消防水泵维修细则.docx

消防水泵维修细则.docx

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消防水泵维修细则

FireWaterPumpMaintenanceInstruction

No.：

GDOPS-MAN-P3MEC-015

Version:

0

Category:

OperationManagement

Department:

Operations

EffectiveData:

2012-04-30

TABLEOFCONTENTS

1Purpose3

2ScopeofApplication3

3PreparationBases3

4Definitions3

5DivisionofWork3

6OperationProcedure4

7Supplementaryrules20

8RevisionRecords21

Purpose

Inordertosecuresafetyandcorrectoperation,thosetotakepartinthemaintenanceoperatinghavetoreaditthoroughlybeforeworkinganddoitinthisway.

ScopeofApplication

ThisdocumentdescribesinstructionformaintenanceofFireWaterPump（P-8201）mountedinDPLNGRECEIVINGTERMINAL.

PreparationBases

ThisprocedureisbasedonGOULDS“OPERATIONANDMAINTENANCEMANUALP-8201”anditprovidesmaintenanceoperatinginstructionfortheFireWaterPumpP-8201A/B/CmountedintheDPLNGRECEIVINGTERMINAL.

Definitions

1.1Dischargehead

Thedischargeheadisafabricated“L”typehead.Portsareprovidedforconnectingthedischargegage,stuffingboxormechanicalsealbypassreturn.Thedriversupportportionofthedischargeheadisdesignedwithlargehandholesforeasymechanicalsealorstuffingboxadjustment.

1.2Column

Flangedcolumnconstructionprovidespositiveshaftandbearingalignment,andalsoeaseofassemblyanddisassembly.Bearingsarespacedtoprovidevibrationfreeoperationbelowtheshaftfirstcriticalspeedinordertoinsurelongbearingandshaftwear.Thelineshaftissupportedwithinthecolumnbyuseofbearingretainerswithinthecolumnassembly.Theseretainersareusuallyintegrallyfabricatedforalldiameters.

1.3Bowlassembly

Thebowlsaregenerallyofflangedconstructionforaccuratealignmentandeaseofassemblyanddisassembly.Impellersmaybeeitheropenorenclosed,dependingonthedesignrequirements.Fortemperaturesover1800°F（820°C）andinthelargersizebowls,impellersarekeyedtotheshaft.AspecialfirststagelowNPSHimpellermaybeprovidedincertainapplications.

DivisionofWork

1.4Operators

Inchargeofprocessisolateandissuethepermittowork.ClosethePTWaftermaintenancecompleted.

1.5I/E

Inchargeofpowerisolateanddismissisolateaftermaintenancecompleted.

1.6M/E

InchargeofapplythePTWandconductmaintenanceworkaccordingtotheprocedure.

OperationProcedure

1.7MaterialandEquipmentRequired

1.7.1Bulkmaterial

a）Anti-Gallinglubricant（suchasDowCorning“MOLYKOTE”）;

b）ThreadCompound;

c）LubricationOil;

d）Grease;

e）Solvent,petroleumbased（kerosene,distillateorunleadedgasoline）.

1.7.2Riggingequipment

a）Mobilepowerhoist,travelingcrane,orderrick;

b）Draglineandblocks;

c）Elevatorclamps,ifunitisunassembled;

d）Clevises–forusewitheyebolts;

e）Timbers–size,length,andquantitytosupportlongpumppartsonthefloor;

f）I–Beamsortimberstosupportpumpoverinstallation.

1.7.3Handtools

a）Pipewrenches;

b）Feelergages;

c）Setofmechanicstoolsincluding:

files,wirebrush,pliers,wirecuttersandpocketknife;

d）Cleanrags.

1.7.4Optionaltoolsforpumpassenblyanddisassembly

a）Dialindicatortoassistinmotor&pumpalignment;

b）Colletdrivertoassistinbowlassemblyanddisassembly（forpumpswithtaperlockimpellersonly）.

1.8Preventivemaintenanceprocedure

1.8.1Inspectionmonthly

a）Packingshallbeadjustedwhenevertheleakagerateexceedstwodropspersecond.Ifthereisnoleakageorthestuffingboxoverheats,donotbackoffglandnutswhilepumpsisrunning,stopthepumpandbackoffglandnutsone-quarterturn.Whenpackingbecomecoolrestartthepump.Itmaybenecessarytorepeatthisprocedureseveraltimestogetaproperleakagerate（~60drops/min.）.Ifleakageisexcessive,tightentheglandnutsone-quarterturnforeachadjustment;

b）Cleandirt,oilandgreasefromdriveranddischargehead;

c）Cleandriverventilationpassagetopreventoverheating;

d）Checkthrustpotlubricationoillevel（forP-8201A）;

e）Checkrightanglegearboxlubricationoillevel（forP-8201B/C）;

f）Checkenginelub.oillevel,fueloillevelandcoolingwaterlevel（forP-8201B/C）;

g）Checkengineairfilterindicator（forP-8201B/C）;

h）Whenpumprunning,checkthegearbox/thrustpottemperature;

i）Checkforexcessivevibration.Tightenallloosebolts;

j）Checkforpipingleakage.

1.8.2Yearlyorevery2years（ifrunninghoursless）

a）Changelubricationoilingearbox/thrustpot;

b）Cleanthesuctionfilter;

c）Checkthemotorbearingstemperatureandregreasethebearings.

1.9Correctivemaintenance

Whendothecorrectivemaintenancework,ifhaveanyquestionsthenseethetable1.

Table1TheTroubleAndShooting

1.10Disassembly

1.10.1Headandcolumndisassembly

a）Ifequippedwithmechanicalseals,loosensetscrewsfasteningsealtopumpshaftsopumpshaftcanslideupordownwithintheseal;

b）Onpumpswhicharedriventhroughageardrive,removethedriveshaftbetweenthegearandtheprimemover;

c）Onpumpswhichareelectricmotordriven,removetheelectricalconnectionsattheconduitboxandtagtheelectricalleadssotheycanbereassembledthesamewaytheyweredisassembled;

d）Uncoupledriver（orgearbox）frompumpshaftandmountingflangesandliftoffbytheliftinglugsoreyeboltsasfurnished;

e）Disconnectdischargeheadfromdischargepiping.Removeallholddownboltsandintegralpiping.Removecoupling,packingbox,andproceedwithdisassemblydowntothebowlsbyreversingtheproceduresdescribedindetailforassemblingtheunit.

1.10.2Keyedconstructionbowldisassembly

f）Removecapscrewsthatsecuretopbowl（669）tointermediatebowl（670）;

g）Slidetopbowloffthepumpshaft（660）;

h）Removecapscrews（759）andsplitthrustring（725）frompumpshaft;

i）Slideimpelleroffthepumpshaftandremovethekey（730）.Ifimpellerisseizedtotheshaft,strikeimpellerwithafibermalletanddriveimpelleroffthepumpshaft;

j）Repeattheaboveproceduresuntilthebowlassemblyiscompletelydisassembled.

1.10.3Turbinebowl–wearringremoval

a）Removesetscrewsorgrindofftackweld,whenringsarefurnishedwiththoselockingmethods;

b）Utilizingadiamondpointchisel,cuttwo“V”shapedgroovesonthebowlwearringapproximately180degreesapart.Useextremecarenottodamagethewearringseat;

c）Withachiselordrift,knocktheendofonehalfoftheringin,andprytheringout;

d）Onspecialmaterialssuchaschromesteel,setupthebowlinalatheandmachinethewearringoffusingextremecarenottomachineordamagetheringseat.

1.10.4Impellerwearringremoval

a）Removesetscrewsorgrindofftackweld,whenringsarefurnishedwiththoselockingmethods;

b）Utilizingadiamondpointchisel,cuttwo“V”shapedgroovesontheimpellerwearringapproximately180degreesapart.Useextremecarenottodamagethewearringseat;

c）Withachiselordrift,knocktheendofonehalfoftheringout,andprytheringoff;

d）Onspecialmaterialssuchaschromesteel,setuptheimpellerinalatheandmachinethewearringoffusingextremecarenottomachineordamagetheringseat.

1.10.5Bowl,suctionbellandlineshaftbearingremoval

a）Utilizinganarborpressandapieceofpipeorsleevewithanoutsidediameterslightlysmallerthatthediameterofthebowlorlineshaftbearinghousingbore,pressthebearingoff;

b）Removesuctionbellbearingbysettingthesuctionbellinalatheandmachinethebearingoff.Thesuctionbellbearingcanalsoberemovedbyusingbearingpullersandpullingthebearingout.

1.11Reassembly

1.11.1Inspectionpumpparts

a）Cleanallpumppartsthoroughlywithasuitablecleaner;

b）Checkbearingretainersfordeformationandwear;

c）Checkshaftsforstraightnessandexcessivewearonbearingsurfaces;

d）Checkdeflectionofshafts,averagetotalrunoutshallnotexceed0.010”（0.25mm）T.I.R.forevery10feet（3m）ofshaftlength;

e）StandardWearRingclearanceforthesepumpsis0.026/0.028inches,Maxclearanceisapproximately0.030inches（vendorrecommendation）;

f）Visuallycheckimpellersandbowlsforcracksandpitting.Checkallbowlbearingsforexcessivewearandcorrosion;

g）Replaceallbadlywornordamagedpartswithnewparts.Inaddition,replaceallgasketsandpackingasrequired.

1.11.2Turbinebowlandimpellerwearringinstallation

a）Placechamferedfaceofbowlorimpellerwearringtowardstheringseatandpresstheringintotheseat;

b）Useanarborpressorequalmakingsuretheringisflushwiththeedgeorthewearringseat.

1.11.3Bowl,suctionbellandlineshaftbearinginstallation

a）Pressbearing（653）intoretainer（652）usinganarborpressorequal;

b）Pressbearing（690）intosuctionbell（689）usinganarborpressorequal;

c）Pressbearings（672）intointermediatebowl（670）andtopbowl（669）.Placethebowlwiththeflangedownwardandpressbearingthroughchamferedsideofbowlhubuntilthebearingisflushwiththehubusinganarborpressorequal.Seefig3.

1.11.4Keyedconstructionbowlassembly

k）Installkey（730E）intopumpshaftkeyway,slideimpeller（673）overshaftandlocateitonthekey;

l）Installsplitthrustring（725）onpumpshaftgrooveandsecuretoimpellerwithcapscrews（759F）;

m）Slideintermediatebowl（670）overpumpshaftandsecuretosuctionbell（689）withcapscrews（759F）Seefig3;

n）Repeatprecedingproceduresforthenumberofstagesrequired.

1.12Finalassembly

1.12.1Installingapartiallyassembledpump

a）Cleantheplatemountingflangeandcleanbottomsurfaceofdischargeheadmountingflange;

b）Slingthroughdischargehandholesorthreadtwoeyeboltsthroughboltholesinmountingflangeandhoistunitintopositionoverfoundation.N