BFP

6.5 Instruction Manual for Three Phase Induction Motor

Installation Manual 49
 01 Foreword

This instruction manual describes and provides

NOTE
instructions for installation, operation and
maintenance of induction motors. For service shop requirements, refer to

Service Center in Korea

These instructions do not support to cover all (Hyundai Heavy Industries Co., Ltd.)
Address: 1000, Bangeojinsunhwan-doro Dong-gu,
details or variations in equipment nor to provide Ulsan, Korea
for every possible contingency to be met in Tel: 82-52-202-6671, 6672
Fax: 82-52-202-6996
connection with installation, operation or
maintenance. Should further information be Service Center in USA
(Hyundai Ideal Electric Co.)
desired or should particular problems arise which Address: 330 East First Street, Mansfield,
are not covered sufficiently, the matter should be OH 44902, USA
Tel: 1-419-520-3229
referred to the nearest HYUNDAI HEAVY E-mail: timothy.hahn@hyundaiideal.com
INDUSTRIES business office.

02 Receiving, Handling and Storage

2.1 Receiving 2.2 Handling

Each shipment should be carefully examined upon arrival. To ensure proper handling after unpacking, the motors
If the packing is damaged, unpacking should be made require the chain hoist, wire ropes and other handling
immediately to check whether or not the motor and its equipment. When hoisting the motor, wire ropes should
fitting are in good condition, and any damage to contents be attached to the lifting holes on the side of the motor
should be photographed and reported to the carrier and frame, and should be put in hard rubber, thick cloth, etc.
to the nearest HYUNDAI HEAVY INDUSTRIES business between the external covers for protective purposes.
office. Then the motor is slowly and carefully raised and moved
to the intended position.
All large motors are equipped with a locking device, which
protects the bearing from damage due to the movement
When unpacking and handling the
of the rotor in transit. Do not remove this device until
motor, attention should be given to the
transport is complete and coupling is ready to be fitted.
following points:
- Anticorrosive agent which is applied to
the coupling shaft ends should be
Heavy Equipment removed right before starting the
Improper lifting can cause death, severe motor. The coupling or shaft ends
injury, or damage. Check eyebolts, should be checked to ascertain
lifting lug and eyenuts before lifting. Use whether or not they are in abnormal
proper slings and spreaders. condition.

4 << INSTRUCTIONS FOR THREE-PHASE INDUCTION MOTORS

 THREE-PHASE
INDUCTION MOTORS
02 Receiving, Handling and Storage

2.3 Storage If necessary, use guards or separating walls to provide

If the motors are not put into service at the time of adequate protection. Avoid storage in an atmosphere
delivery, they should be stored according to the following containing corrosive gases, particularly chlorine, sulfur
conditions. dioxide and nitrous oxides.

Top Heavy. Protecting the Cooling-water System

Can cause severe injury or property
When the motors are delivered, the cooling water system
damage.
When lifting motor,
is not filled with cooling water.
1. Lift only at designated locations.
2. Use spreader for lifting. �When you place the motor in storage after use, drain
3. Apply tension gradually to cables. the cooling water systems and purge them with air so
4. Do not jerk or attempt to move unit that they are completely empty.
suddenly.
�The detail instructions are as follows and the caution
5. Do not use cover lugs when lifting.
name plates are installed on the motor

1) Air-to-Water Coolers
Outdoor Storage is Not Recommended. While a motor is not in its operation, and if the ambient
Variations in temperature and humidity can cause temperature goes below the water freezing point, please
condensation, resulting in corrosion of metal parts and drain the cooling water completely to prevent cooler pipe
possibly in insulation failure. Therefore, the following damage from water freezing.
cover the minimum acceptable storage arrangements in The temperature of the cooling water must be over
an unheated but protected environment: 5°C (41°F).
It is preferable to use a heated facility, which would
simplify meeting these conditions. 2) Water Cooled Type Ball or Roller Bearings
When outdoor storage cannot be avoided, contact While a motor is not in its operation, and if the ambient
HYUNDAI HEAVY INDUSTRIES for specific instructions on temperature goes below the water freezing point,
minimizing damage, giving full particulars of the please drain the cooling water completely to prevent
circumstance. cooler pipe damage from water freezing.
The temperature of the cooling water must be over
Storage Facility Requirements 5°C (41°F)

3) Water Cooled Type Thrust and Guide Pad Bearings

Damp Location. While a motor is not in its operation, and if the ambient
Can cause property damage if
temperature goes below the water freezing point, please
equipment is operated intermittently.
Use space heaters to prevent dampness. make the cooling water flow continuously to prevent
Grease machine fits when unit is cooler pipe damage from water freezing.
reassembled to prevent corrosion. The temperature of the cooling water must be over
5°C (41°F)
The storage facility must provide protection from contact
with rain, hail, snow, blowing sand or dirt, accumulations Frost Damage to the Cooling Circuit.
of groundwater, corrosive fumes and infestation by The cooling circuit can be damaged if
vermin or insects. the cooling water freezes.
There should be no continuous or severe intermittent If the ambient temperature falls below
0°C during operation, add anti-freeze to
floor vibration. Power for the space heaters and
the cooling water.
illumination should be available. There should be fire
detection and a fire-fighting plan. The motors must not be
stored where it is liable to be accidentally damaged or
exposed to weld spatter, exhaust fumes or dirt and stones
kicked up by passing vehicles.

>>
HYUNDAI HEAVY INDUSTRIES 5
 02 Receiving, Handling and Storage

Temperature Control.
If the motor is boxed or covered in any
way when the space heaters are
Hazardous Voltage.
energized, there should be thermostatic
Will cause death, serious injury,
control and sufficient surveillance to
electrocution or property damage.
detect an over-temperature condition
Disconnect all power before working on
quickly. Ensure that temporary packaging
this equipment.
does not contact the space heaters.
When windings of motor are uninjured
and their insulation resistance to ground
Whenever the motor temperature is equal to and below
is well above the minimum of rated
ambient temperature, water vapor can condense on and voltage (kV) plus 1 megohm when
within it, promoting rapid deterioration. corrected to 40°C according to IEEE 43 or
Prevent this by energizing the space heaters to keep the as below in Fig. 1, low temperature is not
motor temperature above ambient temperature by at a problem.
However, if the resistance drops, the
least 3°C However, during periods of extreme cold or
windings can be permanently damaged
rapid temperature drops, the space heaters may not be
by freezing. Therefore, the motor
adequate to maintain this differential and supplementary temperature should be kept above
heating may be required. freezing point.

� Fig. 1 Insulation Resistance Temperature Correction

6 << INSTRUCTIONS FOR THREE-PHASE INDUCTION MOTORS

 THREE-PHASE
INDUCTION MOTORS
03 Inspection and Test for Initial Start-up on Site

Generally, inspection and test of motors are performed as 3.1 Installation

in the following chart for initial start-up on site. General
Ensure that the motor enclosure is suitable for its
environment, that the ambient temperature is less than
specifications for operating the motor at all times and
that all bearings are lubricated before operating the
Inspection of installation motor.

Foundation
Measurement of insulation Motors should be mounted on solid and rigid foundations
resistance to ensure proper vibration and free operation. The
desirable foundation and anchor bolt design will
Connection with --- accommodate at least the maximum static and
outgoing cables dynamic foundation loads indicated on the motor
outline dimension drawings.
Inspection of connection cables --- have sufficient rigidity to maintain acceptable alignment
after the application of load.
--- be free of natural frequencies, which are likely to be
excited during normal operation (this could result in
Confirmation of starting panel
vibration problems on the motor).

In some cases where precision is required, a study of

High-voltage test with outgoing cables these factors should be conducted to determine the
(If necessary)
natural frequencies of the motor support.

NOTE: If normal vibration or noise will be objectionable (as

Inspection of lub. oil
in office buildings), it may be advisable to use vibration
dampeners between the machine or driven/drive unit and
the foundation.
Hand turning (If possible)

Foundation Bolt
There are some different methods of installing the
Inching operation foundation bolt as shown in Fig. 2. The methods depend
on the capacity and construction of the motor.

� Fig. 2 Type of Foundation Bolt

Solo running test

Couple to
driven equipment

Inching operation

Load running test

END < J-Type >

>>
HYUNDAI HEAVY INDUSTRIES 7
 03 Inspection and Test for Initial Start-up on Site

� Fig. 2 Type of Foundation Bolt

The rotor is locked by a rotor locking
device for the purpose of protection
during transportation. These are
normally locked on the drive end shaft,
but sometimes locked on the non-drive
end shaft. The locking device shall be
taken off by simply loosening the screw
bolt. As the locking device is generally
painted in yellow-brown, it can be easily
visible.

Bolt Tightening Torque

The following table provides the general guidance of Max.
< Plate-Type > bolt tightening torque, especially mounting bolt tightening
situation. The values are maximum for each case, thus
care should be taken not to exceed the values.
Mounting
After removing the package from the skid of the motor,
remove the polyethylene shroud. Remove the motor from Tightening Torque(kgf�m)
Material
the skidding. The motors should be mounted on a flat S45C
SS400
surface and packed about with shims (shim allowance is (Strength grade:
Thread Size (For anchor bolt)
8.8)
generally 2-3 mm thick).
M6 X 1 0.4 1.1
The shims should support the maximum length of each
motor foot. It is preferable to use corrosion-resistant M8 X 1.25 0.8 2.1

shims such as brass or stainless steel; otherwise “shim M10 X 1.5 1.6 4.3
swell“ due to corrosion may be detrimental to good M12 X 1.75 2.8 7.5
alignment. Care should be taken not to distort the frame M14 X 2 4.6 12.1
during “bolting down”. M16 X 2 6.7 18
M20 X 2.5 13.3 35

A basic rule is to not have more than 5 M22 X 2.5 18.3 49

shims in a shim pack under any one M24 X 3 22.4 60
machine foot. Thick shim packs M30 X 3.5 46.9 124
consisting of many thin shims will cause
M36 X 4 80.5 215
a soft foot and cause vibration or twisted
frame (machine foot out of plane). M42 X 4.5 128 343
M48 X 5 194 518
M56 X 5.5 310 822

NOTE: Experience has shown that any base-mounted M64 X 6 463 1233
assemblies of motor and driven units temporarily aligned at M72 X 6 667 1776
the factory, no matter how rugged or deep, may twist
M80 X 6 922 2454
during shipment. Therefore, alignment must be checked
after mounting. M90 X 6 1325 3540
M100 X 6 1855 4929

Remove the Locking Device of Large Motors

All large motors are equipped with a device for preventing For the maximum tightening torque
the shaft from movement in order to protect the rolling for main power cable connection bolt,
face of bearing from damages due to vibration in transit. please refer to ‘7.4 Operation,
3) Tightening Torque’, page 24.

This locking device is fitted on the drive side or on the

non-drive side. Before connecting a motor to a machine,
the fitting bolts should be loosened, and the fitting device
should be taken off.

8 << INSTRUCTIONS FOR THREE-PHASE INDUCTION MOTORS

 THREE-PHASE
INDUCTION MOTORS

3.2 Inspection of Installation 3.3 Measurement of Insulation Resistance and

After installation, check for looseness of bolts and nuts on Polarization Index
the terminal boxes, cooler boxes and so on. Then, the
foundation and centering of the motors should be
Hazardous Voltage.
checked. These items are normally checked and reviewed Will cause death, serious injury,
on the erection records. electrocution or property damage.
Disconnect all power before working on
this equipment.

Checklist for inspection of installation

The insulation resistance of stator, rotor and auxiliaries
shall be measured before the initial start-up of the
machine or after a long period of standstill. The insulation
1. Outside view of machine resistance testing is available method for determining the
- No rusted portions.
extent of moisture absorption and dirtiness of the
- No damaged portions/parts.
- Confirmation of caution, nameplate. insulation. The insulation resistance of new machines with
dry windings is very high. If the machine has been
subjected to incorrect transportation and bad storage
environment such as high humidity, salty and dirty, the
2. Removal of rotor locking device insulation resistance can be extremely low. Based on the
(If necessary)
result of insulation measurement, correct cleaning and
drying action shall be determined and conducted.

3. Check for no looseness 3.3.1 Procedures for insulation resistance test

- End covers. The insulation resistance is measured by using an
- Terminal boxes. insulation resistance meter (Megger). Guidelines for test
- Cooler boxes.
voltage are presented in the following table.

Winding rated Insulation resistance

4. Check around foundation voltage (V)* test direct voltage (V)
- Motor levelling. < 1000 500
- Tightness of foundation bolts. 1000 - 2500 500 - 1000
2501 - 5000 1000 - 2500
5001- 12000 2500 - 5000
5. Inspection of accessories > 12000 5000 - 10000
- Thermometers * - Rated line-to-line voltage for three-phase AC machines, that
(indication checks at amb. temp.).
is the rated voltage of machines.
- Temperature detectors
* - The test voltage guidelines were quoted from IEEE 43-2000.
(indication checks at amb. temp.).
The test voltage is applied between the winding and the
frame for 1 minute. The test is usually performed to the
whole windings as a group. In case that the test is
6. Confirmation of centering
conducted to each phase winding, the frame and other
windings not under test shall be grounded. Before the
insulation resistance test is conducted, the following
actions shall be taken.
--- Verify that all power supply cables are disconnected.
--- The winding temperature is measured.
--- All resistance temperature detectors are grounded.
--- All other external equipment such as surge capacitors,
lightening arrestors, current transformers and etc are
disconnected and grounded.

>>
HYUNDAI HEAVY INDUSTRIES 9
 INSTALLATION INSTRUCTION
OF BFP

6.6 Instruction Manual for Reduction gear

- The End -

Installation Manual 50
 注文主 CUSTOMER

HYUNDAI HEAVY INDUSTRIES CO.,LTD

REDUCTION GEARS

INSTRUCTION MANUAL

CUSTOMER O.No. ： KJDTBD9SE1

CUSTOMER Doc.No. ： K3213-SP0069

Ｒ０ 2014/8/7 M.Mochida S.Odake T.Hamada

制改訂 作成年月日 担 当 調 査 承 認 承 認 レビュー 備 考 ＮＯＴＥ
REV.No DATE DESIGNED CHECKED APPROVED APPROVED REVIEWED

技 術 部 品質保証部
ENGINEERING DEPARTMENT Q.A. DEPT.

配布先
客  先： 部 生管部： 部 品証部： 部
製造番号 ＷＯＲＫ Ｎｏ．
営業所： 部 製造部： 部 資材課： 部
部 技術部： 部
部 部
13-KAEA03
図書番号
DOC. No. B5-1059-Y270
DSS60790様2 (ｵｰﾀﾞ) 総枚数 ： 14
 INDEX

Page
1 SUMMARY 1
2 SPECIFICATION OF THE GEAR BOX 1
3 PIPING AND CLEANING 2
4 INSTALLATION 2
5 TRIAL OPERATION 3
6 SERVICE OPERATION 4
7 DISASSEMBLING AND REASSEMBLING 4
8 MAINTENANCE CHECKING 6
9 CAUSES OF TROUBLES AND ITS COUNTERMEASURES 8
10 CLEARANCE TABLE 9
11 ALIGNMENT DATA FOR INSTALLATION 10

ATTACHMENTS
GEAR BOX OUTLINE DRAWING No.1
GEAR BOX ASSEMBLY DRAWING No.2
 No.1

1 SUMMARY
Gear box is connected to the steam turbine is used for driving the pump.
Gear box is totally enclosed and single stage.
Built-in pinion and gear are of single helical type.
Gear casing is made of cast iron and is separated in horizontal plane same as a shaft
center line.
Gear casing is equipped with the lifting hooks, oil drain hole, inspection hole, cleaning hole
and thread for thermo-couple
Pinion is integral with the shaft.
Low speed shaft is inserted into the gear.
Lubricating oil is distributed to each bearing and the gear from the oil inlet port of the gear box.

2 SPECIFICATION OF THE GEAR BOX

2-1 Specification
Type NHS1822O
Nominal Transmitting Power 315.6 kW
Input Shaft Speed 5008 min-1
Output Shaft Speed 1490 min-1
Gear Ratio 3.361
Quantity 4 units
2-2 Gear Data
Type Single helical
Module 2.5
No. of Teeth 36 x 121
Pressure Angle 20°
P.C.D. 91.72 x 308.28
Face Width 100 x 90
Helix Angle 11°7′
Center Distance 200
Material SCM420H × SCM420H
Heat Treatment CABURIZED
Finishing GROUND
 No.2

2-3 Specification of Lubrication

Grade ： ISO VG32
Lubricating Oil Inlet Pressure ： 1.5 bar G
Lubricating Oil Inlet Temperature ： 45 ℃
Lubricating Oil Quantity ： 27 L/min

3 PIPING AND CLEANING

Gear box is equipped with the inside piping and outside piping. All the inside
piping are adjusted for the required quantity of the lubricating oil. The inside
piping is connected to the oil inlet port.
As the gear box proper and ancillary piping are all cleaned up thoroughly prior to
shipment from us, should be paid attention for the prevention of inclusion of dust and dirt
into the piping.

4 INSTALLATION
It is important for the gear box to be installed securely on the solid foundation
and to be considered hot alignment so as to be free from disorder even under
a long-time operation. (Refer to “ALIGNMENT DATA FOR INSTALLATION”)
Since unexpected external force may be transmitted to the gear box even if any disorder
occur in the relative machines, the same consideration as above should be given
to the relative machines on the same train.
For making level adjustment of the gear box, establish temporary centering by
the use of a precision square level so that the level difference in axial direction on
the level pedestal becomes less than 0.04mm/m and then insert shims for adjustments
by the use of jack bolts until tooth contact corresponds to the tooth contact record
to be made at the time of delivery.
 No.3

5 TRIAL OPERATION
Before the operation, make sure to circulate the lubricating oil fully by use of
the preliminary pump until the lubricating oil temperature becomes more than 20 ℃.
When the gear box is stopped, oil circulation should be continued for more than five minutes
by means of the preliminary pump even in case the gear box becomes stopped.
When such preparation as the gear box installation, alignment, check of the interlocking
of the bolts, etc. of the rotating parts and the longitudinal clearance of the gear coupling
(if any) is made entirely, the gear box should be operated on trial.
At the first step, ensure to operate at four or five steps up to normal speed of
the output shaft under no load condition. In this case, make sure to increase no.
of revolution step by step.
Should be paid attention at each step to check meshing noise and bearing temperature.
Stop the operation immediately if gear meshing noise and bearing temperature rise
abnormally.
It is required to find out the cause.
After conducting suitable treatment, trial operation should be made from the first sequence.
Ensure that the operation has no problem after continued the operation at least for two
hours under no load condition and normal speed.
When any disorder is not observed during no load operation stated above, load operation
should be carried out in succession.
Load should be increased by four or five steps, and the operation should be continued
at least for ten minutes and more at each increasing step, together with the similar
checking in the case of no load operation.
When the full load is attained, the operation should be continued for more than five
hours. During this period, the measurement of the gear noise and bearing temperature
should be done at constant interval, and should be recorded including the date and kept it.
It is also convenient for the subsequent maintenance service to put the condition
of tooth contact on record by inspecting the contact of tooth face through the
inspection window after completion of the trial operation.
 No.4

6 SERVICE OPERATION
When any abnormal conditions are not observed at each part during the trial operation,
the service operation can be started. The service operation should be done under as
constant load as possible.
Even during long-term operation, the vibration and bearing temperature should be
measured on the basis of daily checking manual at least once a day and should be
recorded including the date and kept it.

7 DISASSEMBLING AND REASSEMBLING

7-1 When disassembling or reassembling the gear box, should be paid attention to
the following.
① When disassembling, make clear its purpose and keep disassembling to the minimum.
② Take care to keep clean all the disassembled parts at all times.
③ Small parts such as bolt and nut should be kept distant from the gear box not to
drop into the gear box.
④ Should be paid attention so that button, pencil, etc. don't drop into the gearbox
from clothes of the worker.
⑤ When difficulty arises in the course of disassembling and reassembling, stop and
study carefully and make sure that you know you are doing.
⑥ Since any slight flaws on the surface of parts, especially on the tooth surface and
hearing, may cause trouble, should be paid attention for the flaws.
⑦ Put the tally mark on the surface of parts before disassembly.
⑧ When reassembling, cleaning the parts completely by cleaning oil.
⑨ The parts furnished with interlocking should be interlocked again when assembling.
When the interlocking pin is found out the damage, the pin should be replaced.
⑩ Oil leakage can be prevented if liquid gasket is applied for the contact surface
of the gear casing before reassembling.
⑪ When inspection and disassembling are made, be sure to keep record of the
measured values obtained and other circumstances for reference along with
the date.
 No.5

7-2 Disassembling and reassembling

Disassembling and reassembling should be carried out in accordance with
following procedure.

7-2-1 Disassemble
Make sure not to place the disassembled parts directly on the ground or concrete
floor so as not to stain and damage them.
The small parts are to be kept in box to prevent them from missing.
Clean the disassembled parts must be fully cleaned and be coated with the
lubricating oil, if necessary.
Should be paid attention so that dust does not stick on the disassembled parts
during reassembling.
The tally mark should be stamped on the disassembled parts for reference
when reassembling.
① Disconnect the driving machine and driven machine from the gear box.
② Clean the outside surface of the gear box before removing the upper casing
in order to prevent dust from dropping into the gear box.
③ Remove the side cover and front cover, etc.
④ Remove the bolts on each connecting part of the upper casing and the clamping
bolts to the lower casing.
⑤ Life and remove the upper gear casing so as not to damage the gears and pinions.
⑥ Remove all the piping which prevent to lift up the shafts, gears, pinions and
bearings.
⑦ Remove each shaft without removing the gears from the shafts in succession.
Should be paid attention so that the shaft is not flawed and not inclined
by applying waste clothes to the location for the hanging rope.
This care is necessary especially in case that the rope comes into contact with
the tooth flank.
When placing the gear, wood block should be applied to the outer periphery
of the teeth, and suitable insertion should be made to support the whole shaft
horizontally. The gears and bearings should not be disassembled from the shaft
excepting special requirement.

7-2-2 Reassemble
To reassemble, follow the reverse order of disassembling, checking the interlocking
pin and tally mark. When assembling is completed, the condition of tooth contact
should be recorded including the date and kept it.
 No.6

8 MAINTENANCE CHECKING
There are in general two kinds of maintenance checking, I.e., daily checking and periodical
checking.

8-1 Daily Checking Manual

Check Judge-
Check Item Check Location Criteria Results
Interval ment
To be free from
Unusual noise Casing Once a day
unusual noise.

- -
Bearing Every 6
temperature Bearing hours
110℃ max
thermocouple
Accept-
1 bar G
able
Lubricating Lubricating oil 0.8 bar G under
Every 6
oil inlet pressure gauge Alarm
hours Watch carefully.
pressure
Shut- 0.5 bar G under
down Examine the cause.
Lubricating
Lubricating Oil Every 6
oil inlet 45℃
thermometer hours
temperature
Every 6
Vibration Casing Max 30μm peak-to-peak.
hours
Periphery of
Oil leaks Once a day To be free from oil leaks.
gear box
 No.7

8-2 Periodical Checking Manual (Once every two years)

Check Checking Judge-
Check Item Criteria Results
Location Method ment
Red Lead Not less than 70% of tooth width and
Tooth Adhesive tape free from end contact.
contact Color photo To be compared with the tooth contact
recorded when gearbox was delivered.
Pinion & Gear
Wearing Visual To be free from wear.
condition inspection
Date recorded when the gear box was
Backlash Dial gauge
delivered.
Lead wire Clearance table max. value ＋0.1ｍｍ
Wearing
micrometer ｍａｘ.（Both radial & ｔｈｒｕｓｔ ｃｌｅａｒａｎｃｅ）
Partial To be free from partial contact.
Bearing Red lead
contact
To be free from pinhole or clack of
Cracking Color check
1ｍｍ or larger.
Lubricating Degree of Oil maker's criteria.
Analysis
Oil deterioration
Precision
Level 0.04 ｍｍ/ｍ max
square level
Ａｌｉｇｎｍｅｎｔ Dial gauge Data recorded when the gear box was
Centering variation installed.
Looseness Hammer& To be free from looseness.
of anchor Visual
bolts inspection
Hammer& To be free from looseness.
Bolts Looseness Visual
inspection

8-3 Maintenance during long term (more than 1 month) suspension

When the operation is suspended over an extended period, the first concern is rust that is
likely to occur at various parts of the gear box. Intrusion of dust is also a problem.
If the gear box is suspended for long term(more than 1 month), each part (machined surface
of gear, shaft, bearing, etc.) should be coated with rust preventive oil, and the whole gear
box should be covered with dust preventive sheet.
Even during long-term suspension, the gear box should be operated for about two hours
at least once a month.
When starting the gearbox after the suspension, the rust preventive oil on the machined
surface exposed from gearbox should be removed completely.
The rust preventive oil of the gearbox interior needs not to be removed.
 No.8

9 CAUSES OF TROUBLES AND ITS COUNTERMEASURES

No. Trouble Countermeasures

When the installation alignment, handling, and operation

In case of the gear noise of the gear box is not correct, the gear noise becomes
9-1
in loud or vibration high loud and vibration becomes high as the result of wrong
tooth contact.

Damage, wearing, and wrong set of gasket, or looseness of

clamping bolts may cause oil leakage.
9-2 In case of oil leaks
Wrong parts should be replaced or adjusted, and the
loosened bolts should be fastened.

Choking in the pipe from the gear casing oil outlet to the
oil inlet and the mesh in the filter may cause decrease
9-3 In case of oil pressure drop
of the oil pressure. The pipeline should be checked and
cleaned by disassembling.

When the section between the gear casing oil inlet and the
In case of oil pressure
9-4 internal piping is choked, the oil pressure rises abnormally
rises abnormally
and the same treatment as stated above is needed.

Oil temperature rising is caused by short quantity of oil

In case of oil temperature and low performance of the cooling device.
9-5
rises Oil should be supplied in plenty.
The cooling devise should be checked and cleaned.
 No.9
No.1
CLEARANCE TABLE

LOW SPEED SHAFT

[[ EE ]]

[ C／2 ]
[B] [A]
[ C／2 ]

[F]

[B] [A]

[D]

HIGH SPEED SHAFT

UNIT mm
LIMIT
ITEM NAME ASSEMBLY CLEARANCE
CLEARANCE

JOURNAL BRG V： 0.100 ∼ 0.132 （DIA.） 0.198

A
(H.S.SHAFT)
― -

JOURNAL BRG 0.120 ∼ 0.152 （DIA.） 0.228

B
(L.S.SHAFT)
― ―
THRUST BRG
C 0.400 ∼ 0.600 0.700
(L.S.SHAFT)
SEAL
D 0.300 ∼ 0.350 （DIA.） 0.450
(H.S.SHAFT)
SEAL
E 0.300 ∼ 0.360 （DIA.） 0.460
(L.S.SHAFT)
BACKLASH
F 0.180 ∼ 0.510 ―
(MAIN GEAR)
No.10
APP.1
APP.2