J910-CQ02-P0PAC-125312 - R0 IOM Manual

FOR INFORMATION
0 16.Aug.2022 J.D.KIM J.S.PARK J.Y.LEE FOR INFORMATION

Rev DATE PREPARED CHECKED APPROVED STATUS
Owner
Owner’s Engineer
Contractor
Sub-Supplier
Project
JAWA 9 & 10 COAL FIRED STEAM POWER PLANT
Document Title
Installation, Operation and Maintenance Manual
Document Type
□ Basic Engineering Document □ Detail Engineering Document ■ Vendor Document □ Other
Document No.
J910-CQ02-P0PAC-125312
Installation, Operation and Maintenance Manual
J910-CQ02-P0PAC-125312
RECORD OF REVISION
Rev Date Page Affected Description of Revision
A 16.Aug.2022 - FOR INFORMATION
Rev. 0
INSTALLATION, OPERATION &
MAINTENANCE MANUAL FOR
VERTICAL MIXED FLOW PUMP (VMF)
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
CONTENTS
CONTENTS ............................................................................................................................... 2
1.0 PRODUCT INTRODUCTION AND GREETINGS .......................................................... 5
2.0 TRANSPORT ............................................................................................................... 9
3.0 RECEIPT ANDSTORAGE........................................................................................... 12
3.1 Receiving Checks..................................................................................................... 12
3.2 Notes on Storage ..................................................................................................... 12
3.3 Check Point During Storage ..................................................................................... 14
3.4 Corrosion Protection Treatment for Long-Term Storage............................................ 14
4.0 INSTALLATION........................................................................................................... 16
4.1 Cautions for Installation ............................................................................................ 16
4.2 Installation Equipment .............................................................................................. 17
4.3 Installation Procedures ............................................................................................. 20
4.3.1 Installation Preparation ................................................................................... 21
4.3.2 Foundation Plate Setting................................................................................. 21
4.3.3 Baseplate Seating........................................................................................... 22
4.3.4 Foundation Bolt Installation............................................................................. 22
4.3.5 Leveling and Grouting of Baseplate ................................................................ 23
4.3.6 Pump and Motor Installation, Lifting Gap Setting and Shaft Alignment ............ 26
4.3.7 Connection of Discharge Piping and Auxiliary Piping, Power Cable ................ 30
4.3.8 Motor Single Test ............................................................................................ 32
4.4 Bolt Fastening Standard (Fastening Torque Value of Each Bolt) ............................... 33
2 |Page
5.0 OPERATION............................................................................................................... 34
5.1 Preparation and Checks for Pre-Start: ...................................................................... 34
5.2 Cautions for Start Up ................................................................................................ 35
5.3 Cautions during Operation........................................................................................ 36
5.4 CAUTIONS FOR STOP............................................................................................ 36
5.4.1 Normal Stopping ............................................................................................. 36
5.4.2 Emergency Stopping: ..................................................................................... 37
6.0 MAINTENANCE.......................................................................................................... 38
6.1 General .................................................................................................................... 38
6.2 Preventive Maintenance ........................................................................................... 39
6.3 Operation Log .......................................................................................................... 40
6.4 Inspection ................................................................................................................. 42
6.4.1 Stuffing Box .................................................................................................... 42
6.4.2 Disassembly Inspection .................................................................................. 43
6.4.3 Maintenance during Prolonged Stoppage ....................................................... 45
6.4.4 Bearing Housing ............................................................................................. 46
6.5 Disassembly ............................................................................................................. 46
6.5.1 Preparations for Disassembly ......................................................................... 46
6.5.2 Cautions for Disassembly ............................................................................... 47
6.5.3 Disassembly ................................................................................................... 48
6.6 Assembly ................................................................................................................. 49
6.7 Disassembly for Worn Parts ..................................................................................... 54
6.8 Assembly of Spare Parts / New Parts ....................................................................... 55
7.0 Troubleshooting .......................................................................................................... 57
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8.0 Guarantee and Repair ................................................................................................ 61
8.1 REPAIR and WARRANTY ........................................................................................ 61
8.2 Guarantee ................................................................................................................ 61
8.3 Recommended Spare Parts ..................................................................................... 62
9.0 CONTACT.................................................................................................................... 64
10.0 APPENDIX ................................................................................................................. 65
APPENDIX A : Piping Arrangement Type
APPENDIX B : Lubrication of Gear Type Coupling
APPENDIX C : Thrust Bearing (Tilting Pad Bearing) Manual
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1.0 PRODUCT INTRODUCTION AND GREETINGS
Thank you very much for purchasing the Vertical Mixed flow type Pump (VMF) from Hyosung
Good Springs (HGS). Our pumps are highly reliable, with their design being based on excellent
technology and long experience. Also, we designed & manufactured with great care for using our
pump safely. However, please note that improper handling will not only result in inadequate
performance, but may also lead to unexpected accidents.
This manual describes the correct methods and precautions for installation, operation and
maintenance. Please read this manual thoroughly. In addition, please keep this manual carefully
in a certain place so that those who use this product can always view it when they need it. If you
have any questions about the manual, please contact us or your supplier and we will respond
immediately. If you have any suggestions, we will make them available in the future.
Please use the following documents with this manual.
(1) Pump outline drawing and sectional drawing

(2) Pump performance curve
(3) Pump datasheet
(4) Other documents submitted
⚫ IF THE PUMP IS OPERATED, REPAIRED, REMODELED, OR REPAIRED WITH NON-

GENUINE PRODUCTS MANUFACTURED OR DELIVERED BY US WITHOUT
COMPLYING WITH THE CORRESPONDING INSTRUCTION MANUAL, THE SAFETY
AND QUALITY OF THE PRODUCT CAN NOT BE GUARANTEED.
⚫ IN ADDITION, WE CAN NOT TAKE RESPONSIBILITY WHEN AN ACCIDENT

OCCURS BY THIS.
<Safety Precaution>
In this manual, we warn you of caution when handling this product by displaying a warning in
[Warning] or [Caution]. Each warning sign has the following meanings. Also, be careful with the
warning display for the [Period].
5 |Page
⚫ USED WHEN THERE IS A POSSIBILITY OF A DANGEROUS SITUATION IN WHICH

THE USER IS KILLED OR SERIOUSLY INJURED IN CASE OF IMPROPER
HANDLING.
⚫ USED WHEN THERE IS A POSSIBILITY OF INJURY OR PHYSICAL DAMAGE TO

THE USER DUE TO IMPROPER HANDLING.
⚫ USE CAUTION WHEN HANDLING THE PRODUCT CORRECTLY OR WHEN YOU

NEED TO BE AWARE OF IT.
⚫ THE PRECAUTIONS NECESSARY FOR SAFE USE OF THE PUMP ARE DESCRIBED
IN THE TEXT OF THIS MANUAL, BUT THE IMPORTANT PRECAUTIONS ARE
SUMMARIZED IN THE FOLLOWING.
⚫ WHEN LIFTING THE PUMP, SELECT THE APPROPRIATE (REFER TO WEIGHT)

CRANE OR HOIST AND WIRE ROPE AND EXAMINE THE POSITION AND PULLING
FORCE OF THE WIRE, AND PAY ATTENTION TO LIFTING. IF YOU MAKE A WRONG
SELECTION OR IF THE CENTER OF GRAVITY IS UNBALANCED (OR LEANED TO
ONE SIDE WHICH IS NOT CENTER), THERE IS A DANGER OF SERIOUS
ACCIDENTS.
⚫ THE LIFTING LUG ATTACHED TO THE BEARING HOUSING OR DRIVER IS

INTENDED TO DISASSEMBLE (DISASSEMBLE) ONLY THAT PART. DO NOT USE
THE PUMP WHEN LIFTING THE ENTIRE PUMP TRAIN.
⚫ NON OBSERVANCE OF THIS CAUTION MAY RESULT IN DAMAGE TO THE

PRODUCT CAUSED BY THE PRODUCT FALLING DURING THE LIFTING PROCESS
AND SERIOUS PERSONAL INJURY.
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⚫ BE SURE TO INSTALL THE COUPLING COVER BEFORE STARTING OPERATION

AND MAKE SURE THAT IT IS CORRECTLY INSTALLED. IF THE COUPLING COVER
IS NOT INSTALLED, SERIOUS PERSONAL INJURY MAY OCCUR.
⚫ WHEN THE PUMP IS RUNNING, MAKE SURE THAT NO PART OF THE BODY,
CLOTHES, OR TOOLS COME INTO CONTACT WITH THE ROTATING PART OF THE
PUMP. THERE IS A RISK OF SERIOUS PERSONAL INJURY.
⚫ ELECTRIC POWER EQUIPMENT, WIRING WORK, GROUNDING WORK, ETC.,

SHOULD BE CARRIED OUT PROPERLY IN ACCORDANCE WITH ELECTRIC
EQUIPMENT STANDARDS AND REGULATIONS. INCOMPLETE WIRING WORK OR
EARTH LUG, ETC BY AN UNQUALIFIED PERSON MAY CAUSE NOT ONLY LEGAL
VIOLATION BUT ALSO HUMAN ACCIDENTS.
⚫ DURING THE WIRING WORK, BE SURE TO TURN OFF THE POWER AND SET UP
THE SIGNBOARD. IT MAY CAUSE ELECTRIC SHOCK.
⚫ WHEN INSTALLING A PUMP IN A PLACE WITH OUTDOOR OR WET CONDITIONS,

IT IS REQUIRED BY LAW TO INSTALL A SHORT CIRCUIT BREAKER (BREAKER)
TO PREVENT ELECTRIC SHOCK.
⚫ WHEN DISASSEMBLING AND INSPECTING THE PUMP, PLEASE TAKE MEASURES

TO PREVENT ACCIDENTS BY MARKING IT WITH A SIGNBOARD SO THAT
OTHERS KNOW WHEN THE PUMP IS IN OPERATION SO THAT THE THIRD
PERSON WILL NOT START THE MOTOR ACCIDENTALLY. IF YOU NEGLECT THIS,
THERE IS A RISK OF CAUSING PERSONAL INJURY.
⚫ IF THERE IS A RISK OF FLAMMABLE MATERIALS OR EXPLOSION AROUND THE

PRODUCT, TAKE MEASURES TO PREVENT IT FROM BEING REMOVED OR
IGNITED BEFORE WELDING.
⚫ DO NOT USE FIREARMS OR GRINDERS WHEN THERE IS A RISK OF FLAMMABLE

OBJECTS OR EXPLOSION AROUND THEM.
⚫ DISCHARGE PIPING SHOULD BE ANCHORED, SUPPORTED, AND RESTRAINED

NEAR THE PUMP TO AVOID APPLICATION OF FORCES AND MOMENTS TO THE
PUMP IN EXCESS OF THOSE PERMITTED BY THE PUMP MANUFACTURER.
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⚫ FOR EXPANSION JOINT, A TIE-ROD TYPE MUST BE APPLIED. IN ADDITION, THE

NUT THAT FIXES THE TIE ROD MUST BE INSTALLED SO THAT THERE IS NO GAP
AND MAINTAINED PERIODICALLY.
⚫ WHEN AN EXPANSION JOINT IS INSTALLED ON THE DISCHARGE SIDE, IT IS

RECOMMENDED TO INSTALL IT ACCORDING TO THE ATTACHED PIPING
ARRANGEMENT RECOMMENDATIONS. IF IT IS NOT INSTALLED ACCORDING TO
THE RECOMMENDED PIPING ARRANGEMENT, THE ENTIRE PUMP MAY BE
MOVED, RESULTING IN A SERIOUS ACCIDENT.
⚫ GENERALLY, THE OVERHEAT PREVENTION DEVICE INSTALLED IN THE PUMP IS

TO DISCHARGE THE MINIMUM OPERATION AMOUNT BY-PASS FROM THE MAIN
FLOW. WHEN THIS DEVICE IS NOT AVAILABLE, DO NOT OPERATE THE PUMP AT
THE BELOW OF MINIMUM FLOW RATE, AND DO NOT OPERATE THE PUMP AT
SHUT-OFF CONDITION. IT MAY CAUSE INTERNAL PRESSURE RISE AND
BREAKDOWN OF THE PUMP OR PLUG MAY HAPPEN. IN EXTREME CASES,
EXPLOSION OF PUMP MAY HAPPEN.
⚫ PLEASE DO NOT OPERATE AT SHUT-OFF (DISCHARGE VALVE CLOSED)

CONDITION OTHERWISE IT IS VERY SHORT TIME (1~2 MINUTE). PUMP MAY
BREAKDOWN CAUSED BY TEMPERATURE RISE OF THE LIQUID INSIDE THE
PUMP, NOISE OR VIBRATION OCCURS. OR IF THE CORROSIVE LIQUID WHICH IS
IN PUMP IS CHEMICAL CAUSE CORROSION OF PUMP BODY AND RESULT IN
DAMAGE ON PUMP BODY. IN PARTICULAR, WHEN HANDLING HYDROCARBONS
WITH HIGH VAPOR PRESSURES, SHUT-OFF CONDITION OPERATION SHOULD
NEVER BE CARRIED OUT, EVEN FOR SHORT PERIODS OF TIME.
⚫ GROUNDING MUST BE DONE ON THE WELDING BASE MATERIAL AND DO NOT

USE THE PUMP GROUNDING PART.
⚫ THE PRODUCT MAY BE DAMAGED DUE TO ELECTRICAL (CAME AS SHAFT

CURRENT) EROSION.
8 |Page
2.0 TRANSPORT
Please observe the following instructions during sea and inland transportation.
(1) Pay attention to the Care Marks printed on the packages; for transportation and storage.
(2) Pay attention to the following when unloading and hoisting the packages:
⚫ WHEN LIFTING A PUMP, CHOOSE A CRANE OR HOIST AND WIRE CABLE THAT
ARE APPROPRIATE FOR THE WEIGHT OF THE PUMP. WHEN ARRANGING THE
CABLE, CHECK ATTACHING POINTS AND THE CABLE TENSION CAREFULLY TO
PREVENT LOAD UNBALANCE.
⚫ MISCHOICE OR PARTIAL LOADING MAY RESULT IN SERIOUS PERSONAL

INJURY.
(3) Do not raise and lower the packages too rapidly, because damage may occur.
(4) Packages must be fixed to the skid with bolts or in a suitable manner to avoid damage
due to shock, impact and vibration during transportation.
(Example) Lifting the pump with 1-crane)
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(Conceptual drawing of assembly of sling or wire rope (Lifting the pump with 1-crane))
(Example) Lifting the pump with 2 or more crane)
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(Conceptual drawing of assembly of sling or wire rope (Lifting the pump with 2 or more crane))
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3.0 RECEIPT ANDSTORAGE
3.1 Receiving Checks
⚫ THE LIFTING LUGS OR EYEBOLTS OF EACH PUMP PARTS ARE FOR LIFTING
THESE UNITS ONLY. WHEN LIFTING THE PUMP AS A COMPLETE PUMP UNIT,
NEVER USE THESE LUGS.
⚫ FAILURE TO OBSERVE THIS PRECAUTION CAN RESULT IN SERIOUS

ACCIDENTS.
When the pumps have arrived at site, unpack carefully and check the following promptly.
(1) Check the nameplate to make sure it is purchased pump or not.
(2) Check whether the harm, defect which caused in delivery. And if it is discovered, please
inform the contractor or manufacturer.
(3) Check that the equipment is not damaged and the fixing bolts-nuts have not become
loose during transport.
(4) Check whether the contents and quantity of the delivered goods are in accordance with
the Packing List or not. If any problem arises, please contact to contractor (purchaser)
or pump manufacturer.
3.2 Notes on Storage
⚫ STORE THE PACKAGE BOX INSIDE THE PRODUCT TO AVOID DIRECT SUNLIGHT
OR RAIN, AND BE FREE FROM MOISTURE. EXPOSURE TO DIRECT SUNLIGHT
MAY CAUSE DEFORMATION OF THE PART AND MAY CAUSE CORROSION IF
STORED IN RAIN OR MOISTURE.
To prevent deterioration or damage, during storage, observe the following:
All of parts shall be stored as packed. If the package box is dismantled, it shall be re-packed.
(1) Storage environment
a) Not exposed to outdoor, shall be stored inside of warehouse.
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b) Rainwater or water should not come into contact with the product near the packing
box.
c) Keep in a dry, well-ventilated place.
d) There should be no significant change in temperature and should be less than 50

degrees.
e) There is no dust, no corrosive or toxic gases.
f) There is no dust, no corrosive or toxic gases.
g) Good drainage system shall be prepared.
h) Storage floor should be flat.
(2) Package box shall be handled carefully when storing or transporting which has a caution
mark on the outside of the package.
(3) Keep the packing box away from direct contact with the floor, and keep it at least 30 cm
away from the window or entrance or between the packing box.
(4) When stored inside a building, it must be stacked at least 2 m from the wall and covered
with a sheet (cover) to protect it from rain and dust.
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(5) Packing boxes should not be stacked.
3.3 Check Point During Storage
(1) Check the packing box once a month for damage.
(2) Ventilate the storage room twice a month on a sunny day.
(3) Remove vented vinyl from the packaging box during ventilation.
(4) Please review APPENDIX D. “Procedure for part storage” for detail check point.
3.4 Corrosion Protection Treatment for Long-Term Storage
(1) If the package is stored for more than six months (including shipping time), observe the
following guidelines for inspection and anti-corrosion treatment.
(2) Also unpack and inspect for antimicrobial treatment every 6 months.
⚫ IF CORROSION PROTECTION IS NOT APPLIED, CORROSION WILL BE

ACCELERATED BY MOISTURE.
(3) Rotate the shaft by hand and apply anti-rust oil to the bearing housing and suction /
discharge casing.
(4) Make sure that machined surfaces, couplings, bolts and flanges are coated with anti-
rusting oil.
(5) Store spare parts in an appropriate place after corrosion protection.
(6) Types and characteristics of antirust oil
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PART NAME PURPOSE
Tectyl 859B Used in metal enclosed spaces such as bearing housings
TORUST GH Used for interior storage parts and assembly parts
Large parts such as bed, casing, etc. Used for surface rust
ANTIRUST 720
Used for machining surfaces for outdoor storage
Exposed surface of the product Painting surface, coloring, not

ANTIRUST 730
plating
RUSTVETO 344 Used for outdoor storage parts
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4.0 INSTALLATION
⚫ WHEN LIFTING THE PUMP, USE APPROPRIATE CRANE (OR HOIST) AND WIRE
ROPES. CHECK POSITION AND TIGHTNESS OF WIRE ROPES SO THAT WEIGHT
CENTER OF THE PUMP IS BALANCED AND NOT SLIPPED.
⚫ FAILURE TO OBSERVE THIS PRECAUTION CAN RESULT IN SERIOUS

ACCIDENTS.
4.1 Cautions for Installation
(1) Pay particular attention to the following during unpacking and lifting.
a) When disassembling the packaging, be careful not to damage the parts.
b) When lifting pumps, motors and other parts, install suitable protective equipment such
as cloth or soft pads to protect the painted or machined surface.
c) Install an eyebolt or shackle in the position recommended by the manufacturer to lift

the pump or heavyweight parts. If any of special jig is provide by manufacturer, work
with the provided jig.
d) If the circular part is stored on the floor, place the protective block on the rim to prevent
the part from rolling. (See Figure 5.1)
Protective blocks
Fig.5.1
(2) Rust prevention
If the packaging is dismantled and stored in a long-term storage facility or if it is

determined that there is a high possibility of rusting due to the surrounding environment,
extra rust prevention should be performed. In particular, be careful not to cause rust on
the machined surface, bearing, or coupling.
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(3) Before starting installation, study the attached drawings carefully to understand pump
construction and determine preliminary arrangements.
(4) Be careful not to drop tools and parts into the water pit.
If these are sucked into the pump, the rotating element, casing and impeller will be
damaged.
4.2 Installation Equipment
Before installation, the following items should be prepared.
(Also, string, sand paper, and oil stone shall be prepared.)
(1) Non-shrink grout
(2) Liners
a) Liners shall be accurately machined with a level surface to prevent partial contact.
b) 1 set of liner is comprised with two tapered liners and one set of parallel liner. The
recommended liner shapes are:
Parallel Liner Taper Liner
Parallel Liner Taper Liner
A B C D E F G H
75 38 8 75 38 15 6 9
100 50 11 100 50 20 8 12
150 90 15 150 90 26 10 16
180 90 18 180 90 30.8 11.8 19
200 75 18 200 75 30 11 19
250 75 18 250 75 28 9 19
Unit : mm
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c) The liner should be prepared according to the requirement of the contractor.

(Supplied by the contractor)
(3) Regular tools ex) Spanner, Screw Driver, Hammer, Pipe Wrench, etc.
(4) Special Tools
(5) Pads are required when lifting components. Ex) Wooden Support, Soft Pad
(6) Measuring instruments
a) level gauge (0.02/1000mm) – Not allowed for civil
b) Straight edge (Min. 2.5m, 3m or longer recommendable)
c) Block Gauge (2-Identical Part)
d) Dial indicator (1/100mm)
e) Feeler Gauge (Thickness gauge) (0.1mm ~10mm)
f) Vernier Calipers
(7) Washing oil, waste cloths
(8) Compressed air
(9) Lifting devices Ex) Crane, Chain block, Rope, Shackle, Eyebolt, etc.
18 | P a g e
(10) Welding equipment
(11) Lube oil and grease
(12) Foundation bolts
If oil, paint, or foreign matter adheres to the foundation bolts, the adhesion between the
concrete and the foundation bolts will deteriorate. Therefore, wipe off with greasy mops
or remove with flame cleaning.
⚫ WHEN USING FIREARMS, BE AWARE THAT THERE IS NO RISK OF BURNING OR

EXPLOSION AROUND THE AREA.
(13) Hydraulic jack (if required)
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4.3 Installation Procedures
Foundation Drawings
Base Line Establishment
Foundation Surface Preparation

Preparations for Installing Base Plate
/ Foundation bolts
Base plate Leveling using Jacking /

Leveling screw
Concrete for foundation bolts and

curing
Base plate level rechecking /

adjustment
Grouting between base plate and

floor and then curing
Pump installation, Set the lifting gap
Motor Installation and Centering
Coupling Connection
Discharge Pipe Connection

`
20 | P a g e
4.3.1 Installation Preparation
(1) Inscribe bench lines or bench marks, which will be the reference for installation, at a site
which will not shift or sink.
(2) Check that the floor level and foundation holes’ diameters of the pump floor confirm with
the requirements shown in OUTLINE DRAWING.
(3) Mark the pump center lines, foundation height and foundation bolt positions, etc. in
accordance with OUTLINE DRAWING.
(4) For better adherence of grouting mortar, chip the foundation floor surface except where
the base lines are marked off.
(5) The concrete surface and foundation bolt holes should be cleaned with compressed air,
and all foreign matter removed.
⚫ DO NOT CONNECT THE GROUNDING CLAMP OF THE WELDER TO THE PUMP TO

PREVENT ELECTRICAL CORROSION OF BALL BEARINGS AND ETC.
4.3.2 Foundation Plate Setting
(1) Check the height and level and install the foundation pads on the foundation concrete.
(2) To installing the baseplate easily, adjust the level of the base pad processing surface to
be within 0.1mm per meter.
⚫ DURING PUMP INSTALLATION, EACH OF BASEPAD SHALL BE CLAMPED ON BED

CORRECTLY SO THAT BASE PADS ARE IN CONTACT WITH THE BASE PLATE IN
ALL DIRECTIONS. (THE BASE PAD FOR LEVEL ADJUSTMENT IS THE SCOPE OF
THE CONTRACTOR'S SUPPLY.)
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LEVELING AND INSTALLATION OF THE BASE PAD
4.3.3 Baseplate Seating
(1) Remove the anti-rust oil applied to the base plate working surface and lift the base plate
to seat it on the base pad.
(2) Seat the baseplate with align the center line of the baseplate and center line of the civil
work.
a) Baseplate shall be seated as the marking lines or arrows marked on the base plate
to be placed in the discharge direction.
b) Or the base plate hole and the base bolt hole to be formed in an equatorial trapezoid
in the north, south, east, and west directions.
North
West East
South
4.3.4 Foundation Bolt Installation
(1) In order to position the foundation bolt at the center of the hole of the base plate, cover
it with plastic tape or the like on the outer diameter of the foundation bolt.
(2) The purpose of installing the foundation bolt in the center of the base plate hole is to
prevent interference due to the foundation bolts in the subsequent installation process.
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4.3.5 Leveling and Grouting of Baseplate
(1) Ensure a gap of 30 ~ 50mm between bed base and foundation to inject mortar.
Jack Bolt for Baseplate Leveling
Baseplate
Liner
30～50 mm
Foundation
(2) Use a jacking bolt or tapered liner to level the baseplate.
(3) Place the block gauge on the baseplate and adjust the level using a straight edge and a
precision leveler, and the tolerance should be within 0.1 mm per meter in all directions.
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⚫ IF THE TOLERANCE LEVEL OF THE BASE PLATE EXCEEDS 0.1 MM PER METER,
IT MAY CAUSE HIGH VIBRATION, MISS-ALIGNMENT OF THE PUMP AND MOTOR
SHAFT, SHAFT BENDING, AND PREMATURE WEAR OF THE SLEEVE / BEARING.
a) Correct method of level check : Use straight edge, precision level, block gauge
b) At least 3 points must be measured based on '0' point
Case of using Inaccurate method about level checking : Use only precision leveling only
(4) Check the level and tighten the nut of the anchor bolt. Make the base bolt nut to be evenly
fastened to the specified torque value when tightened.
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⚫ WHEN ADJUSTING THE HORIZONTAL LEVEL OF THE BASEPLATE ONLY BY

JACKING BOLT, INSERT THE LINER AND STEEL PLATE IN THE GAP BETWEEN
THE BASE PLATE BOTTOM AND THE BASE CONCRETE AFTER THE LEVELING IS
COMPLETED, AND FIX THE BASE PAD AND STEEL PLATE EXCEPT THE BASE
PLATE BY SPOT WELDING SO AS NOT TO SLIP.
Insertion of liner and steel pad Spot welding of base pad and liner
(5) Fill the foundation bolt holes with grouting and cure.
a) The height of the incoming concrete should be 50 ~ 80mm lower than the bottom of
the parallel liner considering the height of the pad.
b) Concrete injection should be done in one direction as possible and take care not to
form avoid air pockets.
c) Concrete injection in one working area is carried out continuously until the filling
operation is completed. At this time, be careful not to tilt the foundation bolt.
d) After the concrete is fully cured, make sure that the foundation bolt nuts are evenly
fastened to the specified torque values and that there is no change in the level of the
baseplate.
⚫ EXCESSIVELY FASTENED OF THE ANCHOR BOLT AND NUT USING A SPANNER

AND HAMMER MAY CAUSE DEFORMATION OF THE BASE PLATE.
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(6) After inspecting the base plate horizontal degree with reviewing the pump outline drawing,
grouting or mortar is filled under and around the base plate.
(7) Maintain the gap between the baseplate and the mold within 5mm or more so that the
air can be sufficiently getting out.
Good status of grouting (No void) Bad status of grouting

(Void occur by insufficient air getting out or filling of mortar)
(8) After grouting is fully hardened, check that the base plate level meets 0.1 mm per meter
finally.
4.3.6 Pump and Motor Installation, Lifting Gap Setting and Shaft Alignment
(1) Install O-ring on the upper surface of the baseplate and apply grease or Molly coat so
that it does not come off.
(2) Lifting the pump to be vertically.
(3) Insert the pump slowly into the pit. Carefully install the pump so that there is no damage
on the machined surface. After mounting on the base plate, fasten the fixing bolt and nut.
(4) Install the motor stool.
(5) Since the rotating part of the pump is placed on the suction bell due to its own weight, it
is necessary to set the lifting gap, and the setting method is as follows.
a) After disassembling the shaft nut which fix the pump shaft, install the eye bolt at the
upper end of the pump shaft.
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① Set LIFTING BOLT on SHAFT END

② Set CHAIN BLOCK and connect
SHAFT
③ Lifting slightly shaft assembly
④ Loose SHAFT NUT on PUMP
SHAFT
⑤ Slow down shaft assembly placed
on lowest
b) After checking the total lifting value of the pump shaft using a chain block, set it to 50%
of the total lifting value.
① Set DIAL GAUGE on SHAFT NUT.

② Slightly lifting SHAFT assembly up to
total lifting stroke
③ Secuel SHAFT NUT on PUMP
SHAFT.
④ Romove LIFTING BOLT
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⚫ PLEASE NOTE THAT THE LIFTING GAP VALUE (DESIGN VALUE / TOTAL
AMOUNT) IS INDICATED IN THE MOTOR STOOL.
(6) Align pump shaft and motor shaft after install the motor. The reference value is within
0.05mm. When aligning the axis, fix the pump shaft and check by rotating the motor shaft.
a) If thrust bearing is installed on the pump, check the shaft alignment between the
coupling hubs.
Shaft alignment (Between Coupling hub) – Thrust Bearing on Pump
b) If thrust bearings is installed on the motor, install the centering jig in the packing box
and align the coupling hubs as described in a) above. In case of the mechanical seal
type (No need centering jig), install a dial gauge on the outside diameter of the
mechanical seal on the pump side and perform shaft alignment.
(Usage of centering jig : After removing the packing gland and packing 1 turn of the
pump, assemble the centering jig to the packing assembly point using the hex bolt
so that it contacts the packing sleeve surface. Since the pump shaft is installed
vertically through the centering jig, align the shaft as in a) above.)
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Conceptual drawing of Centering Jig assembly
Parallel (Radial -OD)
Motor 0˚
Gap 270 90˚
Pump 180˚
Unit : 1/100mm
ALIGNMENT TOLERANCE 0˚ 90˚ 180˚ 270˚ Value
1.PARALLEL OFFSET (± 0.05mm)
2. GAP mm (Tolerance : ± mm )
*Note : Parallel value Dial gauge offset 1/2 = Shaft center offset(± 0.05mm)
c) It is not necessary to check and adjust the angular shaft alignment under the premise
of the base plate horizontal satisfies the reference value of 0.1 mm / m, and it is
recommended that only parallel side alignment of shaft is performed.
* Never put a shim plate in a vertical pump to align the shaft.
d) After aligning the shaft, assemble the coupling.
29 | P a g e
For gear coupling, inject grease before and after assembly.
Grease
4.3.7 Connection of Discharge Piping and Auxiliary Piping, Power Cable
(1) Discharge piping
a) Support the pipe load so that it does not affect the pump, and check and connect the
height and clearance of the discharge pipe connected to the pump elbow so that
stress does not occur on the pump side.
b) The expansion joint is fixed with a tie rod to minimize contraction/expansion.

(Install the tie rod inner/outer fixing nut so that there is no gap)
c) In addition, in order to prevent stress from occurring on the pump side, the piping
support must be strongly supported (pipe anchor) so that the discharge piping does
not move in the flow direction or in the opposite direction.
d) If the length of discharge pipe (horizontal direction) is long, prepare the venting of the
pipe.
30 | P a g e
⚫ IF THE PIPING SUPPORT IS NOT PROPERLY INSTALLED, THERE WILL BE

STRESSES THAT PULL THE PUMP OUT OF THE PIPING DURING PUMP
OPERATION AND MAY CAUSE HIGH VIBRATION IN THE PUMP.
⚫ WHEN THE PIPING AND PUMP FLANGE WHICH ARE SHIFTED(DISLOCATED) ARE
FORCIBLY FASTENED BY BOLTS, IT CAUSE THE CENTER OF THE PUMP SHAFT
TO BE SHIFTED(DISLOCATED) OR THE DISCHARGE BENDING PIPE TO BE
DEFORMED WHICH MAKE VIBRATION AND NOISE OF THE PUMP.
⚫ AFTER TIGHTENING ALL PIPING, CHECK THE ALIGNMENT OF THE PUMP AND
THE MOTOR.
(2) Auxiliary Piping
Install auxiliary piping and accessories marked in AUXILIARY PIPING DRAWING. Take
care not to step on or damage the secondary piping.
(3) Power Cable
The power and instrument cables must be connected according to the drawings and
instructions.
⚫ THE POWER SUPPLY AND WIRING OF THE MOTOR MUST BE PROPERLY

PERFORMED IN ACCORDANCE WITH THE MOTOR OPERATING INSTRUCTIONS
(MANUAL). BE WELL ACQUAINTED YOURSELF WITH THE LAWS AND
REGULATIONS GOVERNING ELECTRICAL EQUIPMENT. WIRING AND
GROUNDING BY NON-EXPERTS IS VERY DANGEROUS.
⚫ IF THE PUMP IS INSTALLED EXTERNALLY OR IN A HUMID AREA, YOU SHOULD

USE AN EARTH LEAKAGE BREAKER TO PREVENT ELECTRICAL ACCIDENTS.
31 | P a g e
4.3.8 Motor Single Test
(1) Ensure that the pump-to-motor coupling is disconnected.
(2) Check that oil and grease are properly filled in the upper and lower bearings of the motor,
and refill if necessary.
(3) Run the motor and check the direction of rotation, vibration, bearing temperature, and
joints.
(4) If a gear coupling is applied, fix the gear coupling cover properly so that it does not
interfere with the coupling hub and perform motor single test.
(5) After the motor single test is completed, connect the coupling between the pump and the
motor.
⚫ DO NOT TOUCH THE ROTATING PART BECAUSE IT MAY CAUSE PERSONAL

INJURY.
32 | P a g e
4.4 Bolt Fastening Standard (Fastening Torque Value of Each Bolt)
When the bolts are continuously tightened while turning in the circumferential direction, they
are not tightened uniformly.
Therefore, the bolts shall be fastened by the diagonal direction (facing direction) and the
bolts in the diagonal direction are fastened evenly each of bolt with turning the angle.
It is desirable to fasten with the torque value in two or three steps while gradually increasing
the torque.)
TORQUE VALUES FOR BOLT/NUT

LUBRICANT NOT USING LUBRICANT(kgf-m) USING LUBRICANT(kgf-m)
STRENGTH 3.6 4.6 5.8 6.8 10.9 3.6 4.6 5.8 6.8 10.9
STS304 STS304
SIZE[mm] SS400 SM25C SM45C SCM435 SS400 SM25C SM45C SCM435
STS316 STS316
M6 0.4 0.5 0.64 0.9 1.3 0.3 0.3 0.30 0.6 1.2
M8 0.9 1.1 1.52 2.2 4.2 0.6 0.8 1.04 1.5 2.9
M10 1.9 2.2 2.96 4.4 303.0 1.3 1.5 2.00 3.0 5.7
M12 3.2 3.9 5.12 7.7 14.3 2.2 2.5 3.52 5.3 9.9
M16 7.9 9.3 12.64 18.9 35.5 5.4 6.4 8.56 12.9 24.1
M20 13.4 18.3 24.64 37.0 69.3 10.5 12.5 16.72 25.1 47.1
M22 20.9 25.0 33.36 50.0 93.9 14.1 16.9 22.56 33.8 63.5
M24 25.6 31.9 42.56 63.9 120.0 18.1 21.7 28.88 43.4 81.3
M30 52.6 63.2 84.00 136.0 237.0 35.6 42.8 57.04 85.5 180.0
M36 91.7 110.0 146.40 220.0 413.0 62.0 74.3 99.20 149.0 279.0
M42 164.0 176.0 234.40 352.0 660.0 98.8 119.0 158.40 237.0 445.0
M48 220.0 254.0 351.20 527.0 988.0 148.0 177.0 236.40 355.0 666.0
TORQUE TOLERANCE : -5% ~ +5%
Applicable Lubricant
Bolt Material Lubricant

Austenitic Stainless Steel NEVER-SEEZ(Ni-Base)
ETC NEVER-SEEZ(Ni-Base), Grease
33 | P a g e
5.0 OPERATION
During the initial trial operation after installation and the operation after disassembly or
maintenance, carefully follow paragraph 5.1 to 5.2. During normal operation, be sure to follow
paragraph 5.2 to 5.4.
5.1 Preparation and Checks for Pre-Start:
(1) Check lifting gap of the pump shaft. (Refer to 5.3.6)
(2) Ensure that the control panel system is correctly connected to the pump set and
functioning satisfactorily.
(3) Remove any objects such as wood or wire from the pump suction pit.
(4) Check the quantity of lubricating oil or grease for pump and motor bearing.
(5) Confirm the motor rotating direction.
(6) Check the auxiliary piping, accessory and etc.
(7) Open the air-vent valve of the pump.
(8) Confirm that the water level in the suction pit is above the lowest level. The lowest level
for which the pump can be normally operated is shown in the outline drawing. If the level
is too low or the shape of the suction pit is not proper, an air entrained vortex may be
produced, resulting in pump vibration. The water level must be verified with a water level
gauge.
(9) Adjust the gland packing so that a small amount of water continuously leaks. If the gland
packing is tightened excessively or unevenly, gland packing and packing sleeve will wear
down and should be replaced if necessary.
(10) If necessary, supply the cooling water to the motor or pump bearings and check the
flowrate.
(11) If the instrument is attached to the pump, check the normal operation, breakage, loose
supply and check the Initial setting value.
(12) Especially, if axial vibration instrument is installed, it should be reset in the field so that
Initial gap becomes -10.0Vdc.
34 | P a g e
5.2 Cautions for Start Up
⚫ DURING PUMP OPERATION, DO NOT TOUCH ROTATING PARTS OF THE

PUMP.KEEP HANDS, HAIR AND TOOLS AWAY FROM THESE PARTS TO PREVENT
SERIOUS HUMAN ACCIDENTS.
Check and make sure that starts up requirements are completely satisfied.
(1) Ensure that adequate lubricating and cooling water is supplied.(If applicable)
(2) Check and ensure correct oil level for thrust bearing. (If applicable)
(3) Check and be sure that the pump discharge valve is fully closed.(For this type of pump,
it is better to start the pump with discharge valve closed condition or crack open(5~15%)
condition for stable start.)
(4) Now start the pump. Check whether the discharge valve is fully open after starting the
pump normally.
(5) At the first time of operation, after pump installation or reassembly, run the pump for a
short period of time. During this time, check that the equipment runs satisfactorily without
detrimental surges, vibration, noise, etc.
(6) If operation is satisfactory, run the pump continuously.
⚫ SHUT-OFF OPERATION SHOULD BE AS SHORT AS POSSIBLE (NOT MORE THAN

2 MINUTE). OTHERWISE THE PUMP CAN BE DAMAGED BY LIQUID
TEMPERATURE RISE.
⚫ FLUSH AND CLEAN THE SYSTEM THOROUGHLY TO REMOVE DIRT OR DEBRIS IN

PIPE SYSTEM IN ORDER TO PREVENT PREMATURE FAILURE AT INITIAL
STARTUP.
⚫ PUMP MANUFACTURE CANN’T WARRANTY REGARDING THE TROUBLE THAT

OCCURRED BY NOT FILLING GREASE OR OIL.
35 | P a g e
5.3 Cautions during Operation
The pump can operate throughout the operation range described in PERFORMANCE
CURVE. Hyosung is not responsible for problems caused by operation out of range.
Operation at the shut off condition should not be more than 2 minutes. Check that lubricating
and cooling water supply are normal. (If applicable)
Pay attention to abnormal noise and abnormal vibration. If air or foreign matter enters the
pump, or if there is a change in the operation duty point of the pump, defect of valve in the
discharge lines, abnormal noise and vibration can occur, and pump discharge pressure can
vary greatly or the current meter of the motor will vary suddenly during operation. In such
cases, immediately check these problems to determine cause. Refer to paragraph 6.10
“TROUBLE SHOOTING” (If applicable) Check the pump thrust bearing temperature. After
starting the pump, regularly check the temperature rise of the pump thrust bearings. Even
after the temperature reaches a steady value, check it. If the temperature rises abnormally,
shut down the pump immediately and investigate the cause.
If a gland packing is applied, adjust the gland packing so that a small amount of water
continuously leaks. If the amount of leakage cannot be adjusted by adjusting the gland
packing, a new gland packing should be replaced. Gland Packing is a consumable item.
Depending on foreign matter and adjustment conditions, the gland packing life time reduced
possible. In addition, excessive tightening of gland packing can cause damage to the gland
packing and packing sleeves.
5.4 CAUTIONS FOR STOP
5.4.1 Normal Stopping
(1) Stop the pump and close the discharge valve fully.
(2) Close the valve of external flushing/cooling water supply line. (If installed)
⚫ IF THE PUMP HAS STOPPED DUE TO POWER FAILURE, TURN OFF THE POWER
SWITCH AND THEN CLOSE THE DISCHARGE VALVE. THIS WILL PREVENT THE
PUMP FROM STARTING SUDDENLY WHEN POWER IS BACK.
⚫ THE DISCHARGE VALVE MAXIMUM CLOSED AND THE PUMP STOP, IF THE PUMP
REVERSE ROATATION OCCURRED WHEN THE PUMP STOP.
36 | P a g e
5.4.2 Emergency Stopping:
If any of the following happens, the pump must be immediately stopped, and the discharge
valve fully closed.
- Motor overload
- High vibration
- Starting delay
- Abnormal sound
- Suction water level at or below the emergency limit
- High temperature of pump and motor bearing, winding and etc.
- Reverse rotation
Recommended alarm and trip temperature (maximum allowable temperature for thrust
bearing) shall be as per the following table.
Bearing Temperature
AlarmTemp. TripTemp.
95 ºC 100 ºC
37 | P a g e
6.0 MAINTENANCE
To maintain good pump operation, carry out the following maintenance and checks.
⚫ DURING PUMP DISASSEMBLY AND ASSEMBLY, WARNING SIGNS MUST BE

POSTED NEARBY AND TURN OFF THE MAIN POWER SUPPLY O PREVENT MISS
OPERATION BY THIRD PARTIES. FAILURE TO OBSERVE THIS PRECAUTION CAN
RESULT IN DAMAGE OR SERIOUS ACCIDENTS.
⚫ DRAIN PUMP AND PIPING AS THEY MIGHT CRACK WHEN INTERNALWATER

FREEZES WHILE STOPPING PUMPING IN WINTER, ETC.
6.1 General
(1) In general, any type of equipment must be maintained in good condition for repair if it is
to give satisfactory and efficient service. HGS pumps are designed to operate for
extended periods with a minimum of regular maintenance, the frequency and scope of
maintenance are different depending on pump installation and operating conditions. Ex)
Grouting strength of base plate, base plate level, slurry in fluid, pump operating range,
miss-alignment and etc.
(2) Under normal circumstances, regular performance of the preventive maintenance tasks
outlined in Paragraph 6.2 will prevent costly breakdowns and detect most problems that
may arise.
(3) Manufacture's recommendation for pump maintenance is about 8,000 hours (annually or
once every two years), but it can be shortened or extended considering pump's operating
condition (efficiency, vibration, bearing temperature and etc.). Maintenance is required
prior to the recommendation period if pump problems such as excessive wear, damage
to internal parts, increased vibration, bearing high temperature.
(4) In the event a pump malfunction is suspected, refer to the Troubleshooting Chart of
Paragraph 7.0.
(5) If major maintenance is required, refer to the procedures of Paragraphs 6.4 thru 6.6. for
driver maintenance requirements refer to the driver manufacturer's instructions.
38 | P a g e
6.2 Preventive Maintenance
Periodic testing or monitoring of critical pump performance factors, such as head, flow, driver
current, speed, temperatures, vibration levels, etc., is recommended to establish a reliable
data baseline for use in evaluating and projecting the pump's condition and in establishing
the maintenance requirements for its particular application. The scope and frequency of
periodic testing is primarily a matter of customer decision based on the severity of pump
operating conditions. In most cases the faithful measurement, recording, review and
extrapolation of periodic test results every few months will provide a sufficiently adequate
and reliable indication of pump condition that major maintenance, when needed, can be
scheduled and performed in a timely manner.
In additional to periodic testing, the following maintenance should be performed regularly:
(1) Check tightness of the pump and driver mounting fasteners, which may loosen, and
tighten them as necessary.
(2) Inspect all piping for evidence of leakage, loosening or other damage and repair as
necessary.
(3) When pump size permits, periodically rotate shaft by hand to check for free rotation. If
binding occurs, recheck pump alignment and impeller setting.
(4) Refer to manufacturer's instructions for driver lubrication, periodic inspection and any
other schedule maintenance tasks to be performed.
39 | P a g e
Pump checks are periodically required to prevent occurrence of damage. Periodic

inspections listed in the table are recommended.
Interval
Inspection Item
Necessary 300hr 2000hr 4000hr 8000hr
Oil Level O
Oil Leakage O
Oil Quality O
Oil Change O
Wash and Clean of Sight
O
Glass (if provided)
Gear coupling oil(grease) O
Vibration O O
Bearing Temp. O O
Noise O O
Mechanical Seal Leakage O O
Leakage of Pumped Liquid O O
Flow Rate of Cooling Water O O
Leakage of Cooling Water O O
Suction Pressure O O
Discharge Pressure O O
Differential Pressure O O
Current O O
Voltage O O
Overhaul O
Overhaul and inspections are recommended after 8,000 hours of operation.
When the pump has been used under unusual conditions, it should be disassembled for
inspection, even before 8,000 hours of operation.
6.3 Operation Log
Keep an accurate operation log and use it as a basis for making operation and maintenance
plans. With a well-kept log, trouble can be detected easily.
Items to be covered by the log:
40 | P a g e
(1) Date and time of measurement
(2) Time of start and stop
(3) Ambient temperature near pump
(4) Bearing temperature of pump (If applicable)
(5) Bearing temperature of Motor
(6) Water level in suction pit
(7) Discharge pressure
(8) Current, voltage, frequency, motor power
(9) Vibration
Take measurements at the same time each day. (Time of measurement should be
established depending on item and use).
Open the pressure gauge valve only when checking gauge reading. The gauge valve should
be closed at all other times; otherwise, the life of the gauge will be shortened.
41 | P a g e
6.4 Inspection
6.4.1 Stuffing Box
(1) Gland packing
The packing needs to be replaced when leak water increases and adjustment is no longer
possible by tightening the gland. Gland packing is a consumable item and stop the pump
and proceed with the following steps carefully. If the packing is improperly installed, leakage
will not be stopped and the sleeve may wear-down unevenly.
⚫ DO NOT TIGHTEN THE GLAND TO THE POINT OF ZERO LEAKAGE. A SMALL

AMOUNT OF LEAKAGE IS NECCESARY TO ENSURE COOLING AND LUBRICATION
OF THE PACKING AND TO PREVENT SHAFT SLEEVE DAMAGE.
a) Removal
Used packing should be removed and discarded. Use the tool like a FIG.6.1 or screw
driver and remove, taking care to avoid damage to the stuffing box and sleeve.
FIG.6.1
b) Replacement
Stuffing box and packing sleeve must be clean and check wear-down. Push the gland
packing, one by one, into the stuffing box. Cut ends of the packing must always be
staggered by 90°～180°. Wrap gland packing on shaft sleeve and cut length 1 or 2 %
longer than normal. Cut ends should be at around 45 degrees. Avoid excessive
tightening of gland packing.
42 | P a g e
Correct Incorrect
FIG.6.2
Pump Size of Packing Quantity Material
MCWP □ 25X25mm 6m PILLAR #6501L
ACWP □ 16X16mm 3m PILLAR #6501L
SWMUP □ 12.5X12.5mm 3m PILLAR #6501L
(2) Packing sleeve
If the sleeve wears unevenly on one side by more than 0.3 mm, the effectiveness of the
packing seal will be reduced, so replace the sleeve. When the sleeve is worn evenly,
refer to 6.4.2 (2).
6.4.2 Disassembly Inspection
Perform disassembly inspection annually or once every two years depending on the
operating conditions. At such times, it is desirable that the interior of the suction pit also be
cleaned. During the disassembly inspection, always take photographs showing a scale, and
make records of the condition of the parts. Each part is to be inspected.
(1) Journal bearing and sleeve
The maximum allowable gap between the journal bearing and the sleeve is shown in
Table 5.1. If the maximum allowable gap in Table 5.1 is exceeded, replace the part(s) as
necessary. Take measurement at two points 90° apart at the center and both ends of the
bearing and sleeve.
43 | P a g e
Table5.1 Gap between Journal Bearing and Sleeve
Max. Allowable Gap(in Diameter) Dimensions in mm
Between journal bearing and sleeve 0.5 mm
⚫ DURING OPERATION IF THERE’S NO VIBRATION AND PROBLEM IN USE, HIGHER

GAP WILL BE ALLOWED THAN SUGGESTED MAX.ALLOWABLE GAP (TABLE 5.1).
JOURNAL BEARINGS AND SHAFT SLEEVES ARE CONSUMABLE PARTS THAT
WEAR-DOWN NATURALLY AS THE PUMP OPERATION. THUS, THE PROBLEM
OCCURS, BEARING AND SLEEVE SHOULD BE CONSIDERED TO REPLACE.
(2) Packing sleeve
The even wear is acceptable if it is less than 2.2 mm in diameter. But the outer surface
of the sleeve must be machined so that it is smooth.
(3) Shaft
Support the shaft on solid V-blocks and use a dial indicator as illustrated in Fig. 6.3.1.
Use care so that there are no foreign matters on the V-blocks or on the shaft surface.
Place the shaft with its keyway on upside. The keyway is supposed to be at 0 degree of
phase angle. Apply the indicator plunger to shaft surface clear of keyway. Turn the
indicator dial so that the pointer comes to zero position. Slowly turn the shaft by hand,
and take readings at each 90 degree position.
If the shaft surface is perfectly concentric, the pointer would not move. Peak to peak
stroke of the pointer shows double the shaft deflection. To obtain shaft deflection, divide
the total stroke by two.
For example, on a shaft having readings in Fig. 6.3.2, total stroke of the pointer in the
horizontal direction is 7.5 - ( -7.5 ) = 15. This means the shaft is bent by 7.5 toward right.
In vertical direction, total pointer stroke is 0 - 15 = -15. This means the shaft is bent 7.5
downward. In general, modification is required when maximum run out of the shaft
exceeds 75/1000 mm.
44 | P a g e
FIG.6.3.1
FIG.6.3.2
(4) KEY
Examine all keys for wear and damage. Ensure that they are flat, parallel and free from
burrs, and properly fit the keyway. Replace if necessary.
(5) Gaskets and O-rings
Gaskets and O-ring must be replaced if they are deformed or lack elasticity.
6.4.3 Maintenance during Prolonged Stoppage
The pump should be maintained so that it may be operated at any time. If Pumps handling
sea water or brackish water must be idled for long periods then operate the pump once every
week or twice to protect the casing from corrosion caused by stagnant sea water.
(1) Remove the gland packing and install packing impregnated with grease.
(2) Turn the shaft by hand about once a month.
(3) Disassemble the automatic air vent valve and overhaul.
(4) Replace the oil in the bearing housing once a year even if the unit is not operated. (If
applicable)
(5) Insulation of the motor will deteriorate when there is high humidity. Take care to keep
the motor dry.
45 | P a g e
6.4.4 Bearing Housing
When oil level decreases, remove the air vent cap on the bearing housing and supply oil to
the required level. Oil should be replaced after 2,000 hours of operation, but at least once
every 6 months regardless of total operating hours.
Proceed as follows for bearing lubrication:
Stop pump operation. Remove the oil drain plug and the air vent cap on the bearing cover,
and completely drain oil. Re-install drain plug. Supply new oil to the required level by
checking with level gauge. Re-install air vent cap. Start the pump.
To obtain detail information, please refer to lubricant list.
6.5 Disassembly
Disassembly procedure shall be performed in the following order. Refer to the PUMP CROSS
SECTIONAL DRAWING and ASSEMBLY AND DISASSEMBLY DRAWING.
⚫ DURING PUMP DISASSEMBLY AND ASSEMBLY, WARNING SIGNS MUST BE

POSTED NEARBY AND TURN OFF THE MAIN POWER SUPPLY O PREVENT MISS
OPERATION BY THIRD PARTIES. FAILURE TO OBSERVE THIS PRECAUTION CAN
RESULT IN DAMAGE OR SERIOUS ACCIDENTS.
6.5.1 Preparations for Disassembly
⚫ WHEN LIFTING THE PUMP, USE APPROPRIATE CRANE (OR HOIST) AND WIRE
ROPES. CHECK POSITION AND TIGHTNESS OF WIRE ROPES SO THAT WEIGHT
OF THE PUMP IS NOT UNBALANCED.
FAILURE TO OBSERVE THIS PRECAUTION CAN RESULT IN SERIOUS ACCIDENTS.
(1) Confirm that the working area is sufficiently wide and that the area is sufficiently level for
crane use. Check the surrounding area for hazards or obstructions.
(2) To prevent loss, provide boxes to hold disassembled parts. For convenience, bolts and
nuts removed should be grouped and stored in separate bags.
46 | P a g e
(3) Prepare lifting devices, wooden supports, soft pads, standard tools, special tools,
washing oil, rags, liquid packing and anti-rust oil diluted with solvent for covering
machined surfaces of the shaft and other parts.
(4) Drain oil from the thrust bearing casing. (if applicable)
(5) In many cases, the following parts cannot be reused when the pump is reassembled, so
prepare their replacements in advance; Rubber rings, O-rings, Gland packing, Three
Bond, and Washers.
6.5.2 Cautions for Disassembly
(1) Cautions for unloading products
a) LUG or eye bolts only use when lifting individual components, do not use when lifting
the pump assembly. Install an eyebolt and shackle in the position recommended by
the manufacturer to lift the pump or heavyweight parts, if supply a lifting jig, work with
the jig.
b) When lifting the pump, use a crane, hoist or wire rope suitable for the weight. Also,
be careful not to slip the wire rope and adjust the tension of the wire rope to prevent
the pump shifting to one side.
c) Use soft padding under the wire to protect the coated or machined surfaces. Do not
raise or lower the parts too rapidly with the crane.
d) When disassembling and assembling components on the floor, use protective blocks
under the components to protect the coated surfaces and prevent rolling.
Protective
FIG.6.4
(2) When laying the shaft horizontally on the floor, it should support at least three positions
(both ends and middle of the shaft) and to prevent bending of the shaft. In the case of
long-term storage, the axle should be kept upright.
(3) Cover the pump parts to protect from damage after disassembly.
47 | P a g e
(4) After disassembly, apply temporary rust prevention to the machined surfaces such as
fitted surfaces, threads, shaft, etc.
(5) Be careful not to drop tools and parts into the suction pit.
(6) To protect against parts loss or mixing of parts with those from another machine, provide
cases for disassembled parts storage.
(7) Store bolts in bags as a set.
(8) The lower bearing housing should be removed from the discharge bowl only when the
journal bearings are to be replaced. Similarly, the shaft sleeves, journal bearings should
be removed only when they are to be replaced.
6.5.3 Disassembly
Always inscribe match marks where necessary during disassembly. The following is the
sequence of steps for disassembly:
(1) Disconnect motor wiring and main and small piping around the pump.
(2) Remove coupling bolts.
(3) Remove motor and motor stool. Pay careful attention to attaching the sling so that the
load will be centered and the sling does not slip.
(4) Remove pump side coupling hub, Shaft nut, bearing housing and bearing stool (If
applicable).
(5) Lift the pump assembly slowly to vertically by using the lifting lugs and shackles, adjust
the chain block for pump weight balancing while lifting pump. Move pump to the
maintenance area, and positioned it from vertical to horizontal position as shown
Dismantlement and Assembly Procedure”, Wooden supporter should be positioned on
the floor and place the pump on them.
(6) Remove packing gland, packing, and stuffing box.
(7) Remove discharge elbow, drive shaft, shaft coupling, and Retainer rings and then
remove Lower column pipe. Verify the match marks on the flange of column pipe and
discharge elbow.
(8) In the same way remove all column pipe and the respective muff couplings, Retainer
rings and shafts. Verify the match marks on the flange of column pipes.
(9) Remove suction bell mouth from diffuser, and then remove impeller nut, and pull out the
impeller.
48 | P a g e
(10) Then remove shaft from diffuser.
⚫ AS TEFLON BEARING IS USED FOR THE INTERMEDIATE JOURNAL BEARING,

PROTECT FROM MECHANICAL SHOCK WHEN REMOVING IMPELLER NUT.
(11) If necessary, remove the sleeve from shaft and journal bearing from bearing housing. If
necessary, the casing ring (If applicable) can also be removed, but take it out only for
replacement.
(12) After disassembly, clean all parts and protect the threaded portion of the disassembled
shaft by wrapping with tape. Coat machined surfaces with anti-rust agent.
(13) Inspect all parts and determine whether repair or replacement is necessary in
accordance with the description in paragraph 6.4.
⚫ WHEN MACHINED SURFACES ARE DAMAGED AND MUST BE REPAIRED, USE AN

APPROPRIATE GRINDER. DURING GRINDING WORK, APPROVED PROTECTIVE
GOGGLES MUST ALSO BE WORN.
6.6 Assembly
Proceed in the reverse order of disassembly while ensuring the match marks are aligned. In
addition, the following instructions must be observed.
(1) When replacing parts, check thoroughly before assembling.
(2) When reassembling each part, remove foreign matter in the tapped holes with
compressed air and check for defects or dirt on the flange surfaces and mating
surfaces.
(3) Before reassembly, remove anti-rust agent, check for corrosion and damage.
(4) Generally, replace consumables (such as O-rings, rubber rings, gland packing, washers,
etc.) with new one.
(5) The shaft nut (pump side) is the only part with left hand thread. All other threads are right
hand.
(6) The fitted and threaded sections of the bearing casing, shaft, and retaining bolts, etc. are
to be cleaned thoroughly and apply molykote or oil to prevent sticking during assembly.
49 | P a g e
⚫ BE CAREFULL NOT TO DAMAGE THE JOURNAL BEARING ON CORNERS OR

THREADED PORTION OF SHAFT.
(7) Check the match marks on the casing fitted surfaces and the shaft.
(8) Be sure to install the rubber rings for the casing joint surfaces and O-rings for the stuffing
box.
⚫ CARE SHOULD BE TAKEN NOT TO DAMAGE O-RINGS OR RUBBER RINGS WHEN

INSTALLING.
(9) When handling the liquid sealant (Three-bond 1102) takes care of the following items.
- Completely wipe off moisture, oil and other foreign matters on joint surfaces.
- Apply as thinly and uniformly as possible.
- Assemble about 2-4 minutes after application.
- Serviceable temperature range: -40ºC～150ºC
- Keep the container airtight and store in a cool dark place while not in use.
- After application, wash hands thoroughly
Brand Name & Type Material Manufacturer
ThreeBond1102
Synthetic resin Three Bond Co., Ltd.
(Non - drying type)
Denatured fatty
Three Bond 2003/2102B Three Bond Co., Ltd.
polyamine
Three Bond 1401B Synthetic resin Three Bond Co., Ltd.
NeverSeez Hydro carbon

Never Seez Compound Corp.
(Aerosol and standard type) compound, etc.
Santac Sealer
Butyl rubber Hayakawa rubber Co., LTD.
(Tacky and viscoelasticity tape)
50 | P a g e
(10) Sealant treatment is executing at re-assembly. (sea water fluid only)
Apply liquid sealant (Three-bond 1102 or equivalent) for the joint surface of pump
casings and bearing housing. As shown in fig. 6.5.
When reassembling the casing, filler (Santac sealer or equivalent), which is used to
prevent crevice corrosion by seawater must be inserted between flanges. Place the
adhesive filler on the female flange side, and then tightening the bolts as shown in fig.
6.5. (only applicable for sea water application)
ⓐ SANTAC SEALER
ⓑ ⓐ ⓑ THREEBOND 1102
ⓔ
ⓒ THREEBOND 1401B
ⓓ MOLYKOTE
ⓔ KE-45
FIG. 6.5
a) Apply liquid sealant (Three-bond 1102 or equivalent) for the packing box area. As
shown in Fig. 6.6
ⓑ ⓐ SANTAC SEALER
ⓓ
ⓑ THREEBOND 1102
ⓔ
ⓒ THREEBOND 1401B
ⓓ MOLYKOTE
ⓔ KE-45
FIG. 6.6
b) Apply a sufficient amount of Screw-lock (Three-bond 1401B or equivalent) to the bolts

fastening the journal bearing housing set screws and etc. to prevent loosing as shown
in Fig. Fig. 6.7
51 | P a g e
ⓐ SANTAC SEALER
ⓔ
ⓑ THREEBOND 1102
ⓒ ⓒ THREEBOND 1401B
ⓓ MOLYKOTE
ⓔ KE-45
FIG. 6.7
c) When assembling impeller bolt, casing bolt and etc., apply liquid gasket as fig.6.8.
ⓔ ⓐ SANTAC SEALER
ⓓ
ⓑ THREEBOND 1102
ⓑ ⓒ THREEBOND 1401B
ⓓ MOLYKOTE
ⓔ KE-45
ⓔ
FIG. 6.8
d) When assembling muff coupling, apply Thee-bond1102, Three-bond 1401B and KE-
45 as shown Fig. 6.9.
ⓔ ⓑ ⓓ ⓐ SANTAC SEALER
ⓑ THREEBOND 1102
ⓒ THREEBOND 1401B
ⓓ MOLYKOTE
ⓔ KE-45
FIG. 6.9
e) When assembling rigid coupling, apply Molykote as shown Fig. 6.10.
ⓓ ⓐ SANTAC SEALER
ⓑ THREEBOND 1102
ⓒ THREEBOND 1401B
ⓓ MOLYKOTE
ⓔ KE-45
FIG. 6.10
f) When assembling Impeller ring, apply Three-bond 1102 as shown Fig. 6.11. (If
Impeller ring applied)
52 | P a g e
ⓐ SANTAC SEALER
ⓑ THREEBOND 1102
ⓒ THREEBOND 1401B
ⓓ MOLYKOTE
ⓔ KE-45
ⓑ
FIG. 6.11
g) When assembling Journal Bearing, apply Three-bond 1102, Molykote, Ke-45 as

shown fig.6.12.
ⓓ ⓐ SANTAC SEALER
ⓔ ⓑ THREEBOND 1102
ⓒ THREEBOND 1401B
ⓓ MOLYKOTE
ⓔ KE-45
ⓑ
FIG. 6.12
h) When assembling Impeller Boss, apply Molykote, KE-45 as shown Fig. 6.13.
ⓔ ⓓ ⓐ SANTAC SEALER
ⓑ THREEBOND 1102
ⓒ THREEBOND 1401B
ⓓ MOLYKOTE
ⓔ KE-45
FIG. 6.13
⚫ PLEASE OBSERVE THE SEALANT TREATMENT PROCEDURE TO PREVENT

CREVICE CORROSION. IF THIS PROCEDURE DON’T EXECUTE AT ASSEMBLY,
HGS DO NOT HAVE RESPONSIBILITY CAUSED BY CREVICE CORROSION.
(11) To prevent uneven tightening, tighten flange bolts in a crisscross pattern as shown in
Fig.6.14.
53 | P a g e
FIG.6.14
(12) After reassembly, check carefully that all bolts on each flange and other parts are
completely and evenly tightened.
(13) Touch up with paint the scratches and scars which are left damaged during reassembling.
(14) Set the lifting gap of the pump after installation.
(15) Insert gland packing in the stuffing box.
If mechanical seal is applied, set to the operating state. Tighten the set screw fixed to
the pump shaft and remove the set plate from the sleeve groove.
(16) Check shaft alignment after installation motor.
(17) After assembly, carefully check that all bolts of each flange and other parts are tightened
evenly and completely.
(18) Assemble main and auxiliary piping, connect power cable, instrument.
(19) Connect the coupling after the motor solo test. Check the direction of rotation by
operating the motor and check that it operates without abnormal vibration or noise.
(20) During and after reassembling, do not step on the auxiliary piping.
6.7 Disassembly for Worn Parts
(1) Sleeve
a) To remove the set screw, drill a hole on shaft set screw as shown in Fig. 6.15, Remove
the set screw lightly so as not to damage the shaft. Then remove the sleeve.
b) If sleeve cannot be removed, cut it off.
54 | P a g e
FIG.6.15
(2) Journal bearing
a) Remove the bearing using a circle jig of similar size to the journal bearing.
b) If it is not possible to remove it naturally, cut off only the bearing with a grinder.
6.8 Assembly of Spare Parts / New Parts
(1) Sleeve
a) Apply molykote to prevent sticking shaft and sleeve. Install the sleeve on shaft.
b) Tap the screws on the shaft, using female screws as a guide through sleeve as shown
in Fig. 6.16.
c) Screw depth into the shaft should be about 3 mm.
d) Apply a sufficient amount of Screw-lock (Three Bond 1401B or equivalent) to the set
screws and install the set screws.
e) Cut the protruding portions of the screws, and calk the cut end.
f) File the calked portion of sleeve so the surface is smooth.
FIG.6.16
55 | P a g e
(2) Journal bearing
a) Apply molykote to bearing outside and assemble to the bearing housing.
b) Apply silicone (KE-45) to both ends of the bearing.
56 | P a g e
7.0 Troubleshooting
If trouble occurs during pump use, take prompt actions. For troubleshooting of common troubles,
the causes and measures are outlined in the table below. If trouble occurs and cannot be
dissolved easily, contact Hyosung after thorough investigation.
No Flow Delivered
CAUSES POSSIBLE CURES
1. Sump water level too low. Fill sump to proper level as indicated on the pump outline drawing.
2. Blockage or obstruction at Check for and remove any blockage or obstruction at pump intake
pump inlet. or impeller.
3. Discharge system head too Check pipe friction losses. Larger discharge piping may correct
high. condition. Check that valves are wide open.
Check whether motor is directly across-the-line and receiving full

4. Speed too low. voltage. Or frequency may be too low; motor may have an open
phase.
5. Wrong direction of rotation. Check motor rotation with directional arrow on pump casing.
6. Impeller is completely Dismantle suction bell as needed and clear obstruction from the
plugged. impeller.
Not Enough Flow Delivered
Check seal leakage and tighten packing gland as needed.

Replace packing if worn. Also check condition of the packing
7. Too much leakage at
shaft sleeve. Replace sleeve if badly worn. Check that bypass
stuffing box.
line valve setting is correct. Also check that all system air &
vacuum valves are working correctly.
8. Speed too low. See item 4.
9. Discharge system head too

See item 3.
high.
10. Pump intake partially

See item 2.
clogged.
11. Impeller partially plugged. See item 6.
a. Increase water level in the sump.

12. Cavitation; insufficient
b. Pump may be running too far out on the curve. Check system
NPSH available.
resistance curve and/or throttle the discharge valve.
Inspect impeller. Replace if damaged or vane sections badly
13. Defective or worn impeller.
eroded.
57 | P a g e
14. Impeller running clearance Check gap at adjustable coupling. Set clearance per instructions
too large. as shown on the pump outline drawing.
Check sump for vortices and eddies entering the pump inlet.
15. Sump disturbances. Change water level in the sump and recheck for vortices and
eddies. If condition persists, sump modifications may be required.
16. Wearing clearances too

Check wear ring clearances and replace if worn.
large.
Symptoms are possibly an overloaded drive and about 1/3 rated

17. Wrong direction of rotation. capacity from pump. Compare rotation of motor with directional
arrow on pump casing.
Check with factory to see if a larger impeller can be used;
18. Impeller too small or
otherwise, cut pipe losses or increase speed-or both, as needed.
diameter too small.
But be careful not to overload driver.
Not Enough Pressure
19. Too much leakage at

See item 7.
stuffing box.
20. Speed too low. See item 4.
21. Mechanical defects. See items 13, 14 and 16.
22. Obstruction in flow Dismantle pump and inspect passages of impeller and casing.
passages. Remove obstructions. See items 2 and 6 as well.
Check pipe friction losses. Smaller discharge piping may correct
23. Discharge system head too
condition. Discharge valves may need to be throttled or system
low.
resistance may need to be increased.
24. Wrong direction of rotation. See item 5.
25. Cavitation; insufficient

See item 12.
NPSH available.
26. Sump disturbances. See item 15.
27. Impeller too small or tilt too

See item 18.
low.
Pump Operates For Short Time, Then Stops

28. Not enough flow Check that pump bearing lubrication system is operating correctly.
to bearings and stuffing Check flow indicator or switch, if provided.
box. Fix as needed.
Check vibration switch or probes, if provided. Possible sources of
vibration are improper operation, loose parts, misalignment, flow
29. High vibration.
disturbances, resonance and worn parts including the impeller,
bearings, sleeves and wear rings.
58 | P a g e
30. Obstruction in flow

See item 22.
passages.
Check that the motor is operating correctly. Check for any
31. Electrical problems.
overheating and vibration conditions.
32. Sump water level too low. Check that sump water level is sufficient.
Check if pump rotates freely. A bound rotating element could be

33. Mechanical problems. an indication of a bent or broken shaft, a damaged or broken
coupling or blockage in the pump.
Pump Takes Too Much Power
34. Head much higher than Check system resistance curve. Impeller could be too large or tilt
rating. is too high for the application.
35. Cavitation. See item 12.
36. Mechanical defects. See items 13, 14 and 16.
The voltage and frequency of the electrical current may be lower

than that for which motor was built; or there may be defects in
37. Electrical problems.
motor. The motor may not be ventilated properly due to a poor
location. Also see item 31.
38. High vibration. See item 29.
39. Obstruction inflow

See items 22 and 2.
passages or intake.
40. Sump disturbances. See item 15.
41. Wrong direction of rotation. See item 5.
42. Running clearances too If new parts have been installed, check the clearances at the
tight. bearings, wear rings and the impeller running clearance.
43. Liquid heavier (in either

Use larger driver. Consult factory for recommended size. Test
viscosity or specific liquid for viscosity and specific gravity. If smaller capacity can be
gravity)than allowed for. tolerated a smaller impeller can be furnished.
Release gland pressure. Tighten reasonably. If sealing liquid

44. Stuffing box too tight. does not flow while pump operates, replace packing. If packing is
(Packing) wearing too quickly, replace scored shaft sleeves and keep liquid
seeping for lubrication.
45. 45. Casing distorted(By

excessive strain from Check alignment. Examine pump for friction between impeller
and casing. Replace damaged parts. Check for pipe strain.
discharge piping.)
46. Shaft bent. Check that shaft total indicator run-out (TIR) does not exceed
59 | P a g e
0.002 in. at the bearings, couplings and impeller fit.
47. Mechanical failure of critical Check bearings and impeller for damage. Any irregularity in
pump parts. these parts will cause a drag on shaft. Also see item 33.
48. Misalignment. Re-align pump and driver.

49. Speed too high. (BHP of
pump varies with cube of
speed; so any increase in
Check voltage on motor.
speed causes consider
able increase in power
demand).
60 | P a g e
8.0 Guarantee and Repair
8.1 REPAIR and WARRANTY
If any abnormality is detected during operation, stop and check immediately, and if there is
a serious problem with the operation of the pump, contact the manufacturer promptly.
When you contact us, please provide the serial number provided on the product name plate
and approved books.
Please contact the manufacturer if there is any uncertainty about the product and contact
the manufacturer for repairs and maintenance of the pump.
The warranty of the pump is as follows.
(1) If the product is defective within the warranty period
(2) Even within the warranty period, failure or repair due to user's responsibility, cost about
replacement of consumable parts will be charged, and the corresponding items are as
follows.
a) Damage due to abnormal use or abnormal storage
b) Damage caused by natural disasters or fire disasters
c) Using the spare part which do not provided by pump manufacturer
d) Driving, installing, and repairing beyond recommended
Consumables: Gland packing, journal bearings, sleeves, wear rings, lubricants, o-rings,
gaskets, etc.
If there is damage in transit, the responsibility lies with the carrier(transporter).
8.2 Guarantee
Please take note that HGS cannot guarantee on the troubles that occurred by not following
the "warning", "caution", procedures and methods provided in the instruction manual,
especially the troubles that are provided below:
(1) Bed leveling and unfilled mortar in bed can cause the following problems. (Ex: high
vibration, bed deformation, high noise level etc.)
(2) When operating the pump without setting the lifting gap (Ex: pump stuck, impeller and
casing damage)
61 | P a g e
(3) The pump movement occurred due to piping stress. (Examples: high vibration, seal
leakage, damage etc.)
⚫ PLEASE ATTACH SUPPORT FIXTURES AT THE PIPING’S CONNECTED TO THE

INLET/OUTLET OF PUMP TO MAKE SURE THAT THE PUMP DOES NOT TAKE ANY
LOADS.
(4) The troubles that occurred by not following the "Recommended Piping Arrangement" (Ex:
high vibration, pump damage, pump stress and etc.)
(5) The trouble that occurred from inflow of foreign substance into the pump fluid. (Ex: Pump
stuck, damage and etc.)
⚫ BEFORE STARTING THE PUMP, PROPER MEASURES MUST BE TAKEN BY

CLEANING PIT AND INNER PIPING SO THAT THERE IS NO FOREIGN MATTER
ENTERING THE PUMP.
(6) The trouble that occurred by starting the pump and did not check the grease or oil filling
at the pump and motor bearing. (Ex: Bearing damage, high vibration, high temperature)
(7) If the pump running out of the operating range or running below the minimum water level.
(Ex: Vortex, high vibration, pump damage and etc.)
8.3 Recommended Spare Parts
When ordering spare parts, always state HYOSUNG GOODSPRINGS serial number, and
indicate part name and item number from pump sectional drawing. It is imperative for service
reliability to have a sufficient stock of readily available spares.
(1) It is suggested that the following spare parts be stocked, where applicable
 Gasket & O-Ring
 Casing Wear Ring & Impeller Wear Ring
 Journal Bearing
 Packing or Mechanical seal
 Shaft Sleeve
62 | P a g e
 Anode (2 years replacement)
(2) For critical service, the following parts should also be stocked, where applicable
 Impeller & Key
 Shaft & key
 Muff Coupling & Key
An alternative approach is to stock a complete back pull-out assembly.
This is a group of assembled parts which includes all but the casing and coupling. In case
of an emergency, the plant can quickly normalize.
63 | P a g e
9.0 CONTACT
If you have questions or would like to order spare parts, please refer to the information below,
(1) Headquarted of HYOSUNG GOODSPRINGS. (Seoul)
a) Address : P.O Box 04144, Gongduk-dong 450, Mapo-daero 119, Mapo-Gu, Seoul,
Korea
b) Information Phone : +82-2-707-7000 +82-2-3279-8200
c) Hompage : http://www.hsgoodsprings.com
(2) For A/M & SPARE PARTS
a) E-mail : amsales@hyosung.com
(3) For A/S (Technical support)
a) E-mail : hyosungpump-cs@hyosung.com
b) Information Phone : +82-55-279-7725 (+82-2-1544-5580)
(4) HYOSUNG Abu Dhabi Office (For A/M & SPARE PARTS, A/S)
a) Address: P.O Box 133662, #326 A & B, 3rd Floor Al Fahim Building, Street No.10,
Plot M4, Mussafah Industrial Area, Abu Dhabi
b) Information Phone : +971-2-550-2866, +971-2-554-7834
64 | P a g e
10.0 APPENDIX
APPENDIX A : Piping Arrangement Type
ARRANGEMENT 1 : (Not recommended) EXPANSION JOINT or FLEXIBLE PIPE COUPLING

BETWEEN THE PUMP AND THE PUMP IN THE
PUMP ANCHOR can cause the pump to have
the same magnitude of force as the nozzle
pressure acting on the pipe inner diameter

area. This force acts on the casing, the pump
fastening bolt, the base, the anchor bolt, and
the pump flange from the nozzle. It is
impractical to design a pump to withstand
such forces, and this arrangement is not
recommended by the Hydraulic Institute and

pump institutes because it reduces pump life.
ARRANGEMENT 2 :
This is better than Arrangement 1, but it is not
as good as Arrangement 3 because it is like

using an insufficient TIE RODS. TIE RODS
should be designed to have a sufficient safety

factor in view of the stresses acting. From the
viewpoint of axial stiffness, the following

formula must be satisfied so that the TIE RODS
array is equivalent to the RIGID PIPE array

(Arrangement 3).
AR= AP (EP/ER)
AR = Total sectional area of TIE RODS (sq.in)
AP = Total sectional area of piping material

(sq.in)
ER = Elastic modulus of TIE RODS material (psi)
EP = Elastic modulus of piping material (psi)
ARRANGEMENT 3 : Although TIE RODS is better than

Arrangements 1 and 2, axial flow may occur in
65 | P a g e
the pipeline, which places a load on the pump,

because the pipe length between the pump
and the nearest pipe anchor is long.
When pressure is applied to such a long pipe,

a load is applied to the pump.
ARRANGEMENT 4 : (권장) Recommendation refer to ANSI/H.I. 1.1-5-

1994(Centrifugal Pump) and ANSI/H.I. 2.1-2.5-
1994(Vertical Pump)
 Suction and discharge piping shall be

fixed, supported and restricted near the
pump to avoid application of force and
moment to the pump..
 PIPE ANCHOR should be installed between
EXPANSION JOINT and pump to relieve

axial force.
 The "L" dimension should be made as
small as possible.
In order to obtain the best effect on the piping

ARRANGEMENT 5 : (Optional Design)
arrangement refer to ANSI/H.I. 1.1-1.5-1994
and ANSI/H.I. 2.1-2.5-1994,
 When adequate fixation can not be
provided, sufficient TIE RODS must be

installed and properly adjusted to protect
the pump and the EXPANSION JOINT.
 The suction of TIE RODS and the
movement in the direction of discharge

piping shall be restricted. (Within 0.2 mm
recommended) and the total movement in
the axial direction does not exceed the

specified value.
66 | P a g e
APPENDIX B : Lubrication of Gear Type Coupling
(1) When assembling the coupling, fully apply the recommended grease to the sleeve and
hub and assemble the coupling. Then use a grease gun to inject grease through the plug
hole.
(2) One month after the first run, remove the existing grease, clean it and inject new grease.
After that, I exchange grease every three months.
EQUIPMENT PARTS TO BE LUBRICATED LUBRICANT Q'TY / PART AND INTERVAL

PART BRAND INITIAL REPLACEMENT MAKE-UP
TYPE NOTES
Coupling Model PART NAME Q'TY / CHARGE QUANTITY QUANTITY
SHELL CALTEX MOBIL (Oil/Grease) INTERVAL INTERVAL
UNIT (g) (ｌ/SET) (ｌ/SET)
ALVINIA MULTIFAK MOBILUX
SSM112 SLEEVE 1 EP1 EP1 EP1
GREASE 50 50 3MONTH 50 3MONTH




Gear
ALVINIA MULTIFAK MOBILUX Coupling
Maker :
NARA




67 | P a g e
APPENDIX C : Thrust Bearing (Tilting Pad Bearing) Manual
68 | P a g e
Operations and Maintenance Instruction
for Vertical Combined Bearings
Turbolink Co., Ltd

Tel : +82-55-312-2800
Fax : +82-55-312-2851
E-mail : sales@turbolink.co.kr
Operation and Maintenance Instructions
for Vertical Combined Bearings
1. PRELIMINARY NOTES ---------------------------------------------------------------------------- 1
1-1. Introduction ----------------------------------------------------------------------------------------- 1
1-2. Safety ------------------------------------------------------------------------------------------------ 2
2. DESCRIPTION ---------------------------------------------------------------------------------------- 4
3. HANDLING THE BEARING ----------------------------------------------------------------------- 5
3-1. Introduction ----------------------------------------------------------------------------------------- 5
3-2. Points on handling --------------------------------------------------------------------------------- 5
4. INSTALLATION -------------------------------------------------------------------------------------- 6
4-1. Introduction ----------------------------------------------------------------------------------------- 6
4-2. Assembly of the Bearing -------------------------------------------------------------------------- 7
4-3. Points before use --------------------------------------------------------------------------------- 13
5. OPERATING. ---------------------------------------------------------------------------------------- 14
5-1. Introduction -------------------------------------------------------------------------------------- 14
5-2. Operating Risks ---------------------------------------------------------------------------------- 14
6. CARE AND MAINTENANCE ------------------------------------------------------------------- 15
6-1. Introduction --------------------------------------------------------------------------------------- 15
6-2. Procedures ---------------------------------------------------------------------------------------- 15
6-3. Lubricant Change Intervals --------------------------------------------------------------------- 16
6-4. Dismantling --------------------------------------------------------------------------------------- 17
6-5. Maintenance -------------------------------------------------------------------------------------- 19
6-6. Insulation check of the assembled bearing (if insulated type)----------------------------- 21
APPENDIX 1. Spares ---------------------------------------------------------------------------------- 22
APPENDIX 2. Table of Torque’s --------------------------------------------------------------------- 23
APPENDIX 3. Bearing Preservation During Storage -------------------------------------------- 25

1. PRELIMINARY NOTES
1-1. Introduction
This manual is to be used by qualified engineers only. It contains information that will
familiarize the user with the machine and its safe operation. It is recommended that the
health and safety advice given in this manual is followed and is kept in mind throughout
all aspects of installation, storage, operation, etc.
- General points on safety can be found in the first section.

- More specific points on safety can be found in each separate section.
 Make sure that all safety points are clearly understood and carefully noted.
Warrantee
Unless otherwise stated all warrantee claims shall be dealt with in accordance with
Turbolink Bearing.
These warranty obligation will automatically become void if the product is :
 Subjected to overloads.
 Improperly handled.
 Supplied with spare parts not approved by Turbolink Bearing.
 Exceeding, or falling short of the technical characteristics specified.
1
1-2. Safety
When operating this machine danger may arise to the user, the product and plant and/or
other assets. Therefore when running this machine make sure that all the safety procedures
give in this manual are strictly adhered to.
The below procedures should be noted.
1. Under no circumstances should the engineer work alone when operating the machine.
2. At least one of the engineers should be trained in basic first aid techniques and wear
clear identification to show that he/she is a first aider.
3. No maintenance, assembly, adjustment or any other work should be carried out on the
bearing while the shaft is rotating or capable of movement.
4. Personnel that manipulate the product should be sufficiently trained.
5. No modifications of the product should be made unless it is approved by Turbolink.
6. All users responsible for the operation of the machine must understand the chapters
fully and be familiar with the associated dangers described. These are instructions that, if
ignored, could result in death or injury.
2
Before working on the bearing the engineers should familiarize themselves with the layout
of the manual.
Attention is drawn to the following formats:
This symbol signifies a warning.

These are instruction that, if ignored could result in death or injury.
This symbol signifies that attention should be made by the operator.
If ignored it could result in minor injury or failure to carry out a

particular process correctly.
This symbol signifies additional instructions. This is usually a check.

Missing out this stage could lead to an error going unnoticed.
3
2. DESCRIPTION
The bearing supplied is one of the Turbolink vertical combined bearings , as manufactured
by Turbolink Bearings. Turbolink vertical combined bearings are a standard range of
vertical bearings, which are robust, lightweight (dependant on size) and self lubricating.
vertical combined bearings can be fitted with a variety of resistance temperature devices to
measure the temperature of the lubricating oil or pads. Turbolink vertical combined
bearings are usually self contained with water coolers which can be modified for different
methods (i.e. air cooled and circulated oil variations) with minimum modifications to the
basic casing.
The bearing can also be insulated as an option to protect against stray currents while the
machine is in operation.
4
3. HANDLING THE BEARING
3-1. Introduction
This section points out the relevant information essential when handling the bearing.
The bearing is supplied fully assembled (see arrangement drawing for mass of complete
bearing).
Threaded holes are provided for the fitting of eyebolts on the bearing casing and other
components.
It is advisable to keep the bearing within any casing and packaging until it is necessary to
remove it for assembly.
3-2. Points on Handling
Under no Circumstances should the completed bearing be handled

manually.
Before using any lifting equipment, ensure that it is certified to carry a load
greater than that of the bearing.
When handling the bearing use only provided lifting points.
Make sure bearings are stored in the intended mounting position in a dry room only.
Please check all product equipment to ensure that it is complete before Installation.
Any damage due to transit must be reported to Turbolink straight away.
5
4. INSTALLATION
4-1. Introduction
Prior to installation the bearing should be dismantled into a series of sub-assemblies.
Do not touch moving parts.
Additionally the following sub-assemblies may also be present depending upon which
type of bearing is being used, and may be handled manually;
Circular Cooler(s), Journal Pads, Oil level gauge, Oil level S/W, RTD assembly, Air Vent,
Lower Thrust Pads and Anti Vortex Guide.
The bearing is also supplied with proper sealant.
Remove all packaging. All parts are coated in a rust preventative. This must be removed
and all parts thoroughly cleaned before installation begins. To remove the rust preventative,
white spirit or a strong spirit based cleaner should be used.
There may be fumes given off during the cleaning process.

Clean parts in a well ventilated area. Always follow cleaner manufacturers’
instructions.
Use a lint free Cloth When cleaning the bearing.
6
4-2. Assembly of the Bearing
The disassembling and reassembling of the equipment by an individual

who is inexperienced can cause danger. Turbolink will not take on any
liability for any damage resulting from non-compliance with detail given
in this manual.
To assemble the bearing the below procedure (Fig.1) should be followed which if carried
out correctly could increase the working life of the machine.
Fig.1 Vertical combined bearing assembly
7
Coat all bearing surfaces in clean oil of the correct grade.
1 Place O-Ring into the groove in the sleeve.
Care should be taken when handling components to avoid the risk of

trapping hands when assembling.
2 3 Secure the sleeve to the baseplate with wrench bolts.
4 Position the baseplate on to the studs located on the supporting structure and set
baseplate concentric with centerline of machine.
5 Place O-Ring into the groove in the baseplate.
6 7 Secure lower thrust casing to the baseplate with wrench bolts.
8 Secure lower thrust pad stopper to the lower thrust casing with wrench bolts.
Ensure that stopper is fully tightened and locked in place with Loctite 222
or similar adhesive.
Always follow instructions on adhesives.
9 Fit lower thrust pads and push well in.
10 11 Fit inner support to the baseplate with the hex bolts.
Check that the clearance between the pads is correct. The clearance is
given on the arrangement drawing.
8
12 Lower the collar until it rests on the lower thrust pads.
Fit collar to the shaft and ensure that it runs true.
Check alignment. Follow the below procedure:
 Check that no thrust pads are loose (i.e. all pads are firmly clamped by the collar).
 Use feeler gauges to check the clearances between the thrust pads pivots and the
baseplate. The clearances should be equal and no greater than 0.04mm.
When using feeler gauges, take care not to damage the whitemetal
surfaces.
13 14 Fit journal pads to the inner support with the journal pad stop bolts.
Check that the pads are placed in the correct rotation. Check that the
clearance between the pads is correct. The clearance is given on the
arrangement drawing.
Ensure that stopper is fully tightened and locked in place with Loctite
222 or similar adhesive.
Always follow instructions on adhesives.
Coat both the casing and baseplate mating surface with sealant.
Always follow sealant manufacturers’ instructions.
15 Fit the upper thrust to the inner support.
16 Secure the upper thrust to the inner support with the hex bolt.
9
17 18 Assemble the anti vortex guide to the upper thrust with the hex bolts.
19 20 Secure vertical casing and baseplate to the supporting structure using stud bolts
and nuts. Torque nuts to value indicated in Appendix 2.
This appendix should be adhered to as over tightening could damage

the shell.
21 22 23 Assemble the retaining plate to cover with bushes and wrench bolts.
24 25 Fit cover to the casing. Secure the cover to the casing with hex bolts.
Torque cover securing bolts to value indicated in Appendix 2.
26 27 Fit the labyrinth seal to the cover. Secure the seal to the cover with wrench bolts.
28 29 Fit the labyrinth seal upper to the collar. Secure the labyrinth seal upper to the
collar with wrench bolts.
30 31 Assemble the fan blade assembly to the labyrinth seal upper with the wrench bolts.
Fit and seal in oil level gauge, Note! Not required for circulated oil bearings,
blanking plugs and any thermometry or detectors.
Always follow sealant manufacturers’ instructions.
Ensure that RTD assembly (Fig.2) is not damaged and is working

correctly before fitting it.
10
Ensure that all plugs, pipework joint and instruments are secure and
sealed.
Fig.2 Journal pad T/C and thrust pad T/C assembly
Fluid Seal Fitting

An o-ring and/or a compression ring are supplied with each fluid seal fitting. Either the
o-ring or the compression ring may be installed as the seal. The o-ring is silicone rubber
and is resistant to petroleum oils, and most hydraulic fluids. The compression ring is
recommended where there is longitudinal vibration or force on the probe.
O-Ring Seal
 Thread fluid seal fitting into mounting hole, using an open end or adjustable
wrench to tighten.
 Tighten sealing nut, turning clock wise, to apply slight pressure to o-ring seal,
then back off approximately 1/2 turn to permit probe insertion through o-ring.
 Insert probe, tip end first, through hole in sealing nut, push slowly through o-ring
seal to approximate depth desired.
 Tighten sealing nut, turning clock wise, to apply moderate pressure to o-ring seal.
Use wrench to tighten. Adjustment of probe can be made when sealing nut is
loosened.
11
Compression Ring Seal
 Thread fluid seal fitting into mounting hole to fit, using an open end or adjustable
wrench to tighten.
 Remove sealing nut and compression ring from fitting and slide them on probe.
 Insert probe, tip end first, into fitting to approximate depth desired.
 Slip compression ring into approximate location. Engage sealing nut on mating
threads. Use wrench to tighten. DO NOT OVER-TIGHTEN. Adjustment of
probe cannot be made after nut is initially tightened.
32 33 Assemble the protection cover to the casing with the wrench bolts.
34 Connect up external pipework.
35 Remove air vent and fill bearing with oil up to the standing oil level marked on the
oil level gauge. Note! Not necessary for circulated oil bearings.
For temperature probe fitted bearings; run the bearing and establish a steady state
operating temperature then set temperature alarm to 5℃ above the steady state operating
temperature. Shut down temperature alarm is to be set at 10℃ above steady state operating
temperature.
12
4-3. Points before use
The bearing is now complete, it must not be used until the items below have been
dealt with;
1. The entire machine has received a Declaration of Conformity, or has been declared
exempt from the Supply of Machinery (Safety Regulations) Act 1992 and the
Machinery Directive.
2. Lubricating oil has passed through the bearing and is at the proper level .
Note!!
The lubricating oil must be a mineral based turbine oil inhibited against
oxidation, corrosion and foaming, with an lSO viscosity grade as indicated on the
arrangement drawing.
The use of any other oil should be referred to Turbolink.
Do not use the bearing unless the cooling system is operating.
3. Local safety regulations have been met.
13
5. OPERATlNG
5-1. lntroduction
This section points out the risks that can occur when operating the machine.
Do not touch any moving parts.
5-2 Operating Risks
If the bearing has been correctly assembled, using the procedure already given, there is
only a marginal risk of the bearing failing which would be due to the design conditions
being exceeded.
Examples of these conditions are;
overspeed, low lubrication levels and excess load. In order to avoid these situations, it is
suggested that;
 Control panels are labeled with the bearing limitations.

 The shaft should be stopped immediately if;
1) Coolant circulation fails.
2) Bearing temperature exceeds normal operating temperature by 10℃
The users’ attention is drawn to the fact that both the pipework and
bearing surface may be hot during operation.
In order to avoid leakage of lubricant, plugs, RTDs and seals must never be removed while
the bearing is operating.
14
6. CARE AND MAINTENANCE
6-1. lntroduction.
This section demonstrates the care and maintenance needed for the smooth operation of
the machine.
Do not touch any moving parts.
6-2. Procedures
Once the steady state operating temperature has been determined, the alarm point should
be set at 5℃ above this.
Shut down is to occur at 10℃ above the steady state operating temperature.
Regular inspection should be made of all seals and pipework.

Any large leakage of lubricant or coolant will indicate that a seal or join is failing.
Maintenance must then be carried out as soon as possible.
Collect used oil and dispose of under the correct regulations.
15
6-3. Lubricant Change Intervals
Oil changes will be at differing periods depending on the frequency of bearing operation
and the conditions in which the bearing is operating.
To decide whether the lubricant is to be changed, check it visually for apparent changes.
Generally, it is recommended to change the lubricant after about 365 days(about 8700 hr).
The best way to determine the optimum change intervals is to have the lubricant examined
periodically. It should, however, be ensured that the lubricant volume to be changed
justifies the cost incurred for such examination.
Contact the lubricant supplier to determine the applicable change intervals. If the lubricant
is examined at fixed time intervals, make sure to cut back the intervals as soon as quick
changes are observed for certain properties.
Having the lubricant changed at optimum time intervals will minimize unintended
interruptions and alleviate the routine purification of the lubricant circulation.
Otherwise, the installation will have to be cleaned and scavenged, which is a costly and
time consuming job to do, if the lubricant is used beyond the optimum interval.
Carry out a lubricant change if
 You notice such change as the darkening or the thickening of the lubricant.
 Certain values such as viscosity, acid value or contamination increase.
Switch off the installation before starting work on the bearing.

Prevent the installation from restarting.
In case the lubricant contains unusual residues or is visibly changed

eliminate the causes. If necessary, Carry out an inspection.
6-4. Dismantling
The below procedure should be followed when dismantling the bearing.
1. Switch off machinery. Lock off controls. Secure and isolate shaft.
Ensure control gear, bearing gear and any other equipment capable of
moving the shaft is locked out and labeled “Not to be used”.
Beware hot oil. Allow machinery to cool off before proceeding further.
2. Drain and disconnect cooling water supply (in case of water cooling).
3. Remove drain plug and drain oil from bearing.
Any oil spillage should be collected in suitable containers.
4. Disconnect and remove any thermometry and instrumentation.
5. Remove cover and fan blade assembly.
Before removing bolts, fit eye bolts and lifting gear to the cover. Ensure
that the eye bolts are tight and secure.
Before using any lifting equipment, ensure that it is certified to carry a

load greater than the mass of the Component or sub-assembly.
When removing the cover and fan blade assembly, take care not to
damage any equipment.
17
6. Remove casing, anti vortex guide, and upper thrust.
7. Fit lifting bolts and remove the journal pads from the inner support.
The anti vortex guide and journal pads will be oily and may stick.
They will also be very slippery when handling. Take care to avoid
dropping the pads and ring.
8. Jack up the shaft until there is a clearance between the collar and the lower thrust pads.
Ensure that jacking equipment is safely positioned and certified to carry

a load greater than the mass of the shaft.
Once the shaft is raised, secure it in position using other equipment.

Do not rely on jacking equipment alone.
9. Lifting the inner support using lifting gear and remove thrust pads by sliding out.
The thrust pads will be oily and may stick to the casing. The pads will
also be slippery when handling. Take care to avoid dropping and
damaging pads.
18
6-5. Maintenance
Carry out the following maintenance procedures every 1000 operation hours (about 45 day):
With the bearing dismantled, (refer to assembly drawing with parts list) examine the thrust
pads, journal pads, anti vortex guide. There may be some scoring and wear on the pads
and ring, but provided wear is no greater than 0.125mm the pads and ring are still
serviceable. If there is any sign of the white metal surface coming away from the pad or
ring, they must be replaced. Examine the jointing between the casing and cover and that
between the base plate and the sleeve. If the jointing has decayed so that it is either
disintegrating or leaking, it should be replaced.
Examine the O-Ring, if it has started to leak or decay, it should be replaced.
Inspect the collar surface for any signs of damage. If it is necessary to change the pads, the
collar should also be replaced or repaired, otherwise the replacement pads will only have a
short life.
19
Clean the cooler assembly, using the below routine; when fitted.
1. Remove cooler assembly from bearing cover.
2. Clean the bore of the tubes using a high pressure water jet or steam cleaning.
3. Any remaining deposits or blockages can be removed by using a cleaning rod or

hypochlorite based cleaning solution.
There may be fumes given off during the cleaning process.

Clean parts in a well-ventilated area. Always follow cleaner manufacturers’
instructions.
When using cleaning rods, take care not to damage the cooler tubes.
Period to re-assembly, all the old sealant should be removed and fresh sealant applied in
the positions identified in the section on Installation (4.2).
20
6-6. Insulation check of the assembled bearing (If insulated type)
Insulated vertical bearings should undergo an insulation check before being put into operation.
if the bearings are assembled it is possible to carry out such a check only if there is no
conductive connection between shaft and foundation.
① Check if there is no conductive connection.
② Use suitable testing equipment to measure the resistance.
③ Following minimum resistance values at the testing voltage indicated should be given:
- Testing voltage 250 V Minimum resistance: 5 MΩ

500 V 2 MΩ
④ If you can no reach these values, please check:
- if there are other conductive areas outside the bearing.
- the insulation between shaft, runner and the foundation.
⑤ After elimination of other conductive areas, check the insulation again as described above,
until you can reach the indicated minimum values.
21
Appendix 1. Spares
Thrust pads
Guide pads
RTD Assemblies
O-Rings
22
Appendix 2. Table of Torque’s
1. Torque rates for hexagon socket head cap screws, hexagon bolts and hexagon nuts of
property class 8.8, to be tighten by hand.
Bolt Size (mm) Tightening Torque (Nm)
6 8.3
8 20
10 40
12 69
16 170
20 340
22 470
24 590
30 870
32 1200
36 2000
42 3200
48 4800
23
2. Torque rates for hexagon socket head cap screw, hexagon bolts and hexagon nuts for
connections with insulating components, to be tighten by hand.
Bolt Size (mm) Tightening Torque (Nm)
8 8
10 17
12 30
16 70
20 140
24 235
30 475
36 830
42 1330
48 2020
24
Appendix 3. Bearing Preservation During Storage
Caution:
Wear protection clothes when using preservatives. Please observe the instructions for the use
of the preservatives and the accident prevention rules.
Before installation :
Make sure bearings are stored in the intended mounting position, in a dry room only.
1. Bearing Preservation for Standstill Periods up to 6 months.

To protect the bearing mounted on an installation against corrosion proceed as follows:
① Remove all instruments.
② Dismantle the bearing
③ Clean the bearing
④ Paint or spray all bare metal parts inside and outside with anti-corrosive such as TECTYL 511 or
equivalent anti-corrosive.
⑤ Put a bag of desiccant (silica gel) inside to absorb humidity and prevent the formation of
condensation in the bearing.
⑥ Assemble the bearing
⑦ Close all connection holes for the corresponding fittings with screw plugs.
⑧ Use self adhesive, permanent tape to seal the gaps between shaft, baffle, seal and casing.
⑨ Store the bearing parts including all instruments separated in units in a dry room only.
2. Bearing Preservation for Standstill Periods Longer than 1 year.

① Dismantle the bearing completely.
② Spray or paint all bearing parts with anti-corrosive such as TECTYL 511 or equivalent anti-corrosive.
③ Store the bearing parts separated in units, in a dry room.
25
3. Bearing Preservation during transport.
When the bearing is fitted to the machine during transport.
① Carry out the corrosion protection procedure described in the section on Storage (7.1).
② Apply liberal lubricant to the running surfaces of the bearing.
③ Secure the shaft against axial and radial movement
④ Should there be any heavy shock loads anticipated during transportation, white metal surface
components should ideally be replaced with packing to prevent indention of the white metal
surface.
26

J910-CQ02-P0PAC-125312 - R0 IOM Manual

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J910-CQ02-P0PAC-125312 - R0 IOM Manual

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FOR INFORMATION

0 16.Aug.2022 J.D.KIM J.S.PARK J.Y.LEE FOR INFORMATION

JAWA 9 & 10 COAL FIRED STEAM POWER PLANT

Installation, Operation and Maintenance Manual

□ Basic Engineering Document □ Detail Engineering Document ■ Vendor Document □ Other

Rev Date Page Affected Description of Revision

A 16.Aug.2022 - FOR INFORMATION

1.0 PRODUCT INTRODUCTION AND GREETINGS .......................................................... 5

2.0 TRANSPORT ............................................................................................................... 9

3.0 RECEIPT ANDSTORAGE........................................................................................... 12

3.1 Receiving Checks..................................................................................................... 12

3.2 Notes on Storage ..................................................................................................... 12

3.3 Check Point During Storage ..................................................................................... 14

3.4 Corrosion Protection Treatment for Long-Term Storage............................................ 14

4.1 Cautions for Installation ............................................................................................ 16

4.2 Installation Equipment .............................................................................................. 17

4.3 Installation Procedures ............................................................................................. 20

4.3.1 Installation Preparation ................................................................................... 21

4.3.2 Foundation Plate Setting................................................................................. 21

4.3.3 Baseplate Seating........................................................................................... 22

4.3.4 Foundation Bolt Installation............................................................................. 22

4.3.5 Leveling and Grouting of Baseplate ................................................................ 23

4.3.8 Motor Single Test ............................................................................................ 32

5.1 Preparation and Checks for Pre-Start: ...................................................................... 34

5.2 Cautions for Start Up ................................................................................................ 35

5.3 Cautions during Operation........................................................................................ 36

5.4 CAUTIONS FOR STOP............................................................................................ 36

5.4.1 Normal Stopping ............................................................................................. 36

5.4.2 Emergency Stopping: ..................................................................................... 37

6.1 General .................................................................................................................... 38

6.2 Preventive Maintenance ........................................................................................... 39

6.3 Operation Log .......................................................................................................... 40

6.4 Inspection ................................................................................................................. 42

6.4.1 Stuffing Box .................................................................................................... 42

6.4.2 Disassembly Inspection .................................................................................. 43

6.4.3 Maintenance during Prolonged Stoppage ....................................................... 45

6.4.4 Bearing Housing ............................................................................................. 46

6.5 Disassembly ............................................................................................................. 46

6.5.1 Preparations for Disassembly ......................................................................... 46

6.5.2 Cautions for Disassembly ............................................................................... 47

6.5.3 Disassembly ................................................................................................... 48

6.6 Assembly ................................................................................................................. 49

6.7 Disassembly for Worn Parts ..................................................................................... 54

6.8 Assembly of Spare Parts / New Parts ....................................................................... 55

7.0 Troubleshooting .......................................................................................................... 57

8.0 Guarantee and Repair ................................................................................................ 61

8.1 REPAIR and WARRANTY ........................................................................................ 61

8.2 Guarantee ................................................................................................................ 61

8.3 Recommended Spare Parts ..................................................................................... 62

10.0 APPENDIX ................................................................................................................. 65

APPENDIX A : Piping Arrangement Type

APPENDIX B : Lubrication of Gear Type Coupling

APPENDIX C : Thrust Bearing (Tilting Pad Bearing) Manual

1.0 PRODUCT INTRODUCTION AND GREETINGS

Please use the following documents with this manual.

(1) Pump outline drawing and sectional drawing

⚫ IF THE PUMP IS OPERATED, REPAIRED, REMODELED, OR REPAIRED WITH NON-

⚫ IN ADDITION, WE CAN NOT TAKE RESPONSIBILITY WHEN AN ACCIDENT

⚫ USED WHEN THERE IS A POSSIBILITY OF A DANGEROUS SITUATION IN WHICH

⚫ USED WHEN THERE IS A POSSIBILITY OF INJURY OR PHYSICAL DAMAGE TO

⚫ USE CAUTION WHEN HANDLING THE PRODUCT CORRECTLY OR WHEN YOU

⚫ WHEN LIFTING THE PUMP, SELECT THE APPROPRIATE (REFER TO WEIGHT)

⚫ THE LIFTING LUG ATTACHED TO THE BEARING HOUSING OR DRIVER IS