CUSTOMER Fuji Electric Co.,Ltd.

USER PT Pertamina Geothermal Energy

PROJECT Kamojang5 Geothermal Power Plant

INSTALLATION MANUAL

Hotwell Pump

APPROVED BY CHECKED BY DRAWN BY

2014/09/30 1110590 Revised M.I M.I T.T 1 M.Iwabuchi M.Iwabuchi T.Tashiro

2014/09/12 1110590 First Issue 0 DRAWING No.

DATE SERIAL No. DESCRIPTION APPR. CHECK. PREP. REV. 11-VS6T109-00005X

BORE: 52"x28" TYPE: VPFC-W-M NACD: T109

(2/52)
 Safety Page
1 Safety Precautions
Be sure to completely read this Installation Manual and other accompanying documents before
installation of this pump. Read all about the knowledge, safety information and precautions
concerning the equipment prior to using it.
In the Installation Manual, precautions have been classified into "DANGER," "WARNING,"
"CAUTION," and "NOTICE."

This indicates an urgent and dangerous situation which may cause

death or serious injury unless it is avoided. This will be used only
for an extremely dangerous situation.

This indicates a dangerous situation which may result in death or a

serious injury unless it is avoided.

This indicates a dangerous situation which may result in a slight

injury or an injury of intermediate degree unless avoided.

This indicates a message related to the safety of persons or the

protection of equipment (loss of property)

Even an item indicated by has the possibility of causing a serious result depending on the
situation. You have to strictly observe the precautionary messages since they all explain
important matters.
General safety precautions for this product will be explained after the next paragraph and should
be observed, together with the above.

2 Exemption Clauses
We are unable to take the responsibility for any incongruent created due to inobservance of the
items described in the Installation Manual.

(3/52)
 Assembly and disassembly

1 Cautions during assembly

Assembly work should be carried out reliably by paying attention to the following items:

NOTICE Work should be started after performing curing work to prevent

dropping of nails, bolts or small steel pieces into a suction sump or
inside of the pump during the work.
Otherwise, the pump and auxiliary equipment are liable to be
damaged by suction.
Be careful not to break the submerged bearing by hitting it on the shaft
end of the main shaft or the edge of the sleeve.
Avoid eccentricity by applying an excessive load to a discharge elbow
during flange coupling with the piping at the discharge side.
Otherwise, it may cause vibration, a damaged bearing, or bending of
the main shaft.

Special assembly and disassembly tools have been furnished as accessories for the
assembly, disassembly and inspection of the pump. Be sure to use these after looking at the
list of assembly and disassembly tools accompanied.

WARNING Do not lift the whole body of the pump by a suspension lug of the barrel
case. Doing so may result in death or a serious injury, if the equipment
falls due to a break in the suspension lug or the like.

For lifting up or lowering, carefully consider the wire position and proper protection for
wire to prevent the product being damaged.

Do not remove protection tape around the threaded portion at the end of the main shaft.

Carefully handle the main shaft so as to prevent its bending by an excessive load applied.

When installing the impeller and coupling into the main shaft, carefully give a whirl-stop
by folding and bending the lock plate, set screw or using another methods.

Protect the mating face, fitting portion and sliding portion of each part so they are not
damaged.

(4/52)
 Wipe clean all the flange surfaces and other contact surfaces and then after a sealant
application (*1),start assembling.

For tightening flanges or shaft joints, be sure to assemble while aligning the match marks
on the outer periphery of the flanges.

Tightening of bolts must be performed using the specified torque.(*2)

(*1) Refer to the included sealant application manual.

(*2) Refer to the included Tightening Torque Control Enumeration.

(5/52)
2. Levelness of pump base
2.1 Installation flowchart
Setting the pump base is refer to the included SUB-SOLE PLATE WORK PROCEDURE
and PUMP BASE WORK PROCEDURE.

Referrence line setting PUMP BASE WORK PROCEDURE

Check foundation surface

SUS-SOLE PLATE WORK

Install Sub-Sole Plate PROCEDURE
(Check of Sub-Sole Plate Levelness)
alowable 0.30mm/m
Install a pump base on Sub-Sole Plate
(Check of Pump Base Levelness)
Leveling and centering of Pump Base

(Check of Pump Base Levelness)

Fixing Foundation Bolts
(Non-shrinkable concrete Insert of
Foundation Hole)

Primary centering

Mortar work Inspection Record Sheet

(Check of Pump Base Levelness)
See Table 2 and Fig. 2
Install Barrel Case

Installing the pump Inspection Record Sheet

(Check Lifting allowable)
Pump centerimg
(Check Alignment Coupling)
The notes at the time of the
Connecting the main pipe discharge flange connection
(Check Tolerance of the gap:0.17mm)
Pump centerimg Inspection Record Sheet
(Check Alignment Coupling)
See Table 7 and Fig. 7
Assenmbly of flexible coupling

Connecting the small pipe etc.

Ornamental mortar finish

Equipment finish painting

(6/52)
2.2 levelness of pump base work
When setting the pump base,Confirm that the pump base is level by using a level as shown
in Fig. 2 (Reconfirm also duringdisassembly and inspection of the pump.) Refer to Table 2
for the allowable value of levelness. And same value of barel case.

If the levelness during the initial setting of pump base exceeds 5/100 mm
NOTICE
against every 1meter, then it is likely to cause vibration. In this case, the
pump bases should be set again.
Also, if the allowable value shown in Table1 2 is exceeded.
During disassembly and inspection, it is necessary to review whether the
pump can be reassembled or not.
Please inform us of the necessity of the review
Table 2 Allowable value of levelness of pump base
Units are in mm/m

Allowable values during

Pump size (mm) Allowable value for initial setting
disassembly and inspection
Less than 500 0.10
Exceeding 500 & up to 1,500 0.05 0.15
Exceeding 1,500 0.20

Level
Straightedge

Block gauge

Pump base

Discharge
direction

Level in two directions of ,and

is measured using a level

Fig.2 Levelness of pump base

(7/52)
 3. Assembly of pump
Assembly should be carried out by the following procedure by referring to the procedure diagram
shown in Fig. 3-2 shows the general assembly procedure and thus the construction and shape of
the pump may be sometimes different from the actual ones.

WARNING Fix the interval of two channels with stay bolt during assembly. If not
fixed, parts placed temporarily are liable to fall down.

(1) Lower the pump portion assembled up into the barrel case and support the temporary seat
or the flange of column pipe by means of VA2-01:Channel bars(= Special tool).

(2) The intermediate shaft coupling shall be set on the upper shaft to be connected.
Set the split ring around the shaft connection and slide down the coupling.
(Refer to Fig. 3-1 Procedure diagram for assembly and disassembly at intermediate shaft
coupling)

(3) After connecting the assembly of the discharge elbow and column pipe, slightly lift the
entire assembled portion and remove the assembly-disassembly tool.

(4) Assenmble the mechanical seal(*3).

Assemble the thrust bearing unit.
Assemble the adjusting nut and the flexible coupling.

(5) Assemble the motor pedestal.

Adjust the clearance of the rotor base after checking assembly.
(Refer to 4. Confirmation of assembly and 5. Lifting up the rotating element)

(6) Motor shall be tentatively connected to the motor pedestal.

The final connection shall be made after alignment work.
Shaft alignment of the pump and motor should be performed carefully and accurately.
(Refer to 6. Adjustment of coupling distance and 7. Centerring)
Please carry out attachment of a spacer after centering.
(Refer to 8. Assembly of flexible coupling)

(7) Assemble the accessory parts. i.e., piping, RTD, etc.

(*3) Refer to the included AQ Seal Instruction Manual.

(8/52)
Fig.3-1 Procedure diagram for assembly and disassembly at
intermediate shaft coupling

(9/52)
(10/52)
4. Confirmation of assembly

After assembling the pump, confirm by the following procedure that the rotating element,
such as the impeller and main shaft, are not in abnormal contact with the stationary portions,
such as the pump casing and submerged bearing.

Attach an eye bolt to the top of the main shaft, and lift the rotating element of the
pump by a chain block.

Slightly lift the rotating element by a chain block until they are slightly floated (lifting
clearance of the rotating element is less S=5 mm, slowly turn the shaft coupling by
hand and check its turning condition.

Next, carefully lift the rotating element until the impeller hits the pump casing and
the main shaft becomes unmovable, and check the moving situation of the main
shaft and measure the stroke of all L=15mm(approx) of the rotating element.

Slowly lower the rotating element and adhere them closely to the bell mouth to the
impeller. The assembly is good if there is no abnormal condition observed.

Fig.4 Rotating element stroke confirmation

(11/52)
5. Lifting up the rotating element

For operating pump, an adequate gap must be provided between the impeller and the
bell mouth.
Upon completion of the confirmation of assembly, lift up the rotating element by the
procedure by the following procedure.

As shown in Fig.6, loosen the adjusting nut(V30-27) and lay down the rotating
element on the bell mouth.

Lift up the rotating element equal to the lifting clearance S=5 mm by turning the
adjusting nut(V30-27).

Make sure that the rotating element moves smoothly by turning the rotor by hand.

Lay down the rotating element Lift up the rotating element

Fig. 5 Lifting up the rotating element

(12/52)
6. Adjustment of coupling distance
Move the coupling pump half on the pump shaft, adjust the distance between each face
as specified "t".t=191mm After adjustment, lock the adjusting nut (V70-02) to fix the
coupling to the pump shaft.

Fig. 6 Adjustment of coupling distance

(13/52)
7. Centering
After confirmation of the pump assembly, mount a driver and perform the centering work.

As shown in Fig.7, attach a dial gauge to the flexible disc coupling on the motor
side, turn the pump shaft slowly by hand, measure the outer diameter of the flexible
disc coupling on the pump side, and move and adjust the motor so as to drop the
value within the allowable range shown in Table 7.

Measure the face-to-face dimension of the shaft coupling using a clearance gauge
and confirm that its face-to-face dimension (parallelism) is within the allowable
value shown in Table 7. If the face-to-face dimension deviates from the allowable
value, then slightly lift up the rotating element (lifting clearance of the rotating
element is less than S=5 mm ), then slowly lower it and repeat the steps again from
(1).

No. Name

Calipers

F,D,Coupling (Motor side)

Dial gauge

F,D,Coupling (Pump side)

Fig.7 Centering

Table 7 Allowable values for centering

Outer diameter of Outer diameter Face-to-face dimension

F,D,Coupling (mm) (deviated center) (parallelism)
Less than 200 0.05 0.06
200 to 300 0.05 0.06~0.09
300 to 900 0.08 0.09~0.27
More than 900 0.10 0.30

Face-to-face dimension (parallelism) is 0.03mm per 100mm of outer diameter as standard

Outer diameter:346 mm

(14/52)
8. Assembly of flexible coupling
(1) The drive side element is assembled as in a figure.
Please refer to FLEXIBLE COUPLING DRAWING (11-VS6R030-00004X)
The interval of a hub and a spacer shall be as a size of drawings.
The fastening torque of a bolt nut is taken as 570 N-m.

The insertion direction of a bolt should be based on a drawing.

(15/52)
9. Disassembly
For disassembly and inspection or repairs, the pump should be disassembled in the
reverse order of the assembly procedure. For disassembly, take precautions for the
following items in addition to the precautions for the assembly.

NOTICE If any damage to the paint coat is recognized after disassembly,

then touch-up painting is required. If nothing is done, then
corrosion or the like may occur.

At the time of reassembly, sealing parts such as sheet packing,

O-rings and the like should be replaced with new ones. Reuse
of sealing parts may cause a leak and thus should be avoided.

Confirm the match marks during disassembly. If it is hard to see them, perform
marking again and then start the disassembly.

Small parts such as bolts and nuts should be classified and stored in proper
containers to prevent them from becoming lost.

After disassembling the main shaft, wrap protection tape around the threaded
portion at the shaft end and do not remove the tape until reassembly.

Do not remove the submerged bearing except for replacement. Also, normally do
not disassemble the impeller from lower shaft.

Pay due attention to the storage of disassembled parts and never lose them.

(16/52)
 Refer to drawings and documents

Refer to drawings and documents

PUMP DATA SHEET (11-VS6T101-00008X

OUTLINE DRAWING (11-VS6T122-00008X)

CROSS SECTIONAL DRAWING (11-VS6T123-00008X)

PUMPBASE SETTING DRAWING (11-VS6T124-00001X)

PAINTING SPECIFICATION (11-VS6T992-00008X)

SEALANT APPLICATION MANUAL (11-VS6T993-00005X)

FLEXIBLE COUPLING DRAWING (11-VS6R030-00004X)

(17/52)
 Accompanying drawings and documents

Accompanying drawings and documents

Tightening torque control enumeration

The notes at the time of the discharge flange connection

AQ Seal Instruction Manual

<SAMPLE SHEET>

INSPECTION RECORD (LEVELNESS OF PUMP BASE)

INSPECTION RECORD (RECORD OF LIFTING ALLOWANCE)

INSPECTION RECORD (Alignment Record)

(18/52)
 CUSTOMER Fuji Electric Co.,Ltd.
USER PT Pertamina Geothermal Energy
PROJECT Kamojang5 Geothermal Power Plant

PUMP DATA SHEET

Hotwell Pump

2014/03/27 1110590 Revised D.T D.T T.T 3

2014/01/22 1110590 Revised M.I M.I T.T 2 APPROVED BY CHECKED BY DRAWN BY
2014/01/21 1110590 Revised M.I M.I T.T 1 M.Iwabuchi M.Iwabuchi T.Tashiro
2014/01/14 1110590 First Issue 0 DRAWING No.

DATE SERIAL No. DESCRIPTION APPR. CHECK. PREP. REV. 11-VS6T101-00008X

BORE: 52"x28" TYPE: VPFC-W-M NACD: T101

(19/52)
 VERTICAL PUMP DATA SHEET
Customer :Fuji Electric Co.,Ltd. Serial. No. : 1110590
User :PT Pertamina Geothermal Energy Outline Dwg.No. : 11-VS6T122-00008X
Project :Kamojang5 Geothermal Power Plant Cross Sectional Dwg.No. : 11-VS6T123-00008X
Pump name :Hotwell Pump Performance Curve Dwg.No. : 11-VS6T102-00008X
Equipment No. :HWP(A): KMJ5PAC01AP001 Quantity : 2
:HWP(B): KMJ5PAC02AP002 Applicable codes and Standards : API 610-10th.ed.

Flow rate (Rated) : 4600 m3/h Total head : 26.0 m
(Normal) : 4435 m3/h Shut off head : 38.5 m
3
(Max) : 5290 m /h NPSH Re. : 4.8 m
Density : 0.991 kg/L NPSH Av. : 6.33 m
Viscosity : 1.0 mPas Liquid Pumped : Geothermal Steam Condensate
Condenser Pressure : 0.10 bar.a Pumping temp. : 42.7 deg.C (Max:65 deg.C)
Minimum flow (Thermal) : 500 m3/h Column Length : L= 6.65 m
(Stable) : 3220 m3/h Location : Indoor

Type of pump : VPFC-W-M Rotation Speed 3 : 594 min-1
No. of Stage : Single Rotation (Viewed from Top) : CW
Rated Efficiency : 85 % Shaft Power : 380 kW
Suction Dia. : 52inch (DN1300) Rating and Face Flange : AWWA C207 Class B FF Position : SIDE
Discharge Dia. 1 : 28inch (DN700) Rating and Face Flange : AWWA C207 Class B FF Position : SIDE

Discharge Bowl 2 : SCS16A (Equivalent of A351 CF-3M) Column Pipe 2 : SUS316LTPY (Equivalent of A358 316L)
Suction Bell 2 : SCS16A (Equivalent of A351 CF-3M) Motor Pedestal 2 : SS400 (Equivalent of A36)
Impeller 2 : SCS16A (Equivalent of A351 CF-3M) Pump Base 2 : SS400 (Equivalent of A36)
Casing Wearing 2 : SUSF316L (Equivalent of A182 F316L) Flexible Coupling 2 : S45C (Equivalent of ANSI 1045)
Shaft 2 : SUS316L (Equivalent of A276 316L) Bearing Sleeve 2 : SUS316LTP (Equivalent of A312 316L)
Submerged Bearing : RUBBER Bolts&Nuts 2 : SUS316 (Equivalent of A276 316)
Barrel Case 2 : SUS316LTPY (Equivalent of A358 316L) (Contact with Water)
Discharge Elbow 2 : SUS316LTPY (Equivalent of A358 316L) Bolts&Nuts (Atmospheric) 2 : SUS304 (Equivalent of A276 304)
Anchor Bolts 2 : SS400 + Hot Dip Zincing (Without Coupling Bolts
(Equivalent of A36 + Hot Dip Zincing) & Anchor Bolts)
Pump Outline Type
Common base plate 1set
Anchor bolts & nut 1set
Coupling with guard 1set
Suction compound/ Discharge pressure gauge
with gauge valve 1set
Auxiliary piping(316L Stainless Steel)
with required valve and auxiliaries 1set

Pump Thrust(Supported by Pump) Refer to Outline Drawing.
NOR. 44 kN MAX. 67 kN
Net mass Elec.Motor 3
Pump :Approx. 9,900 kg Spec. 420 kW, 10 P, 6000 V, 3 phase, 50 Hz, IP55
Barrel case :Approx. 9,000 kg
Pump base :Approx. 1,050 kg Hydraulic Test : YES (Pump:7.1bar.G,Barrel:1.5bar.G)
Noise Material Test : YES
Combined with Motor: Max. 85dB(A) Dimension Test : YES
(measured one meter from equipment Performance and : YES
in operating condition) Operation Test (Using actual motor)
APPROVED BY CHECKED BY MADE BY
D M W CORPORATION
MIwabuchi MIwabuchi Tashiro
Dwg.No. 11-VS6T101-00008X
(20/52)
 CUSTOMER Fuji Electric Co.,Ltd.
USER PT Pertamina Geothermal Energy
PROJECT Kamojang5 Geothermal Power Plant

OUTLINE DRAWING

Hotwell Pump

2014/06/11 1110590 Revised M.I M.I T.T 3

APPROVED BY CHECKED BY DRAWN BY
2014/03/27 1110590 Revised D.T D.T T.T 2
2014/01/21 1110590 Revised M.I M.I T.T 1 M.Iwabuchi M.Iwabuchi T.Tashiro
2014/01/16 1110590 First Issue 0 DRAWING No.

DATE SERIAL No. DESCRIPTION APPR. CHECK. PREP. REV. 11-VS6T122-00008X

BORE: 52"x28" TYPE: VPFC-W-M NACD: T122

(21/52)
(22/52)
 CUSTOMER Fuji Electric Co.,Ltd.
USER PT Pertamina Geothermal Energy
PROJECT Kamojang5 Geothermal Power Plant

CROSS SECTIONAL DRAWING

Hotwell Pump

APPROVED BY CHECKED BY DRAWN BY

2014/06/11 1110590 Revised M.I M.I T.T 1 M.Iwabuchi M.Iwabuchi T.Tashiro

2014/03/20 1110590 First Issue 0 DRAWING No.

DATE SERIAL No. DESCRIPTION APPR. CHECK. PREP. REV. 11-VS6T123-00008X

BORE: 52"28" TYPE: VPFC-W-M NACD: T123

(23/52)
(24/52)
 CUSTOMER Fuji Electric Co.,Ltd.
USER PT Pertamina Geothermal Energy
PROJECT Kamojang5 Geothermal Power Plant

SEALANT APPLICATION MANUAL

Hotwell Pump

APPROVED BY CHECKED BY DRAWN BY

M.Iwabuchi M.Iwabuchi T.Tashiro

'14/6/5 1110590 First Issue 0 DRAWING No.

DATE SERIAL No. DESCRIPTION APPR. CHECK. PREP. REV. 11-VS6T993-00005X

BORE: 52"x28" TYPE: VPFC-W-M NACD: T993

(25/52)
 11-VS6T993-00005X2/9

General

Small gap at the joints between the parts of the pump is inevitable due to the manufacturing constraints and
assembly procedure. During operation of pump, corrosion due to the water being pumped (geothermal steam
condensate water), epsecially at the surfaces near these gaps, is a matter of concern. As a preventive measure to
avoid corrosion, sealant is filled in these gaps at the time of assembly and before shipment to prevent
geothermal steam condensate water from entering into these gaps.

This manual describes the recommended brands of the sealant, locations where sealant is applied and application
procedure. In addition to this, the coating procedure of seizure preventive agent is explained.

CAUTION

Repair the sealant applied on the parts after disassembling for the periodic inspection. Make sure
that all gaps are coated with sealant during assembly.

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 11-VS6T993-00005X3/9

1. Applicable limits
This manual prescribes the sealant for the pump.

2. Applicable brands and locations

Applicable brand (*)

Applicable location Life Mark
Name Trait Maker Time
Gap on the water contacting
portion of the rotating parts
and coupling surface.
1 Silicon
Three Bond THREE BOND 12
(1) non-solvent S
1212 non-fluid type Co., Ltd. Head of the bolt used for months
(2)
the water contacting portion
of the part etc.
The applicable outside

Non solvent Flange surface column pipe,

NIHON
Hermeseal non-dried barrel case, discharge elbow, 24
2 HERMETICS H
No.723 fluid type Co., Ltd. pump casing, bell mouth, months
gasket mechanical seal etc.

Tape type
sealant mainly HAYAKAWA Faucet portion of flange column
Santack 12
3 composed of RUBBER Co., pipe, discharge elbow, pump T
Sealer TM butyl rubber Ltd.
months
casing, bell mouth etc.
mixture

Screw & AGENT: main shaft thread part

Never Seize engagement KYOKUTO thread part of the bolt and nut 24
4 BOEKI
N
Nickel Special seizure engagement portion of reamer months
prevent agent KAISHA, Ltd. bolt

LOCTITE
Screw loose 6
5 (JAPAN) all bolts L
Lock Tite 243 prevent agent CORPORATION
months

One
component Calking compound for the dent
Three Bond THREE BOND 12
6 non-acid Co., Ltd.
part of the flange in the C
5211 months
silicon atmosphere
sealant type

(*)Life time = After it is delivered, it is an unopened keeping time.

The condition of Life time : normal temperature, normal humidity and avoid direct sunlight.

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 11-VS6T993-00005X4/9

3. Coating procedure

1Three Bond 1212

[The surface treatment]
Clean-off oil, water and dust from the surface by Acetone etc.

(1) Three Bond 1212 (coating) -------------------------------------------------------------------------- S

Cleaning of application surface

Clean-off oil, water and dust from the surface by Acetone etc.

Application of 1212
Apply the sealant to the center of flange so that the sealant can spread over the whole flange
face when flanges are tightened.

[Standard]
Flange surface width Bead diameter
10 mm or less Approx. 1.5 mm
10 to 20 mm 2.5 mm
20 to 30 mm 3.5 mm

Connect flanges before the sealant surface becomes hard (while the surface is sticking
condition).
Connect flanges within 20 minutes as the sealant becomes less adhesive and less effective in
20-30 minutes after application.
No primer coat is required for sealing of flange surface.

[Cure rate]
15-16 hours of time is required until sealant surface becomes rubber-like condition.
Longer time is required in lower temperature (5 deg.C or less) until the surface becomes
rubber-like condition.

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 11-VS6T993-00005X5/9

(2) Three Bond 1212 (filling) -------------------------------------------------------------------------- S

Cleaning of surface
Sealant does not work effective or dirt remains on application surface.
Clean off dirt by solvent such as Acetone etc and dry the surface well.

Sticking of masking tape

Use the masking tape to prevent protrusion of 1212, and finish neatly.

Filling of Three Bond 1212

After primer surface has dried sufficiently, cut nozzle top to suitable size, and apply 1212 by
pressing nozzle to deep position.
(Use Three Bond Tube Gun as viscosity of 1212 is high.)

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 11-VS6T993-00005X6/9

Filling procedure of 1212 into bolt neck and a bolt hole.

) Coat Three Bond 1212 in the neck of a bolt.

) Put Lock Tite 243on the thread of bolt and screw in the hole.

) Fit Three Bond 1212 in the gap of the bolt head the hole.

) Carry the flowing out Three Bond 1212 away.

Curing
Leave and cure it for 23 days after the handling. Be careful not to make a crack (not to touch
and not to make a tension).
The hardening speed is about 35 mm/day in general under the condition of environment
Temperature (25 deg.C) and humidity (50 %) but the hardening progresses gradually from
the surface to the internal part for 30 minutes.

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 11-VS6T993-00005X7/9

2Hermeseal No.723 -------------------------------------------------------------------------------- H

[The surface treatment]
Clean-off oil, water and dust from the surface by Acetone etc.

[No.723 coating]
Fully coat the No.723 in flange with a brush, a spatula or a flatiron until 0.10.2 mm or proper.
A coating amount is about 3 m2/(500g).
No drying is necessary after applying.

3Santack Sealer TM ------------------------------------------------------------------------------- T

[The surface treatment]
Clean-off oil, water, dust and rust from the surface.

[Sealer pressing]
Assemble the flange and press that in plug side after connecting insert side.
Sealer is wound in a wheel, but the following order is efficient.

4Never Seize Nickel Special ---------------------------------------------------------------------- N

Coat that with a brush until 0.020.10mm.
Be careful not to coat more than is required.

Washing above-mentioned Sealant

Embrocation surface of the Sealant is washed in solvent (Acetone etc.).

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 11-VS6T993-00005X8/9

5Lock Tite 243 --------------------------------------------------------------------------------------- L

[The surface treatment]
Clean the oil, water and dust from the surface with Acetone etc. and dry that.

[No.243 coating]
Sufficiently fit that in the clearance of thread.
Coating amount ; 3drops in case of M10, 5drops in case of M20.
Quickly bind tight after coat as it is hardened in 515 minutes in ambient temperature
(2025 deg.C).

[Disassembling of parts and reassembling]

Disassembling can be done by a spanner, a wrench or etc.
Distracted Lock Tite will become white powder and sticking.

For that reason, it is necessary to clean the surface with a wire brush to reassemble before coating
Lock Tite again.

[Hardening]
For hardening, leave that for 23 hours after assembling.

6Three Bond 5211

[The surface treatment]
Clean-off oil, water and dust from the surface by Acetone etc.

(1) Three Bond 5211 (filling) --------------------------------------------------------------------------- C

Filling of 5211
It is adjusted to a crevice and is plugged.
After plugging, so as to push it in a spatula and so on, it is completed.

[Cure rate]
24 hours of time is required until sealant surface becomes rubber-like condition.
Longer time is required in lower temperature (5 deg.C or less) until the surface becomes
rubber-like condition.

(32/52)
(33/52)
 CUSTOMER Fuji Electric Co.,Ltd.
USER PT Pertamina Geothermal Energy
PROJECT Kamojang5 Geothermal Power Plant

FLEXIBLE COUPLING DRAWING

Hotwell Pump

APPROVED BY CHECKED BY DRAWN BY

M.Iwabuchi M.Iwabuchi T.Tashiro

'14/6/10 1110590 First Issue 0 DRAWING No.

DATE SERIAL No. DESCRIPTION APPR. CHECK. PREP. REV. 11-VS6R030-00004X

BORE: 52"28" TYPE: VPFC-W-M NACD: R030X

(34/52)
(35/52)
 Tightening torque control enumeration

Tightening torque control enumeration

Nominal Stress SS400 SUS304SUS316 SUS403 SCM440SCM435

diameter area
Tightening torque Tightening torque Tightening torque Tightening torque
M 6 5.3 4.5 7.5 7.7
M 8 13 11 18 20
M10 25 21 36 37
M12 43 37 63 65
M14 115 68 59 100 110
M16 157 110 93 160 170
M18 192 150 130 220 230
M20 245 210 180 310 320
M22 303 280 250 420 430
M24 353 330 310 530 540
M27 459 480 460 770 790
M30 561 650 620 1000 1100
M33 694 890 850 1400 1500
M36 817 1100 1100 1800 1900
M39 976 1500 1400 2400 2500
M42 1121 1800 1700 2900 3000
M45 1306 2300 2200 3600 3700
M48 1473 2700 2600 4400 4500
M52 1758 3500 3400 5700 5800
M56 2030 4400 4200 7200 7300
M60 2362 5500 5200 9000 9100
M64 2676 6700 6300 10900 11000

Units
Stress area mm2
Tightening torque Nm

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 Page

RECORD NO.

DATE

INSPECTION RECORD WITNESSED BY

Fuji Electric Co.,Ltd.

CUSTOMER
PT Pertamina Geothermal Energy
Kamojang5 Geothermal Power Plant APPROVED BY

1110590
SERIAL ITEM MATERIAL CHECKED BY

2
NAME LEVELNESS OF PUMP BASE QUAN. INSPECTED BY

Straightedge
Level
Block gauge

Pump base

Discharge direction

Level in two directions of ,

and is measured using level

Unit: mm/m
Tolerance: 0.05mm/m

Measurement point Remarks

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 Page

RECORD NO.

DATE

INSPECTION RECORD WITNESSED BY

Fuji Electric Co.,Ltd.

CUSTOMER
PT Pertamina Geothermal Energy
Kamojang5 Geothermal Power Plant APPROVED BY

1110590
SERIAL ITEM MATERIAL CHECKED BY

2
NAME RECORD OF LIFTING ALLOWANCE (ROTATING ELEMENT) QUAN. INSPECTED BY

Unit: mm

MARK ITEMS MEASUREMENT VALUE Remarks DESIGN VALUE

L TOTAL STROKE about 15

S LIFTING ALLOWANCE 5
OF THE ROATING ELEMENT

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 Page

RECORDNO.


WITNESSEDBY

Fuji Electric Co.,Ltd.

CUSTOMER
PT Pertamina Geothermal Energy

Kamojang5 Geothermal Power Plant
APPROVED BY

110590
SERIAL No. ITEM No. MATERIAL CHECKED BY

NAME Alignment Record QUAN. INSPECTED BY

NO AA BB CC DD

side side side side side side

DRAWING

side side

Measuring Parameter
UPPER SIDE Type Check Gauge
Dial Gauge
Eccentric Calipers

Dial Gauge
Calipers
ROTATION Parallel

Measurement Method

Check Hand Turning Tolerance

Together(Drive and
Eccentric 0.08 mm
Driven Side)

One Side Parallel 0.10 mm

RESULT
Item DWG Combination Eccentric1/100mm Parallel1/100mm Plane to Plane Motor End Play Vertical
Date Stroke Lift
No No Side SideB mm Tmax Tmin (mm)

Side A
Side B
Side A
Side B
Side A
Side B

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 LONG TERM STORAGE MANUAL

FOR

INDUCTION MOTORS / GENERATORS

(Document No. : HHI-manual-S001)

HYUNDAI HEAVY INDUSTRIES CO., LTD.

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 Maintenance Work during Relatively Long Storage Periods
before First Operation or while Shutdown for Servicing

Induction Motors / Generators

Maintenance

If a machine has been out of service for more than three months, the following procedures should be
followed. The intervals depend on the operating and site conditions. The following work's ate
recommended under normal conditions.

Package conditions. Table 1

Machine with export packing. Without packing or machine with domestic packing.
Package
Machine should be stored in a correct mounting position. Machine should be covered with suitable
condition
water-proof canvases.

Storage 1. Machine with packing should preferably not 1. Machine should not be stored in outdoors. where

location be stored in outdoors. where possible, possible, machines should be stored indoors in a

machines should be stored indoors in a clean, dry area.

clean, dry area. 2. If indoor storage is impossible for totally-enclosed,

2. If indoor storage is impossible for machine outdoor application machine, it is recommended

with packing, it is recommended that the that covering it with canvases.

storing it under a weather-proof roof. or

alternatively cover it with canvases.

1. In the case of condition before installation.

(1) Stacking of heavy machine stop one another should be avoided. Machine should be stored in such
Works for
in a way that no base frame will suffer distortion.
packing
(2) Attention should be paid to the loading capacity of floor. Care should be taken the floor, on which

machine is stored, is not subjected to vibration and free from moisture.

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 (3) Storing of machine for longer than one year (3) The store room should be well ventilated and

is not recommended. If the storing is selected for possible protection against moisture

continued, following procedures described and dirt.

in Table 2 should be done in year : 2. Cover the air intake and discharge openings of

1) Seal the silica-gel within packing and open-enclosure machine by canvases to be

replace at regular intervals. prevent the dust deposits inside the machine.

2) Fully seal the packing. 3. If the other works are still in progress even after

completed installation of machine, machine should

be protected to ingress of foreign matters by a

temporary protection covering.

Maintenance work preparatory on machine parts. Table 2

During long storage Prior to operation

External, Apply the following rust-preventive materials or Remove the rust-preventives with suitable

unpainted equal : RUST VETO 244. 342.(E.F.Houghton). solvents.

metal P101(Nippon Sekiyu). TECTYL 506(Valvoline Oil).

surfaces.

Bearings. Rotate the shaft slowly at least 10 revolutions by 1. Check to see that shaft locking-provisions

hand (*) or for several minutes by temporarily and temporary-covers have been

operate (**) the machine once every three months. removed, when provided.

Exception : In machine with export packing. 2. Check for irregular noise by shaft rotation

by hand.

3. If possible, check that bearings are free

from rust.

Regreasable Supply the following amount of grease to the 1. Remove the old grease from the grease

anti-friction bearing while rotating the shaft by hand. outlet opening before beginning

bearings. Regreasing amount is indicated on the rating plate. operation.

Supply the grease once a year. Prior to grease 2. Supply new lubricant of the amount

supply, Open the grease outlet. indicated on rating plate while rotating

Remove the original grease to avoid excessive the shaft by hand or while the machine

filling the bearing cavity and to avoid grease leaks is running.

from shaft seals. 3. Remove old grease by running the

machine for a few hours with the grease

outlet open.

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Oil lubricated 1. Check the reservoir filled with lubricant up to the 1. Open the drain plug and remove the

bearings proper line on the oil level gauge. original oil. Fill the reservoir with the new

2. If a machine is out of service for more than one lubricant up to the proper line on the oil

month, the following procedures should level gauge.

preferably be followed monthly : 2. In the forced-feed, oil-lubricated bearing.

(1) Lubricate a machine with combined. angular- (1) Clean the inside of the oil pipings and

contact ball (72 or 73 series) bearings by refresh them, when required.

operating it for about 10 minutes. Lubricate a (2) Fill the bearings connected to a feed-oil

bearing of large output machine, provided with oil system with specified oil, check the

inlet plug on the top of oil reservoir, by pouring oil system for satisfactory operation.

through the oil inlet. Then immediately rotate its

shaft at least 10 revolutions by hand. After that,

drain off excess oil.

(2) For a machine with a spherical-roller thrust (293

or 294 series) bearings. A machine should be run

for about 10 minutes or the shaft rotated at least

10 revolutions by hand.

(3) In a machine with sleeve bearings, a machine

should be run for about 10 minutes or the shaft

rotated at least 10 revolutions by hand. When

rotate the shaft, supply about 50 to 100cm3 of

the lubricating oil through the screw plug (or

sight-glass) of bearing housing.

3. Replace with new oil once per year.

Insulated Insulation resistance between winding and earth be measured every six months (Every
windings one year in machine with export packing) and before the machine is started. If the lower
insulation resistance value is measured, open the terminal-box cover and, if the value
does not increase, winding should be dried before being energized.
Anti- Heater should be energized, in machine Heater should be disconnected before
condensation without packing, when power-supply cables machine is started up.
heater, and heater leads are connected. To prevent
when moisture accumulation, some form of heating
provided. must be utilized to prevent condensation.
This heating should maintain the winding
temperature at a minimum of 5 above
ambient.
Water drain Drain water by opening the drain plug in the enclosure.

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 plug, when At regular intervals of not longer than six -
provided. months. One year in machine with export
packing.
Sliprings Check the surface for signs of corrosion every six months and prior to operation (one
year in machine with export packing.)
Openings Any unused cable entry into terminal box(s) Remove the temporary protection
should be closed. covers, when provided
Painted Repaint at regular intervals, when necessary.
external
surfaces
Notes (*) : When possible. (**) : When the machine is installed ready for operation.

Check and inspection items prior the operation, addition to items described
above

Enclosure :
(1) Check that cooling air can flow unobstructed to and form the machine.
(2) Check the enclosure and external rotating parts for damage or corrosion.
(3) Check to insure that rotating parts do not contact with stationary one.
(4) Inspect the shaft sealing for correct mounting.
(5) Check the screws and base or flange-bolts have been tightened.
(6) In maintain the necessary degree of protection required for enclosures of machines used for outdoor
applications, refit gaskets. When provided, and carefully coat all surfaces to be sealed with a sealed
with a sealing agent when reassembling.

Terminal box, terminals :

(1) Check cable terminals are correctly connected electrically.
(2) Check all electrical terminals have been tightened.
(3) With flexible leads : Check the cable connections are properly insulated, all bare, live metal should be
wrapped with insulation tape.
(4) Make sure that direction of rotation of machine is correct.

Storage of spare parts

Storage locations :
Packing should be stored in the storeroom. The storeroom should be well ventilated and selected for
possible protection against moisture and dirt. Spare machine with anti-friction bearings should be stored
in a place not subject to vibration.

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Packing conditions :
(1) Anti-friction bearings : Spare bearings with packing which protects for long storage-periods should
preferable be purchased.
(2) Sleeve bearings : Apply RUST VETO HEAVY (E.F.Houghton), TECTYL 506 (Valvoline Oil) or equal
to finished surface, P103 (Nippon Sekiyu) or equal on lining. Coat the painting for other faces. Re-
coat them every one year.
(3) Other parts : Fully seal the packing.

End.

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