SHS 03044-92(英文版)高速离心泵维护检修规程.doc

The Chinese version of standards has precedence to their English translations which are only for internal reference.本英文版为内部资料，仅供参考，以中文版为准。Maintenance and Service Procedure for Petrochemical Equipment Chemical EquipmentMaintenance and Service Procedure for High-speed Centrifugal Pump(高速离心泵维护检修规程)SHS 03044-92(For Trial Implementation)Promulgated by SINOPECSINOPEC Publishing HouseContents1. General 2. Period and Content of Maintenance3. Maintenance and Quality Standard 4. Trial Running and Acceptance5. Service and Troubleshooting1. General 1.1 Subject content and applicable scope1.1.1 Subject contentThis Procedure specifies the period and content of maintenance, maintenance and quality standard, trial running and acceptance and service and troubleshooting for high-speed centrifugal pumps.1.1.2 Applicable scopeThis Procedure is only applicable to the maintenance and service of Type LMV/BMP-311, LMV-331 and LMV-322 high-speed centrifugal pumps. 1.2 Reference documents for compilationa. SHS 01002-92 “Management System of Lubrication of Petrochemical Equipment”;b. SHS 01003-92 “Vibration Standard for Rotating Petrochemical Machinery”;c. SHS 01028-92 “Maintenance and Service Procedure for Variable Speed Motor”;d. SHS 03059-92 “Maintenance and Quality Standard for General Parts of Chemical Equipment”;e. Technical documents supplied with the equipment;f. HGJ1023 “Maintenance and Service Procedure for High-speed Pumps used in Chemical Plant”.2. Period and Content of Maintenance2.1 Period of maintenance (refer to Table 1) Table 1 MonthCategory of MaintenanceMinor MaintenanceMedium MaintenanceOverhaulPeriod of Maintenance61236Note: The period of maintenance may be adjusted appropriately with complete monitoring devices and approval of relevant management.2.2 Content of maintenance2.2.1 Minor maintenancea. Check and clean oil circuit, cooling liquid pipeline, oil cooler and heat exchanger for cyclone separated liquid;b. Replace oil filter and change oil.c. Check oil seal;d. Align coupling.2.2.2 Medium maintenancea. Contents of minor maintenance are included;b. Clean the pump chamber, diffuser, cyclone separator and seal liquid system;c. Check the erosion of impeller and inducer, check for any crack on the surface;d. Repair the leaks of mechanical seal;e. Check the displacement of high-speed shaft;f. Check and clean the spline shaft and change grease.2.2.3 Overhaula. Contents of medium maintenance are included;b. Check the wear of low-speed shaft, intermediate shaft and bearing, if necessary, replace them.c. Check the wear of high-speed shaft journal and bearing bush, if necessary, replace them.d. Check the wear of gear;e. Dynamic balancing tests shall be carried out for the repaired or replaced impeller, inducer and high-speed shaft assembly.f. Check and repair the lubrication oil pump;g. Disassemble the seal cavity and check the wear of parts for each section.3 Maintenance and Quality Standard3.1 Preparation before dismountinga. Check the technical and operating conditions of equipment and the monitoring records, analyze the causes of failure and location and work out a detailed technical scheme for maintenance; b. Get familiar with the design drawings and technical documents;c. Get ready the tools, measuring tools and clamping apparatus necessary for maintenance;d. The replacement parts necessary for maintenance shall conform to the design requirements;e. Construction can be commenced only after the processes such as deenergizing, emptying and displacement are completed according to regulations, the maintenance conditions are ready and the maintenance safety permits are obtained.f. For unstated matters related to the safety of maintenance operation, relevant stipulations of “Management System of Safety in Production of China Chemical and Petroleum Corporation” shall be implemented.3.2 Dismounting and Check3.2.1 Pumpa. Dismount the pipelines of oil circuit, seal liquid and cooling system connected with the pump;b. Remove the nut of pump cover and lift the pump;c. Remove the cover plate of diffuser, check and clean the diffuser and every part of the pump body;d. Remove the impeller nuts, the setting nuts of inducer and seal box, check the impeller, inducer and drive shaft for any damage and deformation.3.2.2 Speed-up gearboxa. Disassemble the speed-up gearbox, remove the low-speed shaft, intermediate shaft and bearing, and remove the gear oil pump and limit spring, clean and check them;b. Remove the high-speed shaft and the upper and lower bearing bushes, check the journal and bearing bush for wear and the correct fitting clearance (refer to Table 2);Table 2 mmClearanceType and bearing bushNormal clearanceMaximum allowable wear clearanceLMV-311LMV-331BMP-311Upper end bearing bush0.070.110.15Lower end bearing bush0.070.110.15LMV-322Upper end bearing bush0.0550.090.13Lower end bearing bush0.070.110.15c. The bearing bush shall be free of defects such as ablation, sticking and abrasion damage, The surface roughness of the journal shall not be greater than Ra 0.20 and the depth of groove mark shall not exceed 0.01mm, otherwise it shall be ground or replaced;d. Check the wear of the thrust disc and bearing. The run-out of the end face and radial circle of the thrust disc shall be 0.02mm. For the seriously eroded or defective thrust pad, it shall be replaced;e. The error of linearity of the low, medium and high-speed shaft axes shall be less than 0.01mm;f. K7/h6 shall be adopted for the fitting of high-speed shaft and impeller. The clearance after worn shall not be greater than 0.03mm. Torque wrench shall be used for tightening the fastening bolts of the bearing of high-speed shaft;g. The journal shall be precooled and the gear and rolling bearing shall be warmed up when assembling shaft, gear and rolling bearing, the temperatures shall be controlled within those specified in Table 3;Table 3 0CType of pumpPart LMV/BMP-311 LMV-322 LMV-311Gear190-205 (shall be lower than the tempering temperature)Journal-18Rolling bearing120h. H7/h6 shall be adopted for the fitting of the outer diameter of bearing with the bushing, the inner diameter of the bushing after worn shall not be greater than 90.065mm, the radial clearance of the rolling bearing shall not be greater than 0.06mm and the bearing shall rotate smoothly and be free of spots, scars and burrs;i. The rolling bearings of the low-speed shaft and intermediate shaft shall be installed in position;j. Thoroughly clean the inner oil path and nozzle of the speed-up gearbox, however, it is not allowed to enlarge the bore of the oil nozzle;k. Check that the oil pump is assembled properly after completing the assembling of the speed-up gearbox, the correct method is: when pressed down with hand the low-speed shaft shall be elastic, otherwise the pins are not aligned; also, the low-speed shaft can be turned at the coupling to check that the oil pump is running properly. l. The displacement of the high-speed shaft is 0.33-0.42mm;m. The surface of the gear shall be free of obvious defects such as pitting, scar and ablation; the engaging of the gear surface shall be greater than 80% and 55% in the direction of width and height respectively. The clearance between gears on the top of engagement is 0.20-0.30m (m is the module of gear), the tolerance of parallelism between the two gear shafts shall be less than 0.025mm. n. The rolling bearing, gear and gasket ring shall be installed securely in position;o. Grease shall be applied to the lip of shaft seal when the shaft seal on the motor side of the low-speed shaft of the speed-up gearbox is installed.3.2.3 Mechanical sealMaintenance and Repair Procedure SHS 03059-92 shall be implemented.3.2.4 CouplingMaintenance and Repair Procedure SHS03059-92 shall be implemented.3.2.5 Spline shafta. Change grease.b. Check for wear, repair or replace.3.3 Quality standard3.3.1 Impeller and inducera. The run-out of the radial circle shall be 0.38mm while that of the end face shall be 0.15mm;b. The displacement in the axial direction is 0.33-0.42mm;c. The dynamic balance accuracy of impeller, inducer and high-speed shaft assemble shall be G0.4, the permissible unbalanced moments used for calibrating plane is:M=1/2e G (g mm)Where ethe permissible eccentricity, mm; Gthe weight of rotor, g.d. K7/h6 is adopted for the fitting of the impeller with the high-speed shaft, the clearance after worn shall not be greater than 0.03mm.3.3.2 Fastening boltTorque wrench shall be used for tightening the pump cover bolts, the connecting bolts for impeller and inducer and the fixing bolts for seal assembly. For the torque values, refer to Table 4.Table 4 N mType of pumpParts and componentsLMV-311BMP-311LMV-331LMV-322Mounting bolts for the pump cover120-13545-137Bolts for the impeller and inducer50-6050-60Fixing bolts for the static seal ring 13-158.0-114. Trial Running and Acceptance4.1 Preparation before trial running4.1.1 Confirm that all maintenance are completed, the maintenance records are complete, the maintenance quality conforms to the stipulations of Article 3 and the trial running scheme is available.4.1.2 The parts and components of equipment are complete, the bolts are tightened, the conditions of trial running are ready.4.1.3 Instruments and interlocks are complete, accurate, sensitive and reliable.4.1.4 Fill the lubrication points with lubricant (grease) according to the specifications, the water cooling system shall be free of obstructions.4.2 Trial runninga. Jog the motor to check the direction of rotation (for motors with auxiliary oil pump, only one jog is necessary to determine the direction of rotation), if the direction of rotation is correct, jog for the second and third time, the time interval between the jogs is 5s, increase the speed incrementally. If no abnormalities are found, the jogging for the third time is considered as the formal start-up;b. Adjust the outlet valve immediately after the start-up in order that the pressure and flow reach the normal values, the current stabilizes not exceeding the rated value and various instruments are sensitive and operative;c. Adjust the cooling water flow for oil cooler, maintaining the oil temperature at 60-930C;d. Trial- run the pump for 2 hours to check for proper oil temperature and pressure;e. The operation is smooth without abnormal noise, the double amplitude is not greater than 30 mm ;f. The oil seal and static seal shall have no leaks, the mechanical seal is reliable with the acceptable leaks of 1drop/min.4.3 AcceptanceGo through the acceptance formalities after the trial running is acceptable and conforms to standards. The technical documents for acceptance shall include:a. Records of maintenance quality and defects;b. List of replacement parts and components;c. Records of trial running.5. Maintenance and Troubleshooting5.1 Daily maintenance5.1.1 Contents of maintenancea. Check the current, flow, pump head, oil temperature, seal leaks, vibration value for abnormalities, fill in the records carefully;b. Anti-freezing measures shall be taken for the cooling system and pump chamber during the outage in winter;c. “Management System of Lubrication of Petrochemical Equipment” SHS 01002-92 shall be implemented strictly.5.1.2 Maintenance periodCarry out the maintenance and troubleshooting every 2 hours.5.2 Normal faults and troubleshooting (refer to Table 5)Table 5FaultCause of faultCorrectionNo flow or insufficient flow, no pressure or insufficient pressure.The pump is not filled up with liquid.The feed liquid evaporates.Air leaks or blocks in the suction line.The suction head is low.The motor rotates in the reversed direction.The assembling is not correct.The coupling and the impeller key are damaged or fallen off during assembling.Remove gas from pump chamber.Cool the feed liquid sufficiently.Repair the leaks or clean the line.Increase the suction head.Rewire the motor.Reassemble.Check and repair.Large fluctuation of pressure The flow is too low.The suction head is low.The flow control valve fails.The feed is not sufficient for two pumps while they are running in parallel.The cyclone separator is seriously corroded.Increase the flow, open the bypass valve if necessary.Increase the suction head.Repair the control valve.Stop one pump.Repair or replace the cyclone separator.Overload of motorThe viscosity and specific gravity of feed liquid is increased or the solid particles are entrained.Mechanical faults.The inner surface of pump is seriously eroded.The throat diameter of diffuser is enlarged.Change the conditions of feed liquid to prevent the solid particles from being entrained.Disassemble, check and repair.Replace the parts.Inspect and repairLeaks of mechanical sealThe mechanical seal is damaged.Solid particles or foreign matters are entrained by seal liquid or feed liquid.Moisture is entrained when transferring low temperature feed liquid. Check and replace the mechanical seal.Install a strainer to prevent the solid particles or foreign matters from being entrained.Prevent moisture from being entrained or fill the anti-freezing agent into the seal chamber before the start-up.Oil leaks of oil sealThe oil seal is damaged.Replace the oil seal.Too much oil foam in the speed-up gearbox.The oil is deteriorated.The oil level is too high.The oil temperature is too low.Change oil.Reduce the oil quantity.Adjust the cooling water quantity.The oil inside the speed up gearbox changes color into white, pink or yellow.The lubricant is mixed with water.The lubricant is mixed with operating liquid.Check for leaks of oil cooler.Check the lubricant.The oil temperature inside the speed up gearbox is too highThe oil is too much.The oil filter is blocked.The oil cooler is scaled or the water quantity is insufficient.Drain the oil.Replace the oil filter.Remove the scale or adjust the cooling water quantity.The quantity of lubricant in the speed up gearbox reduces sharply. Seal leaks from the input shaft.Seal leaks from the output shaft.Inner leaks of the oil cooler.Change seal if necessary.Change seal if necessary.Check for leakage of oil cooler, repair or replace the cooler.Large vibration or noiseThe gear, bearing bush or bearing are seriously worn.The impeller and inducer are seriously worn or eroded resulting in the lost of balance.Gas is entrained by the suction feed liquid or air cavitation occurs due to the low suction head.Check, repair and replace.Repair or calibrate the dynamic balance.Remove gas from the feed liquid, increase the suction head. Explanatory notes:The Procedure is drafted under the charge of Tianjin Chemical and Petroleum Corporation.The draftsman of the Procedure is Li Bengui.9