HAYWARD TYLER

ENGINEERED PRODUCTS

BHARAT HEAVY ELECTRICALS LTD

(BHEL)
Kahalgaon Power Station

SERIAL NUMBERS
EP/03/10757A,B,C,D,E & F
EP/04/10794A,B & C

3 X 500 MW BOILER CIRCULATING PUMPS

 FOREWORD

This instruction manual provides comprehensive
installation, operating and maintenance information
of a Hayward Tyler Glandless, Wet Stator, Motor
Pump Unit, referred to in the text as the circulator.
The General Contents list shows that the manual is
divided into eight main sections. Paragraph
references are consecutive throughout each section,
and are preceded by the appropriate section
number. For example 5.1. designates:-
Each section contains an itemised Contents List.
The major illustrations of the Pump and Motor are
included at the rear of Section 7. Additional
illustrations of particular features are incorporated
in the text.
Note! Where a customer boiler layout drawing is
shown, this is used in good faith. However,
Hayward Tyler can accept no responsibility for any
errors or consequences that may result.

Section 5, Commissioning. Hayward Tyler Manuals are for guidance only and
5.1. Pre-Start Check List. we reserve the right to update, revise and modify
this manual in accordance with our continuous
Hayward Tyler Engineered Products Ltd. research and development programme.
1 Kimpton Road
Luton Revised manuals will not automatically be issued,
Bedfordshire however, should they be required, Hayward Tyler
ENGLAND may be contacted and arrangements can be made.
LU1 3LD

Telephone: +44 (0) 1582 731144

Email: engineering@haywardtyler.com
Fax: +44 (0) 1582 452198

i
 GENERAL CONTENTS

BOILER CIRCULATING PUMP – INSTRUCTION AND MAINTENANCE MANUAL

SECTION 1 TECHNICAL DATA

SECTION 2 STORAGE

SECTION 3 DESCRIPTION

SECTION 4 INSTALLATION

SECTION 5 COMMISSIONING

SECTION 6 OPERATION

SECTION 7 MAINTENANCE

SECTION 8 STUD TENSIONING

ii
 SECTION 1
TECHNICAL DATA

CONTENTS

PARAGRAPH PAGE

1.1 GENERAL 1.1

1.2 CHARACTERISTICS 1.1

1.3 MOTOR CHARACTERISTICS 1.2

1.4 CLEARANCES AND SETTINGS 1.2

1.5 HEAT EXCHANGER 1.3

1.6 INSTRUMENTATION 1.3

1.7 TORQUE LOADINGS 1.3

1.8 WEIGHTS (APPROXIMATE) 1.3

ILLUSTRATIONS

FIGURE 1/1 MOTOR ASSEMBLY 1.4

FIGURE 1/2 WINDING RESISTANCE DIAGRAM 1.5

FIGURE 1/3 PUMP PERFORMANCE CURVE 1.6

FIGURE 1/4 MOTOR PERFORMANCE CURVE 1.7

1. 0
 SECTION 1
TECHNICAL DATA

1.1 GENERAL

Unit Serial Nos: EP/03/10757 A B C D E F & EP/04/10794 A B

Customer Order No: 0130645 & 0140593
Service: Boiler Water Circulating Pump with
Motor below Pump.
Number Supplied: 9
Electrical: 3300V - 3 Phase - 50Hz

1.2 CHARACTERISTICS

Type: Single Suction - Double Discharge

Size: (2 x 13) x 16 x 19H Volute
Design Pressure: 214 kg/cm2
Design Temperature: 370°C
Hydrostatic Test pressure: 321 kg/cm2
Suction Pressure: 197.4 kg/cm2
Specific Gravity at pump suction 0.542
N.P.S.H. required: 15 m (3% head drop)
Quantity Pumped: 3135 m3/hr
Differential Head: 32.37 m
Pump Efficiency: 83 % Cold 83 % Hot
kW Absorbed: 333.1 Cold 180.5 Hot

1.3 MOTOR CHARACTERISTICS

Type: Wet Stator Squirrel Cage Induction

Output: 360 kW
Service Factor: 1.0
Winding Insulation: XLP
Motor Case Design Pressure 214 kg/cm2
Motor Case Design Temperature 368oC
Speed: 1450 RPM.
Hot Duty Cold Test
Motor Efficiency: 89.5 % 89.5 %
kW Input: 201.7 372.2
Power Factor: 74.0 82.5
Overall Efficiency: 74.3 % 74.3 %
Full Load Current: 85 amps
Motor Starting Current: 410 amps

1. 1
 SECTION 1
TECHNICAL DATA

1.4 CLEARANCES & SETTINGS (mm)

Initial Maximum

Impeller Wear Ring Clearance : ∅ 1.46 – 1.58 2.03

Journal Bearing Clearance : ∅ 0.20 - 0.38 0.55

Reverse Thrust Wear Ring Clearance : 0.42 - 0.52 0.76

∅

Rotor End Float: 0.50 - 0.80 1.50

Impeller Setting (Dimension ‘Z’): 572.5 – 571.5 mm

1.5 INSTRUMENTATION:
Temperature Switches: Ashcroft Model T.461-T20-030-69C-XNH:
20-950C with 6096 mm capillary. 15amp. 125 to 250 Volt AC.

Alarm Setting 60°C Trip Setting at 65°C

Thermometer: Ashcroft Model 600A-03-C41-B01-A1-L07-BS-

XNG
0-1200C – CD1
Pressure Gauge: Ashcroft Model 60-1379SSL-04L-XNH-XNG
0-250 Kg/cm2 – CD1.

Flowmeter: KDG Mobrey Series 250 Rotameter

Model 250-50-CX-M12-TO-S6-Z6
Relay Mains supply: 220V 50/60 Hz
Contact Cut Off Capacity: Max 250V/4A/500VA
Thermocouples: Type ‘K’ Dual Element – Ungrounded

1.6 TORQUE LOADINGS:- Refer to Figure 1/1, Schedule of Torque Loadings

1.7 WEIGHTS (Approximate)

Pump Case 3425 kg

Motor Complete 6020 kg

Heat Exchanger 410 kg

1. 2
 SECTION 1
TECHNICAL DATA

TOTAL 9855 kg

1. 3
 SECTION 1
TECHNICAL DATA

Figure 1/1 Motor Assembly

1. 4
 SECTION 1
TECHNICAL DATA

Figure 1/2 Winding Resistance Diagram

1. 5
 SECTION 1
TECHNICAL DATA

Figure 1/3 Pump Performance Curve

1. 6
 SECTION 1
TECHNICAL DATA

Figure 1/4 Motor Performance Curve

1. 7
 SECTION 2
STORAGE

CONTENTS

PARAGRAPH PAGE

2.1 ENVIRONMENT 2.2

2.2 STORAGE - GENERAL 2.2

2.3 INHIBITOR 2.2

2.4 HEAT EXCHANGER 2.2

2.5 EXTERIOR SURFACES 2.2

2.6 STANDARD STORAGE CHECKS FOR STORAGE UP TO 3 YEARS 2.3

2.7 STORAGE PERIODS GREATER THAN 3 YEARS 2.4

2.8 PREPARATION FOR STORAGE AFTER USE 2.4

2.9 INSPECTION RECORD CARDS 2.4

ILLUSTRATIONS

FIGURE 2/1 MOTOR STORAGE / TRANSIT DETAILS 2.1

FIGURE 2/2 PUMP CASE STORAGE DETAILS 2.2

FIGURE 2/3 INHIBITOR FILLING VALVE 2.3

FIGURE 2/4 ROTATING THE ROTOR ASSEMBLY 2.5

FIGURE 2/5 INSPECTION RECORD CARD 2.6

FIGURE 2/6 CHECK LIST 2.7

2.0
 SECTION 2
STORAGE

Figure 2/1 Typical Motor Transit/Storage Details

2.1
 SECTION 2
STORAGE
2.1 ENVIRONMENT
The storage area must have a hard standing
floor that will be capable of supporting the
weight of the units.
2.2 STORAGE – GENERAL
2.2.1 Pump Case (Fig. 2/2)
1) The pump case internal cast areas and all
machined faces must be cleaned and a
suitable removable solvent rust
preventative, with a minimum effective
life of 6 months, applied. Recommended
rust preventatives are, Jenolac J400 or
Shell Ensis Fluid 264, or their
equivalents.
2) All pump case openings must be closed
with covers. These covers to be secured
to the weld preparations with steel
banding and the pump case main flange
with the existing studs and nuts supplied
on the pump flange.
Figure 2/2 Pump Case Storage Details
2.2.2 Motors (Fig. 2/1)
1) The motor and transit assembly must be
stored in a vertical position standing on
the motor cover end.
NOTE:
When the terminal box protrudes
below the motor cover stand, rest the
motor cover on balks of timber of
sufficient height to keep the terminal
box clear off the ground (Fig. 2/1)
2.2
2) The motor apertures must be blanked off
with flanges secured with studs, bolts and
nuts (Fig. 2/1).
3) The motor and transit assembly must be
filled to the top of the transit canister with
inhibitor of the appropriate concentration,
through the filling connector located in
the temporary transit flange, sealing off
the motor heat exchanger bottom outlet.
2.3 INHIBITOR
Inhibitor is to be produced from a pre-mixed
concentration of mono-propylene glycol and
distilled water in a 50/50 solution by volume.
The mono-propylene glycol must contain
corrosion inhibitors and meet BS6580 or
equivalent. A tolerance of ±5% on the normal
glycol/water mix may be applied.
The distilled water used must have a
conductivity of less than 10 reciprocal
megohms (microsiemens) per centimetre.
Check the specific gravity of the inhibitor to
ensure the correct concentration.
The specific gravity of the mixture at 20°C is
as follows:-
Mixture by%Volume Specific Gravity
45% MPG /55% Water 1.036
50% MPG /50% Water 1.038
55% MPG /45% Water 1.040
MPG = Mono-propylene Glycol
2.4 HEAT EXCHANGER
The heat exchanger should be stored as
instructed by the manufacturers.
The heat exchanger interconnecting pipe work
and the fill and drain assemblies must also be
filled with the same inhibitor as the motor,
blank flanges being used to seal both ends.
2.5 EXTERIOR SURFACES
All exterior surfaces of the motor must be
maintained in a good painted condition.
Scratched or damaged paintwork must be
repainted.
 SECTION 2
STORAGE
2.6 STANDARD STORAGE CHECKS FOR
STORAGE UP TO 3 YEARS
A visual examination and inspection of the
motor and transit assembly must be made at
least every three months as follows:-
NOTE:
When stored by the contractor, or by an
agency, a record card should be kept of the
intervals between inspections and the results
of the following inspection checks recorded.
2.6.1 MOTOR
1) The motor is stored vertically resting on
the motor cover - not horizontally.
2) The exterior paintwork is in good
condition. Repaint where necessary.
3) All flanges and joints are tightly secured
and no leakage of the inhibitor has taken
place.
2.6.1.2 Topping up/Draining Inhibitor (Fig 2/3)
4)
a) All studs, bolts and nuts are present
and in sound condition.
b) The phosphate, or any other plating,
applied to these items has not
deteriorated.
5) Measure and record the ambient
temperature of the storage area.
6) Check and record the insulation resistance
of the stator windings as follows:
a) Remove the terminal box cover.
b) Check the insulation resistance at the
terminal stems using a l000V megger.
Record the result.
IMPORTANT: -
If any insulation resistance value falls below
200 megohms at 20°C this, and any previous
readings, with dates, must be reported to
Hayward Tyler for comment.
c) Fit the terminal box cover.
7)
a) Remove the inspection cover from the
top of the transit canister (Fig.2/1).
Fit impeller wrench onto the impeller
nut and rotate the rotating assembly
seven complete revolutions in an anti-
clockwise direction when viewed from
the pump-end.
2.3
CAUTION:
To rotate the assembly in a clockwise
direction may damage the impeller nut
locking screw.
b) If the shaft cannot be rotated or is
very difficult to turn, the motor must
be stripped down and inspected as
outlined in Section 7.
8) Check the inhibitor level in the motor and
transit assembly. The level of inhibitor
must not fall below the level of the
impeller. Top up if necessary.
9) Check the glycol/water concentration by
measuring the specific gravity of the
inhibitor. The inhibitor is considered
acceptable if it conforms to the
concentration and tolerance given in
paragraph 2.3.
10) Replace the transit inspection cover
when the inspection is satisfied.
1) Remove the access cover plug.
2) Attach a hose leading from a pumping
device to the hose tube of the inhibitor
filling valve.
3) Unscrew the filling valve screw by two
turns. This action opens the valve to allow
the pumped liquid to enter the motor.
4) When the sufficient inhibitor has been
pumped in, turn screw to close the valve.
5) Remove the hose from the inhibitor
filling valve.
NOTE:
If the motor is to be drained, allow the
liquid to flow out of the valve hose tube.
Ensure disposal of inhibitor is carried
out in accordance with local
regulations.
Figure 2/3 Inhibitor Filling Valve
 SECTION 2
STORAGE
2.6.1.3 Pump Case and Transit Assemblies
Inspect the pump assembly and check the
following: -
1) No extensive corrosion has occurred on
the internal pump cast or machined areas.
2) The protective coating is satisfactory.
Re-apply if necessary.
3) Visually examine the assembly for
damage.
4) Check that the pump case protective
flanges are correctly fitted and secure.
2.6.2 Stud Tensioning Equipment
After use, the stud tensioning components
must be thoroughly cleaned, examined for
damage and a rust preventative lubricant
applied to all surfaces.
The components must be then wrapped in
suitable waterproofed material and stored in
a clean, dry area.
2.7 STORAGE PERIODS GREATER
THAN THREE YEARS
Units that remain in store over three years
require special consideration and Hayward
Tyler Limited should be consulted for
specialist advice.
Motor assemblies that are stripped must be
reassembled using new gaskets, the details
recorded on the storage record card stating that
it has been stripped and listing any relevant
findings.
CAUTION:
Precautions must be taken prior to use that
the unit is pressure tight.
2.4
2.8 PREPARATION FOR STORAGE
AFTER USE.
1) Remove the motor from the pump case
and drain the motor as described in
Section 7.
2) Disassemble the motor cover and clean
out any loose material, sediment etc.
3) Disassemble the motor as described in
Section 7.
4) Check all fittings and clearances and
general condition (Section 1). Fit spare
parts as necessary.
5) Reassemble the motor as described in
Section 7.
6) Using special wrench provided on the
impeller nut, check that the shaft rotates
freely, approximately seven revolutions in
an anti-clockwise direction.
7) Check the insulation resistance of the
winding. This should not be below 200
megohms.
8) Fit the transit canister to the main flange
and stand the motor upright on the motor
cover.
9) Seal off all apertures with appropriate
transit flanges and gaskets.
10) Fill the motor with a pre-mixed
concentration of inhibitor, in accordance
with paragraph 3, through the filling
connection in the transit flange, sealing
the motor heat exchanger bottom outlet.
11) Fit the transit canister inspection cover.
12) Re-check the insulation resistance of the
motor windings.
13) Check that the storage conforms to Para
2.2.
2.9 INSPECTION RECORD CARD
(Fig. 2/5 and Fig 2/6)
A typical inspection record card and check list
is given on the following pages.
 SECTION 2
STORAGE

Figure 2/4 Rotating the Rotor Assembly

2.5
 SECTION 2
STORAGE

Figure 2/5 Inspection Record Card

2.6
 SECTION 2
STORAGE

Figure 2/6 Check List

2.7
 SECTION 3
DESCRIPTION

CONTENTS

PARAGRAPH PAGE

3.1 GENERAL 3.1

3.2 PUMP 3.1

3.3 MOTOR 3.1

3.4 TERMINAL BOX 3.5

3.5 HEAT EXCHANGER 3.5

3.6 ALARM SYSTEMS 3.5

ILLUSTRATIONS

FIGURE 3/1 AUXILARY COOLING CIRCUIT 3.2

FIGURE 3/2 TERMINAL GLAND 3.4

3.0
 SECTION 3
DESCRIPTION
3.1 GENERAL
The Hayward Tyler Glandless Motor
Circulator Pump is designed for recirculating
boiler water through the boiler water systems
of fossil fuel or liquid cooled nuclear reactor
power stations and similar applications.
The circulators consist of a single stage
centrifugal pump and a wet stator induction
motor, which are mounted within a common
pressure vessel. The vessel consists of three
main parts, a pump casing, motor housing and
motor cover.
The motor is suspended beneath the pump
casing and is filled with cold boiler water at
full system pressure. No seal exists between
the pump and motor, but provision is made to
thermally isolate the pump from the motor in
the following respect: -
1) Thermal Conduction. Because the pump
temperature is so high, usually above 340°C
and the motor temperature is limited to
about 55°C, a simple restriction, in the form
of a 'neck', is provided to minimise heat
conduction.
2) Hot Water Diffusion. To minimise
diffusion of boiler water, a narrow annulus
surrounds the rotor shaft, between the hot
and cold regions. A baffle ring restricts
solids entering the annulus.
3) Motor Cooling. The motor cavity is
maintained at a low temperature by a heat
exchanger in a closed loop water circulation
system, thus extracting the heat conducted
from the pump.
In addition, this water circulates through the
stator and bearings, extracting the heat
generated in the windings and providing
bearing lubrication. An internal filter is
incorporated in the circulating system.
4) In emergency conditions, if low pressure
coolant to the heat exchanger fails, or is
inadequate to cope with heat flow from the
pump case, a cold purge can be applied to
the bottom of the motor to limit the
temperature rise.
NOTE:
A high pressure cold purge is to be used
only as an emergency. (para 6.3.8)
3.1
3.2 PUMP
The pump comprises a single suction and
double discharge branch casing, welded into
the boiler system pipe work at the suction and
discharge branches with the suction branch
uppermost.
Within the pump cavity rotates a key driven,
mixed flow type impeller, mounted on the end
of the extended motor shaft. 'Renewable’ wear
rings are fitted to both the impeller and pump
case. The impeller wear ring is the harder
component to prevent galling
3.3 MOTOR
The motor is a squirrel cage, wet stator,
induction motor, the stator wound with a
special water tight insulated cable. The phase
joints and lead connections are also moulded in
an insulated material. The motor is joined to
the pump casing by a pressure tight flange joint
and a motor cover completes the pressure tight
shell.
The motor shell contains all the moving parts,
except for the impeller. Below the impeller is
situated an integral heat baffle which reduces
the heat flow, a combination of convection and
conduction, down the unit. A baffle wear ring-
cum-sleeve above the baffle forms a labyrinth
with the underside of the impeller to limit
sediment penetration into the motor. Should
foreign matter manage to pass the labyrinth
device into the motor enclosure, a filter located
at the base of the cover end bearing housing
strains it out.
The motor design is such that for ease of
maintenance, the stator shell, complete with the
stator pack, the rotor shaft, the journal bearing
housings and the thrust assembly, can be
withdrawn from the motor case in sequence.
Lifting lugs are supplied to secure hoists when
raising and lowering the motor.
 SECTION 3
DESCRIPTION

Figure 3/1 Auxiliary Cooling Circuit

3.2
 SECTION 3
DESCRIPTION

3.3.1 Auxiliary Cooling Circuit (Fig. 3/1)

The motor is provided with its own auxiliary 3.3.3 Internal Filter
closed circuit, which besides cooling the motor
A stainless steel woven wire strainer, fitted at the
lubricates the bearings. The water is
base of the reverse thrust seat, filters the liquid in
continuously circulated through the bearings,
the motor before it is circulated through the
motor windings and an external heat exchanger
bearings after passing through the heat exchanger
(cooler), by an auxiliary impeller at the thrust
(cooler).
bearing end of the motor shaft.
The filter should be cleaned at normal
When the motor is stationary, thermosyphon
maintenance periods, removing any accumulation
circulation takes place to remove conducted heat
of foreign matter in the motor cover.
from the pump end of the motor.
3.3.4 Main Flange Joints
3.3.2 Bearings
The pressure joints at the pump and motor cover
The motor rotor shaft is supported by water
flanges employ spiral edge wound gaskets,
lubricated tilting pad type radial and thrust
specially designed for very high pressure and
bearings mounted on the stator shell, thus making
temperature. The main pump/motor flange
the motor internals into a separate construction
gasket is housed in stainless steel overlay,
independent of the motor pressure vessel.
recessed into the joint face.
3.3.2.1 Journal Bearings
The studs and nuts securing the flanges are made
The journal bearings of the circulator are from special high tensile steel and, because
the water lubricated Michell type located at torque tightening these nuts is inadequate, the
the ends of the motor shaft, i.e. pump-end studs are hydraulically stretched and the nuts
and cover-end. Each bearing comprises a tightened down by hand. When the hydraulic
hardened steel sleeve on the shaft running tension in the stud is released, the load is
in six radially located tilting pads whose transferred to the nut giving the required
bearing surfaces are lined with a composite tightness.
material. The bearing surfaces must never
Stud tensioning equipment is supplied with each
be allowed to operate in a dry condition.
circulator order.
3.3.2.2 Thrust Bearing
3.3.5 Terminal Gland
A main thrust bearing is situated below the
The electrical supply to the motor is taken
cover-end journal bearing and takes the full
through special high pressure single lead cable
hydraulic thrust of the pump. This bearing,
terminal glands of the high temperature, safety
also of the Michell water lubricated type, is
type.
formed by a steel thrust disc, with a
composite bearing surface, on the bottom of The seal is effected by a terminal gland
the rotor shaft running on stationary moulding, together with o-rings located between
hardened steel tilting pads. an insulating sleeve and an inner casing, and
between the inner casing and the motor case.
The thrust disc is also designed to operate
The addition of a cone-shaped collar within the
as an auxiliary impeller to circulate the
terminal moulding, plus the design of the inner
internal water content of the motor.
casing, prevents any possibility of a gland
3.3.2.3 Reverse Thrust Bearing blowout at high temperatures. However, if the
motor is subjected to sustained overheating, a
The weight of the rotating assembly, as well
slight leakage may occur into the terminal box.
as the down thrust imposed at start-up and
shut-down, are taken by a reverse thrust
bearing located on a reverse thrust housing
which forms the bottom of the cover
housing cylinder.
The reverse thrust housing also includes a
composites reverse thrust wear ring and is
the mounting for the internal filter.

3.3
 SECTION 3
DESCRIPTION

Figure 3/2 Terminal Gland

3.4
 SECTION 3
DESCRIPTION
3.4 TERMINAL BOX
Robust fabricated steel terminal boxes are
provided on the side of the motor casing for
connecting the power supply to the motor.
Each phase supply cable for the motor enters a
box at its base and should be sealed by a cable
gland. Each phase notation is identified by a
colour coding, Red, Yellow or Blue.
Bursting discs are fitted to the wall of the
terminal boxes to relieve excessive pressure
build up within the box should a flash over
occur at the terminals.
Desiccators are fitted to absorb atmospheric
moisture that may decrease the electrical
resistance to ground. Each assembly is
completely enclosed by a bolted on cover.
3.5 HEAT EXCHANGER
A heat exchanger (cooler) must be fitted to
dissipate the heat generated by the motor and
the heat transferred from the pump casing.
High pressure outlet and inlet raised facings are
situated at the bottom and top of the motor case
respectively for connection to high pressure
heat exchanger / motor case stub pipes.
Interconnecting pipework must be short and
direct with the heat exchanger mounted as high
as possible to promote good thermosyphon
circulation when the unit is on hot standby.
3.6 ALARM SYSTEMS
3.6.1 Thermometer
The thermometer instrument is mounted adjacent
to the motor, and gives visual indication of the
motor temperature.
3.5
3.6.2 Temperature Switches
Two temperature switches, remotely mounted,
are provided for actuating the alarm. When a
pre-set temperature is reached, the alarm circuit
is energised via one of the switches. Should the
motor temperature continue to rise, the second
switch is activated to de-energise the motor.
3.6.3 Thermocouples
A thermocouple is provided for measuring motor
cavity temperature. Two thermocouples are also
supplied with weld on pads for measuring the
skin temperature of the pump case and suction
manifold. These are to be installed on site by the
user.
3.6.4 Instrument Pockets
Temperature switch, thermometer and
thermocouple pockets are provided where
required.
3.6.5 Differential Pressure Transmitter with
manifold
These are to be connected to the process
connections in the pump case by the user.
(Customer supply)
3.6.6 Pressure Gauge
A pressure gauge is remotely mounted to the
motor case.
3.6.7 Flow Meter
A flow meter is supplied to be fitted in the low
pressure cooling water return line by the user.
3.6.8 Ground Detection Relays
The motor windings should be protected by
ground detection relays, sufficiently sensitive to
detect the development of a pinhole or minor
crack in the stator winding insulation.
 SECTION 4
INSTALLATION

CONTENTS

PARAGRAPH PAGE

4.1 GENERAL 4.2

4.2 PUMP CASE INSTALLATION 4.2

4.3 PREPARATION FOR MOTOR INSTALLATION 4.2

4.4 MOTOR INSTALLATION 4.4

4.5 FITTING THE HEAT EXCHANGER 4.5

4.6 FILLING THE CIRCULATOR WITH BOILER COLD 4.6

4.7 HYDROTESTING BOILER WITH CIRCULATOR INSTALLED 4.6

4.8 ELECTRICAL CONNECTIONS 4.8

4.9 MOTOR PROTECTION 4.9

ILLUSTRATIONS

FIGURE 4/1 PUMP CASE INSTALLATION 4.1

FIGURE 4/2 MOTOR INSTALLATION 4.3

FIGURE 4/3 TERMINAL BOX 4.7

FIGURE 4/4 BURSTING DISC ASSEMBLY 4.8

FIGURE 4/5 EARTH LEAKAGE PROTECTION CIRCUIT DIAGRAM 4.10

4.0
 SECTION 4
INSTALLATION

Figure 4/1 Pump Case Installation

4.1
 SECTION 4
INSTALLATION
4.1 GENERAL
WARNING
The Hayward Tyler boiler circulating pump is
a precision piece of heavy machinery.
It should only be installed under the
supervision of a qualified professional engineer
who should ensure that the staff directly
concerned are adequately trained and have
read and understood this manual.
When installing the circulators the following
conditions MUST be observed.
1) The system pipe work should be adequately
supported to accept the weight of the
circulator.
2) When mounted, the pump should
accommodate movement in the pipe work
due to thermal expansion without imposing
excessive loads on the casing and branches.
3) Sufficient clearance should be allowed
beneath the motor to permit lowering of the
motor from the pump case for maintenance.
(See Section 7 Fig. 7/35.). If removable
floors or girders etc. are fitted after the
motor is installed, ensure that the terminal
boxes or low pressure cooling water supply
lines will not foul them when the boiler is on
load and the circulator moves downwards
due to thermal expansion.
NOTE:
Two long lift hoists should be used to
raise the pump or motor, each hoist being
capable of taking the full weight of the
pump or motor
4) The pump should be positioned so that the
N.P.S.H. available exceeds the N.P.S.H.
specified in the Technical Data - Section 1).
NOTE:
When operating at temperature, sub
cooling of the inlet water is normally
present and this gives a considerable
increase in the N.P.S.H. available. The
worst condition is normally operating
cold.
4.1.2 Installation Notes
The following conditions must be observed
when installing the circulator:
1) Ensure that the main system is free from
solids before mounting the circulators.
2) Permanent insulation should be applied
only to the pump case. No insulating
material must be applied to the motor case
or to the main flange studs and nuts, as this
will cause the motor to overheat.
4.2
3) The cables, leading to the motor, should be
flexible and looped immediately prior to
entering the terminal boxes. The looping
should be sufficient to accommodate unit
movement caused by expansion and
contraction of the boiler pipe work.
4.2 PUMP CASE INSTALLATION (FIG 4/1)
1) Remove the pump case flange and branch
covers and clean the pump branches.
2) Attach shackles and slings to the casing
eyebolts. A plate on the pump case
indicates the front of the pump.
3) Raise the case to meet the system pipe
work, with the suction branch uppermost.
4) Ensure that the main motor/case flange is
horizontal to within 1°. Tack weld to the
system pipe work and re-check the
horizontal limits.
5) Complete the weld to the procedure
approved by the boiler manufacturer and test
radiographically for flaws.
6) On completion of a satisfactory
radiographic test, fit any pressure
differential transmitters using the stub pipes
on the pump case branches.
7) Fit the blanking off plate until the motor is
installed.
4.3 PREPARATION FOR MOTOR
INSTALLATION
CAUTION:
The motor should be stored, topped-up with
inhibitor for as long as possible. If it is
necessary to install the motor before boiler
water is available, install in the inhibited
condition to provide additional protection for
the motor internal components. However,
the inhibitor must then be drained
immediately before mounting the heat
exchanger.
We do not recommend motor installation on
a Hot Boiler.
1) Hose down internally, the pump case, the
valves and adjacent-piping, to ensure the
removal of all loose debris.
2) Fully close the pump suction and discharge
valves.
 SECTION 4
INSTALLATION

Figure 4/2 Motor Installation

4.3
 SECTION 4
INSTALLATION
4.4 MOTOR INSTALLATION (FIG. 4/2)
1) Using a 1000V megger, check that the
insulation resistance to ground of the motor
leads is above 200 megohms when measured
at the terminal stems with the unit full of
water below approximately 20°C, if
possible, or at normal ambient temperature.
2) Stand the motor in a vertical position, on
the motor cover stand, and in the correct
orientation to the pump.
3) Remove the pump case main flange nuts
and cover and ensure there is no debris in
the pump pipe work system that could enter
the pump case.
4) Clean and inspect the pump case flange,
remove any burrs.
5)
a) Remove the plug or inspection cover at
the top of the transit canister.
b) Loosen the inhibitor filling valve
situated in the motor fill and drain
transit flange, (Section 2 Fig. 2.1), of
approximately 40-45 litres of inhibitor.
Close the inhibitor filling valve.
6) Remove the transit canister from the motor
case.
7)
a) If the motor is to be operated
immediately upon installation,
completely drain then proceed as (8)
b) If motor operation is not imminent,
install the motor in the inhibited
condition, proceed as 9), leaving 8) to be
performed when fitting the heat
exchanger.
8)
a) Connect a clean cold water supply to the
motor cover fill and drain connection,
and flush the motor until inhibitor-free
water flows from the top of the motor.
b) Check that the shaft freely rotates, if not,
strip the motor as described in Section 7
to establish the reason and correct the
fault.
9) Clean the overlay that provides the seat for
the gasket in the main flange of the motor.
Inspect for burrs and surface discontinuity,
dress if necessary with a fine grade stone.
Fit a new gasket. NEVER apply any
compound to the gasket and ensure that it is
dry.
4.4
10) Ensure that the motor is in correct
orientation with the pump case. See Section
7, Fig 7/35.
WARNING
The Hayward Tyler boiler circulating
pump is a precision piece of heavy
machinery.
It should only be installed under the
supervision of a qualified professional
engineer who should ensure that the staff
directly concerned are adequately trained
and have read and understood this
manual.
11) Attach shackles and slings to the motor
casing lifting lugs and lift into position,
taking care to avoid damage to the terminal
box.
12) Fit the motor to the pump case as follows:-
a) Using the chain type hoists, lift the
motor until the impeller is about to enter
the pump case.
b) Measure the distance between the pump
case and the motor flanges at four 90°
degree points on the flange periphery. If
necessary, adjust the lay of the motor by
the chain hoists to make the distances
approximately equal.
c) Bring the gap between the flanges equal
all round. This is best achieved by using
a spring-loaded 'inside' calliper, set to
the gap directly in line with one of the
chain hoists. The set calliper is then
moved to the opposite side of the flange
and the gap adjusted, using the chain
hoist. Check the gaps at right angles to
the first two and adjust the lay of the
motor to make the gaps equal.
d) Check that the studs are centred in the
motor flange holes. Adjust the motor
“lay” as required.
e) With the chain hoists working in unison,
slowly raise the motor.
CAUTION.
If any increase in effort is required on
the chain hoists to raise the motor -
stop raising it immediately as the
impeller may be fouling the pump case
wear ring. In which instance,
fractionally lower the motor, check the
gap and raise the motor again.
 SECTION 4
INSTALLATION
f) Check the gaps every 10 mm, or less,
during the last 100 mm of the motor
raising sequence to ensure that the motor
does not 'cock' or rotate as it is raised.
Adjust the gap as necessary.
g) Continue raising the motor until an
increase in the effort required on the
hoists indicates that the gasket is in
contact with the pump case face. At this
stage, the gap between the flange faces
should be approximately 2.5mm and
should be equal all round the flange.
CAUTION:
If the gap is unequal, the gasket may
have come out of its recess. If the gap
is unequal, lower the motor
sufficiently to check the condition of
the gasket. If the gasket is damaged -
renew. Never use any substance on
the gasket to make it adhere to its
recess.
h) Coat the stud threads with high
temperature anti-seize compound or
silicon grease and install the nuts by
hand.
NOTE:
Do not coat the exposed extended
diameter threads of the studs as these
threads are for the tensioner
application.
i) Tighten the nuts, using the hydraulic stud
tensioner in accordance with the
instructions in Section 8. Remove the
lifting tackle and removable lifting lugs.
j) Thoroughly flush out the fill and drain
system piping, to the motor cover and
when satisfied that the piping is clean,
connect to the motor cover.
k) Install the heat exchanger: see Para. 4.5
l) Install the appropriate thermocouples,
the thermometer, pressure guage and
temperature alarm switches.
m) Connect the power supply cables to the
motor terminals, See 4.8.
n) Install the vibration pick up probes if
permanent vibration monitoring is
required.
13)
a) If, after fitting the heat exchanger,
running is not reasonably imminent, the
motor and heat exchanger circuit must
be refilled immediately with inhibitor.
b) If, after fitting the heat exchanger, sub-
freezing temperatures are envisaged the
motor and heat exchanger circuit must
be refilled immediately with inhibitor.
4.5
c) If, after fitting of the heat exchanger,
running the motor is reasonably
imminent, and sub-freezing
temperatures are not envisaged, the
motor and heat exchanger must be filled
with treated boiler water or condensate
within 3 hours of fitting.
4.5 FITTING THE HEAT EXCHANGER
(CUSTOMER SUPPLY)
1) Remove the blank flanges from the motor
high pressure outlet to cooler and fill and
drain connection.
2) Ensure that the motor, the heat exchanger
and the high pressure pipe work and high
pressure purge lines, have been flushed free
from all obstructions and foreign matter.
3) Flush out the secondary cooling water
system until clear water is discharged.
4) Mount the heat exchanger onto the motor
case brackets and proceed.
a) Bring the heat exchanger parallel to the
motor supporting the weight with the
lifting tackle.
b) Clamp the heat exchanger to the motor
by tightening up the securing bolts, nuts
and washers.
c) Ensure the motor / heat exchanger
interconnecting pipe work assembly is
correct for the circulator.
d) Offer up the interconnecting pipe work
to the heat exchanger and motor flanges
and complete all pipe welds and NDE in
accordance with site approved
procedures.
5) Install gauges and recorders for temperature
and pressure. Connect the low pressure
cooling systems to the heat exchanger.
6) Fit temporary strainers to the low pressure
cooling systems, and then check that
circulation meets the heat exchanger
specification.
7) Close the shut off valve in the high pressure
fill and purge line and blow down piping.
The motor and heat exchanger circuit must
now be refilled with inhibitor (See 4.4, Para.
13 (a) or (b) or with treated boiler water or
condensate.
 SECTION 4
INSTALLATION
4.6 FILLING THE CIRCULATOR WITH
BOILER COLD
Filling the circulator correctly is a prerequisite to
ensure satisfactory operation. If air is present in
the motor it could affect bearing lubrication and
precipitate bearing failure.
If air pockets are present in the stator this would
affect dissipation of heat generated in the
windings, creating hot spots and consequent
degrading of the insulating material, and
ultimately cause winding failure.
Due to the complexity of the passages in the
motor through which water must flow to displace
all air, it is necessary to fill the motor very slowly.
If air pockets are present in the stator this would
affect dissipation of heat generated in the
windings, creating hot spots and consequent
degrading of the insulating material, and
ultimately cause winding failure.
The maximum filling rate is 2 litres /min.
The motor must NOT be filled via the pump
casing, but only through the filling connector
located at the motor cover.
1) Isolate the circulator from the boiler by
closing appropriate discharge valves.
2) Supply the low pressure side of the heat
exchanger as follows: -
a) Open the supply valves in the low
pressure cooling water system.
b) Flush out the piping for the supply of
low pressure treated boiler water, or
condensate, for filling the motor, until
clean air free water is discharged.
NOTE:
The flushing must always be carried out
before introducing any water through the
lines to the motor and heat exchanger.
3) If the low pressure supply contains an
orifice, check that it is clean and that its flow
rate is correct.
4) Adjust the flow rate to approximately 2
litres/min.
4.6
5) After connecting the supply, open the heat
exchanger vent on the high pressure side, fill
the motor from the bottom and vent air from
the top, until clean air free water is
discharged from the vents.
6) Close the vent on the high pressure side of
the heat exchanger.
7) Continue to fill the motor and vent any air
via the vent connections in the boiler system
pipe work.
8) Isolate the now filled circulator.
9) Ensure that the terminal box is dry and with
the unit full of water below 20ºC or at
normal ambient temperature, using a 1,000
Volt Megger, check winding resistance to
ground at the terminals. The resistance
should exceed 200 megohms.
IF NOT, CALL HAYWARD TYLER.
DO NOT ATTEMPT TO RUN THE
MOTOR.
4.7 HYDROTESTING BOILER WITH
CIRCULATOR INSTALLED
Treated Water or Condensate Available: -
Should the customer wish to hydrotest the
circulator, the hydrostatic test pressure must not
exceed the maximum specified in Section 1.
Treated Water Not Available: -
If the boiler is to be hydrotested at an early state
of construction, the pump casing can be pressure
tested without the motor once the blank off plate
is installed – refer to para.4.2.
4.7.1 Post Hydrostatic Test Procedure
1) Boiler circulators are not to be drained, but
left filled to a level above the suction
downcomer.
2) Freezing can be avoided by filling with
glycol in the concentration detailed in
Section 2.
 SECTION 4
INSTALLATION

Figure 4/3 Terminal Box

4.7
 SECTION 4
INSTALLATION
where it should be maintained at a
temperature of 110oC until the colour
4.8 ELECTRICAL CONNECTIONS reverts to blue. The re-activating time is
4.8.1 Power Supply to Motor between 1 and 2 hours.
c) Screw the desiccators into the terminal
Refer to the terminal box arrangement shown in
box covers taking precautions not to
Fig. 4/3.
damage the desiccators.
WARNING:
7) Fit and secure the terminal box covers using
Disconnect the power supply and the starter
the nuts and washers previously removed.
before commencing any work.
CAUTION:
Ensure that the cable length will
accommodate expansion and removal of the
circulator.
Ensure that the voltage connected to the
circulator is the correct operating voltage as
stamped on the motor nameplate situated on
the bottom of the motor case.
1) Remove the nuts and washers, and then
remove the terminal box cover using lifting
gear, if necessary.
2) Feed the cable through the conduit entry
gland and connect to the terminals in the
phase rotation RED, YELLOW, BLUE (‘U’,
‘V’ or ‘W’). When so connected the unit
will operate in the designed direction, i.e.
clockwise when viewed from above. All
connecting cables and links are marked with
appropriate phase colours.
3) Earth the circulator adequately. Earthing
studs are provided on the motor casing
adjacent to the terminal box.
4) Ensure that all electrical connections
particularly at the terminal box entry gland
are secure.
5) Fit the bursting discs to the terminal box as Figure 4/4 Bursting Disc Assembly
follows: -
NOTE:
The bursting discs are supplied as loose
items and are packed separately to
prevent damage in transit. They are 4.8.2 Recommended Instrumentation
fitted to the terminal box on the
installation of the motor. It is recommended that the following be
provided: -
a) Dismantle the bursting disc assembly
and discard the cardboard sheet fitted in 1) Pump suction and discharge pressure
lieu of the disc. gauges.
b) Reassemble the bursting disc assembly 2) Continuous record of motor voltage.
with the bursting disc in place, as
depicted in Fig. 4/4. 3) Continuous record of motor current.

6) Fit the desiccators, also supplied as loose
equipment, as follows:-
a) Check that the desiccator crystals are
coloured blue.
b) If pink, reactivate by placing the
desiccator in a well ventilated oven
4) Ground leakage relay to warn of very low
winding resistance in order to prevent
winding insulation failure.
5) Indication and record of downcomer
temperature and pump case temperature.
This is required to avoid thermal shocks
when starting a pump on a hot boiler.

4.8
 SECTION 4
INSTALLATION
4.8.3 Alarm Circuits (Fig.4/5)
WARNING:
Lethal voltage is present in the alarm system
when the motor is inoperative. To make the
circulator safe - open the isolator.
Suitable alarm and trip devices should be fitted
to protect the motor and arranged to provide: -
1) An alarm - as an indication of motor
overheat conditions.
2) Motor trip (shut down) - if the temperature
rise continues above the alarm setting.
The normally advised settings for the protection
devices are: 57°C for alarm and 60°C for trip. In
practice, the alarm setting should be reduced to
5°C above normal motor operating temperature.
4.9 MOTOR PROTECTION
The following protective devices must be
provided for the motor: -
4.9.1 Continuous Overload Protection
The overload trip setting should be 10% above
the maximum current requirements which could
occur with the pump running on cold water at
some other point than the specified duty,
assuming nominal specified supply voltage. If
voltage variation can occur, then the trip setting
should be increased to 15% above maximum
current value.
NOTE
Overload relays are now typically calibrated
in motor full load current (FLC) where the
relay trips with a current 10% above the
FLC setting point. Hence the overload relay
of this type should have a setting point of the
cold duty current.
Maximum current at nominal voltage:
See Technical Data, Section 1.
4.9.2 Instantaneous Trip Setting
To allow for transients during the first cycles of
the starting period, the instantaneous trip should
be set at 12 times the motor full load current.
Full Load current: See Technical Data, Section
1.
4.9
4.9.3 Starting Period Protection
If the motor fails to start, trip out after a period
of approximately 5 seconds. The starting
current is based on a locked rotor test with an
allowance made for saturation of the magnetic
circuit.
Motor Starting Current: See Technical Data,
Section 1.
4.9.4 Earth Leakage Protection (Fig. 4/5)
Ground detection relays are recommended,
sufficiently sensitive to sound an alarm if a pin-
hole or minor crack should develop in the stator
winding. This protection is arranged in either of
the ways shown in Scheme A, Scheme B or
Scheme C.
If the neutral point of the supply transformer is
grounded, a current transformer (CT) is inserted
into the ground lead, and a relay connected
across the current transformer secondary, see
Scheme A.
Experience indicates that in the event of a fine
crack in the stator winding, the resistance to
ground drops to between 20,000 and 30,000
ohms. The relay should not trip the motors but
initiate an alarm.
If the neutral point of the supply transformer is
not grounded, three potential transformers (PT)
are connected to the motor leads, with the
secondaries connected in an open delta, closed
by the relay winding, see Scheme B. The relay
should not trip the motors but initiate an alarm.
Scheme C shows a core balance earth leakage
relay system where a core balance current
transformer encloses supply lines L1, L2 & L3
supplying the motor.
NOTE
It is important that no earth conductor is
allowed to be enclosed by the current
transformer. The earth leakage sensitivity
and trip time can generally be selected to
prevent nuisance tripping. Typical setting
points are 300 mA and 1 second. This may
require adjustment depending on supply
conditions.
 SECTION 4
INSTALLATION

Figure 4/5 Earth Leakage Protection Circuit Diagram

4.10
 SECTION 5
COMMISSIONING

CONTENTS

PARAGRAP PAGE
H

5.1 PRE-START CHECK LIST 5.1

5.2 INITIAL STARTING-COLD BOILER CONDITION 5.1

5.3 STOPPING 5.3

5. 0
 SECTION 5
COMMISSIONING
5.1 PRE-START CHECK
The following pre-start checks must be
satisfied before starting the motor.
1) Ensure that the circulator is completely
vented.
2) Ensure that the low pressure cooling
water valves are open and the cooling
water flow rate agrees with that specified
in the heat exchanger manufacturer's
specification. All other valves must be
closed.
NOTE:
If the circulator is to be started on hot
standby, the pump delivery by-pass
valves must be open. Refer to the hot
standby procedure in Section 6.
3) Ensure that the high pressure cold water
purge at 20°C maximum temperature is
connected but isolated.
4) Using a 1000V megger, check that the
insulation resistance to ground of the
motor leads conforms to the Winding
Resistance curve shown in Section 1,
Fig. 1/2 when measured at the terminal
stems with the unit full of water below
approximately 20°C, if possible, or at
normal local ambient temperature.
5) Check that the correct voltage is
connected to the circulator.
6) Check that the electrical supply is
available at the point of control selected
and that the starting equipment is
functioning correctly.
7) Test the operation of all instrumentation
and alarms.
8) Ensure that sufficient N.P.S.H. is
available for the pump to run without
cavitation.
9) Start parallel operating boiler circulating
pumps with the stems of the discharge
valves withdrawn to prevent overheating
of the boiler water in the pump case.
5.2 INITIAL STARTING-COLD BOILER
CONDITION
In systems where the circulators are arranged
in parallel, to avoid cavitation, sufficient
circulators must be operated to limit the
capacity per pump to a value where the
N.P.S.H. required is less than the amount of
N.P.S.H. available.
5. 1
When a boiler is started from cold, a minimum
of two circulators must be operated. It is
normal practice to simultaneously warm the
standby circulators to permit immediate staring
when required.
CAUTION:
1. Motors must not be energised if the
motor cavity temperature is below 2°C.
2. There should be at least ten-minute
intervals between two repetitive starts.
This must never be exceeded;
otherwise the motor winding
temperature will rise and could
damage the winding insulation.
3. The motor may be damaged if motor
temperature exceeds 65°C.
1) Ensure that the motor has been vented as
detailed in Section 4, Para. 4.7.
2) Ensure that a flow of approximately 2
litres/min., is entering into the motor
through the low pressure fill line.
3) Ensure that the pre-start checklist, as
described in Para. 5.1, has been satisfied.
4)
a) Release any air trapped below the
discharge valves by opening valves.
b) When air-free water is discharged to
atmosphere, close valves.
5)
a) Vent the pump by opening vent
valves.
b) When air-free water is discharged
from vent valve to atmosphere, close
valves.
6) Make sure that the boiler is full and open
the discharge valves.
NOTE:
The by-pass valve should never be
fully closed. It is normally throttled to
provide a minimal flow between the
pump suction and discharge system
7) Switch on power to the starter.
8) Press the starter button on the control
console and energise the motor for 5
seconds only.
 SECTION 5
COMMISSIONING
CAUTION:
The motor runs up to full R.P.M. in
appropriately one second. If the
motor fails to start after five seconds,
press the stop button and do not
attempt to restart the circulator for 20
minutes.
9) After ten minutes pause, run the
circulator for a further (2nd) five
seconds. During this run, check the
following:-
a) Motor Current (after ammeter has
come off initial surge of current)
b) Differential pressure - when the
check valves open, the differential
pressure should rise immediately to
approximately 3 bars.
NOTE:
If the differential pressure does not
rise, stop the motor immediately; it
may be an indication that the motor is
running in reverse. Reverse rotation
will result in approximately 30% less
head generated and about 10% more
power absorbed than specified.
10) After a further (3rd) ten-minute pause,
repeat operation (9).
5.3 STOPPING
11) After another (4th) ten-minute pause,
energise the motor and run for twenty
minutes. During this running period,
carry out the following checks:-
a) Check the motor for vibration, using
a vibration detector, several times and
record reading for future comparison.
b) Check for rubbing or excess bearing
noise by holding a listening rod
against the pump and motor case.
c) Check the motor operating
temperature at regular intervals.
Initially it should rise several degrees
then stabilise. If necessary, adjust the
secondary cooling water flow after
checking that the strainers are not
obstructed.
d) Check, as the motor warms, that the
high pressure circulation pipe entering
the heat exchanger from the top of the
motor becomes warmer than the high
pressure circulation pipe from the
bottom of the heat exchanger to the
motor case. This indicates correct
functioning of the heat exchanger.
e) Check that motor current and
differential pressure readings several
times and record the readings.
5. 2
12) When the motor temperature has
stabilised: -
a) Adjust the high temperature alarm
setting to 10% above this point, or to
57°C, whichever is the lower. The
trip setting must never exceed 60°C.
b) Make adjustment to other
instrumentation as necessary.
c) Check all flanges, glands and valves
for leaks.
d) As the boiler water temperature
increase, its specific gravity decreases
and the amount of N.P.S.H., available
increases. The temperature of the
high pressure water to the heat
exchanger may alter due to lower
losses in the motor, or because of
increased heat flow from the pump.
NOTE:
It is normal procedure to commission
circulators separately, but if required,
before the last circulator is stopped,
the others may be energised and their
recordings taken after each one is
brought on-line.
1) Press the stop button on the control
console. The run-down time is
approximately 2.5 seconds.
2) Close the discharge valves.
3) Maintain the low pressure cooling water
supply to the heat exchanger.
NOTE 1:
If the circulator is to stand idle for
some considerable time with the boiler
cold, the low pressure cooling water to
the heat exchanger may be turned off,
especially on systems where the
cooling water runs to waste.
NOTE 2:
On hot boilers, and whenever the
circulator is run, the low pressure
cooling water to the heat exchanger
must always be on.
CAUTION:
If the circulator is to be idle for an
extended period, and be subjected to
freezing temperatures, make sure that
provision is made to protect the
motors from freezing (see Section
2.2.2.)
 SECTION 6
OPERATION

CONTENTS

PARAGRAP PAGE
H

6.1 STARTING THE CIRCULATOR 6.1

6.2 SHUTTING DOWN THE CIRCULATOR 6.2

6.3 ROUTINE CHECKS AND OPERATIONAL CONDITIONS 6.3

6.4 FAULT FINDING 6.5

ILLUSTRATIONS

Figure 6/1 FAULT LIST CHART 6.6

6.0
 SECTION 6
OPERATION

Any of the following conditions may exist 6) Ensuring the boiler is still full, energise
when putting a circulator into service. Follow the second duty circulator on line and run
the relevant procedures below and refer to 6.3 up to speed.
for routine checks and operational fault action.
7) Perform the operational checks below.
Refer also to Para. 6.3.
6.1 STARTING THE CIRCULATOR a) Amperage.
6.1.1 Boiler Cold - Circulator Cold and b) Motor cavity temperature on alarm
Filled (Boiler Start-Up). thermometer.
c) Differential pressure.
1) Ensure that the pre-start checklist, 5.1 is
satisfied. d) Low pressure cooling flow and
temperature.
2) Vent the motor as follows: - e) Vibration.
a) Release any air trapped below the f) Drum level.
suction by opening the by-pass valves
and the filling valves. g) Valve and gland leakage.
b) When air-free water is discharged 8) Energising other motors: When the
through the vent valve, close vent boiler differential pressure parameters
valve. require the other circulators to be
energised: -
3) Vent the pump as follows: -
a) Check that the differential
a) Open the vent valve. temperature, between the pump case
b) When air-free water is discharged and boiler water in the downcomers,
from vent valve, close vent valve and is within 28°C.
filling valves. b) Energise the other motors.
c) Open the stems of the discharge c) Close by-pass valves on the newly
valves. energised pump(s).
CAUTION: d) Perform the operation checks on the
The pump must always be re-vented in newly energised pump as detailed in
this manner prior to starting when the para.6.1.1 (7).
drum pressure is below 3.5 kg/cm2.
6.1.2 Boiler Hot - Circulator Hot and
NOTE: Filled (Hot Standby)
The motor starting procedure following
is based on a normal boiler starting NOTE:
procedure where usually two circulators The low-pressure coolant to the heat
are initially operated with the remainder exchanger must be on.
brought-on line as required. 1) Check the differential temperature
4) between the pump case and the boiler
a) On circulators that will not be water in the downcomers.
energised, open the pump discharge CAUTION:
by-pass valves. This ensures that as The differential temperature between the
the boiler heats up, a flow passes pump case and the boiler water in the
from the discharge legs to the pump downcomers must not exceed 28°C. Non-
case and impeller etc. adherence to this may cause thermal
b) Check the motor temperature on the shocks and damage to occur.
alarm thermometer; this should not 2) Energise the motor.
exceed 49°C or be less than 5°C.
3) Close by-pass valves.
5) Energise the first motor. The current will
drop from full starting current after a few 4) Check circulator operation as detailed in
seconds to approximately the value para.6.1.1 (7).
corresponding to the operating point on
the makers test curve.

6.1
 SECTION 6
OPERATION
6.1.3 Installation on a Hot Boiler
NOTE:
Not recommended for safety reasons – but
not possible on this installation since no
suction valves are fitted and hence pumps
cannot be isolated.
6.2 SHUTTING DOWN THE
CIRCULATOR
CAUTION
Low pressure cooling water flow and motor
temperatures must always be within the
specified limits, whenever the circulator is
on hot standby.
6.2.1 Boiler Hot - Circulator to go on Hot
Standby
1) Press the stop button on the control
console.
2) Ensure that the low-pressure cooling line
valves are open.
3) Open by-pass valves to provide
circulation of high temperature boiler
water through the pump casing, suction
and discharge lines.
6.2.2 Boiler Hot - Circulator to be Isolated
for Maintenance
1) Press the stop button of the control
console to de-energise the motor.
2) Close the stems on the discharge valves.
3) Close the pump jumper line service
valves.
4) Crack open the pump suction bypass
valves to prevent a vacuum forming in the
pump case during the circulator cooling
process.
5) Maintain the low pressure cooling
system to the heat exchanger, via the low
pressure flowrator valves in the cooling
pipes open until the motor has been
separated from the pump.
CAUTION:
Keep a close watch on the motor cavity
temperature, should the temperature
increase, apply a high-pressure purge as
described in para. 6.3.8.
6.2
6) Check the pump case temperature as the
pump case is cooling to ensure that the
cooling rate does not exceed 120°C per
hour. If necessary, correct the cooling rate
as follows:
a) Cooling rate too fast: - If the pump
case cooling rate is too fast, slow the
cooling rate by partially opening the
by-pass valves as necessary.
b) Cooling rate too slow: - If the pump
case cooling rate is too slow, increase
the rate by injecting a high pressure
purge as detailed in Para. 6.3.8.
7) When the pump case has cooled to 45°C
de-pressurise the circulator as follows: -
a) Ensure the pump discharge by-pass
valves and shut-off valve are closed.
b) Slowly depressurise the circulator by
closing the pump suction by-pass
valve and partially opening the pump
and suction leg vent valve.
c) Open the motor cavity pressure
gauge shut-off valves and check the
pressure on the motor cavity gauge.
When the pressure has stabilised,
close the pump suction leg vent valve.
d) Re-check that the pressure does not
increase. Should it increase, check the
following: -
i) Make sure that all valves between
the circulator and high-pressure
system are closed.
ii) De-pressurise the circulator
again, if necessary.
8) On completion of depressurising, the
motor is ready for removal.
CAUTION
The low pressure cooling water must
be maintained until the motor has been
separated from a hot pump case.
6.2.3 Boiler Cold
1) Press the button on the control console.
2) Leave open the low pressure cooling
water line valves.
3) Pump discharge valves may be left open.
 SECTION 6
OPERATION
6.3 ROUTINE CHECKS AND
OPERATION CONDITIONS
(Also see fault list chart)
6.3.1 Supply Current
1) Check the motor running current each
shift. The current should be constant and
comply with that specified in section 1.
NOTE:
High amperage readings or fluctuating
motor currents indicate wear or partial
seizure at the bearing or wear ring
surfaces. This condition can cause
vibration necessitating motor removal
strip and re-installation.
6.3.2 Motor Temperature
1) During normal operation, the motor
temperature should be checked at weekly
intervals. The thermometer is originally
set to initiate an alarm if the motor cavity
temperature reaches 57°C and to de-
energise the motor if the temperature
reaches 60°C. If desired, the
aforementioned alarm temperature
settings may be lowered, on the
temperature alarm thermometer, to suit
normal operation but only after the boiler
and circulator has been operated long
enough to stabilise.
2) Immediately investigate the following
possible causes for high temperature
alarm sounding: -
CAUTION
Do not stop the motor.
a) Check the low pressure cooling water
supply for adequate flow, temperature
vapour locks and leakage in piping
(see 6.3.7.).
b) Check the circulator for leaks from
the motor casing, high pressure fill
and drain cooling water connections,
particularly the motor fill and purge
line shut-off valves and the motor
drain valves.
c) Check that the cooling water strainers
are not obstructed.
d) Check for indication of bearing
damage (noise, vibration).
6.3
3) If temperature increase continues and
exceeds the 60°C - trip setting - and the
cause cannot be detected or the condition
corrected, refer to the relevant shutdown
procedure in Para. 6.2. If necessary, blow
down the boiler system or apply a high-
pressure purge to the motor. See 6.3.8.
a) After cooling and draining, remove
and disassemble the motor and
examine for worn bearings, blocked
internal strainer, motor passages,
auxiliary impeller and fouled cooling
surfaces. In addition, leaks in the heat
exchanger.
4) Should the alarm sound whilst the
circulator is on stand-by, start the
circulator to accelerate internal high
pressure cooling water flow. Check
possible causes for temperature increase
as above. The circulator should be tripped
if the temperature exceeds 60°C and the
shutdown / purge procedure 6.2 carried
out.
6.3.3 High Temperature Alarm and Trip
Settings
At weekly intervals check that the motor
high temperature alarm setting does not
exceed 57°C or 5°C above normal operating
Temperature (whichever is the lower) and
that the trip setting does not exceed 60°C.
Re-set if necessary.
6.3.4 Pump Head and Quantity
1) Check the total head generated by each
pump at weekly intervals.
2) Correct possible causes of decrease in
head and quantity as follows: -
a) The gate valve in the circulating
pump suction line and the check valve
in the circulating pump discharge
lines are not fully open. Check and
adjust the setting as necessary.
b) Discharge through the pump and
suction leg vent or the pump casing
and suction leg drain valves. Ensure
both are closed.
c) Low N.P.S.H., available due to
reduced water level in the steam
drum, changes in system pipework or
system blockage. Check and adjust
the number of circulators operating to
suit until the fault can be corrected.
 SECTION 6
OPERATION
d) Vent the pipe system to remove
vapour locks.
e) Power supply and reverse rotation
checks are given in 5.5.1 (5) and 5.2
(9).
f) Worn wear rings and a blocked or
damaged impeller can be corrected
only after removing the motor
assembly from the pump case.
Clearances are specified in section 1.
6.3.5 Insulation Condition
Before initially energising the motor and
thereafter at monthly intervals, check the
following: -
1) The insulation resistance to ground of the
motor leads.
a) With the unit filled with water below
20°C or at normal local ambient
temperature, the resistance measured
at the terminal links, using a 1000V
megger, must exceed 200 megohms.
NOTE:
The insulation resistance of the stator
winding varies with temperature and
must always be measured cold 20°C or at
normal local ambient temperature.
2) Ensure that the interior of the terminal
box is dry, especially the insulation
projecting over the gland stems.
6.3.6 Vibration
Check the circulators for excessive noise or
vibration, which can be either hydraulic or
mechanical in origin.
Vibration should be monitored and recorded
daily. If a permanent vibration transducer is
not installed, check at weekly intervals
using temporary pick-ups. If the reading
increases, check for the following causes: -
a) Cavitation due to low N.P.S.H., as
described in 6.3.4.
b) Unequal settings of the discharge
valves. Check and re-set in the fully
open position.
c) Incorrect directional rotation as
described in section 5.2, para. 9.
d) Excessive pipe strain on the pump
casing due to expansion or inadequate
support of pipes. Eliminate any strain
by providing adequate support.
e) Damaged or unbalanced rotor or
impeller, worn bearings, excessive
end float or incorrect impeller setting.
6.4
f) Electrically induced vibration also a
factor, i.e. Rotor bar breakage etc.
NOTE:
When (e) is the cause, the motor must be
removed, as detailed in section 7.2,
before repairs can be undertaken.
6.3.7 Low Pressure Cooling Water Supply
Failure.
If the cooling water to the heat exchanger is
lost while the circulator is at operating
temperature, the motor must be de-energised
within five minutes and the suction and
delivery valves closed as soon as possible.
CAUTION
Damage to the windings may occur if:
a) the motor remains in operation after 5
minutes from the loss of cooling water.
Or
b) if the cooling water is not
restored before the motor
temperature rises above 60°C.
CAUTION
Do not attempt to operate the motor by
overriding the temperature controller trip
mechanism and restore the low pressure
cooling water as quickly as possible.
Damage to the windings may occur if the
cooling water is not restored before the
motor temperature rises above 60°C.
NOTE:
Before re-starting a circulator after an
emergency shutdown, low pressure cooling
water must be supplied to the pump to
reduce the motor temperature to at least
38°C.
6.3.8 High Pressure Purge Supply To
Motor.
On some boiler installations the motor fill
and drain connection may be connected to a
high pressure cold purge system which can
be used for emergency motor cooling and to
protect the motor during boiler cleaning.
During normal operation this purge supply
must be isolated with a double isolation
valve fitted to the motor, as any leakage or
reverse flow from this point can result in
motor overheating, winding and / or bearing
damage. (Reverse flow totalling no more
than 2 – 3 litres is sufficient to cause
damage).
 SECTION 6
OPERATION

NOTE:
If the boiler is “laid-up” under a nitrogen
Continuous purging of the motor during
blanket, take necessary precautions to
operation is recommended only during
prevent damage to the motor through
boiling-out and acid cleaning. A purge rate
gaseous water. Any pump start-up, when
of 3.8 litres / min., is normally sufficient to
the boiler is in this condition, must be
prevent the ingress of harmful fluids and
undertaken and initial start and the full fill
solids into the motor.
and vent procedure, as detailed in section
1) Flush down the fill and purge system to 4.7, must be followed.
ensure the line is clean.
6.3.10 Boiler Cleaning
2) Check that the low pressure cooling
water supply valves are open. During any boiling-out or acid cleaning
operation of the boiler, the de-energised
3) Introduce high pressure purge through circulators must be isolated completely prior
the filling valves. Check that the purge to introducing any chemicals to the boiler.
temperature does not exceed 49°C and The circulators must be continuously purged
that the purge pressure is above the boiler with clean cool water at a pressure of
pressure. approximately 7 bar, in excess of the existing
drum pressure to eliminate infiltration of
6.3.9 Extended Shut-Down
contaminated water into the bearing and
When the circulator remains shutdown for motor components.
an extended period: -
CAUTION
1) Check regularly that it remains full of Severe damage can be caused if acid is
water. allowed to enter the motor. If
contamination from acid cleaning is
2) Run the circulator for a minimum of ten
suspected, motor must be purged
minutes every two months.
immediately with clean water and
CAUTION inspected for damage.
If the motor is to be subjected to extreme
low temperature, the motor must be
prevented from freezing, see section 2.2. (5)
6.4 FAULT FINDING
Refer to the fault list chart that follows.

6.5
 SECTION 6
OPERATION

Figure 6/1 Fault List Chart

6.6
 SECTION 7
MAINTENANCE

CONTENTS

PARAGRAP PAGE
H

7.1 INTERNAL INSPECTION 7.3

7.2 MOTOR REMOVAL 7.3

7.3 DISASSEMBLY 7.4

7.4 INSPECTION OF COMPONENTS 7.16

7.5 ASSEMBLY NOTES 7.27

7.6 ASSEMBLY 7.29

7.7 RE-INSTALLATION OF MOTOR 7.42

PARTS LIST – GENERAL 7.43

ILLUSTRATIONS

FIGURE 7/1 MOTOR REMOVAL 7.2

FIGURE 7/2 MAIN IMPELLER REMOVAL 7.5

FIGURE 7/3 TERMINAL BOX 7.6

FIGURE 7/4 UP - ENDING THE MOTOR 7.7

FIGURE 7/5 TYPICAL WORKING PLATFORM 7.8

FIGURE 7/6 MOTOR COVER AND FILTER REMOVAL 7.9

FIGURE 7/7 THRUST BEARING 7.10

FIGURE 7/8 COVER – END JOURNAL BEARING ASSEMBLY - REMOVAL 7.11

FIGURE 7/9 ROTOR ASSEMBLY - REMOVAL 7.12

FIGURE 7/10 TERMINAL GLAND REMOVAL 7.13

FIGURE 7/11 STATOR ASSEMBLY - REMOVAL 7.14

FIGURE 7/12 JOURNAL BEARING TILTING PADS - REMOVAL 7.15

FIGURE 7/13 JOURNAL BEARING CLEARANCE 7.16

7.0
 SECTION 7
MAINTENANCE

FIGURE 7/14 JOURNAL BEARING SLEEVE - REMOVAL 7.17

FIGURE 7/15 THRUST BEARING CLEARANCE 7.18

FIGURE 7/16 IMPELLER AND CASE WEAR RING 7.19

FIGURE 7/17 DETAILS OF TAPING HOOK 7.22

FIGURE 7/18 DETAILS OF TAPING NEEDLE 7.22

FIGURE 7/19 OUTER COIL TAPING 7.23

FIGURE 7/20 INNER COIL TAPING 7.24

FIGURE 7/21 TYPICAL KNOT SEALING 7.26

FIGURE 7/22 ASSEMBLY OF FLANGE STUDS 7.27

FIGURE 7/23 WIRE LOCKING 7.28

FIGURE 7/24 JOURNAL BEARING - ASSEMBLY 7.29

FIGURE 7/25 STATOR ASSEMBLY 7.30

FIGURE 7/26 JOURNAL SLEEVE 7.31

FIGURE 7/27 TERMINAL GLAND ASSEMBLY 7.32

FIGURE 7/28A COVER END BEARING ASSEMBLY 7.33

FIGURE 7/28B COVER END BEARING ASSEMBLY 7.33

FIGURE 7/28C COVER END BEARING ASSEMBLY 7.34

FIGURE 7/29 END FLOAT CHECK 7.35

FIGURE 7/30 MOTOR COVER AND FILTER ASSEMBLY 7.37

FIGURE 7/31 TERMINAL BOX 7.38

FIGURE 7/32 TERMINAL LINK INSULATION 7.39

FIGURE 7/33 BURSTING DISC DETAILS 7.40

FIGURE 7/34 IMPELLER SETTING 7.41

FIGURE 7/35 GENERAL ARRANGEMENT 7.47

FIGURE 7/36 SECTIONAL ARRANGEMENT 7.48

FIGURE 7/37 TERMINAL BOX ARRANGEMENT 7.49

FIGURE 7/38 TOOL KIT LIST 7.50

7.1
 SECTION 7
MAINTENANCE

Figure 7/1 Motor Removal

7.2
 SECTION 7
MAINTENANCE
NOTE 1:
Some of the illustrations shown are typical
only and not necessarily specific to the
circulator described, i.e. motor proportions
and number of studs etc., but indicate
generally the basis of the unit breakdown.
NOTE 2:
For items not annotated on the drawings
within the text refer to the Main Sectional
Arrangement at the rear of the Section.
NOTE 3:
A tool kit is supplied with each circulator
contract, containing specialised tools
necessary for the disassembly and assembly of
the motor.
7.1 INTERNAL INSPECTION
Internal inspection of the circulator should be
carried out to the recommendation of the station
maintenance authority.
Partial inspection of the internal filter and thrust
bearing is possible in-situ after removal of the
motor cover.
WARNING:
Inspection must only be carried out with the
circulator isolated from the electrical supply,
depressurised and the motor cover removed
as in Section 7.3.4.
A full inspection requires the motor assembly to
be removed as described below.
7.2 MOTOR REMOVAL (FIG. 7/1)
WARNING:
Before removing the motor, the circulator
must be completely isolated from the system,
depressurised and cooled as described below.
7.2.1 Motor Removal
1) Isolate the electrical supply; disconnect all
instrument cables from the motor identifying
the connections and leads.
2) Remove the terminal box covers and
disconnect the external power supply cables
from the terminal box as described in 7.3.4,
identifying each lead for reassembly.
3) If hoses are not fitted in the low pressure
cooling system, adjacent to the heat
exchanger, with sufficient slack to allow the
motor to be separated from the pump case, fit
temporary hoses as follows:-
a) Close the low pressure cooling water
shut-off valves.
7.3
b) Immediately secure temporary cooling
water hoses to the inlet and outlet
connections of the heat exchanger to
maintain a low pressure cooling water
flow within the heat exchanger.
c) Maintain cooling water until the motor is
separated from the pump.
CAUTION:
The low pressure cooling water flow, and
motor temperature must be maintained
within the specified limits, whenever the
motor is in contact with the pump case.
4) Check the pressure gauges to ensure that the
circulator is depressurised.
5) Make sure that the discharge valves, the
suction valve, the by-pass valves and the
shut-off valves are closed to isolate the
circulator from the boiler and fill system.
6) Drain the pump casing.
WARNING:
Never drain the pump casing through the
motor fill & drain line as this could cause
contamination of the motor.
7) Fit the removable lifting lugs to the welded
brackets on the motor case.
8) Set up two chain hoists and rigging, of
sufficient capacity for each to take the full
weight of the motor, and connect to the
lifting lugs.
WARNING:
Normally two hoists are used for removing
the motor and because the load can shift
from one hoist to the other during the
removal, each hoist must be capable of
taking the full weight of the motor.
9) Take the initial strain of the motor.
CAUTION:
The motor must be removed from the
pump casing without a break in the
sequence (9) and (11).
10) Loosen the pump/motor flange stud nuts in
accordance with the hydraulic stud
tensioning instructions - section 8.
CAUTION
Always double check that the motor and
pump case are cooled and depressurized
before loosening the studs nuts.
11) Disconnect the fill and drain line upstream
of shut-off valve if there is not sufficient play
in the line to permit motor removal.
 SECTION 7
MAINTENANCE
12) Remove the flange stud nuts and lower the
motor clear of the pump casing, keeping the
flange faces parallel until the impeller is
clear of the pump casing.
13) When the impeller is clear of the pump case,
check the motor cavity temperature. When
the temperature falls below 54oC remove all
instruments and store safely.
14) Lower the motor to the floor.
15) Drain the motor via the drain valve and
remove the valve and pipework
16) Remove the heat exchanger from the motor,
in accordance with site procedures, as
described in 7.2.1.
CAUTION:
To prevent damage never stand or turn
the motor on either the drain valves or
terminal box.
17) Lower the motor to the horizontal position
to give access to the terminal box, remove
the lifting tackle and cover all joint faces and
openings with clean rags.
18) If necessary, transport the motor to a
working area where adequate facilities are
available for disassembly, inspection and
maintenance.
7.2.1 Heat Exchanger Removal
NOTE:
As the heat exchanger is welded to the motor
case via the interconnecting pipework,
removal of the heat exchanger is at the
discretion of, and the procedure will be
determined by, the senior station engineer.
Check the heat exchanger during the first
motor maintenance removal for build up of
sediment in the shell base; this will provide a
guide to any future attention that may be
required.
7.3 DISASSEMBLY
CAUTION:
Lifting tackle must not be attached to the
protruding rotor shaft nor must the shaft be
subject to any shock loads.
The motor must be adequately supported
before and during any disassembly.
7.3.1 Case Wear Ring
1) The case wear ring can be left in place,
bolted inside the pump case.
7.4
2) To remove the wear ring, remove the six
screws securing the wear ring inside the
pump casing. Carefully lower the wear ring
from its location within the casing.
Lower to ground level, and store in a safe
place for inspection.
7.3.2 Impeller (Fig. 7/2)
1) Unlock the punch marks and remove the
impeller cap screw.
2) Remove the LEFT-HAND threaded impeller
nut using the special spanner and tommy bar
provided in the tool kit.
NOTE:
Do not use any leverage in the water
passages of the impeller to oppose force
exerted on the special spanner; the weight
of the rotor will oppose rotation if the
tommy-bar is given a few heavy blows
with a lead faced hammer.
If the nut shows any tendency to seize on
the shaft, do not continue to exert force,
but drill and split the nut to remove.
3) Fit the puller, provided in the tool kit, to the
tapped holes in the top of the impeller boss,
using the applicable studs and nuts in the tool
kit. Withdraw the impeller from the motor
shaft.
4) Withdraw the impeller washer and remove
the impeller key.
5) Immediately refit a serviceable impeller nut
to permanently protect the shaft threads.
7.3.3 Baffle Wear Ring
Examine the baffle wear ring. If damaged,
remove the socket headed cap screws and lock
washers. Remove the wear ring for a fuller
inspection or renewal
7.3.4 Terminal Boxes (Fig. 7/3)
1) Remove the nuts and washers from the studs
and remove the terminal box cover.
2) Remove the nuts and washers from the
terminal studs.
3) Identify the motor supply cable links for
reconnection.
4) Carefully cut the insulation from around the
cable connections and links.
CAUTION:
Do not damage the link insulation.
5) Remove the washers and the nuts from the
terminal stem as the link is removed.
 SECTION 7
MAINTENANCE

6) Remove the nuts and washers from the NOTE:

terminal box support studs. Using lifting A small metal cover should be fabricated
tackle, lift off the terminal boxes and remove and placed over the terminal stems to
the gaskets. protect them during motor repair.

Figure 7/2 Impeller Removal

7.5
 SECTION 7
MAINTENANCE

Figure 7/3 Terminal Box

7.6
 SECTION 7
MAINTENANCE

Figure 7/4 Up-Ending the Motor

7.7
 SECTION 7
MAINTENANCE

7.3.5 Motor Cover and Filter (Fig. 7/6)

1) Using two cranes and lifting tackle attach one
with shackles to the motor cover and the
other via a sling around the motor flange
neck. Lift and up-end the unit as depicted
Fig. 7/4 until the motor is vertical, with the
motor cover uppermost. Lower the motor
pump flange on to a suitable building stand;
a typical building stand is shown in Fig. 7/5.
Support the rotor shaft beneath the stand
using a screw or hydraulic jack. Care must be
taken to avoid damaging the shaft or flange
faces. If a pit is not available, erect a suitable
working platform, similar to that depicted in
Fig. 7/5.
CAUTION:
Firmly support the impeller end of the
rotor shaft on a suitable wooden block
when placing the motor on the stand and
jack so that when the thrust nut is
removed during a subsequent operation,
the rotor will be adequately supported.
2) Mark the cover relative to the motor case to
ensure correct alignment on reassembly.
3) Using the stud tensioning equipment (Section
8), release the tension of the motor cover nuts
and remove the nuts.
4) Attach the lifting tackle and carefully remove
the motor cover from the motor case.
5) Remove the flexitallic spiral wound gasket
and before discarding, inspect the gasket for
any unusual markings or depressions that
indicate a seat dressing is required.
6) Remove the filter by removing the hexagon-
headed screws and lock washers.

Figure 7/5 Typical Working Platform

7.8
 SECTION 7
MAINTENANCE

Figure 7/6 Motor Cover and Filter Removal

7.9
 SECTION 7
MAINTENANCE

Figure 7/7 Thrust Bearing

7.3.6 Thrust & Reverse Thrust Bearing (Fig.
7/7)
CAUTION:
Ensure that the impeller end of the rotor
shaft is supported firmly. This will prevent
damage to the rotor upon removal of the
thrust nut.
When cutting removing locking wire, ensure
that no wire is permitted to fall into the
windings.
1) Remove the reverse thrust housing, complete
with reverse thrust wear ring as follows: -
a) Remove the socket-headed cap screws and
lock washers securing the reverse thrust
housing to the bearing housing.
b) Lift off the reverse thrust housing
complete with the composite reverse
thrust wear ring. Lower the jack.
2) Remove the thrust disc assembly as follows:
-
a) Set up the jack, with ram extended beneath
the rotor shaft and floor.
3) Remove the split pin and loosen the thrust
nut using the thrust nut spanner provided in
the tool kit.
a) Remove the thrust nut - right handed
thread – and the spacer washer.
b) Lower the jack ram, sufficiently to lower
the rotor, leaving the thrust disc sitting on
the thrust pads.
c) Remove the thrust disc, taking care not to
damage the running surfaces on the disc.
d) Alternatively, use the thrust disc puller, to
remove the thrust disc from the shaft.
4) Remove the thrust key.
5) Remove the thrust seat as follows:-
a) Remove the socket-headed cap screws and
the spring washers securing the seat to the
bearing housing.
b) Lift off the thrust seat complete with
thrust pads.

7.10
 SECTION 7
MAINTENANCE

Figure 7/8 Cover – End Journal Bearing Assembly - Removal

7.3.7 Cover End Journal Bearing
Assembly (Fig. 7/8)
1)
a) Remove the locking wire and the stator
lock ring hexagon headed screws.
b) Push down the stator lock ring sufficiently
to permit split ring to be prised out of its
groove.
c) Remove the split ring from its casing
groove, using screwdrivers as levers.
d) Withdraw the stator lock ring, using
screws as lifters, from the motor case.
2) Match-mark the cover end bearing housing
and the motor case to ensure that they are re-
fitted in their original radial location.
3) Remove the bearing housing securing screws
and lock washers.
4) Attach eyebolts and lifting tackle to the cover
end bearing housing and lift the housing,
complete with the journal bearing assembly,
to just above the motor casing.
5) Lower the bearing housing and remove and
discard the `O` ring.
6) Place the housing in a clean and safe place
for subsequent disassembly.

7.11
 SECTION 7
MAINTENANCE
7.3.8 Motor Shaft (Fig. 7/9)
7.3.9 Terminal Gland Removal (Fig. 7/10)
1) Fit an eyebolt, supplied in the tool kit, and
lifting tackle to the rotor shaft as indicated.
With an exact vertical lift, slowly lift the
rotor out of the stator, taking particular care
not to damage the cable ends whilst doing so.
2) Lower the rotor into the horizontal position
and position it carefully on to wooden 'V'
blocks at floor level. Fit suitable protection,
i.e. clean rags, over the journal sleeves. Refit
the thrust nut to protect the threads.
Figure 7/9 Rotor Assembly - Removal
7.12
1) To facilitate re-assembly, identify each
terminal stem body and its respective
position.
CAUTION
Make sure that the gland moulding does
not turn with the gland nut by holding the
moulding stationary using a clamp
connector and the connecting link.
2) Remove the nuts and link from the terminal
block. Unscrew the gland nut and tap the
connector lightly until the gland assembly
can be carefully drawn out of the motor case.
3) Remove the gland nuts from two of the stems
and placed on the third stem.
4) Replace the clamp connector over this stem
and undo the cable gland nut. This action
will draw the gland assembly from the motor
case.
5) Remove the inner casing & the ‘C’ shaped
support ring. The two belleville washers and
back up sleeve remain on the cable.
NOTE:
The terminal gland stems are moulded on
to the stator windings in a continuous
waterproof sheath, which must not be
broken or damaged
CAUTION
Never hammer the end of the stem if the
assembly is tight, as this will damage the
moulding.
6) Remove and discard the 'O'-ring from the
inner casing neck.
7) Feed the remainder of the gland moulding
and the cable assembly through the gland
body into the motor casing.
8) Remove the ‘O’ rings and back up rings from
the inner casing.
9) Suitably tape the terminal stems to prevent
them from damage and lay them over the
case flange.
10) Protect the cables from sharp corners.
 SECTION 7
MAINTENANCE
Figure 7/10 Terminal Gland
7.3.11 Heat Exchanger
7.3.10 Stator Shell and Bearing Assemblies
(Fig. 7/11)
1) Place the cable leads within the stator bore.
2) Using guide rods temporarily re-fit the cover
end bearing housing in position on the stator
shell. Re-fit the housing screws and tighten.
3) Attach lifting tackle to the bearing housing
eyebolts. With an exact vertical lift, slowly
and carefully withdraw the stator assembly
out of the motor case.
4) Lower the stator and support it horizontally
on wooden blocks placed at floor level.
Ensure that the tapped hole for the eyebolt
(used in lifting the pump end bearing
housing) is located at the top centre.
7.13
CAUTION:
Protect the chamfer on the pump side of
the bearing housing from damage, as this
will affect alignment of the rotating
assembly within the motor case.
5) Mark the stator shell and the pump-end
bearing housing, so that the slot in the
housing for the anti-rotation peg and the
stator winding leads can be correctly aligned
upon assembly. (Fig. 7/25).
6) Fit an eyebolt, sling and tackle, to the pump
end bearing housing, and take the weight of
the housing.
7) Remove the socket-headed cap screws and
lock washers. Draw the bearing housing
away from the stator shell.
8) Fit the lifting tackle to the cover-end bearing
housing. Take the weight of the housing;
remove the temporary fitted screws and
carefully ease the housing from the stator
shell.
Further dismantling of the stator assembly is
unnecessary unless the motor is to be
rewound. If rewinding is necessary, contact
Hayward Tyler.
Check the heat exchanger during the first
maintenance removal for build up of sediment
in the shell base; this will provide a guide to
any future attention that may be required.
De-scale and inspect the heat exchanger as
follows:-
1) Remove the inlet/outlet and return covers
from the heat exchanger shell. Discard the
gaskets.
2) Using cleaning rods and a metal brush,
remove all deposits from inside the tubes of
the shell and from each end cover.
3) Inspect generally for good order of the heat
exchanger.
4) Clean the mating faces of the shell and return
cover and inlet/outlet cover. Fit new gaskets
to their respective ends of the shell.
5) Bolt up the end covers with the existing bolts
and nuts.
6) Pressure test the heat exchanger for adequate
sealing.
 SECTION 7
MAINTENANCE

Figure 7/11 Stator Assembly - Removal

7.14
 SECTION 7
MAINTENANCE

Figure 7/12 Journal Bearing Tilting Pads - Removal

7.15
 SECTION 7
MAINTENANCE

7.4 INSPECTION OF COMPONENTS c) Journal Bearing Clearance

i) Place the tilting pads in their correct
7.4.1 Journal Bearing Tilting Pads (Fig. 7/13) sequence on their corresponding journal
The following procedure applies to both the sleeve and clamp firmly in position,
pump end and the cover end bearing housings. using large hose clips, as shown.
ii) Measure the dimension across the pivots
NOTE:
of each opposing pair of pads to
Pads must be kept in their sets and each set
determine the average dimension.
identified with its original bearing housing
and position in the housing for correct re- NOTE:
assembly Do not use feeler gauges between the
pads and sleeve due to the risk of
1) Remove the securing ring screws and lock damage to the sleeve and the inherent
washers from the applicable bearing housing. inaccuracy of this method.
2) Remove the securing ring, cover end or pump iii) Subtract this dimension from that of the
end. inside dimension of the mating bearing
ring bore. Record the result and
3) Identify the journal tilting pads with their
compare it with the bearing clearance
respective housings and mark the sequence
limits detailed in Section 1. Technical
of removal in a counter clockwise direction,
Data.
1 to 6.
iv) If the clearance is excessive, fit a new
4) Withdraw the tilting pads, noting the location set of tilting pads and a new journal
of the pivot and direction of arrows stamped sleeve.
on the rear side.
v) Remove the clips and tilting pads from
5) Remove the bearing ring. the journal and suitably protect the
journals and pads until required for re-
6) Remove the two anti-rotation stop pegs from assembly.
each bearing ring.
7) Clean and dry all components (except
composite parts).
8) Inspect all components as follows:
a) Tilting Pads
i) Check the surface for scoring or
breakdown of the composite. Slight
scoring is permissible but if the
composite surface is pitted or laminating
renew or return the complete set to
Hayward Tyler for possible reclamation.
NOTE:
Under no circumstances renovate the
pad surfaces with Carborundum Paste
or Emery Cloth.
ii) There should be no evidence of
'brinelling' of the tilting pivot.
iii) Ensure that the edge of the working
face has a 3 mm radius.
b) Bearing Rings
Check the seat surface for brinelling and
renew if grooved on the pad location.

Figure 7/13 Journal Bearing Clearance

7.16
 SECTION 7
MAINTENANCE
7.4.2 Journal Bearing Sleeves (Fig. 7/14)
1) Very slight scoring or scratching of the
journal sleeve is permissible but if excessive
or cracked, the sleeve must be removed.
2) If the journal sleeve is to be renewed, screw
the journal locking screw into the shaft and
carefully mill through the sleeve along the
keyway until the sleeve splits.
3) Remove the sleeve and the journal key.
Protect the sleeve seat until the new sleeve
can be fitted as Para 7.6.2.
Figure 7/14 Journal Bearing Sleeve - Removal
7.4.3 Thrust and Reverse Thrust Bearing (Fig.
7/15)
CAUTION:
Thrust bearing pads must be retained in sets
and each pad numbered consecutively in a
clockwise sequence, as viewed from the thrust
end.
1) Remove the split cotter pin from the thrust
pad stops.
2) Carefully remove the thrust pads from the
thrust seat.
3) Clean and dry all components.
7.17
4) Inspect and record findings as follows: -
a) Thrust Pad
i) Slight scoring on the face is acceptable,
but if excessive, the pad must be either
renewed or reground within the limits of
the end float (see Section 1) to a surface
finish of 0.15 micrometers.
ii) The thickness of the pads must be
uniform and parallel within .01 mm.
Evidence of brinelling on the pivot is
unacceptable. The radius on the edge of
the face should be 1.5mm.
b) Thrust Pad Stop
i) Examine for fretting on the shank and
head. If evident, re-new.
c) Thrust Seat
i) Examine for brinelling under the pivots.
If evident, re-new.
d) Thrust Disc
i) Check by lightly tapping that the
composite facings are correctly bonded
to the metal disc. Renew the disc
assembly if the composite plate is loose
i.e. if a ‘hollow’ sound is heard.
ii) Check the composite face is not badly
worn or scored.
iii) With the thrust disc mounted on a
suitable mandrel, check that the working
faces for both forward and reverse
thrusts are flat to within .025 mm.
e) Auxiliary Impeller (Fig. 7/15)
i) Measure and record the outside diameter
of the auxiliary impeller skirt.
ii) Ensure that the water passages are clear.
NOTE:(1)
The auxiliary impeller is an integral
part of the thrust disc.
NOTE:(2)
All parts containing composite must be
submerged until assembly.
f) Reverse Thrust Wear Ring.
i) Measure and record the bore of the
composite reverse thrust wear ring.
ii) Subtract the outside diameter of the
thrust disc skirt from the bore of the
wear ring to establish the clearance.
iii) Compare the clearance obtained with
that specified in Section 1, Technical
Data.
iv) Re-new the reverse thrust wear ring if
either the clearance is excessive or if the
composite has deteriorated.
v) To remove the wear ring, remove the
philidas nuts and the cap screws
 SECTION 7
MAINTENANCE
Figure 7/15 Thrust Bearing Clearance
7.4.4 Impeller and Case Wear Rings (Fig.7/16)
1) Clean the impeller and the case wear rings
and check them for damage.
2) Subtract the impeller wear ring outer
diameter from the case wear ring bore,
allowing for any temperature difference and
compare with the clearance specified in
Section 1, Technical Data
3) Check the hardened surface of the impeller
wear ring.
4) If necessary, renew the impeller wear rings as
follows:-
a) Carefully machine away the old ring
without damaging the impeller. If
necessary, clean up the wear ring seating.
b) Heat the new impeller wear ring until it is
considered sufficiently expanded to slide
on the impeller rim. Heat by playing a
gentle gas flame round the rim.
c) Lift the heated wear ring on to the impeller
rim, using suitable heat resistant tongs.
d) Tap the wear ring down to its position on
the impeller.
7.18
e) Allow the wear ring to cool and shrink
onto the impeller.
f) Drill new grub screw holes using a
Tungsten Carbide tipped type drill.
g) Tap for, and fit, new grub screws. Punch
lock on the inside of the impeller.
h) Machine the grub screws flush with wear
ring.
i) Check the impeller wear ring for
concentricity. If eccentric, machine the
wear ring, in situ, a maximum of 0.25mm.
The maximum wear ring clearance
permitted is 2.03mm.
j) Re-balance the impeller. Refer to
Hayward Tyler for the balancing data.
5) If the impeller has been damaged or repaired,
always check the dynamic unbalance.
6) If the pump case wear ring requires renewal,
fit the new ring and secure using the six
socket head cap screws and lock washers.
Tighten the screws in accordance with the
torque figures detailed in Section 1.
 SECTION 7
MAINTENANCE

Figure 7/16 Impeller & Case Wear Ring

7.19
 SECTION 7
MAINTENANCE
7.4.5 Rotor Assembly
1) Clean and inspect for damage all keys, threads,
keyways and sleeve locking screws, located on
the rotor shaft.
2) Fit the impeller washer, impeller key, impeller,
and impeller lock screw on to the pump end of
the shaft.
3) Fit the thrust disc key, thrust disc, spacer
washer and thrust nut on to the thrust end of
the shaft.
4) Thoroughly clean the rotor shaft.
5) Check the shaft for run-out, as follows:-
a) Place the shaft on rollers that locate
between the journal sleeves and the short
circuit rings.
b) Check the run-out along the shaft and
laminations; maximum run-out permissible
0.05mm.
c) Check the run-out at the impeller wear ring;
maximum run-out permissible 0.125mm.
d) Check the run-out at the thrust disc;
maximum run-out permissible 0.10mm.
e) Check the run-out at the journal bearing
sleeves: maximum run-out permissible
0.025mm.
6) Check that the laminations, short circuit ring,
rotor bars and balance rings are undamaged.
NOTE:
If any components on the rotating assembly
have been damaged, or renewed, the
complete rotating assembly must be
dynamically balanced within 5000 gm.mm.
7) Take the rotor assembly off the rollers and
remove the impeller and thrust disc along with
their connecting components.
8) Protect all parts of the rotor until required for
assembly.
7.4.6 Stator Assembly
Unless an electrical fault is suspected, a visual
inspection of the windings, followed by an
insulation check, fulfils normal requirements but
the following checks should be made:
1) No slackness exists in wedges located at the
bottom of the stator slot behind the cables.
2) Windings coils are taped together and secured
to the support brackets. Damaged winding
tapes must be renewed to the procedure given
in para. 7.4.9.
7.20
3) That there is no apparent damage to the
windings or cable leads.
4) White insulating sleeve, (see detail para.7.6.6)
is below the level of the XLP gland moulding.
The difference when new is approximately
0.65mm. If the nylon and XLP surfaces are
flush, renew the complete tail moulding.
5) Immerse the complete stator in water of a
temperature below 20ºC ensuring that on the
lead cables the water reaches no higher than the
inner face of the gland moulding.
6) Check and record the insulation resistance
using a 1000V megger. If the resistance is
below 5 megohms, check carefully for breaks
in the insulation. If a visual check is
insufficient to locate a fault, check for the fault
as follows: -
a) With the stator still immersed in water, using
a Flash-Tester, apply a voltage at one third
operating volts and gradually increase until
a visual indication of the fault location
appears. This should occur before the full
operational voltage is reached, but if it does
not, the voltage may be increased to 1.5
times operating voltage for a period not
exceeding one minute. For operating
voltage, refer to Section 1 - Technical Data.
NOTE
DC high voltage testing of old windings at
values higher than 150% rated volts is not
recommended as further damage to aged
windings can occur causing premature
failure.
7.4.7 Motor Case and Cover
Check the condition of the following: -
1) The weld round the anti-rotation peg.
2) The motor case and cover flanges.
3) The baffle wear ring. With normal usage this
wear ring should not require renewal
throughout the life of the unit. However, if it is
damaged, remove the screws and the tab
washers and remove the wear ring.
4) Faces of all pump case and motor cover nuts for
freedom from damage and burrs.
7.4.8 Terminal Boxes (Fig. 7/37)
Check that the bursting discs are not ruptured and
the inside of the terminal box is dry.
 SECTION 7
MAINTENANCE
7.4.9 General
Winding tapes must only be renewed with Heat
Set Nylon 66 braided tape 18mm wide x 0.5mm
thick. The taping knots must be secured with an
epoxy resin adhesive, using only those grades
specified (see 'knot sealing'). No other grade of
adhesive is permitted.
It is essential that the tapes are thoroughly dry
when the adhesive is used in sealing the knots
because if the tapes are damp, the adhesive will
not adhere successfully. The adhesive should
cover the knot completely but must not be
indiscriminately smeared in the general vicinity
of the tape.
7.4.9.1 Tools (Figs. 7/17 & 7/18)
The following locally made tools should be used
to assist the tapering operation.
1) Make one taping hook (Fig. 7/17), from
∅2.4mm x 460mm long gas welding rod as
follows:
a) Bend the rod about 25mm from the end at a
90 degrees angle. File and emery cloth
smooth.
b) Form the opposite end into a loop handle
giving the tool an approximate length of
300 to 350mm
2) Make one flexible needle (Fig. 7/18), about
255mm long, from ∅0.8mm steel or copper
wire.
3) Bend the wire double leaving a small loop and
solder the ends of the loop together.
a) File and smooth all edges-
4) Wooden wedges (various sizes) smooth with
no sharp edges.
7.4.9.2 Preparation
1) The winding coils are known as first and
second and windings. The first (Fig. 7/19)
being nearest the shell, the second (7/20) being
nearer the bore.
2) Remove the existing wrapping tape from the
coils and ensure that the nitrile rubber inserts
are in between the layers in the centre of the
coils.
3) Thoroughly wash out the stator to remove any
foreign debris, such as magnetite or rust
deposits, from the windings.
4) Dry out the stator windings using a hot air fan
heater positioned nearby; this is to ensure that
the new tape is kept clean and dry for knot
sealing.
7.21
7.4.9.3 Taping Outer Coils (Fig. 7/19)
Using one piece of Heat-set Nylon tape 18mm
wide x 0.5mm thick approximately 4.5m long,
bind and anchor the outer windings coils at the
stator end as follows: -
NOTE:
Take extreme care when retaping not to
damage the winding cable insulation
covering.
1) Place a smooth wedge of wood between the
stator shell and the outer coil to hold the end
turns away from the shell and to allow the
taping hook or needle to be inserted and slid
through.
2) Insert the taping hook between the stator shell
and coil towards the end plate. Bend the shank
of the hook as necessary to be seen or felt
behind the coil.
3) Using the hook tool, hook the tape up from the
bottom and from behind coils, leaving at least
250mm of tape free at the beginning of the
band for knotting purposes.
4) Starting from the centre of the coil, spiral wrap
the tape around the conductors to form a band
of two 50% overlaps of tape fully 50mm wide
to cover the Nitrile rubber insets in the coil.
Sufficient tension should be applied to hold the
conductors together.
5) Continue taping the coil to the anchorage
bracket, welded to the stator end plate, or
winding support ring, whichever is fitted, using
four spiral half-tape (50%) overlaps. (i.e. eight
thickness’) of Nylon tape. The band should
again be made 50mm wide with enough tension
to prevent movement of the coils.
6)
a) Tie the ends of the tape into a square (reef)
knot so that the knot is positioned on the
outer edge of the coil as far as is practicable
and so that if pressed into the coil it would
be between two cables, rather than pressing
on the top of one.
b) Cut the tape ends protruding from the knot
to 25mm long.
c) Seal the knot with the approved epoxy resin
adhesive to prevent the knot from coming
loose in accordance with para. 7.4.9.6.
7) Remove the wooden wedge(s), and any taping
tools.
 Figure 7/17 Details of Taping Hook

7.22
SECTION 7
MAINTENANCE

Figure 7/18 Details of Taping Needle

 SECTION 7
MAINTENANCE

Figure 7/19 Outer coil Taping

7.23
 SECTION 7
MAINTENANCE

Figure 7/20 Inner Coil Taping

7.24
 SECTION 7
MAINTENANCE
7.4.9.4 Taping Inner Coils (Fig. 7/20)
Bind the inner winding coils as follows:-
1) Remove the damaged binding tape from one
of the inner coils.
2) Ensure that the nitrile rubber inserts are in
position between the layers and the centre of
the coil.
3) Bind the second coil bundles, using a length
of Heat-Set Nylon 66 braided tape 18mm
wide x 0.5mm thick, approximately 2.75m
long, as follows:-
a) Thread one end of the tape on the needle
tool.
b) Leave at least 250mm of tape at the
beginning of the band for knotting
purposes.
c) Bind the coil bundle to form a 50mm wide
band of two spiral half overlaps, four
layers thick.
d) Tie of the band with a square (reef) knot on
the outside of the band , as shown, and so
that the final anchorage tape will not press
the knot into the coil bundle.
e) Cut the bundle tape end 25mm from the
knot and seal the knot with epoxy resin
adhesive, as described in para. 7.
4) Anchor tape the inner coil bundle to the stator
anchor bracket, or winding ring, whichever is
fitted, with a length of heat-set Nylon 66
braided tape 18mm x 0.5mm thick, as
follows:-
a) Leave at least 250mm of tape at the
beginning of the band for knot tying
purposes.
b) Bind the coil bundle to the winding ring
anchor bracket loop, welded to the stator
with four spiral half-width overlaps, eight
layers off tape, with enough tension to hold
the coil bundle in position away from the
stator bore. The complete anchorage
should be 50mm wide.
c) Tie off the band using a square (reef) knot
positioned over the top outer coils of the
bundle, as shown. The knot should be
located between two cables rather than
pressing on top of a cable.
NOTE:
The knot must be tied on part of the tape
between the coils and the anchorage
bracket
d) Cut the tape ends 25mm from the knot and
seal with epoxy resin type adhesive as
described in Para. 7.4.9.6
7.25
5) Bind and anchor the other two inner coil
bundles in a similar manner.
7.4.9.5 Taping the Lead Cables
Arrange and tape the connections and lead
cables in groups of three - two in a clockwise
direction and one in an anti-clockwise
direction, as follows:
1) Anchor the cables in position to the windings
with four spiral half-laps of Heat-Set Nylon
66 braided tape 18mm wide x 0.5mm thick.
2) Make the band 50mm wide and tie the ends
into a square (reef) knot.
3) Cut the tape end to 25mm long and seal the
knot with an epoxy resin adhesive to prevent
it becoming loose. the adhesive should
completely cover the knot.
4) Make the last binding on the lead cable
300mm from the respective holes in the
bearing housing.
7.4.9.6 Knot Sealing (Fig 7/21)
1) Either of the following adhesives must be
used to prevent the knots becoming loose.
a) Fast-setting epoxy resin adhesive:
AV/HV115, as supplied by CIBA-GEIGY
(UK) LTD.
NOTE:
A handipack kit comprising two tubes;
one resin, the other hardener, known as
'Rapid Araldite' in the United Kingdom,
is generally equivalent to the above
specification.
b) Fast-setting epoxy resin adhesive XD738
as supplied by CIBA-GEIGY (UK) LTD.,
available in bulk containers.
c) Alternatively use Ren Epoxy RP106/ H953.
2) Ensure that the tapes are thoroughly dry
before applying the adhesive.
3) Mix and apply the adhesive in accordance
with the manufacturer's instructions. Curing
time of the adhesive is 3 to 6 hours.
4) The adhesive should completely cover the
knot.
5) Check adhesive does not have jagged edges
by smoothing with finger after dipping finger
in water.
6) Check that the adhesive has properly hardened
on all knots before proceeding to further
operations.
 SECTION 7
MAINTENANCE
7.4.10.3 Studs on Extended Circulator Service
Figure 7.21 Knot Sealing
7.4.10 Main Flange Stud Inspection
Stud inspection must be carried out in
accordance with the inspection cycles indicated
below.
7.4.10.1 Stud Inspection at each Flange
Breakdown
Whenever either the pump case/motor case or
the motor case/motor cover flange joint is
7.4.11 Repairs to Windings
broken, the exposed portion of all the flange
studs must be thoroughly inspected visually
for indications of damage or corrosion,
mainly in the form of pitting and cracks etc.
Pitted or cracked studs must be renewed -
7.4.11.1 Rewinding the Motor
Para 7.5.2.
7.4.10.2 Stud inspection at Pump Overhaul
At each convenient circulator overhaul
period, approximately 4 - 5 years, a
percentage of the studs must be given a non-
destructive examination, as follows:
1) Remove two random studs from the Pump
Case/Motor joint and any one stud from the
motor-case/motor-cover joint.
7.26
2) Clean up the studs, and using a liquid dye
penetrant and/or magnetic particle
examination, examine for surface cracks,
particularly in the stud threads and thread run
out areas.
NOTE:
If there has been a history of leakage in
service from the joints and/or previous
recorded damage, remove and inspect at
least 10% of each flange stud.
3) Identify any corrosive deposits that may be
present, i.e. pitted areas etc., and if corrosion
is evident, consider its stress corrosion
influences. If any stud condition raises doubts
as to the stud's serviceability, renew all the
studs in the flange.
4) If necessary renew the studs as described in
para. 7.5.2
Life
If at the end of the circulator nominal service
life, or as otherwise defined, an extension of
circulating pump life is proposed, it is
recommended that all studs should be
renewed. However, should a request be made
for an extension to the life of the existing
studs, then the following points must be
satisfied:-
1) The general condition and surface integrity of
the studs must be satisfactory.
2) There should be adequate residual fatigue life
in the studs for the extended life proposed;
this can be obtained by suitable fatigue tests
carried out on a minimum of three studs
selected at random from the pump case/motor
case joint.
Always consult Hayward 'Tyler if any doubts
exist when repairing windings or making new
joints.
Contact Hayward Tyler for assistance should
major faults develop which necessitate a
complete rewind of the motor.
 SECTION 7
MAINTENANCE

7.5 ASSEMBLY NOTES 3) Apply high temperature anti-seize compound

or silicone grease to the casing end of the
NOTE: stud.
In the event of new components being required
refer to the 'Parts List' on Sectional 4) Assemble the stud as follows: -
Arrangement Drawing (Page 7.43) and quote a) Screw the stud into the case until
the circulator Serial No.- stamped on the dimension ‘L’ measures 255 mm
motor nameplate - in all correspondence with b) Maintain the ends of the studs on a
Hayward Tyler. common plane to adjacent studs within 2
7.5.1 General mm, this is essential to prevent fouling of
the Hydraulic Stud Tensioner on the studs
1) Ensure that all the parts are free from grease either side of the stud being tensioned.
and oil.
NOTE:
2) Clean all the stud and screw holes. Inspect for When fitting an individual stud to an
and remove any burrs. assembled unit, screw the stud in until its
3) Check for full and free movement of bolts and protruded end is on the same plane as
screws by threading them by hand into their adjacent studs.
respective mating component prior to 5) When initially fitting the nut, prevent the stud
assembly. from turning and ensure the 255 mm
4) Torque wrenches must be calibrated before protrusion dimension is maintained.
use.
5) Tightening must be progressive and in a
diametrically opposed sequence
culminating at the required setting.
CAUTION:
Ensure that the torque is applied about the
axis of the screw by holding the socket and
wrench square to the screw head.
6) Threads inside the motor and pump cases
must only be lubricated with glycol or
glycerine.
7) External threads e.g. pump case and motor
cover studs are to be lubricated with silicone
grease.
8) Socket head cap screws must be punch locked,
unless lock washers or spring washers are
used.
9) Always use new spring / lock washers, as
applicable.
7.5.2 Assembly of Main Flange Studs
Renew damaged or corroded studs, with
reference to Fig. 7/22 and in accordance with
the following instructions.
1) Thoroughly clean the threads in the case with
a suitable solvent and/or by wire brushing.
Remove any very hard encrustation in the
threads by running down a tap but this should
be used only as a last resort.
2) Check the replacement studs for damage to
the threads or protective coating during
transit. Renovate or reject damaged studs as Figure 7/22 Assembly of Flange Studs
necessary.

7.27
 SECTION 7
MAINTENANCE

7.5.3 Wire Locking

Hexagon headed bolts and screws must be
wirelocked in groups of three, (Fig. 7/23, details
A, B & C), in accordance with the following
instructions:-
1) Bend a 460mm length of wire into two equal
lengths and insert one leg through the bolt
head hole, as shown in detail A.
2) Using the wire twister tool, twist the wires
together at the rate of between 6 and 12 turns
to 25mm, ensuring that no undue strain
occurs. Bring the twist to within 3mm, of the
next bolt head, and with the wire held taut,
insert one leg of the wire into the head and
pass the other wire around the hexagon, as
shown in detail B. Press the outside leg of the
wire close to the bolt-head and twist the wire
as described.
3) After threading the wire through the third
bolt-head, twist the two legs of the wire
together for a further 25mm. Cut off the
excess and bend the tail around the bolt head,
as shown in detail C.

1. Open the jaws of the pliers by squeezing the

handles together and moving perforated
slider, at the centre of the pliers, forward, to
release the lock hook.
2. Grip both legs of the wire in the pliers’
jaws. Squeeze the plier handles together
and pull the perforated slider rearwards to
lock pliers by the hook lock.
3. Twist the locking wire by pulling the twist
knob and twist rod out of the pliers, letting
the pliers spin free as shown.
4. Return the twist rod by holding the pliers
steady with one hand and pushing the flat of
the other hand against the end of the knob.
5. Repeat twisting cycles as necessary.

Figure 7/23 Wire Locking

7.28
 SECTION 7
MAINTENANCE

d) Position the securing rings, on the housings

7.6 ASSEMBLY
Assemble the components to the motor as
follows: -
7.6.1 Stator Shell and Journal Bearings
1) Fit the journal bearings (Fig. 7/24) as
follows:-
a) Fit the two bearing anti-rotational stop pegs
in each bearing ring.
b) Fit the bearing rings in the bearing
housings.
c) Assemble the tilting pads in the correct
sequence, against the bearing ring housing.
and tilting pads. Check that the pads are
free to pivot. Secure the ring with the
screws using lock washers as applicable.
NOTE:
The tilting pads are numbered to
identify each set and marked with an
arrow to indicate the rotational
direction.
e) Check that the pads are free to tilt slightly
when the trailing edge is depressed. If
there is no movement, remove the pads and
grind the spacers on the side to allow a
tilting action.
f) Torque tighten the screws.

Figure 7/24 Journal bearing - Assembly

7.29
 SECTION 7
MAINTENANCE
3) Prepare the stator shell, complete with pump-
2) Install the pump-end bearing housing to the
stator shell, (Fig. 7/25) as follows: -
a) Lay the stator shell horizontally and wedge
firmly.
b) Clean the mating surfaces of the stator
shell ends and the bearing housing.
c) If previously removed, insert the housing
lock rings in their respective end of the
stator shell observing the matching up
marks for screws.
d) Fit the split rings in their grooves in the
stator shell.
e) Pull the bearing housing lock rings up to
the split rings, and secure the lock rings to
the stator shell with socket-headed cap
screws.
f) Fit an eyebolt to the periphery of the pump
end bearing housing. Attach a shackle and
sling and lift the bearing housing to the
stator end opposite to the end with the
cable leads.
g) Align the slot in the pump-end bearing
housing with the anti-rotation peg match
marks on the stator shell, and locate the
housing in the shell.
h) Fit the socket-headed cap screws and lock
washers to secure the pump-end bearing
housing to the stator shell and torque
tighten.
Figure 7/25 Stator Assembly
7.30
end bearing housing, for insertion in the
motor case as follows: -
NOTE:
The cover-end bearing housing and the
reverse thrust housing are temporarily
fitted at this stage to provide the means of
lifting the stator assembly into the motor
case.
a) Fit an eyebolt to the cover-end bearing
housing periphery. Sling and lift the
bearing housing to the stator shell.
b) Ensure that the terminals and cables are
stowed in the stator bore and temporarily
fit the cover-end bearing housing, securing
with the socket-headed cap screws. Tighten
the screws.
c) Temporarily fit the reverse thrust housing,
securing with the socket-headed cap
screws. Tighten the screws.
d) Using chalk marks, transfer the radial
location of the anti-rotation peg from the
pump-end bearing housing along the stator
shell to the cover-end bearing housing.
NOTE:
The anti-rotation peg slot should line up
with the centre gland hole in the stator
shell.
e) Ensure that the motor case is in a true
vertical position, with the pump end
downwards, and stable.
 SECTION 7
MAINTENANCE

4) Install the stator assembly in the motor case

(Fig. 7/11) as follows: -
CAUTION
Do not damage the chamfered register on
the pump end bearing housing when
handling the stator assembly. Before
leaning over the motor ensure that you
remove headgear and any other objects
liable to drop into the motor case.
a) Attach eyebolts and lifting tackle to the
reverse thrust housing.
b) Carefully raise the stator assembly over the
motor case. Align the chalk marks made in
operation 3(c) and lower it vertically into
the motor case.
c) Raise the stator assembly approximately
3mm and try and turn the stator in the
direction the starting torque is applied,
against the anti-rotation stop peg. If the
peg stops the stator from turning, lower the
stator back onto its register.
d) Remove the reverse thrust housing and
cover-end bearing housing from the stator
and withdraw the cable leads from the
stator bore. (The removal of the cover-end
bearing housing is the reversal of its
temporary fitting.).
7.6.2 Journal Sleeves (Fig. 7/26)
1) If a journal sleeve has been removed, fit a new
sleeve as follows: -
a) Clean the journal seat and the bore of the
journal sleeve.
b) Re-fit the sleeve key and ensure that the
journal locking screw is below the shaft Figure 7/26 Journal Sleeves
surface.
c) Heat the new sleeve in water at a
temperature of 80°C for 15 minutes then 7.6.3 Rotor Assembly (Fig 7/9)
quickly slide the sleeve into position on the 1) Attach an eyebolt, shackle and sling, to the
shaft, tapping it home with a soft faced thrust end of rotor assembly.
hammer.
d) To secure and lock the sleeve after it has 2) Ensure that the winding cable leads do not
cooled, unscrew the locking screw. foul the stator bore.
CAUTION: 3) Carefully raise the rotor assembly vertically
Too much force applied to the locking over the stator bore. Lower into the stator,
screw could result in a damaged sleeve. resting the shaft at the impeller end in its
e) Check the bearing clearances as detailed in approximate final position on a wooden block
Para. 7.4.1. supported by a screw or hydraulic jack.
4) Remove the lifting tackle but leave the
eyebolt fitted.

7.31
 SECTION 7
MAINTENANCE
7.6.4 Terminal Glands (Fig 7/27)
CAUTION:
Always fit new ‘O’-rings and back-up rings
whenever assembling glands.
1) Observing the colour identification, pass the
gland moulding complete with back-up sleeve
and two belleville washers, through the hole
in the motor casing
2) Clean all components, particularly the 'O'-ring
recesses.
3) Apply a light coating of non-conductive
silicone grease to the gland moulding and
white insulating sleeve.
4) Fit a new ‘O’ ring in the inner casing neck and
slide the inner casing over the insulating
sleeve and gland moulding, until the gland
moulding is fully located inside the inner
casing.
5) Fit the 'C' shaped support ring on the lead
cable beneath the Belleville washers as
indicated.
Figure 7/27 Terminal Gland - Assembly
7.32
6) Fit new 'O' rings and back up rings in the
inner casing recesses. Make sure that the 'O'
ring is below the back-up ring, i.e. nearest the
motor. Sparingly coat the ‘O’ rings and back-
up rings with silicone grease.
7) Carefully slide the complete assembly into the
motor case, until firmly seated on the support
ring, belleville washers and back-up sleeve.
NOTE:
If the rings are improperly fitted,
considerable pressure will be necessary to
force the inner casing into the motor case
and either the back-up rings or 'O'-rings
will be damaged. Also never hammer the
end of the terminal stem if the assembly is a
tight fit in the inner casing.
8) Fit the gland nut and tighten. A torque of
100Nm should be sufficient.
9) Ensure that there are no tight bends in the
cable and that the cable protective sleeves are
correctly positioned. Check the lead cable
binding is in good order and keep the lead
cables well away from the stator bore
 SECTION 7
MAINTENANCE
7.6.5 Cover End Bearing Assembly (Fig. 7/28)
1)
a) Fit a new 'O' ring to the periphery of the
cover-end bearing housing.
b) Using the lifting eyebolts, hoist the bearing
housing to just above the motor case and
protruding rotor shaft.
2) Re-fit the cover-end bearing housing using
guide rods and observing the correct location
match marks. Make sure that the housing
seats evenly all round.
3) Re-fit the socket-headed cap screws and lock
washers and torque tighten.
4) Position the stator lock ring in the motor case
and fit the split ring.
Figure 7/28A Cover End Bearing Assembly
7.33
NOTE:
Make sure that the screw holes in the stator
lock ring do not line up with any of the
bearing housing screws.
5) Using the hexagon-headed screws, draw the
lock ring up to and over the split ring. Torque
the screws and wire lock in groups of three.
6) Assemble the thrust bearings, as follows: -
a) With the thrust seat standing edge-wise, fit
the thrust pads, in their correct sequence on
the seat with the thrust pad stops and the
split pins.
CAUTION:
Pads are supplied as sets and must not be
mixed.
Figure 7/28B Cover End Bearing Assembly
 SECTION 7
MAINTENANCE

b) Ensure that the thrust pads tilt freely to

form a liquid wedge with the thrust disc,
with the point of the wedge in the direction
of rotation.
c) Centre the thrust seat, Fig.7/28 detail B,
complete with the thrust pads, on the cover
end bearing housing. Assemble with the
socket-headed cap screws and spring
washers. Torque the screws.
NOTE:
If the thrust pads reclaimed by grinding
are fitted, a shim, the thickness of the metal
removed, must be fitted between the thrust
seat and bearing housing. This is to ensure
that the rotor laminations remain
centralised with the stator laminations.
7) Fit the thrust disc key to the rotor shaft.
CAUTION:
Before fitting the thrust disc ensure that the
thrust disc and thrust pad contacting
surfaces are scrupulously clean.
8) Fit the thrust disc as follows: -
a) Extend the jack beneath the rotor assembly
to raise the rotor higher than normal.
b) Lower the thrust disc on to the shaft and
key. Once the disc is located on the shaft,
lower it smartly to ensure that it seats
firmly against the shaft.
c) Fit the thrust disc spacer washer.
d) Fit the thrust nut. Hand tighten the thrust Figure 7/28C Cover End Bearing Assembly
nut until the thrust disc has no movement.
e) Lower the jack until the thrust disc is
seating positively on the thrust pads.
f) Tighten the thrust nut and fit the split pin as 9) Fit the reverse thrust seat housing (Fig 7/28C)
follows:- as follows: -
i) Using the castellated wrench, supplied in a) Ensure that the reverse thrust components
the tool kit, and by un-assisted manual are scrupulously clean.
strength only, tighten the nut as far as b) Fit the composite reverse thrust wear ring
possible. to the reverse thrust housing, the radial
ii) Remove the wrench and radially match grooves outwards, using the six socket-
mark the top of the shaft and nut. headed cap screws and the Philidas nuts.
iii) Re-fit the wrench and ‘slog’ tighten the CAUTION:
nut until one of the castellations (cut- Avoid damaging the composite ring when
outs) in the nut lines up with the split-pin tightening the screws.
hole in the shaft.
c) Fit the assembled reverse thrust housing
iv) Check that the nut has turned at least using the socket-headed cap screws and
3mm from the match marked position. If spring washers.
this tightness is not obtained, re-slog the
d) Torque tighten the screws.
nut up until the next hole lines up
(maximum 12mm further). 10) Check the rotor end float, as detailed in
v) Fit the split pin and splay the legs to 7.6.6., before completing the reverse thrust
wrap around the nut. housing assembly.

7.34
 SECTION 7
MAINTENANCE

Figure 7/28 End Float Check (Typical Method)

7.35
 SECTION 7
MAINTENANCE
7.6.6 Checking End Float (Fig. 7/29)
There are two methods of checking the rotor
end float, a recommended method using a dial
indicator or if such an instrument is not
available, an alternative method with a
straightedge and feeler gauges.
7.6.6.1 Recommended method - Dial Indicator
1) Make sure that the thrust disc is seating on the
thrust pads.
2) Set up a dial indicator as follows:
a) Set up the dial indicator on the top of the
reverse thrust housing, using a magnetic
block to hold the indicator to the housing.
b) Set the indicator to record any vertical
movement of the rotor using a suitable
spacer if necessary.
c) Set the indicator dial to zero.
3) Using the jack beneath the rotor, raise the
rotor, complete with thrust disc, until the
thrust disc is positively in contact with the
underside of the reverse thrust plate.
4) Check the dial indicator reading: the reading
is the amount of end-float. The end-float
must conform to that specified in Section 1 -
Technical Data
5) Adjust the end float, if necessary, as described
in operation 3 - End Float Adjustment.
6) When the end float is satisfactory, fit all the
twelve socket-headed cap screws and lock
washers in the reverse thrust housing. Torque
tighten the screws.
7.6.6.2 Alternative method - Feeler Gauges
1) Check that the rotor assembly is supported by
the thrust pads.
2) Place a straight edge across the reverse thrust
seat housing. Using a suitable spacer resting
on the rotor and long enough to reach to
within 10mm. of the underside of the straight
edge, measure with feeler gauges and record
the exact clearance between, and straight
edge. Dimension Y.
3) Using the jack beneath the rotor, raise the
rotor until the thrust disc is in positive contact
with the underside of the reverse thrust pads.
4) Measure and record the exact clearance
between spacer and straight edge, dimension
X. The difference between Dimension X and
Y is the end float. See Section 1, Technical
Data, for limits.
NOTE:
As a further alternative, a straight edge
and depth gauge can be used.
7.36
7.6.6.3 End float adjustment
1) Below limits: If the dimension obtained is
below the specified limit (Section 1) remove
the reverse thrust plate and either:
a) Method 1
Make a steel shim to fit between the reverse
thrust plate and the cover-end bearing
housing, the shim thickness to bring the end-
float within limits.
Or
b) Method 2
Lightly machine the face of the reverse thrust
housing where it makes contact with the
reverse wear ring. The amount machined is
determined by the difference between actual
measurement and the required end-float.
2) Above limit: if the end-float exceeds the
specified limit, remove the reverse thrust
housing and either:-
a) Method 1
i) Remove the reverse thrust wear ring from
the reverse thrust housing.
ii) Make a steel shim of a thickness to bring
the excess end float within limit, and fit
between the reverse thrust wear ring and
the housing.
b) Method 2
i) Lightly machine the outer face of the
reverse thrust housing where it contacts
the cover-end bearing housing.
ii) Re-fit the reverse thrust wear ring with
the six socket-headed cap screws and
Philidas. Torque tighten the screws.
3) Fit the reverse thrust housing finally to the
bearing housing with the twelve socket
headed screws and lock washers. Torque
tighten the screws.
7.6.7 Motor Cover Filter – Assembly (Fig 7/30)
1) Fit the filter assembly as follows:-
a) Offer the filter assembly to the reverse
thrust housing.
b) Secure with the hexagon-head screws and
lock washers and torque tighten.
2) Fit the motor cover as follows:-
a) Ensure that the flange faces are
scrupulously clean.
b) Position a new flexitallic spiral wound
gasket in the motor case recess.
c) Using lifting tackle, lower the cover into
position on the motor case flange, aligning
the case/cover match marks.
 SECTION 7
MAINTENANCE

NOTE: 3) Using two cranes and slings, lift the motor

If the cover does not seat correctly, raise it
again and check that the gasket has not
been damaged.
d) Coat the threads of the studs and nuts with
anti-seize compound or silicone grease. Fit
and hand tighten the nuts.
e) Tension the studs as detailed in Section 8.
from the building stand and lower the motor
into a horizontal position, terminal stems
uppermost (see Fig.7/5). Chock to prevent
movement.
4) Blank-off all the motor case openings until the
unit is installed.

Figure 7/30 Motor Cover and Filter Assembly

7.37
 SECTION 7
MAINTENANCE

Figure 7/31 Terminal Box

7.38
 SECTION 7
MAINTENANCE

Figure 7/32 Terminal Link Insulation

7.39
 SECTION 7
MAINTENANCE

7.6.8 Terminal Boxes (Fig. 7/31, 32, 33)

Fit the terminal boxes as follows: -
1) Ensure that the neoprene gasket is located on
the terminal box support.
2) Using the lifting tackle on the terminal box
eyebolt hoist the terminal box onto the
terminal box support and secure with nuts and
washers.
3) Fit each terminal link as follows: -
a) Connect the terminal link clamp connector
to the terminal gland stem with the socket
headed cap screws and nuts.
4) Insulate the terminal connecting links with
reference to Fig. 7/32 as follows: -
a) Cover the complete length of the
connecting link including the terminal
clamp connector with 3M No. 70 silicone
thermosetting tape to a minimum thickness
of 3mm in three staggered layers.
b) Slide a length of heat shrink tubing over
the insulated section and, as far onto the
clamp connector as possible removing all
wrinkles.
c) Using a hot air gun or propane gas torch
operating at a temperature of 150°C, heat
the tubing and working outwards from the
centre, heat shrink until a tight fit over the
taped area.
5) Re-fit the respective terminal link ends to the
terminal block, and secure with washers and
nuts.
6) Check that the bursting discs are intact. The
details of the bursting disc assembly are
shown as an exploded view in Fig 7/33.
7) Re-new the cover gasket.
8) Fit the terminal box cover and secure with
nuts and washers to protect the terminal stems
until the main supply cables are fitted.
Figure 7/33 Bursting Disc Details
9) Temporarily fit and secure the terminal box
cover until the main supply cables are fitted.

7.40
 SECTION 7
MAINTENANCE

Figure 7/34 Impeller Setting

7.41
 SECTION 7
MAINTENANCE
7.6.9 Baffle Wear Ring (Fig.7/34)
If the baffle wear ring has been removed, re-fit
as follows: -
1) Place the ring on the integral baffle and attach
with the socket-headed cap screws and lock
washers.
2) Torque tighten the screws.
7.6.10 Main Impeller (Fig. 7/34)
Fit the impeller as follows: -
1) Remove the protective impeller nut and fit the
impeller key.
2) Fit the impeller washer with the internal
chamfer towards the shaft shoulder.
3) Coat the threads of the left-hand threaded
impeller screw with silicone grease, then re-fit
the impeller and the impeller nut
4) Check that the gap between the key and the
top of the impeller hub does not exceed
0.25mm.
5) Using the special impeller nut spanner and
tommy bar, supplied in the tool kit, and a
lead-faced hammer, tighten the impeller nut.
NOTE:
The impeller nut has a left-handed thread.
Do not use any leverage in the water
passages of the impeller to oppose force
exerted by the spanner, the weight of the
rotor will oppose rotation if the spanner is
given a few heavy blows with a lead-faced
hammer.
7.42
6) Draw the impeller and rotor assembly
forwards until the thrust disc rests upon the
thrust pads.
7) Measure the dimension between the top of the
impeller and the pump/motor case flange
(Dimension ‘Z’ shown in Fig. 7/34). Adjust
the thickness of the impeller washer as
necessary, to obtain the dimension given in
Section 1.4 - Technical Data.
8) Re-new the locking screw, torque tighten and
punch lock.
9) If the unit is to be stored, cover the impeller
with the transit canister and the flanges with
the flange covers. Slowly fill the motor with
inhibitor through the inhibitor filling valve.
7.6.11 Heat Exchanger
Ensure that the heat exchanger is serviceable
before refitting as described Para. 4.3 – Section
4
7.7 RE-INSTALLATION OF MOTOR
The re-installation of the motor assembly to the
pump case is carried out in accordance with the
installation procedure described in Section 4,
para. 4.3
 SECTION 7
MAINTENANCE

PARTS LIST – SECTIONAL ARRANGEMENT

ITEM NO. PART NO. DESCRIPTION QTY.

1 42789/1003 PUMP CASE 1
2 16884M16/50 SKT HEAD CAP SCREW 1
3 42789/1010 CASE WEAR RING 1
4 42789/1202 IMPELLER NUT 1
5 42789/1401 IMPELLER 1
6 42789/1204 IMPELLER KEY 1
7 42789/2030 BAFFLE WEAR RING 1
8 16884M12/35 SKT HEAD CAP SCREW 6
9 42577/212 NORDLOCK WASHER 6 PR
10 42488/433 GASKET - PUMP/MOTOR FLANGE 1
11 42789/1801 PUMP END BEARING HOUSING 1
12 42789/1227 JOURNAL SLEEVE 2
13 42789/1806 JOURNAL TILTING PAD ASSEMBLY 2 SETS
14 42401/111 HEAT EXCHANGER SPOOL PIECE 2
15 16884M12/60 SKT HEAD CAP SCREW 12
16 42577/212 NORDLOCK WASHER 12 PR
17 42789/1704 BEARING RING 2
18 42789/2108 SPLIT RING – STATOR SHELL 3
19 42789/2111 BEARING HOUSING LOCK RING 2
20 16884M10/55 SKT HEAD CAP SCREW 8
21 42577/210 NORDLOCK WASHER 8 PR
22 42789/1805 SECURING RING- PUMP END 1
23 42789/2101 STATOR SHELL 1
24 42789/2110 STATOR KEY 1
25 42789/2104 STATOR LAMINATION 805 MM
26 42789/2105 STATOR END PLATE 2
27 42789/1705 SECURING RING - COVER END 1
28 16801M10/55 HEX HD SCREW 8
29 42577/210 NORDLOCK WASHER 8 PR
30 16884M6/12 SKT HEAD CAP SCREW 6
31 42789/1701 COVER END BEARING HOUSING 1
32 42789/1601 THRUST SEAT 1
33 42789/1605 THRUST PAD STOP 12
34 167WBDGJ62M0 SPLIT PIN 12
35 42789/1603 THRUST PAD 12
36 42789/1501 THRUST DISC 1
37 16884M12/120 SKT HEAD CAP SCREW 12
38 17207M12 SINGLE COIL SPRING WASHER 12
39 42789/003 TERMINAL BOX ASSEMBLY 3
40 42488/431 FLEXITALLIC GASKET – MOTOR COVER 1
41 42789/2028 STUD – MOTOR CASE/MOTOR COVER 16
42 42789/2029 NUT – MOTOR CASE/MOTOR COVER 16
43 16884M6/45 SKT HEAD CAP SCREW 6
44 16526M6 PHILIDAS NUT 6
45 42789/1242 THRUST NUT SPACER 1
46 42789/1243 THRUST NUT 1
47 42789/1205 THRUST DISC KEY 1
48 42789/028 FILTER ASSEMBLY 1
49 167WBCNN10M0 SPLIT PIN 1
50 42789/2502 REVERSE THRUST PLATE 1
51 42789/2501 REVERSE THRUST HOUSING 1
52 42789/1901 MOTOR COVER 1
53 16201M10/45 HEX HEAD SCREW 6
54 42577/210 NORDLOCK WASHER 6 PR
55 42401/112 FILL & DRAIN SPOOL PIECE 1
56 16884M8/25 SKT HEAD CAP SCREW 6

7.43
 SECTION 7
MAINTENANCE

57 17207M8 SINGLE COIL SPRING WASHER 6

58 42789/2910 STATOR LOCKING SCREW 18
59 169XYNFB LOCKING WIRE A:R
60 42789/2903 SPLIT RING – STATOR LOCK RING 1
61 42789/2904 STATOR LOCK RING 1
62 16884M12/90 SKT HEAD CAP SCREW 12
63 42577/212 NORDLOCK WASHER 12 PR
64 42789/1711 ‘O’ RING – BEARING HOUSING 1
65 40744/123 WINDING SUPPORT BRACKET 6
66 42789/013 ROTOR ASSEMBLY 1
67 42789/2125 WINDING CABLE 3
68 42789/2001 MOTOR CASE 1
69 42401/112 PRESSURE GAUGE SPOOL PIECE 1
70 16884M6/12 SKT HEAD CAP SCREW 1
71 36810/185 LOCKING PIECE - SPLIT RING 1
72 42789/1208 JOURNAL SLEEVE KEY 2
73 42789/1710 ANTI-ROTATION PIN 4
74 42789/1209 JOURNAL LOCKING SCREW 2
75 42789/2017 ANTI-ROTATION PEG 1
76 42789/2016 THERMOMETER POCKET 1
77 42789/2015 THERMOWELL 2
78 42789/2016 TEMPERATURE SWITCH POCKET 2
79 42789/1018 NUT – PUMP/MOTOR CASE 18
80 42789/1018 STUD – PUMP/MOTOR CASE 18
81 42789/1201 IMPELLER WASHER 1
82 16884M10/55 SKT HEAD CAP SCREW 6
83 42577/210 NORDLOCK WASHER 6 PR
84 38882/102 GRUBSCREW 3
85 42789/1405 IMPELLER WEAR RING 1

PARTS NOT ILLUSTRATED

ITEM NO DESCRIPTION QUANTITY

42554/035 FILLING VALVE ASSEMBLY (TRANSIT ONLY) 1

INSTRUMENTS

ITEM NO DESCRIPTION QUANTITY

42401/156 JUNCTION BOX – TEMPERATURE SWITCH 1

42401/157 JUNCTION BOX – THERMOCOUPLES 1
42401/201 FLOW METER 1
42646/203 THERMOCOUPLE – PUMP SUCTION MANIFOLD 1
42646/203 THERMOCOUPLE – PUMP CASE 1
42401/204 TEMPERATURE SWITCH 2
42401/205 THERMOMETER 1
42401/206 THERMOCOUPLE – MOTOR CAVITY 1
42401/207 PRESSURE GAUGE – MOTOR CAVITY 1
42478/117 DIFFERENTIAL PRESSURE TRANSMITTER WITH MANIFOLD 2

7.44
 SECTION 7
MAINTENANCE

PARTS LIST - TERMINAL GLAND

TERMINAL GLAND ASSEMBLY - 3 OFF - EACH COMPRISING:

PART NO. DESCRIPTION QTY.

42789/2320 THREADED BUSH (GLAND NUT) 1
42789/2314 INNER CASING 1
42789/2315 SUPPORT RING 1
42789/2331 ‘O’ RING (CABLE GLAND) 2
42789/2333 ‘O’ RING (STEM) 1
42789/2332 SPIRAL BACK-UP RING 2
42789/2313 BELLEVILLE WASHER 2
42789/2312 BACK UP SLEEVE 1
SP42789/023 GLAND MOULDING AND CABLE ASSEMBLY 1

PARTS LIST - TERMINAL BOX

ITEM No PART NO. DESCRIPTION QTY

.
SP42789/027 TERMINAL BOX ASSEMBLY- EACH COMPRISING 3

1 42789/2705 GASKET-TERMINAL BOX SUPPORT 1

2 16012M10/25 STUD- TERMINAL BOX SUPPORT 12
3 17207M10 SHAKEPROOF WASHER - TERMINAL BOX SUPPORT 12
4 16501M10 NUT- TERMINAL BOX SUPPORT 12
5 SP42789/023 TERMINAL GLAND ASSEMBLY 1
6 16220M12 EYEBOLT 1
7 42789/2701 TERMINAL BOX 1
8 - FLASHPLATE ASSEMBLY 1
9 42789/2708 GASKET - TERMINAL BOX COVER 1
10 16012M10/25 STUD- TERMINAL BOX COVER 26
11 17207M10 WASHER- TERMINAL BOX COVER 26
12 16501M10 NUT- TERMINAL BOX COVER 26
13 42789/2707 TERMINAL BOX COVER 1
14 16220M12 EYEBOLT 1
15 42789/2732 TERMINAL LINK ASSEMBLY 3
16 42715/2721 TUBULAR LUG SOCKET 1
17 16884M6/50 SKT HEAD CAP SCREW – BURSTING DISC HOUSING 8
18 42789/2723 BURSTING DISC 2
19 42789/2713 PANEL DESSICATOR 1
20 42789/2711 GASKET – GLAND PLATE 1
21 16012M10/35 STUD - CABLE ENTRY PLATE 4
22 17207M10 WASHER - CABLE ENTRY PLATE 4
23 16501M10 NUT - CABLE ENTRY PLATE 4
24 42715/2740 CABLE GLAND 1
25 42789/2741 GLAND PLATE 1
26 42789/2720 NUT – TERMINAL SCREW 10
27 42789/2719 WASHER – TERMINAL SCREW 8
28 - EPOXY RESIN -
29 16884M12/55 SKT HEAD CAP SCREW – TERMINAL BLOCK 2
30 42789/2717 TERMINAL BLOCK ASSEMBLY 1

7.45
 SECTION 7
MAINTENANCE

SPARES PARTS –COMMISSIONING

PART NO. DESCRIPTION QTY *

42789/2333 SMALL ‘O’ RING - TERMINAL GLAND 3
42789/2331 LARGE ‘O’ RING - TERMINAL GLAND 6
42789/2332 BACK-UP RING - TERMINAL GLAND 6
42488/431 GASKET - MOTOR COVER 1
42488/433 GASKET - PUMP / MOTOR 1
39930/207 GASKET – FILLING VALVE (HP) 1

* QUANTITIES ARE PER UNIT

7.46
 SECTION 7
MAINTENANCE

Figure 7/35 General Arrangement

7.47
 SECTION 7
MAINTENANCE

Fig. 7/36 Sectional Arrangement

7.48
 SECTION 7
MAINTENANCE

Fig. 7/37 Terminal Box Arrangement

7.49
 SECTION 7
MAINTENANCE

Fig. 7/38 Tool Kit List

7.50
 SECTION 8
STUD TENSIONING EQUIPMENT

CONTENTS

PARAGRAPH PAGE

8.1 INTRODUCTION 8.2

8.2 APPLICATION 8.2

8.3 DESCRIPTION 8.2

8.4 ASSEMBLING THE STUD TENSIONER 8.3

8.5 REPLENISHING THE PUMP TANK 8.6

8.6 INDEXING 8.6

8.7 SAFETY PROCEDURES 8.7

8.8 TIGHTENING THE FLANGE NUTS 8.7

8.9 RELEASING FLANGE NUTS 8.8

PARTS LIST 8.11

ILLUSTRATIONS

FIGURE 8/1 HYDRAULIC STUD TENSIONING EQUIPMENT 8.1

FIGURE 8/2 SINGLE PISTON STUD TENSIONER (EXPLODED VIEW) 8.4

FIGURE 8/3 SINGLE PISTON STUD TENSIONER (GENERAL ARRANGEMENT) 8.5

FIGURE 8/4 QUICK RELEASE COUPLING 8.6

FIGURE 8/5 NUT TIGHTENING SEQUENCE 8.9

NUT TIGHTENING SEQUENCE (CONTINUED) 8.10

8.0
 SECTION 8
STUD TENSIONING EQUIPMENT

Figure 8/1 Hydraulic Stud Tensioning Equipment

8.1
 SECTION 8
STUD TENSIONING EQUIPMENT
8.1 INTRODUCTION
All items mentioned herein relate to the M56 Stud
Tensioner Equipment supplied as a comprehensive
kit. This must be used ONLY in conjunction with
the circulator manual for the equipment supplied
for the specific contract.
8.2 APPLICATION
The physical dimensions of the pump case/motor
case joint and the motor case/cover joint prevent
adequate pressure sealing by hand-tightened nuts.
For these applications, hydraulically operated stud
tensioner heads are supplied with each contract.
The tensioner heads stretch the studs and the nuts
are then tightened down by hand. When the
tension on the stud is released, the load is
transferred to the nut to give the required tightness.
When working on a circulator flange joint, all the
heads are employed simultaneously, each being
diametrically opposed. The heads are positioned
on the studs in a prescribed sequence, and are
pressurised to specified limit in accordance with
each of five consecutive stud tensioning
programmes. As the studs are progressively
tensioned, the mating flanges are drawn together,
so allowing the circulator flange nuts to be
tightened or released.
8.3 DESCRIPTION (FIG. 8/1)
The Hydraulic Stud Tensioner Equipment
comprises three principal components: -
1) Tensioner head assembly, including the
bridge, tensioner body and piston and threaded
insert (see Fig. 8/3).
2) Hand-pump - including oil reservoir.
3) High Pressure Couplings, hoses and pressure
gauge.
Four metal rods are provided in the kit. One end of
the rod is used for tightening the threaded inserts
when installing the heads. The other end is used
for pulling down the flange nuts.
Although each Stud Tensioner is operable by one
engineer, this practice is not recommended due to
weight and environmental criteria.
8.2
8.3.2 Hand Pump
The stud tensioner equipment hydraulic
pump is a hand operated, dual piston, high
pressure unit. Initially, both low and high
pressure flow is applied at each pump handle
stroke until the tensioning head starts to take
load, when the high pressure application
continues and the low pressure is diverted
back to the oil reservoir. Re-setting of the
low and high pressure takes place
automatically allowing the pump to operate
with maximum efficiency at all times.
Pressure limiting valves trip when the
pressure exceeds the pump capacity.
The pump body contains the oil reservoir,
incorporating an oil filter plug and oil
pressure return valve for variable pressure
release, the pump handle, gauge and quick
release high pressure hoses complete the
assembly. All the pump components are
easy to dismantle for servicing.
8.3.3 Stud Tensioner Heads
The stud tensioner heads each comprise a
bridge that fits over the stud and stud nut to
seat on the flange and is retained by the
bridge retainer. A tensioner body
incorporating a seal, sits on the bridge and is
held in position by the threaded insert,
screwed on the stud. The head is
hydraulically pressurised via a quick release
coupling and high pressure hose.
Three of the four heads have two connectors
fitted. The fourth head has one connector and
one blanking plug. The fourth head is
always the last in line in the system, the other
heads are interconnected.
8.3.4 Operation
When the hydraulic pressure, in accordance
with the stud tensioning program, is applied to
the tensioner head, the body reacts against the
threaded insert which in turn stretches the
stud. While the stud is stretched, the stud nut
is hand tightened, using the bar provided in
the kit.
 SECTION 8
STUD TENSIONING EQUIPMENT
Having hand tightened the stud nut, the hydraulic
pressure on the tensioning head piston is gradually
released, via the hand pump oil return valve, and
the load is transferred to the stud nut to give the
required tightness. The threaded inserts are
unscrewed from the studs and the heads are
transferred to the next studs in the tightening
sequence.
8.4 ASSEMBLING THE STUD TENSIONER
(FIG. 8/3)
The hand pump and its accessory hoses are
normally provided, in the toolbox, already
assembled needing only to be connected to the
tensioning heads. However for information
purposes, the assembly of the stud tensioner kit is
as follows: -
1) Remove the hand pump, complete with
pressure gauge, high pressure hoses and hose
couplings from the hydraulic pump tool box.
Ensure that all studs are scrupulously clean
and that their threads are undamaged.
Carefully examine that portion of each stud
thread protruding beyond the flange nut after
fitting. If the studs have been in service for
some time, inspect as described in the
Circulator Instruction and Maintenance
Manual.
When tensioning studs of the circulators which
have been in service, inspect all faces of each
flange nut. Reject any damaged nuts.
(Damaged faces of nuts can be re-ground for
subsequent re-use).
CAUTION:
Never lubricate the stud top threads, or
those of the threaded insert.
2) Install and hand tighten all flange nuts. Apply
silicone grease or high temperature anti-seize
compound to the threads and faces of each
flange nut
3) Connect the high pressure feed hose via the
quick release female connector to the gauge
tee on the pump.
4) Assemble the load cell and bridge, over the
first set of bolts (diametrically opposed) to be
tightened. The bridge window should be
positioned so that access to the nut is obtained.
It is normal for the bridge window to face
radially outwards from the centre of the
circular flanged joint.
8.3
NOTE:
The bridge base circumference should
sit flatly against the surface against
which it is being tensioned.
5) Attach each threaded insert into the bolt
tensioners by screwing onto the threads
protruding above each nut. Screw down
the inserts using the tommy bars supplied
with the equipment, until contact with the
load cells is achieved.
CAUTION:
Body and piston seals will be damaged
if the piston protrudes excessively from
the tensioner body, observe the yellow
maximum extension warning line.
(Maximum extension 6mm)
NOTE:
If the seals need replacing, refer to the
operator’s manual provided with the
stud tensioning equipment.
6) Connect the end of the high pressure feed
hose to the first tensioner head.
7) Fit one of the inter-connecting hoses
between the first and second heads.
8) Connect up the second and third heads
and finally, using the one remaining hose.
Connect the fourth head (i.e. with a
blanking plug fitted) to complete the
circuit.
9) Check the oil level in the hydraulic hand
pump, fill or top-up if necessary.
NOTE.
The quick release female connectors
have a knurled security locking ring in
the centre. This must be turned to lock
the spring-loaded end of the coupling
to eliminate the possibility of an
accidental disconnection.
CAUTION:
Do not pressurise an un-connected
male coupling.
 SECTION 8
STUD TENSIONING EQUIPMENT

Figure 8/2 Single Piston Stud Tensioner

Exploded View

8.4
 SECTION 8
STUD TENSIONING EQUIPMENT

Figure 8/3 Single Piston Stud Tensioner

General arrangement

8.5
 SECTION 8
STUD TENSIONING EQUIPMENT

Figure 8/4 Quick Release Coupling

8.6 INDEXING
8.5 REPLENISHING THE PUMP TANK
The pump is supplied already filled with oil
but after repeated use the oil should be
replenished as follows:-
1) Unscrew the oil filler plug from the top
pump tank.
2) Replenish the tank from the 5 litre
container of hydraulic fluid to the bottom
of the level tube.
It is essential that the gasket is uniformly
compressed and the studs evenly prestressed.
To ensure this, diametrically opposed flange
nuts are tightened simultaneously in
accordance with a predetermined numbering
sequence.
Using any convenient nut as No. 1 and
working in a clockwise direction, sequentially
mark with chalk on the flange periphery, the
appropriate nut tightening sequence. Refer to
Fig.8/5 for Nut Tightening Sequences.

8.6
 SECTION 8
STUD TENSIONING EQUIPMENT

8.7 SAFETY PROCEDURES 3) Depress the hydraulic piston fully in the

1) Eye protection and gloves should be worn
when working with high pressure
hydraulics.
2) Pressurise slowly, do not exceed the
maximum working pressure (1500 bar).
Gauge pressure should be constantly
monitored during pump operation.
3) Do not exceed the maximum piston
extension 6mm. indicated by a yellow
line.
4) Do not leave a pressurised system
unattended, release pressure if leaving the
working area.
5) Check the equipment
a) Ensure that the hoses are undamaged.
b) Check that all hose couplings are
serviceable and tight on the hose ends
and tensioning heads.
tensioner body by: -
a) Opening the oil return valve on the
hydraulic hand pump using the winged
control valve screw.
b) Fully tightening the threaded inserts
using the rod provided.
c) Closing the oil return valve on the
hydraulic pump.
4) The pump, hoses and tensioner heads are
pre-filled and system venting should not
be necessary. However, should venting of
the system be required, loosen the
blanking plug from the last head in the
circuit and operate the pump until air free
fluid emerges from around the plug on
completion of venting.
5) Using the hydraulic hand pump, obtain a
true pressure stipulated for the 1st pass of
the 5 passes given in the following table.

6) Check equipment is correctly assembled; CAUTION;

The indicated gauge pressures are true
a) Tensioning head components must be operating pressures. Never exceed
seated squarely within each other and maximum working pressure for the
with the motor cover face or motor head when tensioning, or damage to the
pump flange. tensioner or to the studs may occur.
b) The thread engagement between the
stud and the threaded insert must be
48 mm minimum.
c) Before pressurising, ensure hose PASS LBF/IN.2 BAR
connector security by pulling on each
locked connection. 1ST 5000 350
7) Do not attempt to use stud tensioner if
unsure of the correct assembly and 2ND 10000 700
operation of the equipment. 3RD 15000 1050
8) Do not attempt any repairs on the system
4TH 21000 1450
when under pressure.
5TH 21000 1450
8.8 TIGHTENING FLANGE NUTS
1) Fit the four tensioner bodies complete
with threaded inserts onto the studs and
screw down on to each bridge. Attach the TENSIONING PRESSURE PROGRAM
hydraulic link hoses (See Section 4).
2) Ensure that the insert is fully depressed
within the tensioner body.

8.7
 SECTION 8
STUD TENSIONING EQUIPMENT
6) The piston stroke and pressure should be
continually monitored so that neither go
above the corresponding working
pressures. If the maximum piston stroke is
reached before working pressure is
achieved go straight to procedure (8).
Close the pump stop valve, then
pressurise the system to the required
pressure, when this is reached stop the
pump to hold the pressure.
7) Check the pressure gauge to ensure the
pressure is holding constant. When
satisfied that the pressure is stable, use the
tommy bars to rotate the nuts, through the
access windows, down towards the joint
surface. Fit the appropriate rod (bar) to
the flange nuts and fully hand tighten.
Hand tighten adjacent loose nuts.
8) Remove the stud tensioner heads by:-
a) Screwing in the oil return valve on the
pump to release the oil pressure
(which transfers the load to the nuts).
b) Tightening, then releasing the threaded
insert.
c) Screwing out the oil return valve on
the hand pump.
d) Removing the threaded insert
complete with body.
e) Removing the bridge.
f) Disconnect the hydraulic hoses.
NOTE:
If the required pressure is not reached,
return to step 2.
9) Transfer the stud tensioners to studs
numbered 2 in the tightening sequence.
Repeat operations 2) to 8).
10) Continue tightening progressively to the
numbered sequence until all the nuts are
tightened to the 1st pass pressure i.e. nuts
2 in turn then nuts 3 followed by nuts 4,
then 5 and so on.
11) Repeat the tightening sequence round the
flange of a 2nd, 3rd, 4th or 5th pass, at the
stud tensioning pressure stipulated for the
applicable pass.
12) If, on the 5th pass, the flange nuts can be
tightened further, additional passes at
maximum pressure should be made until
no further tightening is possible.
8.8
13) When all flange nuts are correctly
tightened, the gasket is fully compressed
and the nuts pre-stressed.
14) Check at several equi-distant points on
the flange periphery that the gap between
the faces of the pump case and motor
flanges is less than 1.5 mm.
8.9 RELEASING FLANGE NUTS
WARNING:
Ensure that the motor is electrically
isolated, adequately supported and de-
pressurised, before any nuts are slackened.
1) Fit the tensioner heads to the studs and
connect the hoses and hand pump. If one
head is used for this operation it must be
the head with the blanking plug fitted.
2) Screw down the threaded insert fully, then
release it one half (½) turn. Pressurise the
system to 1500 bar and unscrew each
flange nut one half (½) turn using the
appropriate bar. Repeat for every stud on
each pass.
3) Should the nuts fail to move, a slow
gradual increase in pressure should be
made until the nut lifts of the flange face.
At this stage, a further increase in
pressure is un-necessary and will not
assist in freeing a tight nut.
CAUTION:
Never exceed the maximum system
pressure when removing the nuts.
4) If the nuts are still in contact with the
flange and cannot be removed with the
system at absolute pressure, consult
Hayward Tyler for advice.
5) Repeat the stud tensioning and nut
unscrewing sequences diametrically until
all flange nuts are released.
6) After use, thoroughly clean, examine for
damage and lubricate each component of
the stud tensioner equipment. Wrap all
components in suitable water-proof
material then store in a clean, dry area in
their respective tool boxes.
 SECTION 8
STUD TENSIONING EQUIPMENT

Figure 8/5 Nut Tightening Sequence

8.9
 SECTION 8
STUD TENSIONING EQUIPMENT

Figure 8/5 Nut Tightening Sequence (Continued)

8.10
 SECTION 8
STUD TENSIONING EQUIPMENT

PARTS LIST

PART NO. DESCRIPTION QUANTITY

42751/080 M56 STUD TENSIONER 1
COMPRISING: -
42751/8000 TENSIONERS 4
COMPRISING; -

ITEM NO PART NO DESCRIPTION QUANTITY

1 42751/8001 BODY 1
2 42751/8002 RAM 1
3 42751/8003 BRIDGE 1
4 42751/8004 INNER SEAL SET 1
5 42751/8005 OUTER SEAL SET 1
6 42751/8006 BONDED SEAL 4
7 42751/8007 ADAPTOR 2
8 42751/8008 SNAP NIPPLE 2
9 42751/8009 SOCKET 1

ALSO INCLUDED: -
HAND PUMP COMPLETE WITH 1600 BAR PRESSURE GAUGE
HYDRAULIC HARNESS MANUFACTURED FROM FLEXIBLE HOSE AND QUICK RELEASE
COUPLINGS TO TENSION 4 TOOLS SIMULTEANEOUSLY.
HARNESS CONSISTING OF 3 METRE LEAD HOSE AND 1.5 METRE INTERCONNECTING HOSES
TOMMY BARS, OIL PACK, SPARE SEALS, STORAGE BOX FOR TENSIONING HEADS, STORAGE
BOX FOR PUMP AND HARNESSES.
MANUALS FOR TENSIONER AND HAND PUMP.

8.11