ML17276B654
| ML17276B654 | |
| Person / Time | |
|---|---|
| Site: | Columbia  |
| Issue date: | 07/23/1981 |
| From: | WASHINGTON PUBLIC POWER SUPPLY SYSTEM |
| To: | |
| Shared Package | |
| ML17276B653 | List: |
| References | |
| 10.6.1, NUDOCS 8210190586 | |
| Download: ML17276B654 (31) | |
Text
UNCONTROL LEG'gPP7,',,"" Verified Prior To use e fiedSy Date IC POWER SUPPLY SYSTEiiI'I'.l3 U RI'.S IKIAiV UAI, p 2 n'd OCEOURE NUMBER D t APP VEO OATE 7/23/81 SLCTION 10.6 MAINTENANCE PRO S AND OCEDURES HPCS AND LPCS SYSTEMS FROCEDURES TITLE+10.6el HPCS PUMP REMOVAL, OVERHAUL AND REINSTALLATION 10.6.1.1~pur oee This procedure provides instructions for the HPCS pump removal, disassembly, inspection, cleaning, reassembly and reinstallation.
10.6.1.2 Discussion The HPCS pump is a vertical 8 stage enclosed impeller unit driven by a 3000 H.P.motor located at the 442'evel in the South East Quadrant of the reactor build-ing.It is designed to supply emergency cooling to the reactor pressure vessel at high pressure and is part of a Quality Class I system.This pump will operate only a few hours per year and therefore should have a long maintenance free life.The unit should be overhauled per this procedure only when analysis of flow, vibration and/or motor load, give definite evidence of internal failure.10.6.1.3 References A.Ingersoll-Rand Instruction Manual, HPCS Pump, CVI 2-02E22-06, Sheet 14 B.PFM 10.1.13, System Cleanliness Control A.Work Request approved by Shift Supervisor in accordance with PFM 1.3.7.B.Clearance Order in accordance with FPM 1.3.8.C.System taken out of'ervice per Tech Spec requirements.
D.RWP in accordance with PPM 11,.2.8.10.6.1.5 Precautions A.Assure that pump is properly isolated and tagged out as specified in the Clearance Order.PROCEDURE NUM,3ER REVISION NUMBERS 10.6.1 PAGE NUMBE)0 6 1-VVP'19'/ENCLOSURE 4 B.This is a heavy rigging job;make certain chokers, sl'ngs, etc.are a¹-quate and inspected before use.Follow approved rigging practice specified in the WFPSS Safety Manual, Chapter l.l.~nI'wQp6/~u<y u~>P~C Y<6Ilay'NZizonŽtal zn over-haul area if necessary.(Lifting described in RETA pages 18-22.)Place cribbing for pump motor and-pump.B.Motor Removal 2.3.4.5.6.7.When disconnecting motor electrical leads from motor terminal box, identify leads for proper"Phase" installation.
Shen disconnecting thermocouple, heaters, ground wire and elec-trical leads (if necessary) as required to remove pump and motor, identify all lifted leads for reinstallation.
Remove casing vent pipe by unbolting flange connection.
Identify parts for re-installation.
Remove seal inlet and leak off piping by breaking flange/union, and pipe hangers as necessary to withdraw pipe from stand area.Also remove the three flanged seal piping.connections.(See Attachment 3)Tag parts for identification.
Refer to Attachment 2 and install spacer (18).Back off set screws (17)as required to free them from shaft and prevent galling.Oo not remove set screws..NOTE: Refer to Attachment 1 for the following steps.Disconnect spacer coupling (439)by releasing tab lockwashers (241E), bolts (35A)and (35B)and HEX Nuts (258H).Identify bolts and nuts for e-installation.
Discard lockwashers.
8.9.10.Remove coupling (439).Remove driver to discharge head flange (361-2).Remove cap screws (179A)and lock washers (241A)from driver to discharge head flange.Identify cap screws for reinstallation.(Bag and tag lockwashers.)
za<o Rig motor by lifting lugs, to overheadhoist.(motor weight 21,000 lbs.)Lift motor to laydown area and place on blocking on the floor.WP.$98 PROCKDURK NUMGKR REVISION NUMGKR 10.6.1 0 PACK NUMBER 10.6.1-3 Removal NOTE: Refer to Attachront 1 and 2 for Part ()numbers.Remove shaft adjustment (69), pump half coupling (33), and key (12).2.3.4.5.6.7.8.9.10.11.12.13.14.Remove the gland studs (178B), KX nuts (258C)and washers (241B)from mechanical seal.Identify parts for re-installation.
Pull the complete seal packing (429)including sleeve (Attach-ment 2)from stuffing box extension (361-7).Store seal package in protective area until re-installation.(Free from damage, dirt, etc.)Remove"0" Ring (456H), gasket (363B), and spacer bushing (156)from pump stuffing box (361-7).Oiscard"0" Ring (456H)and gasket.Release the three (3)allen set screws (259C)in shaft nut (126B).Loosen shaft nut (1283)by use of face spanner wrench and remove shaft nut from endof shaft (10).Install yoke dismantling tool against face of stuffing box (361-7)using mechanical seal gland bolting (258C/241B/178B)
.Install four (4)3/8" x 10" studs provided thru the 1/2" holes of the 5.38" diameter yoke bolt circle and thread into mating holes in throttling sleeve (440).Install plain washer and nuts (provided) on each of the 3/8" x 10" studs.Tighten nuts evenly against yoke to extract throttling sleeve (440)from pump stuffing box (361-7).Remove throttling sleeve (440)over end of shaft (10).Remove the discharge head flange (361-1)to shell flange bolting (258A/178A).
Verify match marks exist between head flange (361-1)and shell flange (359-1).I Install four (4)chokers thru discharge head motor mounting flange (361-2)thru the side"windows" and anchor one on each lug located just beneath the mounting flange.Lift pump element sufficient to install two (2)lifting plate assemblies dismantling tool spaced 180o apart on flange dis-chazge head (361-1).Secure lifting plate using the ten (10)studs and twenty (20)nuts provided.Place protective blocking across shell flange (359-1)and lower pump element back into'he shell (359)until lifting plate as-semblies (dismantling tool)mounted on the discharge head flange (361-1)corns to rest on the blocking.ROQKDURC NUMBER RKV'lSION NUMBER 1 PAQ R N UM GKA 1 Ii
15..Remove the four (4)chokers from lugs, under flange (361-2).16.Install chokers thzu eye in each lifting plate assembly and rig to overhead hoist.Install spreader between chokers such that the chokers aze held away from motor mounting flange (361-2)and any piping protruding from discharge head.Prepare laydown area for pump suction head.17.Lift out pumping clem nt using care so as not to damage pumping element.NOTE: Leave pump in the vertical position.18.Remove protective blocking from shell flange (359-1).Remove" and discard gasket 363A.Pt~1.Stage suction head (360)to laydown area.2.Verify tab lock washer (241C)are installed properly (i.e.,)a tab is bent on nut and on flange so nut (2580)will not turn).Inspector 3.Release table lockwashers (241C).Date 4.Carefully remove th'e suction head (360)from end of shaft (10).5.Remove"0" Ring (456A)and discard.6.Remove retaining ring (397)from its groove and move towards the fist stage impeller (3A).7.Slide journal sleeve (135)towards the impeller and remove jour-nal sleeve key (291)from shaft.Remove journal sleeve (135)and retaining ring (397).Inspect journal sleeve (135)for dam-age and repair if required.Inspector Date 8.Verify threads for set screws (2598)have been peened.Inspector 9.Prepare cribbing under first stage impeller (3A).Date WP.59B ROCKDURK NUMBKR 10.6.1 REVISION NUMBKR 0 PAGE NUMBKR 10.6.1-5
24.Loosen cap screw in throttling sleeve key (211)and remove key from shaft (10).25.Install two 3/4" eyebolts (shoulder type)spaced, 180 degree apart, in tapped holes on last stage channel ring (6CB).26.Rig onto the two 3/4" eyebolts and carefully lift and remove last stage channel ring (6CB)over the end of shaft (10).27.Remove"0" Ring (456C)and discard.28.Verify four socket head cap screws (179C)are peened.Inspector Date 29.Remove the four socket head cap screws (179C)from lock collar (312)and remove split lock collar.Identify cap screws and lock collar to the approximate stage of pump for assembly identification.
30.Remove impeller (3B)and impeller key (118).N0TE: A deep penetrating oil such as"free-all" by 3ohn Crane Company or equivalent should be applied to shaft (10)to ensure easy removal and reinstallation of parts.31.Repeat steps 3.2.28 through 3.2.31 for eighth through third stages.Identify parts to applicable stage of pump for re-installation.(Eighth).(Seventh)(Sixth)(Fifth)(Fourth)Inspector Inspector Inspector Inspector Inspector Date Date Date Date Date Inspector Date NOTE: Ensure shaft (10)is supported as each stage is removed.~dDD OCKDURK NUIAOKR REV'ldlON NUMBER 10.6.1~aad: NuaeOD'.R 10.6.1-7
32.Remove channel ring (60A)from second pump stage.33.Inst'all shaft yoke (provided) on threaded coupling end of shaft (10)and rig.to hoist.34.Withdraw the shaft, (10)(with second stage impeller (3B)at-tached)from bottom cover (394).35.Place shaft (10)on blocking to prevent rolling such that mea-surements can be made.37.Remove impeller (33)and key (118).38.(7th-3rd Stage)Remove the tw nty cap screws (1798)holding the diffusor (56)from the bottom cover.(No"0" Rings are installed.)
39.(8th Stage)Remove the cap screws (1798), twenty each, holding the diffusor (56)and cover plate (232)from channel rings (60A)and (6CB.40.Remove"0" Rings (456D and E).This completes disassembly.
41.Record dimensions required on Data Sheet I.E.Examination/Ins ctions/Cleanin 36.Remove sockethead cap screws (179C)from lock collar (312)and remove lock collar." Identify cap screws and lock collar to ap-propriate stage of pump for assembly identification.
Verify the threads for headless screw pins (259A)located in the casing rings (6A/B)are properly staked such that pins are locked.Indicate below any unsatisfactory conditions as to stage and if upper or lower ring (total of 48 pins in 16 locations.
)STAGE SATISFACTORY UNSATISFACTORY INSPECTOR I 6 ROCEbURE NUMQKR REVL5ION NUMSCR~aaC NUMaCR lo.6.1-8 2.Visually inspect all bearings and casing rings for cracks, for excessive wear, scratches, or other damage.Also verify bear-ings are not loose in casing.Note any unsatisfactory condi-tions and indicate parts, location, and problem.3.Clean all pump parts particularly mating surfaces using clean stainless steel brushes, stoddard solvent, methanol or other materials approved by G.E.document 408HA110.4.Refer to sectional assembly drawings, seal drawing and running clearances, and torque value and operating check sheets for re-spective pump.5.'heck for pump shaft straightness by the following method: Attach a sketch with readings to this procedure.
indicate each section of shaft on"V" blocks or rollers for Total indicated Runout (TER).The shaft shall be supported by two"V" blocks (rollers)near the ends'of the shaft at the bearing and/or coupling areas of approximately the same diameter.The TIR of the rollers ("V" Blocks)shall not exceed 0.001 inches.The shaft journals or journal sleeves must be round to within 0.001 inch at the support areas on the"V" Blocks or Roll'ers.b.Total indicator readings should be taken at every bearing and coupling area and/or every 12 inches between long bear-ing spans.Record distances from end of shaft to each TiR measurement and for every 90 degrees around the shaft.c.Maximum allowable TiR is 0.001" X total length of shaft in feet.Shafts that exceed this limit can be straightened by either cold straightening or heat straightening.
Refer to Cameron Pump Division for heat straightening procedure.
inspector Date 6.Examine all parts for cracks, excessive wear, corrosion and/or erosion, distortion, etc.Report discrepant conditions by de-scription, part number, and locati.on.
F'.~Assembl NOTE: See Data Sheet No.1 for required clearances and"as-found" and"as-left" data to be recorded.l.For the first stage, install diffusor (56)to bottom cover plate (394)using (20)cap screws (179B).No"0" Rings required.Use loctite (screw lock grade)on cap'screws.Tighten 14-16 ft/lbs, and set cap screws taking care not to strip KX socket.l Torque Wrench I.O.As Le t Inspector ROCKDURE NUIABKR 10.6.1 REVI5IGN NUMBER PAGE NUMBER 10.6.1-9 2.Install"0" Ring (458)and E)in grooves on each of channel rings (60A)and channel rings (608).Inspector Oate 3.For Stages Two through Seven, install diffusor (56)to channel rings (60A)using twenty cap screws (1798)in each ring.Use (screw lock grade)"loctite" on cap screws.STAGE ITORQUE WRENCH I.O.INSPECTOR 7', 5.For Stage Eight, install cover plate (237)to last stage channel ring (6CB)using cap screws (1798).Use (screws lock grade)"loctite" on cap screws.Tighten all cap screws (1798), torqu to 14-16 ft/lbs, using care so as not to strio FKX socket.Torque Wrench I.O.As Left Torque Inspector NOTE: Oeep penetrating oil, i.e.,"Free All" by 3ohn Crane, may be applied on the shaft to ensure easy assembly of impellers and shaft coupling, etc.6.'nstall second stage key (118)and second stage impeller (33)over upper end of shaft (10)and position key (118).(Sixth)Inspector Oate 7.Install split lock collar (312)and four cap screws (l79C)torque cap screws to 14-16 ft/lbs.Torque Wrench I.O.As Left Torque Inspector~DDD OCf'OURC NUMBER REVISION NUh1SD:R 10.6.1 PACK NUMBER 10.6.1-10
8.,With shaft yoke installed, install shaft (10)with second stage impeller (3B)to bottom cover (394).NOTE: Support bottom cover (394)and stabilize shaft (10)while insEalling subsequent pump stages.9.Remove shaft yoke from pump shaft (10).10.Install two 3/4" eyebolts, 180 degrees apart on second stage channel ring (60A)and rig to hoist.11.Install new"0" Ring (456C)in bottom cover (394)and install channel ring (60A)on bottom cover.Insure second stage channel ring (60A)is properly seated on bottom cover (394).Inspector NOTE: Repeat Steps 12 through 15 to install Stages 3-8.Date 12.Remove two 3/4" eyebolts from second stage channel ring and rig to next stage channel ring, continue through eighth stage.13.Install third stage key (118)and impeller (33)or shaft (10).14.Install split lock collar (312)and four cap screws (179C)torque cap screws to 14-16 ft/lbs.STAGE ITORQJE WRENCH I.D.f TORQJE AS LEFT INSFECTOR 15.Install new"0" Ring (456C)between pump stage, and be sure all channel rings (60A and 8)are properly seated.(THIRD STAGE)(FOURTH STAGE)Inspector Inspector Date I Oa e OCKDURK NUMSKR 10.6.1 RKVLSION NUMbKR PACK NUMbKR 10.6.1-11 (FIFTH STAGE)(SIXTH STAGE)(SEVENTH STAGE)(EIGHTH STAGE)Inspector Inspector Inspector Inspector Date Date Date Date 16.Install key (211)for throttling sleeve (440)on shaft (10).Tighten and set cap screw in key (211).Torque to 14-16 in/lbs.Torque Wench I.D.As Left Inspector 17.Install"0" Ring (456G)in groove on discharge head flange (36 1-1).18.Rig hoist to lifting plate assemblies installed on discharge head flange (361-1), use spreader to keep chokers from con-tacting head mounting flange.19.Install choker around tie rods (374).20.Lift discharge head (361)and place in.the vertical position.Then remove choker from tie rods (374).CAUTION: Use care so as not to damage t'e rods by striking them against the floor or other objects.21.Align matchmarks on tie rod/bottom cover and lower the discharge head (361)and tie rod assembly over shaft (10)and pump stages.Insure tie rods (374)line up and enter respective hole in bottom cover (394).Verify components of the channel ring (60A/B)bundle are properly seated.Inspector Date 22.Install tab washer ('299)and nut (258B)on each tie rod (374)and snug down.Torque nuts to a total of 3500-4000 ft/lbs as follows: TORQJE WRENCH I,D.AS LEFT INSPECTOR First pass 100-150 lbs.Second pass 500-600 lbs.Third pass 1000-1500 lbs.WP 558 PROCEDURE NUMBER 10.6.1 REV'ISIQN NUMBER 0 iF.6.1-12
Fourth pass 3500-4000 lbs.23.Raise discharge head flange (361-1)vertically from the support blocking sufficient to install first stage casing and remove support blocking.24.Install"0" Ring (4568)in groove in first stage casing (1).Inspector Date 25.Position first stage casing (1)under pumping element install first stage casing over the end of shaft (10).Note clearance on data sheet 26.Install studs (1780), tab lockwashers (241D), and nuts (258E)to bottom cover (394)and first stage casing (1)and snug up nuts and position against bottom cover (394)to ensure proper seating.27.Torque nuts (258E)to a final value of 175-195 ft/lbs as follows: TORQJE WRENCH I.D.AS LEFT INSPECTOR First pass 50-60 lbs.Second pass 100-150 lbs.Third pass 175-195 lbs.28.Set tab lockwasher" (2410).Inspector Date 29.Position first stage impeller (34A)under suspended pumping element.30.Install impeller key (11A), impeller (3A), and shaft nut (126A).Tighten shaft nut with pin spanner wrench.(No torque requirement listed.)Note clearance between casing ring and impeller.Inspector Date 31.Tighten and set the three screws (259B)in shaft nut (126A)and peen the set screws.Torque to 20-30 in/lbs.Torque Wrench I.D.As Left Inspector 32.Install retaining ring (397)on shaft beyond its groove and install journal sleeve (135)beyond key-way then install key (291).Record journal sleeve (135)to suction head bearing clearance.
QCKOURK NUAIBKR RKVIEION NUMBKR 1 PAGE NUMBKR 10.6
33.Position journal sleeve (135)on key (291)and move retaining ring (397)into its groove on shaft (10).34.Install"0" Ring (456A)in groove of suction head (360).Inspector Date 35.Position sucti'on head (360)under pumping element and against first stage casing (1).Install the suction head over the end of shaft (10)and into position against the first stage casing (1)-36.Install the tab lockwashers (241C)and bolting (17GC/2580) to suction head and first stage casing.Snug nuts (2480).37.Torque nuts (2583)to a final value of 48-58 ft/lbs as follows, and set tab lockwashers (241C).TORQJE WRENCH I.D.AS LEFT INSFECTOR First pass 20-30 lbs.Second pass 48-58 lbs.38.Install new gasket (363A)in position on shell flange 359-1).Inspector Date 39.Place protective blocking across shell flange (359-1).40.Lower pumping element into shell (359)until lifting assemblies are resting on blocking.Insure head flange (361-1)into shell flange (359-1)match marks lineup.Inspector Date 41.Remove lifting rings from lifting assemblies and install (4)chokers through discharge head motor mount flange (361-2)side"windows" and anchor one choker to each lug beneath mounting flange.42.43.Lift pump elettent enough to remove the two lifting plate assem-blies from discharge head flange (361-1).Remove blockiing from shell flange (359-1).Lower pumping element so that discharge head flange (361-1)con-tacts shell flange (359-D)nuts (2589).Snug nuts.ROCGDURK NUMSKR RKVl5ION NUMSKR 10.6.l.PAQK NUMGCR 0 6->4
44.Torque nuts (258A)to a final value'of 450-475 ft/lbs as follows: TORQUE WRENCH I.D.AS LIFT INSPECTOR First pass 50-60 lbs.Second pass 100-150 lbs.Third pass 200-300 lbs.Fourth pass 450-475 lbs.45.Install throttling sleeve (440)onto shaft (10),and slide into position on key (211).Start three set screws (259C)into threaded holes in shaft nut (1268)but do not allow screws (259C)to project into the bore of the shaft nut.Note clearance between throttling sleeve and throttling bushing.Inspector Date 46.Slide the shaft nut (1263)into shaft (10)and install on to threaded portion of shaft until nut (1268)has metal to metal contact with throttling sleeve (440).Tighten shaft nut 1268 using face spanner wrench.Inspector Date 47.Tighten and set the three set screws (259C)in shaft nut (1268).nspector Date 48.Slide spacer bushing (156)onto shaft (10)and install into pos-ition in stuffing box (361-7).49.Install"0" Ring (456H)/gasket (3638)in groove on gland flange (429), and gasket (3638).Insure"0" Ring (11)is lubricated or"soaped" and shaft, t'hreads are protected.
50.Refer to Attachment 2: The Mechanical Seal Drawing", after the seal has been assembled with all"0" Rings/Gaskets installed bolt the guard plate (14)uptight to the discharg plate (361-3)'nstall spacer (18)which automatically sets the alignment of the inner seal element, and drive collar (16)to the shaft.51.Torque nuts (258C)to a final value of 130-140 ft/lbs as follows: TORQJE WRENCH I.D.AS LEFT INSPECTOR First pass 50-60 lbs.Second pass90-100 lbs.OCKDURK NUIIIQKR REVISION NUMBKR 10.6.1 0 PA(1K NUA4$KR 10.6.1-15
Third pass 130-140 lbs.NOTE: Set Attachment 2 for following steps: 52.Install spacer (18)and drive collar (16)on sleeve (10);53.Tighten set screws (17)so drive collar (16)is fixed on sleeve (10).Do not allow set screws (17)to protrude from ID of sleeve (10)or drive collar (16)this will damage shaft when installing seal or setting rotor.NOTE: See Attachment 1 for the following steps: 54.Install coupling key (12), pump half coupling (33), and ad-~justing nut (69)on pump shaft (10).55.This completes the re-assembly/installation of the pump.Inspector Date G.Startu and Testin 1.Following completion of the pump installation and after"bump-ing" the motor to check for free rotation, have Operations re-store the unit to service, and..tart the pump up following pre-scribed operating procedures.
2.Take motor amperage readings, bearing temperatures, measure dis-charge pressure, measure f lou, m asure differential pressure across the suction strainer and~onitor vibration.
Record this data on the data sheet.10.6.1.9 Documentation A Complete the Data Sheet I and work request format.Record any repair work performed and attach the check sneet and material acceptance tags to the Work Request.10.6.1.10 Attachments A.1-R Drawing-F-12X20KD500X3A B.John Grane Packing Co., Drawing H-SP-1666 C.Data Sheet I WP>>544 HQCKOURK NUhIGKR j.O.6.1 RKVISIQN NUMBKR PAGK NUMOKR 10.6.1-16
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r I DATA SI.GET I Descri tion-ournal Slv.(135)to~~~~Suction Head Bearing (227A).Casing (227B)to Shaft (10)Re uired 0.004" to 0.008" 0.007"to 0.011" As Found As Left Ins ection Casing Ring (wea'r ring)~to lm aller 3A (1st st)0.018" to 0.022" I U per I Lower er Lower U er I Lower Casino Ring (wear ring)(68)to impeller (38)4.l 2nd Sta e 4.2'rd Sta e 4.3 4th Sta e 4.4'th Sta e 4.5 6h Sta e, 4.6 7th Sta e a e E 0.018" to 0.022" I U per Lower 0.018" to 0.022" 0.018" to 0.022" II o I 0.018" to 0.022" 0 II to I I 8II to 22II 0 U er Lower Up er Lower Bushirg Channel Ring (357)to Shaft (10)5.1 ind Sta 5.2-:"rd Sta e ace 5.4'th Sta e 6n ae 5.6 7th Sta e n a e Throttling Sleeve (440)to Thzottling Bushing (441).Shaft (10)Runout (TIR)NOTE: Runout to be in-dicated should be with Rollers or."U" blocks loca-ted at the coup-ling impeller or bearing journals I areas.I 0.007" to 0.011" I.0 007" to 0.011" 0.007" to 0.011" 0.0 7" to 0.11" 0 0.007" to 0.011" 0 0.008" to 0.012" 0.008" to TIR-U er Lower U er Lower Upper'ower RQCKOURE tJUMBKR REVlSION NUMBER 1 1 0 I aalu SUMSCR-9 1 I I AS FOUNO AS LEFT ACCEPTABLE Motor Voltage Motor Amperage Oischarge Pressure Pump Flow Oif ferential Pressure Across Suction Strainer Vibration Top of Motor (Axial)Top of Motor-A'op of Motor-B (90o from A)Top of Pump Discharge Flange Side ofPump Oischarge Flange WP SSI OCKDURK NUMBKR 10.6.1 RKI/IS I ON NUM 8 KR PA(2 K NUM B KR 10.6.1-"0