PUMP Manual Erection Kalwakur

Spiral casing pumps -
KALWAKUR, C-01-987226-085
5 ERECTION WORK and TRANSPORT

5.1 General
This chapter describes certain steps for transport, storage and installation
of the pump, which may be the responsibility of the operator.
The description does not include preliminary works assembly carried out
by ANDRITZ.
5.2 Safety instructions
Do not disregard the safety regulations.

If the safety regulations are disregarded, this may cause a risk to life
and limb and damage to the machine or its components.
DANGER
All safety instructions in this section must be strictly observed!
General safety All applicable accident prevention regulations must be observed.

instructions
Do not exceed permissible crane loads and weights on lifting gear and
ropes/shackles. Secure loads to prevent them from falling.
Do not step or walk below suspended loads! Standing below suspended
loads can have fatal consequences and thus is strictly forbidden!
All general safety measures applicable to welding equipment and work
must be observed. The safety measures must take account of the
demands on this special welding equipment.
Qualification of Transport and unloading of the machine are to be carried out by

personnel personnel specially familiar with such work.
assigned
Personnel assigned to operate lifting gear and conveying equipment must
have the required national qualifications.
Welders carrying out welding work must have the required national
qualifications.
Erection work may only be carried out by trained, skilled personnel.
Personal The following protective equipment must be worn when carrying out
protective apparel installation and transport work:
• Hard hat
• Protective gloves
• Safety shoes
• Eye protection
Rev. 0, 2010.03.08 ERECTION WORK and TRANSPORT Chapter 5 , Page 1 of 50

GRZ-3464387-v1-Erection.FM
KALWAKUR, C-01-987226-085
5.3 Transportation
During transport or loading/unloading there is a risk to life and limb

from falling machine components and also a danger that machine
components may be damaged.
DANGER
Do not lift machine and transport crates except at the points marked
for lifting by crane or forklift!
If the entire component is lifted and there are several different types
of lifting lug available, personnel should only use suitable lugs
(according to the transport sketch) for the work in hand.
Do not step or walk below suspended loads!
Delivery Machine components and auxiliary materials are packed in crates.

Transport sizes and weights are stated in the shipping documents.
Largest supply weights:
.../TECHNICAL DATA
Acceptance • Check whether supply is complete (against shipping documents and

packing lists) and in perfect condition.
• In the event of transport damage or short supply, do not accept goods,
but notify forwarder and the ANDRITZ shipping department
accordingly.
• If there is a hidden loss or defect, notify the forwarder and the
ANDRITZ shipping department within two weeks of receiving the
goods.
5.4 Storage
The following instructions must be observed if the system is not to be
installed immediately:
• Please inform the ANDRITZ shipping department.
• Provide weather protection for stored machine components. In
particular, avoid wide variations in temperature and ensure that the
equipment is kept clean.
• Small items should be protected against damage and unauthorized
withdrawal by storing in a lockable room.
• Packaging should not be removed until field installation work begins.

KALWAKUR, C-01-987226-085
5.5 General
General
Disregarding the sequence plan and the installation instructions

may result in hazardous situations causing a danger to life and limb,
as well as machine damage.
WARNING
The sequence of erection work is important and must be strictly
observed!
Completion of the various steps must be documented in the certificate of

completion of erection work.
The sequence of erection work is shown in step-by-step tables. The

individual activities are numbered according to the sequence in which
they are to be performed.
Required The following supplementary documentation must be available at the

documentation at beginning of installation work:
installation site
• Foundation and arrangement drawing
• Assembly drawings
• Documentation on electrical, measuring and control equipment
• Packing lists for each individual consignment
Preparations Foundation
Foundation prepared according to the ANDRITZ foundation plan.
The following preparations have to be made to the foundation prior to
erecting the equipment:
• Mark axes and elevations on the foundation.
• Check the workmanship of the foundation before beginning erection
work.
Preservation
Corrodible machine parts are protected with "Cortec VCI 369"
preservative grease.
The preservative grease need not be removed.

KALWAKUR, C-01-987226-085
Welding
Risk of electric shock when performing welding work.

When using electric welding equipment, check the following:
DANGER • The welding equipment must be installed and earthed according
to local standards.
• Personnel must be isolated against earthing and the workpiece.
Live parts or electrodes must not be touched with bare hands or
when protective apparel is wet.
Eyes and hands may be injured when performing welding work.

UV and IR light can cause eye and skin burns.
DANGER Protect eyes and body. Wear protective hard hat with filter unit and
protective garments.
Other workers in the vicinity must be protected by protective
walls/curtains.

KALWAKUR, C-01-987226-085
5.6 Erection of the parts cast in concrete
Parts may fall during transport on site.

Do not lift machine parts except at the points marked for lifting by
crane or forklift!
DANGER
Do not step or walk below suspended loads!
Parts of the body may be trapped or crushed during installation

work.
Do not place your hand below suspended loads.
DANGER
Wear your personal protective apparel.
5.6.1 Drawings
Draft tube liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0HP 109029

Spiral casing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0HP 108932, 1-3
Pit liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0HP109194, 1-2
Erection of draft tube liner . . . . . . . . . . . . . . . . . . . . . . . . 0HP 109026
5.6.2 Concrete casting regulations
Minimum quality according to EN206-1

Compression strength category . . . . . . . . . . . . . . . . . . . . . . . . C20/25
Compression strength (cube 150x150x150) . . . . . . . . . . . . 25 N/mm2
Maximum concrete casting speed . . . . . . . . . . . . . . . . . . . . . . 0.5m/h
Maximum green concrete height during concrete casting . . . . . 0.2 m
5.6.3 Weights
Draft tube liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,600 kg

Spiral casing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,200 kg
Pit liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,300 kg

KALWAKUR, C-01-987226-085
5.6.4 Erection of the draft tube liner
Erection work Relevant drawings:

Draft tube liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0HP 109026
Weights:
Draft tube liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,600 kg
The draft tube liner is to be erected according to the following table:
Step Activity
1 Attach supporting spindles (27a) to the draft tube liner (27).
2 Suspend draft tube liner from the crane with suitable ropes at
the suspension lugs (27.b).
3 Raise draft tube liner into the mounting position and place on
the foundation plates (27c).
4 Attach turnbuckles (27d) between anchor plates (27e) and
draft tube liner and weld on.
5 Align draft tube with the supporting spindles (27a) and the
turnbuckles (27d) according to the drawings mentioned.
6 Mount drainage pipe (27f).
7 Weld on supports (27g) to secure in mounting position.
8 Inspect and record mounting position and shape of flange
(27h).
9 Mount the shuttering as shown in the foundation drawing.
10 Mount the foundation plates for the spiral casing.
11 Cast draft tube liner in concrete according to the foundation
drawings and Section 5.6.2.
Tab. 5-1 Erection of the draft tube liner

KALWAKUR, C-01-987226-085
27h X 27
27b
27d
27e
27b
27a
27g 27c
27f
1
27e 27g 27c
View X
27g
27d
27d
27g
Fig. 5-1 Positioning the draft tube liner

KALWAKUR, C-01-987226-085
5.6.5 Erection of the spiral casing
Relevant drawings:
Spiral casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0HP 108932
Weights:
Spiral casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,200 kg
Welding of the The spiral casing is delivered in two parts and welded together on site.
spiral casing
Attached document:
Inspection plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4HP 108314
Fig. 5-2 Welding of the spiral casing

KALWAKUR, C-01-987226-085
Erection work The spiral casing is to be mounted according to the following table:
Step Activity
1 Insert threaded bolt (1a) and levelling spindles (1b).
2 Attach supporting spindles(1c) to the spiral casing (1).
3 Raise spiral casing into the mounting position and place on
the foundation plates (1d).
4 Align spiral casing with the supporting spindles (12) and the
levelling spindles (1b) according to the drawings mentioned
and bolt together (1a).
5 Inspect and record the installation position of the spiral casing.
Tab. 5-2 Erection of the spiral casing
1b
1c 1c
1a
1d 1d
Fig. 5-3 Erection of the spiral casing

KALWAKUR, C-01-987226-085
5.6.6 Pressure test - spiral casing
Relevant drawings:
Pressure test - spiral casing . . . . . . . . . . . . . . . . . . . . . . 1HP 109142
Press-on cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3HP 109144
The pressure test for the spiral casing is to be conducted according to the
following table:
Step Activity
1 Mount pressure testing device (1e) and test head (1f) with the
required seals.
2 Remove screw plug from the vent hole (1g) and connect up
pressure source to the connection (1h) at the test head.
3 Fill spiral casing with water and close vent hole (17).
4 Apply the necessary test pressure and pressure-test the spiral
casing against the test data.
5 The pressure testing device remains mounted during
subsequent casting of the spiral casing in concrete and the
spiral casing is filled with water without pressure.
Tab. 5-3 Pressure test - spiral casing
1e 1g
1f
1h
Fig. 5-4 Pressure test - spiral casing
Damage to machine due to excess pressure.

The test pressure must not exceed the pressures stated.
DANGER
Test data Test pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21.3 bar

Holding time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 min
Weights Pressure testing device, . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,550 kg

Test head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,350 kg

KALWAKUR, C-01-987226-085
5.6.7 Erection of the pit liner
Erection work Relevant drawings:

Pit liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0HP 109194
Layout and foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701624033
Weights:
Pit liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,300 kg
The pit liner is to be erected according to the following table:
Step Activity
1 Suspend pit liner (4) from the crane using appropriate lifting
gear and ropes.
2 Raise pit liner into the mounting position and place on the
spiral casing (1).
3 Align pit liner according to the drawings mentioned and weld
to the spiral casing (4a).
4 Mounting the shuttering and pipework and making the cutouts.
5 Cast spiral casing (1) in concrete according to the foundation
drawings and Section 5.6.2.
Tab. 5-4 Erection of the pit liner
Casting the pit

liner in concrete
Step Activity
6 Mount the shuttering as shown in the foundation drawing.
7 Mount the foundation plates for the motor according to the
manufacturer's instructions.
8 Cast pit liner in concrete according to the foundation drawings
and Section 5.6.2 (see Fig. 5-6).
9 After the concrete has set, all bracings and the pressure
testing device at the spiral casing must be removed.
Tab. 5-5 Casting the pit liner in concrete

KALWAKUR, C-01-987226-085
4a
27
Fig. 5-5 Mounting the pit liner and concreting the spiral casing

KALWAKUR, C-01-987226-085
27
Fig. 5-6 Concreting the pit liner and the motor foundations

KALWAKUR, C-01-987226-085
5.6.8 Erection of the guide vane mechanism
Relevant drawings:
Guide vane mechanism. . . . . . . . . . . . . . . . . . . . . . .0HP 109186, 1-3
Sequence of erection work . . . . . . . . . . . . . . . . . . . . . . . . 701624041
Bottom guide vane ring (6) . . . . . . . . . . . . . . . . . . . . . . . OHP 109125
Top guide vane ring (7) . . . . . . . . . . . . . . . . . . . . . . . . . . OHP 109131
Guide vane (5). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OHP 108278
Operating ring (18) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OHP 108980
Clamping ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2HP 109135
Straps for the operating ring . . . . . . . . . . . . . . . . . . . . . . 2HP 109071
Weights:
Bottom guide vane ring (6) . . . . . . . . . . . . . . . . . . . . . . . . . . 4,200 kg
Top guide vane ring (7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,040 kg
Guide vanes (5) . . . . . . . . . . . . . . . . . . 24 vanes weighing 90 kg each
Operating ring (19) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,650 kg
Clamping ring (28) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 kg
Straps for the operating ring . . . . . . . . . 2 rings each weighing 108 kg

KALWAKUR, C-01-987226-085
Inspection of the Before mounting the guide vane mechanism, the contact surfaces for the
spiral casing guide vane rings and the position of the draft tube liner, Fig. 5-7, must be
inspected and recorded.
Tolerances according to drawing:
Spiral casing. . . . . . . . . . . . . . . . . . . . . 0HP 108932, page 1, detail Z
Fig. 5-7 Inspection of the spiral casing

KALWAKUR, C-01-987226-085
Bottom guide vane

ring
Step Activity
1 Mount connecting flanges (29,30) to the draft tube liner (27)
loosely at the bottom guide vane ring (6). Insert all seals.
2 Suspend bottom guide vane ring (6) from the crane by looping
rope through the bores in the guide vanes (6a) and lift into the
mounting position.
3 Lift guide vanes (5) into place.
Tab. 5-6 Erection of guide vane mechanism
5 5
6a
6
27
29,30
Fig. 5-8 Erection of guide vane mechanism

KALWAKUR, C-01-987226-085
Spacer plates for the impeller

6
30
29
Fig. 5-9 Erection of guide vane mechanism - connection to draft tube liner
Step Activity
4 Suspend top guide vane ring (7) from the crane and lift into the
mounting position.
5 Centre the two guide vane rings using the guide vane bores
and bolt to the spiral casing.
CAUTION: The guide vane bores in the top and bottom

guide vane rings must be exactly aligned!
6 Secure the guide vane ring in position in relation to the spiral
casing using taper pins.
Drill the taper pins as shown in the guide vane assembly

drawing and ream.

KALWAKUR, C-01-987226-085
17 18
Fig. 5-10 Erection of guide vane mechanism
Step Activity
7 Mount guide vane bearing assemblies according to Fig. 5-11.
8 Check gap between the guide vanes (5) and the protective
walls (1a) of the spiral casing.
9 Check mobility of the guide vanes and bearing play at the
guide vane bearing assembly.
10 Suspend operating ring (18) from the crane and lift into the
mounting position.
11 Place the balls in the bearing (19) and fill with mineral
oil-based roller bearing grease. (e.g. Mobilux EP2)
12 Mount clamping ring (17).
Tightening torques for the clamping ring bolts (17a):

• Mv= 30 Nm

KALWAKUR, C-01-987226-085
18 19 17 17a
1a
Fig. 5-11 Erection of guide vane mechanism - guide vane bearing assembly

KALWAKUR, C-01-987226-085
Split ring and Relevant drawings:

impeller
Lifting device ( . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .701665894)
Step Activity
13 Install split ring (4) in the bottom guide vane ring (6).
14 Lift the impeller (2) into position and place on the spacer
plates.
see Fig. 5-9

15 Check the gap between the impeller and the split ring.
S1 = 1mm
Tab. 5-9 Split ring and impeller
4 6
2
4
s1
Measuring bore for the impeller clearance
Fig. 5-12 Split ring and impeller

KALWAKUR, C-01-987226-085
Pump cover
Step Activity
16 Install pump cover (37).
17 Check the gap between the impeller and the pump cover.
S2 = 1mm
Tab. 5-10 Pump cover
Measuring bore for the impeller clearance

37
s2
37 2
Fig. 5-13 Pump cover
Levers and links
Step Activity
18 Mount guide vane levers (12) and guide vane links (15,16).
CAUTION: Rigid and buckling links must be mounted

alternately according to the assembly drawing for the guide
vane mechanism.
19 Insert taper pins (12a) and bolt guide vane levers together.
20 Check closed position of guide vane mechanism.
Tab. 5-11 Installation of guide vane mechanism - guide vane levers and guide vane links

KALWAKUR, C-01-987226-085
15,16 12 12a
Fig. 5-14 Installation of guide vane mechanism - guide vane levers and guide vane links

KALWAKUR, C-01-987226-085
Servo-cylinder
Step Activity
21 Mount servo-cylinder (12).
22 Set open and closed position of the guide vane mechanism by
machining the fitting plate (33) and the stop ring (36)
accordingly.
Tab. 5-12 Installation of guide vane mechanism - servo-cylinder
36 31 33
33
36
Fig. 5-15 Installation of guide vane mechanism - servo-cylinder

KALWAKUR, C-01-987226-085
Guide vane
locking plate
Step Activity
23 Adjust guide vane locking plate (21) to the operating ring.
Tab. 5-13 Mounting of guide vane mechanism - locking plate
21b
21
21a
Adapt to fit
Fig. 5-16 Mounting of guide vane mechanism - locking plate

KALWAKUR, C-01-987226-085
Sensors
Step Activity
24 Mount and set sensors for guide vane locking plate.
21a: Locking plate mounted / guide vane mechanism locked
21b: Locking plate removed / guide vane mechanism released

25 Mount and adjust sensors (21c) for guide vane mechanism
closed position.
Mount sensors (21c) at each lever fitted with a buckling link

(21d).
26 Mount scale (23), indicator (25) and angle of rotation
transmitter (23a).
The position of the scale and of the angle of rotation

transmitter are shown in the assembly drawing for the guide
vane mechanism.
Tab. 5-14 Mounting of guide vane mechanism - sensors
21d
21c
Fig. 5-17 Mounting of guide vane mechanism - sensors

KALWAKUR, C-01-987226-085
23a
23
25
26
Fig. 5-18 Guide vane mechanism - scale and angle of rotation transmitter

KALWAKUR, C-01-987226-085
5.7 Installation of pump shaft
Relevant drawings:
Guide bearing and shaft seal . . . . . . . . . . . . . . . . . . . . . . 0HP 109357
Pump shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0HP 109537
Lifting device for the shaft . . . . . . . . . . . . . . . . . . . . . . . . . 701665894
Mounting the impeller and the shaft . . . . . . . . . . . . . . . . . . 701624042
Weights:
Pump shaft (50) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,830 kg
Lifting device for the shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 kg

KALWAKUR, C-01-987226-085
Corundum coating The torque is transferred from the impeller to the shaft by adherence and
on the pump shaft pre-tensioned bolts. In order to increase the friction coefficient, the contact
surface on the flange of the pump shaft is coated with corundum.
Step Activity
1 Clean and degrease contact surfaces at the impeller and the
shaft
2 Use a spray gun with a nozzle diameter of 1.8 - 2 mm to apply
the corundum coating.
3 Prepare a mixture of three parts zapon varnish (nitrocellulose
lacquer) to one part corundum powder (silicon carbide, grain
size 160 - 180 microns) suitable for spraying.
4 Test the mixture by spraying it very thinly onto an upright,
bright-finish metal plate.
Keep modifying the mixing proportions and spray method until

the corundum powder grains are lying evenly beside one
another; at least 60% of the surface must be covered by the
corundum powder.
Avoid accumulations of powder grains and uncoated

surface areas!
5 Cover the bore holes (a) in the coupling bolts, the centering
surface (b) and the O-ring grooves (c).
6 Spray the supporting ring surface (x) at the flange of the pump
shaft.
The coating should be sprayed on in one single process.

Avoid cross-coating. The spraying distance should be 250 -
300 mm. Air pressure 1.8 - 2 bar.
7 Do not attach the shaft to the impeller until the coating has
completely hardened.
The hardening time is approximately three hours at a room

temperature of 20° C.
Tab. 5-15 Corundum coating on the pump shaft

KALWAKUR, C-01-987226-085
c
a x
Fig. 5-19 Corundum coating on the pump shaft

KALWAKUR, C-01-987226-085
Bolted connection The shaft (50) and the impeller (2) are bolted together using anti-fatigue
betweens shaft bolts and SUPERBOLT mechanical tensioners.
and impeller
Step Activity
1 Screw in anti-fatigue bolts (55).
2 Suspend shaft (50) from the crane using the lifting device and
lift into the mounting position.
3 Mount SUPERBOLT mechanical tensioners (55a).
4 Tighten mechanical tensioners according to SUPERBOLT
instructions and the pre-tensioning values stated.
see .../SUPPLIER DOCUMENTATION/SUPERBOLT

Tab. 5-16 Bolted connection betweens shaft and impeller
Pre-tensioning force for Superbolt M65x5 . . . . . . . . . . . . . . . . .875 kN

Tensioning torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Nm
Fig. 5-20 Lifting device

KALWAKUR, C-01-987226-085
50
55a
55 2
Fig. 5-21 Bolted connection betweens shaft and impeller

KALWAKUR, C-01-987226-085
Shaft components
Step Activity
1 Secure cover (59) with cheese head screws and sealing rings.
2 Lift 2-part shaft protection sleeve (56) into the mounting
position and clamp onto the shaft using using the clamping
rings (57,58).
Tab. 5-17 Erection of shaft components
57 58 56
59
50
Fig. 5-22 Erection of shaft components

KALWAKUR, C-01-987226-085
5.8 Mounting the maintenance seal
Relevant drawings:
Step Activity
1 Lower sealing ring 1 (61) and sealing ring 2 (60) onto the top
guide vane ring (7) with the maintenance seal (63) in place
and bolt together (60a).
2 Lower support ring (62) onto the sealing ring 2 (60) and bolt
together (62a).
Tab. 5-18 Mounting the maintenance seal
62a 56
62
60a
63
60
61
Fig. 5-23 Mounting the maintenance seal

KALWAKUR, C-01-987226-085
5.9 Mounting the guide bearing
Relevant drawings:
Guide bearing and shaft seal. . . . . . . . . . . . . . . . . . . . . . 0HP 109357
Bearing support (66) . . . . . . . . . . . . . . . . . . . . . . . . . . . . OHP 109270
Guide bearing . . . . . . . . . . . . . . . . . . . . . . . . .V/0/231135 (MICHELL)
Weights:
Bearing support (66) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700 kg
Guide bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1780 kg
Bearing support
Step Activity
1 Lower the bearing support (66) onto the spiral casing (1) and
bolt together.
Tab. 5-19 Mounting the bearing support
66
Fig. 5-24 Mounting the bearing support

KALWAKUR, C-01-987226-085
Guide bearing
Step Activity
1 Lower the bearing housing (66a) onto the bearing support (66)
and bolt together.
2 A description of further steps for installation of the guide
bearing (67) can be found in the drawings and installation
instructions provided by the bearing manufacturer.
see .../SUPPLIER DOCUMENTATION/MICHELL
Tab. 5-20 Mounting the guide bearing
The following illustrations provide a rough overview of the sequence of

assembly:
66a
Fig. 5-25 Mounting the guide bearing, Step 1

KALWAKUR, C-01-987226-085
67

KALWAKUR, C-01-987226-085
5.10 Mounting the combined thrust and guide bearing
Relevant drawings:
Bearing and brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0HP 109358
Bearing support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0HP 109124
Thrust bearing . . . . . . . . . . . . . . . . . . . . . . .MV/0/231151 (MICHELL)
Weights:
Bearing support (73). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,890 kg

KALWAKUR, C-01-987226-085
Bearing support
Step Activity
1 Screw in adjusting screws (73a) and lift the bearing support
(73) onto the pit liner (4).
2 Set the vertical spacing to the shaft (50) according to the
assembly drawings using the adjusting screws (73a).
3 Measure spacing between bearing support (73) and pit liner
(4) and machine the fitting plates (74).
4 Raise bearing support, insert fitting plates (74), and lower the
bearing support onto the fitting plates.
5 Remove adjusting screws (73a) and centre the bearing
support in line with the impeller axis.
6 Secure the bearing support in position with taper pins (73b).
Drill the taper pins as shown in the assembly drawing and

ream.
Tab. 5-21 Mounting the bearing support
50 73
73a 73b 73a
73
74
4 74
Fig. 5-29 Mounting the bearing support

KALWAKUR, C-01-987226-085
Thrust and guide

bearing
Step Activity
1 A description of how to install the bearing (75) can be
found in the drawings and installation instructions
provided by the bearing manufacturer.
see .../SUPPLIER DOCUMENTATION/MICHELL
Tab. 5-22 Mounting the thrust and guide bearing
75
Fig. 5-30 Mounting the thrust and guide bearing

KALWAKUR, C-01-987226-085
5.11 Coupling between shaft and motor
Relevant drawings:
Bearing and brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0HP 109358
Lapped flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2HP 109286
Connection between motor shaft and pump shaft . . . . . . 2HP 108998
Lifting device ( . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .701665894)
Weights:
Lapped flange (86) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,164 kg
Mounting the
lapped flange
Step Activity
1 Insert fitting key (86a) into the shaft (50) and bolt together.
2 Lower lapped flange (86) onto the shaft.
Tab. 5-23 Mounting the lapped flange
50
86
86a
50
Fig. 5-31 Mounting the lapped flange

KALWAKUR, C-01-987226-085
Corundum coating The torque is transferred from the motor to the lapped flange by
of lapped flange adherence and pre-tensioned bolts. In order to increase the friction
coefficient, the contact surface on the lapped flange of the pump shaft is
coated with corundum.
Step Activity
1 Clean and degrease contact surfaces at the lapped flange and
the motor.
2 Use a spray gun with a nozzle diameter of 1.8 - 2 mm to apply
the corundum coating.
3 Prepare a mixture of three parts zapon varnish (nitrocellulose
lacquer) to one part corundum powder (silicon carbide, grain
size 160 - 180 microns) suitable for spraying.
4 Test the mixture by spraying it very thinly onto an upright,
bright-finish metal plate.
Keep modifying the mixing proportions and spray method until

the corundum powder grains are lying evenly beside one
another; at least 60% of the surface must be covered by the
corundum powder.
Avoid accumulations of powder grains and uncoated

surface areas!
5 Cover the bore holes (a) at the lapped flange and the
centering surface (b).
6 Spray the supporting ring surface (x) at the lapped flange of
the pump shaft.
The coating should be sprayed on in one single process.

Avoid cross-coating. The spraying distance should be 250 -
300 mm. Air pressure 1.8 - 2 bar.
7 Do not assembly the lapped flange until the coating has
completely hardened.
The hardening time is approximately three hours at a room

temperature of 20° C.
Tab. 5-24 Corundum coating on the pump shaft

KALWAKUR, C-01-987226-085
Fig. 5-32 Corundum coating of lapped flange

KALWAKUR, C-01-987226-085
Setting the loose

flange
Step Activity
1 Measure and record space (x) between shaft surface (50) and
surface of loose flange (86).
2 Use a lathe to turn the shoulder (Y) on the plate (87)
according to the drawing.
Y = X +0.15/+0.05
3 Bolt the plate (87) to the pump shaft (87a).
Tightening torques for the bolts (87a):

• Mv= 1,450 Nm
Tab. 5-25 Setting the loose flange
87a
87
86
50
Fig. 5-33 Setting the loose flange

KALWAKUR, C-01-987226-085
Mounting the A description of how to install the motor can be found in the
motor drawings and installation instructions provided by the motor
manufacturer.
see .../SUPPLIER DOCUMENTATION/ABB
Bolted connection The shaft (50) and the motor (90) are bolted together using anti-fatigue
between shaft and bolts and SUPERBOLT mechanical tensioners.
motor
Step Activity
1 Mount anti-fatigue bolts (88) with nuts (89) and mechanical
tensioners (88a).
2 Tighten mechanical tensioners according to SUPERBOLT
instructions and the pre-tensioning values stated.
see .../SUPPLIER DOCUMENTATION/SUPERBOLT

Tab. 5-26 Bolted connection between shaft and motor
(M48x5)
Bolt pre-tensioning force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700 kN
Tensioning torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Nm
90 89
88
88a
50
Fig. 5-34 Bolted connection between shaft and motor

KALWAKUR, C-01-987226-085
Brake
Step Activity
1 Mount brake (94), mounting plate (93) and brake disc (95),
then set in position.
The brake (94) is installed according to the instructions

provided by the brake manufacturer.
see .../SUPPLIER DOCUMENTATION/VARIMAX
Tightening torques of the bolts (93a) for the mounting
plate:
• M24: Mv= 680 Nm

Tightening torques of the bolts (94a) for the brake:
• M24: Mv= 680 Nm

2 Move the brake disc (95) into the correct position and clamp
onto the shaft with the bolts (95a).
Tightening torques for the bolts (95a):

• M24: Mv= 680 Nm
3 Drill the taper pins (95b, 93b) as shown in the assembly
drawing and ream.
Tab. 5-27 Mounting the brake

KALWAKUR, C-01-987226-085
95 95a 94 93
93b
95b
93a
94a
Fig. 5-35 Brake - Step 1
95 94 93
93b
95a 95b 94a 93a
Fig. 5-36 Brake - Step 2

KALWAKUR, C-01-987226-085
5.12 Mounting the mechanical seal
Relevant drawings:
Mechanical seal, 510mm . . . . . . . . . . . . . D/65388.01B (John Crane)
Erection work The mechanical seal is mounted after installation and setting of the shaft
bearings.
The mechanical seal is mounted according to the instructions

provided by the seal manufacturer:
see .../SUPPLIER DOCUMENTATION/JOHN CRANE
After pre-tensioning the spring, remove the tool (1).
Fig. 5-37 Mounting the mechanical seal

KALWAKUR, C-01-987226-085
5.13 Connections
Pipework All connections and connecting dimensions at the pump are shown in the
diagrams and assembly drawings.
• Cooling water pipes for the bearings
• Sealing water lines for the shaft seals
• Jacking station for the thrust bearing
• Relieving line from the pump cover to the suction pipe
• Seepage water pipes from the shaft seal
• Compressed air line for the maintenance seal
Errors in the installation of pipework and hoses may result in risks

to life and limb and in damage to the machine.
Mount all pipes stress-free and free of vibration.
DANGER
The pipework must be mounted such that it does not stress the
machine during operation (e.g. by heat expansion of the pipes).
Instruments • Control units and instruments must be installed according to the

control documentation provided by ANDRITZ.
Electrical • Complete electrical installation work must be performed according to

equipment electrical documentation provided by ANDRITZ.
Other work Other work to be completed:

• Clean the machine.
• Mount platforms and covers.
• Touch up paintwork

KALWAKUR, C-01-987226-085
5.14 Cold test (preparation for initial start-up)
Prerequisites The following utilities must be available:

• Electric power
• Compressed air
• Water
Hydraulics
• First filling of the hydraulic plant
Machine may be damaged if the wrong oil grades are used.

Only use oil with the properties listed in the lubrication schedules!
DANGER
Cold test The cold test is to be carried out in the presence of an authorized
representative of the customer.
Final inspection The customer and the site manager shall conduct a final inspection of the
installation after completion of the cold tests.
Certificates The following certificates are issued after completion of the ISO cold test:
• Cold test certificate
• Certificate of completion of erection work

KALWAKUR, C-01-987226-085


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Spiral casing pumps -

5 ERECTION WORK and TRANSPORT

5.2 Safety instructions

Do not disregard the safety regulations.

General safety All applicable accident prevention regulations must be observed.

Qualification of Transport and unloading of the machine are to be carried out by

Rev. 0, 2010.03.08 ERECTION WORK and TRANSPORT Chapter 5 , Page 1 of 50

During transport or loading/unloading there is a risk to life and limb

Delivery Machine components and auxiliary materials are packed in crates.

Acceptance • Check whether supply is complete (against shipping documents and

Rev. 0, 2010.03.08 ERECTION WORK and TRANSPORT Chapter 5 , Page 2 of 50

Disregarding the sequence plan and the installation instructions

Completion of the various steps must be documented in the certificate of

The sequence of erection work is shown in step-by-step tables. The

Required The following supplementary documentation must be available at the

Rev. 0, 2010.03.08 ERECTION WORK and TRANSPORT Chapter 5 , Page 3 of 50

Risk of electric shock when performing welding work.

Eyes and hands may be injured when performing welding work.

Rev. 0, 2010.03.08 ERECTION WORK and TRANSPORT Chapter 5 , Page 4 of 50

5.6 Erection of the parts cast in concrete

Parts may fall during transport on site.

Parts of the body may be trapped or crushed during installation

Draft tube liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0HP 109029

5.6.2 Concrete casting regulations

Minimum quality according to EN206-1

Draft tube liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,600 kg

Rev. 0, 2010.03.08 ERECTION WORK and TRANSPORT Chapter 5 , Page 5 of 50

5.6.4 Erection of the draft tube liner

Erection work Relevant drawings:

Rev. 0, 2010.03.08 ERECTION WORK and TRANSPORT Chapter 5 , Page 6 of 50

Fig. 5-1 Positioning the draft tube liner

Rev. 0, 2010.03.08 ERECTION WORK and TRANSPORT Chapter 5 , Page 7 of 50

5.6.5 Erection of the spiral casing

Fig. 5-2 Welding of the spiral casing

Rev. 0, 2010.03.08 ERECTION WORK and TRANSPORT Chapter 5 , Page 8 of 50

Fig. 5-3 Erection of the spiral casing

Rev. 0, 2010.03.08 ERECTION WORK and TRANSPORT Chapter 5 , Page 9 of 50

5.6.6 Pressure test - spiral casing

Fig. 5-4 Pressure test - spiral casing

Damage to machine due to excess pressure.

Test data Test pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21.3 bar

Weights Pressure testing device, . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,550 kg

Rev. 0, 2010.03.08 ERECTION WORK and TRANSPORT Chapter 5 , Page 10 of 50

5.6.7 Erection of the pit liner

Erection work Relevant drawings:

Casting the pit

Rev. 0, 2010.03.08 ERECTION WORK and TRANSPORT Chapter 5 , Page 11 of 50

Rev. 0, 2010.03.08 ERECTION WORK and TRANSPORT Chapter 5 , Page 12 of 50

Rev. 0, 2010.03.08 ERECTION WORK and TRANSPORT Chapter 5 , Page 13 of 50

5.6.8 Erection of the guide vane mechanism

Rev. 0, 2010.03.08 ERECTION WORK and TRANSPORT Chapter 5 , Page 14 of 50

Fig. 5-7 Inspection of the spiral casing

Rev. 0, 2010.03.08 ERECTION WORK and TRANSPORT Chapter 5 , Page 15 of 50

Bottom guide vane

Fig. 5-8 Erection of guide vane mechanism

Rev. 0, 2010.03.08 ERECTION WORK and TRANSPORT Chapter 5 , Page 16 of 50

Spacer plates for the impeller

CAUTION: The guide vane bores in the top and bottom

Drill the taper pins as shown in the guide vane assembly

Rev. 0, 2010.03.08 ERECTION WORK and TRANSPORT Chapter 5 , Page 17 of 50

Fig. 5-10 Erection of guide vane mechanism

Tightening torques for the clamping ring bolts (17a):

Rev. 0, 2010.03.08 ERECTION WORK and TRANSPORT Chapter 5 , Page 18 of 50

Rev. 0, 2010.03.08 ERECTION WORK and TRANSPORT Chapter 5 , Page 19 of 50