Product Model: IDG

Product Designation: High Pressure Feed Water Pump

Installation & Operation Instruction

SM

Shenyang AST Pump Factory

October 2010
 Contents

I. Preface ..................................................................................................................... 1

II. Technical Specification ........................................................................................ 1

III. Structure Explanation ........................................................................................... 1

IV. Auxiliary Equipment ............................................................................................ 3

V. Disassembly of Pump ........................................................................................... 3

VI. Pump Maintenance ............................................................................................... 5

VII. Pump Assembly ................................................................................................. 9

VIII. Installation Explanation................................................................................... 10

IX. Startup and Operation of Pump .......................................................................... 12

X. Trouble Analysis and Solution ........................................................................... 13

I. Preface

This instruction is mainly applied for model IDG high pressure feed water pump.
High pressure feed water pump is an important unit for steel rolling and power plant. This
instruction and technical documents as well as drawings provided by manufacturer must be read
carefully in order to ensure that the pump can be operated safely and stably, the steel rolling plant
can be operated stably and persons can install, maintain and operate the unit safely. At the same
time, records for operation, maintenance and incidents must be made carefully, which are main
evidences for analyzing and solving the problems.
For new pumps, customers can use them without disassembly. If the feed water pump is stored over
one year, it should be disassembled and checked as per pump manufacturer’s requirements. It can
be used only after it conforms to requirements for installation and operation.

II. Technical Specification

1. Detailed parameters refer to technical agreement and order contract.

2. Driving power associated: electric motor.

III. Structure Explanation

Model IDG feed water pump is a single shell sectional multi-stage centrifugal pump. It is designed
to be operated under normal temperature and high pressure. Detailed structure explanation is as
follows:
1. Stator
It is mainly composed of bearing, suction section, middle section, tap middle section, guide vane,
last guide vane, water discharge section, initial cover, last cover and etc.; all of those components
are connected with tension bolts. Suction nozzle of suction section and discharge nozzle of
discharge section are vertically upwards. Static sealing surfaces of suction section, middle section
and discharge section of the pump are mainly sealed with metal surface seal; at the same time, O
type seal spacers are used as auxiliary seal. During assembly and disassembly, metal seal surfaces
of the stator must be protected carefully. The pump stool is of welding structure.
2. Rotor
The rotor structure has a very close relation with the whole pump structure, stable operation and
product performance.Rotor of model IDG-11 feed water pump is mainly composed of shaft, initial
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stage impeller, second stage impeller, last stage impeller, impeller clip ring, balance disc, thrust
bearing disc, dynamic balance round disc, shaft sleeve nuts at both suction side and discharge side
and bearing nuts and etc. Impeller and shaft of model IDG-11 feed water pump are mounted by
means of hot-shrink interference clearance and single stage of impeller is positioned axially with
clip ring. The whole rotor is supported by the bearings at both ends of the pump.
3. Balance Mechanism
Balance mechanism is mainly composed of balance disc, balance sleeve and balance plate pressure
ring and etc. Working stability of this balance mechanism has a very close relation with operation
reliability of the product and its service life. The balance mechanism can balance most of the axial
force. The journal and thrust bearing can position the rotor axially, and absorb residual axial force
and axial force under balance mechanism failure condition; at the same time, with journal and thrust
bearing, it can ensure that no rubbing will be generated between balance disc and balance sleeve or
the rubbing is not reduced during frequent startup and shutdown of the pump.
4. Shaft End Seal
Packing seal will be used as shaft seal.
5. Radial Bearing
Radial bearing is of multi oil wedge sliding bearing. It can works in two rotations. Radial bearings
at suction side and discharge side can be changed with each other. Those bearings are lubricated by
means of forced lube oil. Oil flows into oil grooves on bearing pad through holes at one side, a ring
space on bearing body and holes on bearing pads.
6. Thrust Bearing
Thrust bearing is installed behind the radial bearing at discharge side. It can bear axial loads in two
directions and restrict axial position of pump rotor. Thrust bearing can absorb the residual axial
force that is not completely balanced by water balance unit. Thrust bearing is lubricated with forced
lube oil. Oil flows into the space at both sides between thrust disc and fan shape pads through
throttle holes, and then passes through double friction surfaces of the thrust bearing, and then
enters into bearing body through upper holes on bearing end cover, and finally returns back to oil
manifold pipe together with lube oil for radial bearing.

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IV. Auxiliary Equipment

1. Lube oil for pump bearings is supplied by the coupling.

Lube Oil Consumption Table for Model IDG Feed Water Pump
Position Pipe No. Lube Oil Quantity (l/S) Lube oil pressure (Mpa) Remark
Radial bearing 4 0.06-0.14
Radial bearing 4 0.06-0.14
Thrust bearing 15 0.06-0.14
2. Coupling
Elastic disc couplings are used for connection between pump and coupling and connection between
coupling and motor.
3. Measuring Instrument
In order to monitor the pump in safe operation, the instrument below should be installed:
1) Pressure gauge (0-40Mpa), for checking pump discharge pressure.
2) Pressure gauge (0-0.6Mpa), for checking lube oil pressure and pressure distribution for radial
bearing and thrust bearing.
3) Pressure gauge(0-2.5Mpa), for checking pump suction pressure and balance pressure.
4. Pressure Coupler
Details refer to its operation instruction.

V. Disassembly of Pump

1. Preparations for Disassembly

1) Prepare space and tools necessary for disassembly, such as dial indicator (with magnetic stand),
filler, straight ruler, micrometer and caliper and etc.
2) When hoisting equipment is not available, prepare pulley unit for lifting heavy components,
with its load of 1.5tons.
3) Dismantle cooling water system pipeline.
4) Dismantle oil system pipeline and drain off rest oil in oil cooler.
5) Dismantle suction water-in gate, re-circulation gate and discharge non-return gate.
6) Dismantle pressure gauge pipe and balance water pipe.
Quality requirement is:
1) Oil pipe nozzle should be packaged with clean cloth.
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2) Carefully drain off the oil to prevent oil flowing onto the ground.
3) Gaskets, nuts, bolts, pipelines and accessories dismantled should be preserved well.
2. Re-inspection Center for Coupling Disassembly
1) Dismantle coupling hood and coupling middle sleeve.
2) Re-inspect coupling center and make record.
3) Push the rotor to driving end and measure end surface distance of the coupling.
Quality requirement is:
1) Pay attention to original mark of the coupling during disassembly and make sure to maintain
original position as per this mark during assembly.
2) Allowable deviation of coupling center: surface deviation less than 0.05mm, round deviation
less than 0.08mm.
3. Measuring Thrust Clearance:
Measure thrust clearance and makes record.
Quality requirement is:
1) Make record for calculating axial distribution.
2) Thrust clearance: 0.08-0.1mm in front and 0.5-1mm at back (free side).
4. Bearing Pad Disassembly, Shaft-Lifting Test:
1) Dismantle bearing cover and re-inspect shaft neck lift with gradienter at both shaft neck
positions.
2) Radial bearing: with four oil wedges bearing, the holes of this bearing are machined
mechanically, which should not be scraped in principle.
3) Measure clearances of bearing pad at two sides with a filler. Depth of the filler is 22-23mm.
4) Shaft lifting test: Check concentricity between feed water pump rotor and stator.
Quality requirement is:
1) Lift of shaft neck: Two ends of the shaft should be lifted up together and numbers of the grids
indicated on the gradienter on the ground should be almost the same.
2) Tension force of bearing pad is ±0.02mm.
5. Balance Unit Disassembly, Measure Total Movement:
1) Open bearing body at free side and measure front and post clearances of journal and thrust
bearing.
2) Loosen end cover and end cover liner at discharge side.
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3) Support the shaft with bracket to prevent rotor drooping on the wearing parts.
4) Dismantle shaft sleeve nut, baffle sleeve, shaft sleeve, balance plate pressure ring, spacer ring
and balance disc.
5) Loosen balance sleeve bolt and dismantle balance sleeve.
6) Install balance disc (without balance sleeve), balance disc pressure ring and spacer ring.
7) Measure total movement of the rotor (total movement for accident).
8) Dismantle balance disc, balance clip ring and spacer ring and etc. after measuring.
Quality requirement is:
Total movement of feed water pump rotor is 80-1.5mm.
6. Disassembly of Pump Body
1) Measure distance between suction section and discharge section and check slope degree of the
pump casing prior to disassembly.
2) Dismantle 12 tension bolts and lift out discharge section.
3) Dismantle last guide vane, last stage impeller and middle section to disassemble stage by stage.
4) Move water-in section towards back and dismantle coupling at pump side.
5) Dismantle bearing body at suction side and lift out pump shaft at discharge side.
Quality requirement is:
1) Slope degree of pump casing is less than 0.05mm.
2) Spacers and nuts for tension bolts should be placed as per original positions.
3) Clean all components disassembled and identify them with marks. Smear them with rust
resistance oil. Place them in specified place. Make sure that all seal surfaces, in particular seal
surfaces of middle section, should not be collided or scored.

VI. Pump Maintenance

1. Coupling Maintenance
1) Check wearing conditions of elastic disc couplings.
2) Check alignment conditions between pump and primer before disassembly and make original
record.
2. Bearing Maintenance
1) Check if bearing tungsten has crack, worn-out, air hole or wearing status or not.
2) Check if shaft bearing is smooth without score or not.
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3) Check if shaft neck is located in the center of the lower bearing pad or not.
4) Thrust bearing pads should be contacted evenly, with at least two contact points every one cm2.
3. Balance Unit Maintenance
Working surfaces of balance disc, balance sleeve and thrust disc should be smooth without grooves.
If there is deep groove, it should be grinded provided that axial and radial clearances should be
maintained unchanged. If not, those parts should be replaced with new ones.
4. Stator Maintenance
1) Allowable eccentricity (runout) of all spigots of suction section, middle section and discharge
section is 0.025-0.04mm.
2) Allowable nonparallelism of all end faces of suction section, middle section and discharge
section is 0.04mm.
3) Maximum clearance of positioning spigot (φ425H7/js6) of stator is 0.08mm. If not, it must be
repaired.
4) Interfaces of each middle section should be smooth and clean, without radial optical groove.
Check by means of coloring, contact percentage should be more than 80% and circle edges
should be continuous without interruption.
5) Allowable eccentricity (runout) of inner circle spigot and outer circle spigot of guide vane
should be less than or equal to 0.025mm.
6) Allowable nonparallelism of guide vane end face should be less than or equal to 0.04mm.
7) Allowable eccentricity (runout) between fisrt stage and second stage seal ring spigot and its
inner circle should be less than or equal to 0.02-0.04mm. Radial runout of spigots of middle
sections is 0.025-0.04mm and parallelism is 0.02-0.04mm. Allowable round runout of end face
is 0.025-0.04mm. (See the figure below).

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 Middle Section
Check Seal Ring Runout
8) Allowable runout between inner circle and positioning circle of guide vane sleeve is 0.025mm.
9) Check O type seal rings, and replace those that are found with aging phenomenon.
5. Rotor Maintenance
1) After pump disassembly, customer should consider to replace the shaft if any of the following
cases occurs:
a) crack on shaft surface; b) especially at balance disc, crack will cause shaft fatigue cracking under
changeable load actions due to crack; c) there is deep groove on shaft surface due to high speed
water flow, especially at key grooves; d) shaft is bent seriously and although it is straightened
several times for operation, it is still bent. Runout at two shaft necks should be less than 0.025mm.
2) Check wearing status of impeller open ring. If it is not seriously worn, the wearing area can be
repaired by clamping the inner hole of impeller with special fixture on the machine, to make
allowable eccentricity (ruout) between impeller open ring and inner hole is 0.025mm.

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 Measuring Runout at Seal Ring Position
3) Static Balance of Impeller
In order to ensure stable operation of the rotor, the repaired impeller must be treated with static
balance. Allowable residual unbalance weight of the maximum diameter of the impeller is 1.1g.
After removing unbalance weight of the impeller, the thickness of its front and post cover plate
should be not less than 4mm. Cutting area should be smoothly transited with its disc. The newly
installed feed water pump may not be treated with dynamic balance because it has been
dynamically balanced by the manufacturer.
4) Trial Assembly of Rotor
a) Allowable runout error between impeller open ring and bearing is 0.04mm.
b) Allowable runout error between balance disc end face and bearing is 0.04mm.
c) Allowable runout error between bearing sleeves at two ends and bearing is 0.04mm.
d) Allowable dynamic balance error of the rotor is 60g-mm(nearest to 2μ).
It is not allowed to eliminate rotor runout by means of partial rubbing and packaging component
end faces. It is strictly forbidden to install gaskets between packaged assembled component end
faces to adjust center distance between impeller water openings.
5) Shaft Seal Maintenance
a) Seal packing box at suction side and discharge side should be treated with water test with

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 pressure above 8kg/cm2.
b) If wearing depth on external circle of the shaft sleeve is deeper than 1mm, the shaft sleeve
should be replaced with a new one.

VII. Pump Assembly

1. Preparations before Assembly

1) Total movement of pump is 80-1.5mm. It is measured as 4±0.5mm.
2) Position the anti-rotation pin of the guide vane properly, with suitable height.
2. Steps for Fixing Tension Bolts
Tension bolts should be fixed properly. Insufficient tension will cause leaking between splitting
surfaces. Too much tension will cause deformation of splitting surfaces of the stator. Wrench torque
of the pump is 3179N.m.
a) Pre-fasten of Tension Bolts
With a 3m long socket wrench, fasten all tension bolts in order symmetrically. The tension should
be not too much. It is suitable to polish and harden the threads and force bearing surfaces and make
torque reach 200N.m. Measure the “L” on end faces at suction section and discharge section and the
length deviation in four directions should be within 0.1mm. If it is out of tolerance, it can be
adjusted by fasten some tension bolts. See the figure below.
Discharge Section Suction Section

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After fastening, mark all 12 tension bolts and 24 nuts and gaskets with 1, 2, 3, 4, 5, 6, 7…..12.
Leave six mutually vertical tension bolts and loosen all other six tension bolts. And then fasten
those tension bolts with wrench (without socket) again, with a torque of 400N.m. And then loosen
those six unloosened tension bolts and fasten them again in the same way. Mark on the plane where
tension nuts are fastened at discharge side and circumference areas of nuts with “0” symmetrically.
b) Fasten Tension Bolts
As per sequence for pre-fixing, fasten all 12 nuts a round and make them parallel with the “0” mark.
Measure L length error in four directions, which should be less than ±0.1mm. If it is out of
tolerance, adjust it by fastening nuts in a small area.
3. Allowable runout error of balance sleeve end face is 0.05mm.
4. Assemble rotor components to make them in small installation position.
5. Re-assemble suction side, initial cover at discharge side, end cover, bearing body and lower
pads.
6. Install dial indicator on the position 30mm from inner side of two bearing pad center and at the
same time, place the lower pads to make them reach specified values and make same distance at
two sides of the bearing pad.
7. Bearing Assembly
1) Measure bearing pad clearance.
2) Measure bearing pad tension force.

VIII. Installation Explanation

Feed water pump foundation undertakes dynamic load and static load of the pump. Pay close
attention to rigidity of the foundation. Pump stool and foundation should be connected firmly.
Grouting quality must be ensured. Bottom of the pump stool should be inserted into the concrete
foundation firmly. Foundation frequency should be at least 20% higher than that of feed water pump
frequency.
1) Grout the foundation with cement and leave the positions for screw holes for pump stool and
motor stool as per drawings.
2) It is better to use “I” shape steel to make two frames. Check if there is any deviation between
motor centerline and pump centerline.
3) When centerline is ready, position the pump and motor.
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4) First align the pump horizontally and axially, with a standard of 0.03-0.05mm/m.
5) Adjust the motor as per above.
6) Align the pump with motor. It is recognized that pump and motor must be aligned under cold
conditions.
Face deviation less than 0.05mm.
Round deviation less than 0.08mm
During the alignment, gaskets for suction section, discharge section and pump stool should be
not more than three pieces respectively.
7) Weld wedge irons and padding irons onto the frames. Wedge irons should be not more than
three pieces.
8) Grout pump stool and motor stool twice. Pay attention to leave out the thread areas of the
anchor bolts.
9) Action force and force torque of water inlet pipeline and water outlet pipeline on pump can refer
to the data below:

Suction Pipeline Discharge Pipeline

Px (N) ±400 ±600
Py (N) ±320 ±650
Pz (N) ±250 ±500
Mx (N.m) ±400 ±500
My (N.m) ±450 ±500
Mz (N.m) ±300 ±400
The pipeline should not be too hard. Flexibility of the pipeline should be increased by means of
adding bellow, extensible joints and etc.
10) Slope of water inlet pipeline should be adverse with the flow direction to ensure that air in the
pipeline can be eliminated smoothly. If pipeline slope does not conform to the requirement
above, air exhaust points must be placed at the dead corners.
11) Clean and purge vessels and pipelines prior to pump operation.
12) Turn the rotor manually to avoid any blocking phenomenon after completing pump assembly.
13) Suction pipeline and discharge pipeline of lubrication system should be treated with seal test,
with respective seal test pressure of 0.15Mpa and 0.5Mpa.
14) Fasten the nuts for connecting water inlet and outlet sections with pump stool and then loose the
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 nut to leave a vertical clearance of 0.03-0.04mm. Fasten this nut when pump is warmed up
sufficiently.

IX. Startup and Operation of Pump

1. Pump Startup
1) Pump Warming
Reasonable pump warming is one of the important steps for pump startup. Pump can be warmed up
in this way: fill the pump through inlet with water from deaerator, and then discharge water with
pressure gauge inside the pump and finally drain off water at the bottom of suction section.
Pump warming requirement is:
a) Temperature difference between upper casing and lower casing is less than 15℃.
b) Temperature difference between upper casing and boiler feed water is less than 8℃ - 10℃.
c) Alignment deviation between pump coupling and motor coupling is less than 0.05mm.
The three requirements above should focus on specified alignment deviation of the coupling.
2) Check cooling water pressure and temperature rise (standard refers to above) and open all
cooling water pipeline.
3) Check water inlet temperature and pressure of feed water pump; water inlet pressure should be
not lower than 1.13 times of saturated pressure at this temperature.
4) Check if electrical activities of the pump unit are all completed, if all instruments are installed,
if oil is qualified under normal conditions, if oil pressure before bearing is in the range of 0.06 –
0.14Mpa and if cooling water and seal water is operated well.
5) Stop the feed water pump quickly after starting constant speed and record idle time.
6) If idle time is not less than 50s, the pump can be started normally.
2. Maintenance during Operation
1) Check water inlet temperature and pressure and ensure water inlet pressure is not less than 1.13
times of gasification pressure at this temperature.
2) Check water outlet pressure.
3) Check balance pressure (generally not 0.3Mpa higher than water inlet pressure)
4) Temperature of bearing oil return should be not more than 70℃.
5) Temperature difference between cooling water inlet and outlet should be not more than 10℃.
6) Pay attention to check oil level and oil quality in oil tank.
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7) Enhance management of feed water pump and record daily operation log carefully; establish
archive for periodic vibration measurement and abnormal vibration measurement; rotor
vibration at two bearing positions in vertical direction should be not more than 0.06mm.
3. Shutdown
1) Close pump outlet gate valve, provided that minimum flow system is ensured to be workable
under minimum feed water conditions.
2) Stop the motor to observe if speed is decreased slowly; feed water pump rotor should not stop
suddenly.
3) Close auxiliary oil pump when unit rotor stops running.

X. Trouble Analysis and Solution

Trouble Phenomenon Causes Solutions

1. No water comes out 1. Water inlet pressure is lower than gasification Check and take actions to
after running pump, no pressure at this temperature. improve water inlet pressure.
indication on pressure 2. Pump rotation is wrong. Correct rotation.
gauge
1 and 2 same as item above. Check and eliminate.
3. Filter gauze for impeller passage and water Check pump and water inlet
inlet pipeline is blocked. pipeline, eliminate all air, clean
2. No water comes out
4. Air in water inlet pipeline and pump is not or replace filter gauze,
and pressure is
completely eliminated. disassemble and check, ensure
insufficient during
5. Static and dynamic clearance friction exceeds drawing requirements and repair.
operation
allowable value.
6. Clearance of balance unit exceeds specified
value.
1. Working flow of pump exceeds specified Check with flow meter.
3. Motor overload value. Re-align and re-flexible.
2. Static and dynamic parts are rubbing.
1. Misalignment between pump and motor.
2. Static balance of impeller is out of tolerance.
4. Pump vibration
3. Dynamic balance of rotor is out of tolerance.
Vibration peak value is
4. Dynamic and static parts are rubbing.
increased gradually,
5. Pump movement due to pipeline action.
and never disappears.

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Trouble Phenomenon Causes Solutions

6. Horizontal vibration 1. Misalignment between pump and motor or Verify coupling center.
of side bearing pad of other drivers. Check rubbing status of bearing
coupling is big. 2. Bearing pad rubbing. pad.
1. Radial clearance of balance unit is too small. Increase radial clearance and
2. Pump gasification. balance force.
Avoid gasification, increase
7. Balance mechanism
hardness of balance disc and
is worn seriously.
balance sleeve, adjust rings and
change axial clearance at balance
disc area.
1. Tension bolts are not fastened. Stop pump and fasten after
8. Seal leakage at 2. Interfacing surfaces are damaged. cooling.
sections and other areas 3. Water temperature drops too quickly. Re-process and scrape.
4. O type ring is aging. Replace with new ones.
1. Seal is not installed properly. Replace seals and replace seal
2. Shaft sleeve and packing are worn seriously; and shaft sleeve if necessary.
packing is not installed properly.
9. Seal packing leakage
3. Vibration is caused due to rotor unbalance,
bearing or seal is worn seriously and thus cause
rotor eccentricity.
1. Alignment between pump and motor does not 1. Re-align under cold
conform to requirement. conditions.
10. Pump bearing is not
2. Bearing pad clearance is too big or too small. 2. Adjust bearing pad clearance
working properly.
3. Lube oil quality does not conform to as per drawing requirement.
requirement. 3. Replace lube oil.
1. Suction pipeline and discharge pipeline are not 1. Enforce pipeline.
11. Pipeline vibration enforced. 2. Improve empty discharge unit.
2. Empty discharge of feed water pump is small.
1. Empty discharge of feed water pump is less 1. Increase empty discharge of
than allowable value. pump.
12. Pump gasification 2. Main machine is out of load. 2. Clean or replace filter gauze.
3. Differential pressure of inlet filter gauze is too
big.

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