ML20140C521
| ML20140C521 | |
| Person / Time | |
|---|---|
| Site: | Millstone  |
| Issue date: | 05/14/1997 |
| From: | NORTHEAST NUCLEAR ENERGY CO. |
| To: | |
| Shared Package | |
| ML20140C499 | List: |
| References | |
| MP-728.1, NUDOCS 9706090297 | |
| Download: ML20140C521 (46) | |
Text
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i MILLSTONE NUCLEAR POWER STATION I
MAINTENANCE PROCEDURE w
Main Condenser Vacuum (Hogger) Pump-Nash Model CL3002 MP 728.1 A
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Approval:
PORC Mtg. No:
/-9 7-082.
Date:
5-/Y 97 Effective Date:
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Level of Use O
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9706090297 97op 603 PDR ADOCK 05000245 P
-4 Millstone Unit 1
.O Maintenance Procedure i
V Main Condenser Vacuum (Hogger) Pump-Nash Model CL3002 TABLE OF CONTENTS 1.
PURPOSE....................................................3 2.
P RER EQ UI S ITES.............................................. 3 3.
P R E CAUTI O N S...............................................
8 4.
I N STR U CTI O N S..............................................
9 4.1 Check Free End Clearance.................................
9 t
4.2 P u m p Re m ova l..........................................
1 1
.)
4.3 Disassembly of Idle End.................................
12 1
4.4 Disassembly of Rotor and Shaft Assembly....................
15 l
l 4.5 Disassembly of Drive End................................
17 j
4.6 Inspection for Wear and Damage........................... 18 j
4.7 Disassembly, Repair, and Replacement of Head, Co n e, Ro to r, a n d S h a ft.................................... 19 3
v' 4.8 Reassembly of the Subassemblies...........................
23 j
4.9 Reassembly of Pump Drive End...........................
26 4.10 Installation of Rotor and Shaft Assembly....................
26 4.11 Reassembly of Pump Idle End.............................
27 4.12 Installation of Pump Bearings.............................
28 4.13 Bearing Lubrication....................................
33 4.14 Stuffing Box Packing Replacement.........................
33 4.15 Syst e m Co nn e ctio n.......................................
34 5.
REV I EW AN D S I G N - O FF....................................
37 6.
R E FE R EN CES.............................................
3 7 7.
S UM M ARY O F CH AN G ES....................................
37 O
Level of Use
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ATTACHMENTS AND FORMS O', "CL3002 Cross Section and Parts List"..............
39 i
' Attachment 2, " Pump Information..............................
40
-,_ " Top View Schematic - Shim Location"'.............
41 I, " Approximate Weights for CL3002".................
42 t, " Pump Inspection Record"........................
43 l
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- 1. PURPOSE 1.1-Objective This procedure provides instructions for the disassembly, restoration, and reassembly as well as preventive maintenance for the Nash Model CL3002 j
vacuum (Hogger) pump.
j 1.2. _ Discussion l
The Nash Model CL3002 vacuum pump performs the rough (initial)
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vacuum pun' ping for the main condenser, j
i There is seldom any reason for inspecting the interior since the pump has j
only one moving part. However, provisions are available for repair or replacement of major components should a serious problem develop.
The free end clearance (end play) of the rotor and shaft assembly within the pump should be checked during each preventive check to determine if l
internal clearances are excessive and whether major restoration or minor adjustment is required to maintain the best pumping efficiency.
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1.3 Applicability AV This procedure applies to M2-12, " Main Condenser Mechanical Vacuum Pump (Hogger)-Nash Model CL3002"
- 2. PREREOUISITES i
2.1 - General l
I 2.1.1 A Radiation Work Permit has been issued as necessary.
j 2.2 Documents 2.2.1 C MP 710A," Horizontal Shaft Alignment" l
2.2.2 MP 790.45," Vibration Monitoring and Predictive Maintenance Program" 2.2.3 MP 791.0 (Att),"Off Gas (324)"
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2.3 Definitions i
l 2.3.1 DEMAGNETIZE-To deprive of magnetic properties.
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2.4 Measuring and Test Equipment (M&TE) 2.4.1 All M&TE has been calibrated in accordance with WC 8,
" Control and Calibration of Measuring and Test Equipment" and the calibration is current.
2.4.2 Outside micrometer with a range of 0 to 1 inches and an accuracy of 0.0005 inch such as OA-1568 2.4.3 Vernier caliper with a range of 0 to 12 inches and an accuracy of 0.0005 inch such as MPS-70 I
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l 2.5. Tools and Consumahics 5
q 2.5.1 Tools 1
-i Mechanic's standard tool kit i -
I Spanner wrench (for shaft nut) a Hexagonal (allen) wrench set l
)
Socket wrench set with extensions l
Open end or box wrench set i
1 Feeler' gage set 1
Gage blocks-u Metal straightedge
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Nonmetallic rnallet
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Packing puller O
. D, Lantern gland puller Packing ring pusher Level 7
i Oxyacetylene torch with rosebud l
l Induction heater for bearings l
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i 2.5.2 Special Tools Split ring (5.630 to 5.635 inches ID x 7.745 to 7.735 inches OD x 2 inches thick) 5 Shaft extension (pipe,5 /8-inches ID x 36 inches long) 5 Bearing seating tool (pipe,5 /s-inches ID x 12 inches long)
(2) shouldered eye bo:ts,1/2 nch-13 thread i
5 Bushing toot (pipe,5 /3 -inches ID x 12 inches long)
Steel plate (1 inch x 10 inches x 10 inches)
Press backup plate (1 inch x 10 inches x 10 inches with 5
5 /g-inches hole) l (4) steel threaded rods,1/2 nch-13 x 36 inches long i
(4) steel threaded rods,5/s inch-11 x 36 inches long (4) nuts,1 i
/2 nch-13 (4) nuts,5/s inch-11
'd 2.5.3 Equipment Chain hoist (3-ton capacity)
Press (50-ton capacity minimum)
Portable hydraulic jack (7.5-ton capacity)
Slings Receptacle for radioactive water 1
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- 7y Packing i
Bearings i
d O-ring j
i 2.5.5 Consumables Approved dry film lubricant such as Molykote or Neolube -
Approved cleaning solution such as Polywater Hydrafoam 2020 Approved 0-ring lubricant such as Versilube Approved solvents i
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' Approved lubricants
'V Grease for coupling.
Reduction gear lubricant l
Motor lubricant i
Pump lubricant i
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2.6 Responsibilities 2.6.1 HP to provide instructions for moving pump to work location.
2.7 Definitions 2.7.1 D.E. - Abbreviation for drive end of vacuum pump which connects to reduction gear and drive motor.
2.7.2 1.E. - Abbreviation for idle end of vacuum pump which does not j
connect directly to other components of drive system.
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- 3. PRECAUTIONS
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3.1 Treat shaft packing rings as asbestos and handle in accordance with U1 WC 1 (Att)," Control of Asbestos Containing Materials."
3.2 Ensure use and disposal of any chemical product is in accordance with CC 1," Control of Chemical Consumable Products."
3.3 Idle-end bearing and drive-end bearing must be kept as individual units because they are not interchangeable.
3.4 Disassemble and reassemble the pump on a level and flat base to provide alignment between mating components and to provide adequate support.
3.5 During disassembly match mark all parts as they become accessible to ensure correct position when reassembling. Do not match mark delicate parts or critical mating surfaces.
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- 4. INSTRUCTIONS
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4.1_
Check Free End Clearance 4.1.1 UNCOUPLE pump from drive unit.
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4.1.2 CIIECK rotor and shaft assembly free end clearance within pump as follows-l a.
DRAIN oil from idle bearing.
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i b.
REMOVE the following from idle end:
- 1) Bearing cap capscrews
-c
- 2) Bearing cap
- 3) Gasket
- 4) Adjusting shims c.
RECORD number and thickness of shims on Attachment 5.
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V NOTE The free end clearance check determines number of shims required to centralize the shaft axially within the pump casing. The bearing cap gasket must be installed for the free end clearance check.
d.
Using through capscrews only, INSTALL bearing cap and gasket removed in Step 4.1.2.b.
e.
TIGIITEN capscrews.
f.
SLIDE shaft toward drive end until rotor is seated against cone and rubbing is felt.
i g.
Using feeler gage, MEASURE distance between idle-end bearing cap and bearing housing as shown in Figure 1.
h.
RECORD as reading (A) on Attachment 5.
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Figure 1-Free End Travel Measurement I
(A)
(p)
(B)
(E)
Pump Head Idle End Bearing Bearing Housing Cap
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Shaft NY.
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SLIDE shaft toward drive end until rotor is seated against cone and rubbing is felt.
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MEASURE distance between idle-end bearing cap and bearing housing.
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RECORD as reading (B) on Attachment 5.
1.
CALCULATE and RECORD free end travel which is the difference in readings (B)-(A) =(C) on Attachment 5.
- m. COMPARE calculated free end travel with Attachment 2.
J.1.3 IE free end travelis within allowable limits AND further disassembly is not necessary, PERFORM the following:
a.
REMOVE the following from idle end:
- 1) Bearing cap capscrews 1
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- 2) Bearing cap i
- 3) Gasket i
b.
PREPARE shim pack thickness removed in Step 4.1.2.c.
c.
Using through bolts, ASSEMBLE the following idle-end bearing cap components:
'i
- 1) Outer bearing cap
- 2) Gasket
- 3) Shims
- 4) Head I
- 5) Seal ring
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- 6) 0-ring
- 7) Inner bearing cap fw Q
d.
TIGHTEN idle-end through bolts.
q e.
INSTALL remaining capscrews on idle-end bearing cap.
l f.
Go To step 4.13 and lubricate bearings.
1 4.2 Pump Removal
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C A UTIO N i
Any residual water in this system must be treated as contaminated.
4.2.1 REMOVE plugs from heads and body and DRAIN all water from pump into receptacle for radioactive water.
4.2.2 DISCONNECT piping from each end.
l 4.2.3 DISCONNECT coupling between reduction gear and drive motor.
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4.2.4 -
DISCONNECT coupling between reduction gear and pump.
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' REMOVE mounting bolts from base of pump and reduction gearbox.
i 4.2.6 To facilitate realignment at assembly, TAG all alignment shims with size and location and RECORD in Attachment 3.
4.2.7 MOVE gearbox from the immediate area.
NOTE lists approximate weights of the pump and its parts.
4.2.8 CONTACT HP and OBTAIN guidance for moving purnp to work' location.
4.2.9 MOVE pump to work location.
4.3 Disassembly ofIdle-End m
4.3.1 REMOVE the following from idle end:
a.
Bearing cap capscrews b.
Outer bearing cap c.
Gasket 4.3.2 BEND car oflockwasher out of notch in shaft nut.
4.3.3 REMOVE shaft nut and lockwasher.
4.3.4 REMOVE spring and water slinger from shaft.
4.3.5 REMOVE two gland nuts and SLIDE gland from pump head.
4.3.6 REMOVE nuts and SEPARATE gland halves from shaft.
4.3.7 To provide access to the bearing, SLIDE inner bearing cap onto gland studs.
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4.3.8 PLACE split ring behind idle-end bearing and SLIDE inner.
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bearing cap against split ring as shown in Figure s
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Figure 2-Idle End Bearing Puller
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l liydraulic Jack Bearing Cap 2
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Steel
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Plate 1
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4 Split Ring i
High Tensile i
Steel Rods j
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l 4.3.9 INSERT threaded rods through bolt holes of bearing housing.
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4.3.10 THREAD nuts onto studs behind inner bearing cap.
i 4.3.11 Refer to Figure 2, and ASSEMBLE bearing puller using the following:
Steel plate Hydraulic jack Steel rod Nuts i
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. Level of Use
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C A UTIO N To avoid damage to the pump components, ensure that the steel plate and the pum bearmg.p shaft are square and provide an evenly applied force to the 4.3.12 Using hydraulic jack, APPLY maximum force of 18 tons and PRESS bearing from shaft.
k 4.3.13 DISASSEMBLE the bearing puller assembled in step 4.3.11.
4.3.14 To provide support during removal of the head, PLACE blocking under body at idle end and drive end.
4.3.15 THREAD two eyebolts into holes that are 180 degrees apart at inlet flange of head.
4.3.16 ATTACH sling to eyebolts and PROVIDE slight tension.
4.3.17 REMOVE head-to-body capscrews.
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C A UTIO N The head-to-body rabbet joint may not disassemble easily. Only the minimal force necessary to separate the joint must be used.
1 4.3.18 Tb help separation of rabbet joint, TAP and carefully PRY head away from body.
4.3.19 SLIDE head and cone together off shaft sufficiently to retrieve inner bearing cap and head-to-body gasket.
4.3.20 SUPPORT exposed shaft with blocking and REMOVE head and cone from shaft.
4.3.21 LIFT and MOVE head out of the way.
4.3.22 MEASURE thickness and COUNT number of gaskets removed from idle-end head-to-body joint.
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l ~p 4.3.23 '. RECORD thickness and number of gaskets on i
Q.
i STOP WARNING STOP The packing rings contained within the stuffing box shall be considered an k
asbestos p(roduct. Handling packing must be in accordance with U1 WC 1 Att)," Control of Asbestos Containing Materials."
j 4.3.24 REMOVE packing from id.le-end stuffing box.
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NOTE The count on each side of the lantern gland is important to correctly align the lantern gland during reassembly.
t 4.3.25 COUNT the number of remaining packing rings removed from stuffing box and RECORD on Attachment 5.
4.4 Disassembly of Rotor and Shaft Assembly-imC 4.4.1 REMOVE the following from drive-end head:
)
Bearing cap capscrews a.
b.
Outer bearing cap c.
Gasket 4.4.2 BEND ear of lockwasher from notch in shaft nut.
4.4.3 REMOVE shaft nut and lockwasher.
4.4.4 REMOVE spring and water slinger from shaft.
4.4.5 REMOVE two gland nuts and SLIDE gland from pump head.
4.4.6 REMOVE nuts and SEPARATE gland halves from shaft.
4.4.7 ATTACH one sling to idle end of shaft and a second sling to f
drive end of shaft.
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MP 7281 Rev' 5 General i
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4.4.8 LIFT and ADJUST rotor shaft assembly until shaft is centered
-Q within the body bore.
4.4.9 BLOCK rotor shaft assembly.
4.4.10 To access drive-end bearing pin, REMOVE hex head plug from bearing housing.
3 i INSTALL /8 nch-16 x 1 inch long capscrew into bearing pin and 4.4.11 REMOVE pin.
Figure 3 Drive End Shaft Pusher Bearing Pin m' s Inner Bearing Ilydraulic Jack Cap
.l..a Shaft Will Mowe I
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A Iligh Tensile Steel Rods Steel Plate 4.4.12 INSERT threaded rods through bolt holes of bearing housing.
4.4.13 THREAD nuts onto studs behind inner bearing cap.
4.4.14 Refer to Figure 3, and ASSEMBLE shaft pusher using the following:
Steel plate Hydraulic jack l
Steelrod
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l Nuts
=
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U Level of Use NCf? ' ' REVIEW Generai "sToV "THINiI ]!s ev.5 a a.
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i pb C A UTIO N To avoid damage to the pump components, the steel plate and pump shaft must be square in order to provide an evenly applied force to the bearing.
4.4.15 Using hydraulic jack, APPLY maximum force of 18 tons and PRESS bearing inner race from shaft.
4.4.16 DISASSEMBLE shaft pusher.
4.4.17 RELOCATE sling at drive end and REMOVE bearing.
4.4.18 PLACE shaft extension over drive end of shaft.
4.4.19 RELOCATE sling on drive-end shaft extension and LEVEL rotor shaft assembly.
4.4.20 MOVE rotor shaft assembly until rotor is approximately 4 inches outside the idle-end of the body.
4.4.21 RELOCATE sling from drive end of shaft to exposed shaft at idle s
end.
4.4.22 REMOVE shaft extension from drive end.
4.4.23 MAINTAIN shaft as level as possible and REMOVE rotor shaft
]
assembly from the body.
4.5 Disassembly of Drive End j
4.5.1 FASTEN two eyebolts into holes that are 180 degrees apart at inlet flange of head.
4.5.2 ATI'ACH sling to eyebolts and PROVIDE slight tension.
4.5.3 REMOVE head-to-body capscrews.
4.5.4 To help separation of rabbet joint, TAP and PRY head away from body.
l 4.5.5 SLIDE body and head apart.
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MP 728.1 Level of Use 97ay +7 sing (ACf ^ "REVIEN General p
3 Rev.5 17 af 45 l
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!.L c-4.5.6 MEASURE thickness and COUNT number of gaskets removed s
(j from drive-end head-to-body joint.
4.5.7 RECORD thickness and number of gaskets on Attachment 5.
STOP WARNING sTop The packing rings contained within the stuffing box shall be considered an asbestos product. Handling packing must be in accordance with U1 WC 1 (Att), " Control of. Asbestos Containing Materials."
4.5.8 REMOVE packing from drive-end stuffing box.
NOTE The count on each side of the lantern gland is important to correctly align the lantern gland during reassembly.
4.5.9 COUNT the number of remaining packing rings removed from.
n stuffing box and RECORD on Attachment 5.
4.6' Inspection for Wear and Damage 4.6.1 Using approved solvent, CLEAN any foreign material, dirt, or gasket residue from all surfaces of pump parts.
4.6.2 REMOVE burrs and raised metal from all parts.
NOTE For repair or rep. lacement disposition of parts with suriace flaws greater than 0.03 inch deep, Engineermg or FLS must be contacted.
4.6.3 EXAMINE cones for surface flaws such as score marks, cracks, pitting, excessive wear, and other unusual conditions.
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O sors For repair or replacement disposition of parts with surface flaws greater f
than 0.03 inch deep, Engineermg or FLS must be contacted.
4.6.4 -
EXAMINE rotor for surface flaws such as score marks, cracks,~
pitting, excessive wear, and other unusual' conditions.-
1 NOTE 1.
For repair or replacement disposition of parts with surface flaws -
greater than 0.03 inch deep, Engineering or FLS must be contacted.
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2.
The packing diameter regions of the shaft are clad with "Metco #2" metal coating. Excessive shaft wear at packing diameter regions is not acceptable and Engineering or FLS must be contacted for repair or l
replacement disposition.
4.6.5 EXAMINE shaft for surface flaws such as, score marks, cracks, pitting, excessive wear, and other unusual conditions.
9(v NOTE For repair or replacement disposition of parts with surface flaws greater l
than 0.03 inch deep, Enginecrmg or FLS must be contacted.
4.6.6 EXAMINE body and both heads for surface flaws such as score marks, cracks, pitting, excessive wear, and other unusual conditions.
4.7 Disassembly, Repair, and Replacement of Head, Cone, Rotor, and Shaft 4.7.1 DISASSEMBLE idle-end head and cone for machining or replacement as follows:
i a.
With cone pointed upward, PLACE head and cone subassembly on work surface.
b.
MATCH MARK orientation of cone within the head.
c.
REMOVE socket capscrews holding cone-to-head.
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d.
ATTACH sling to cone for vertical lift and APPLY slight h
tension.
TAP side of cone with mallet and ADJUST' tension on sling e.
l as required to assist disassembly.
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f.
LIFT and REMOVE cone from head.
i g.
RECORD number of gaskets removed from head-to-cone
' joint on Attachment 5.
j NOTE 3
i The instructions for disassembly of the head and cone are' applicable to both ends.
4.7.2 Refer to step 4.7.1. and DISASSEMBLE drive-end head and 1
cone.
4.7.3 DISASSEMBLE rotor and shaft for machining or replacement as follows:
n i
a.
MEASURE dimension from idle-end rotor face to idle-end bearing journal shoulder.
b.
MARK measurement location on idle-end rotor face.
c.
RECORD as reading (D) on Attachment 5.
d.
To orient rotor blade curvature for proper reassembly, MATCH MARK each rotor face with corresponding shaft end (drive or idle),
e.
CHECK rotor and shaft for presence of locking set screws or pins, and IE present, REMOVE set screws or pins.
f.
LIFT and PLACE the rotor and shaft subassembly onto a 50-ton capacity press:
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- 1) Refer to Figure 4, and ASSEMBLE bushing tool over y
idle end of shaft.
Figure 4-Rotor to Shaft Assembly 2
Idle End Drive End
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5 4
- 1. Backup plate
- 4. Shaft
- 2. Sling
- 5. Keyway
- 3. Press ram
- 6. Bushing or Pipe
- b' ^
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- 2) ENSURE the following:
]
Bushing tool end face contacts rotor hub only.
Sufficient clearance exists for shaft key within bushing tool bore.
- 3) POSITION opposite end of bushing tool against backup plate.
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- 4) MAINTAIN alignment of shaft and press ram.
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- 5) PROVIDE blocking or support for shaft when pushed free of rotor.
g.
APPLY up to 50-tons force to push shaft free of rotor.
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E shaft and rotor do not separate, using a torch, HEAT rotor
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hub to approximately 200*E
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PRY rotor key from shaft.
l 4.7.4 E required, MACHINE cone and rotor 8 degree tapered surfaces to remove unacceptable conditions as follows:
a.
MEASURE diameters of the taper at each end and RECORD on Attachment 5.
b.
MACHINE taper only enough to remove unacceptable surface condition.
c.
MEASURE machined taper diameters at same two reference points measured in step 4.7,4.a. and RECORD on.
d.
DETERMINE stock (material) removed from the machined tapered surface (s) as outlined in Attachment 5:
l Total (Idle End)= Cone (IE)+ Rotor (IE)
Total (Drive End)= Cone (DE)+ Rotor (DE)
NOTE For every 0.006 inch total stock removed from the tapered diameter,0.021 inch (31/2 o 1 ratio) of additional gasket thickness must be added between t
the cone and head at assembly to maintain the proper gap between the rotor and cone. Gaskets to a maximum thickness of 0.500 inch can be placed under each cone at reassembly.
c.
Using previously calculated stock removal values, CALCULATE additional gasket thickness requirements for machined tapered parts and RECORD on Attachment 5.
4.7.5 E required, MACHINE shaft diameter to size established by l
Engineering or FLS.
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4.8 Reassembly of the Subassemblies C.
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NOTE i
This section provides instructions for reassembly of the head, cone, shaft,
.j and rotor subassemblies prior to pump assembly.
l l
i 4.8.1 REASSEMBLE rotor, shaft, and key as follows:
i a.
REMOVE burrs, raised metal, and old gasket material.
l b.
Using approved solvent, CLEAN the following:
Rotor i
Shaft I
a i
Key i
c.
PLACE key into rotor keyway and ENSURE smooth slide fit.
i y
d.
DRIVE key until bottomed in shaft keyway.
Using approved dry film lubricant, COAT rotor hub bore and j
e.
shaft diameter.
i f,
With drive end of rotor facing the press ram and idle end temporarily positioned to rest against the press backup plate, LIFT rotor onto 50-ton capacity press.
i i
O j?..
A MP 728'1 I
!,; V Level of Use sToF ' THINN'
' !AUf
' REVIEW General e1 f4 Ac r^,
[3 Jf 45 l
-r-,.
f 1
l l 1..
- q g.
PLACE bushing tool between idle end of rotor hub and (f
backup plate as shown in Figure 5.
l Figure 5-t L
Rotor to Shaft Assembly h
2 l
Idle End Drive End l
-- Dm l'
~f i
,N 3
0 l
l I
/
[..
\\
]
I l
r L
- j 5
4 l
- 1. Backup plate
- 4. Shaft l
l
- 2. Sling
- 5. Keyway 1
- p
- 3. Press ram
- 6. Bushing or Pipe
! V j
l h.
ENSURE alignment of rotor hub bore and bushing bore.
1 i.
SUPPORT and PROTECT rotor during press assembly.
l
- j.. INSTALL idle end of shaft in drive end of rotor hub and ALIGN key in keyway.
k.
MAINTAIN alignment of shaft and press ram.
l i
l 1.
SET size block eg/16-inches for CL3002).
ual to dimension recorded in 4.7.3.c.
(approximately 9 l
- m. PRESS shaft into rotor bore until set dimension is met and j
RECORD actual assembly force on Attachment 5.
j l
l n.
IE force to assemble shaft to rotor is less than 25-tons, do
(
not INSTALL assembly into pump.
4l p l
[
L CF le0ieW
(.)
Level of Use
~h0P Nf h s
gev. 5 Generai
/ %
- N P4 24 0f 45 i
i l.
1 6
i
\\
l o.
CONTACT Engineering or FLS for disposition.-
\\
!=
p.
WHEN rotor shaft assembly has been successfully assembled, j
REMOVE assembly from press.
4.8.2 ASSEMBLE head and cone as follows.(applicable for idle and i
drive ends):
i a.
VERIFY head and cone are clean and burr free.
b.
IE replacement head or cone is to be installed, IDENTIFY
~ drive-end or idle-end location.
~
NOTE A maximum of 0.500 inch gasket thickness can be placed under each cone.-
i c.
Refer 'Ib steps 4.7.1.g. and 4.7.4.e. and DETERMINE the I
number of cone gaskets required for reassembly.
i d.
RECORD number of cone gaskets to be reassembled on
.g i.
y 1
e.
APPLY a light coat of approved lubricant to replacement l
cone gaskets.
f.
ALIGN holes of gasket (s) with bolt holes in head and' POSITION gaskets for head-to-cone assembly.
J g.
ATTACH sling to cone.
h.
LIFT cone above head for installation.'
)
i.
ALIGN match-marks and LOWER cone until entry into head isjust started.
f j.
Using feeler gages inserted between cone mounting flange OD and head rabbet ID at four places,90 degrees apart, CENTER the cone.
p l'
k.
LOWER cone into head.
i
/>
E N
MP 728.1 1
- (O
,j Level of Use
'gdV "THINK'
~ 0ACT 'REVf5Vi Rev.5 General v'
W*
I4%
t A
25 of 45 t
l I'
l 1
1.
INSTALL socket head capscrews hand tight.
l
/
- m. Using feeler gages, VERIFY cone is centered within head -
rabbet ID.
1 Usmg a criss-cross pattern, TIGIITEN capscrews.
l n.
4.9 Reassembly of Pump Drive End 4.9.1 BLOCK and SECURE drive-end head on level work surface.
4.9.2 Refer To Attachment 5 and OBTAIN replacement body gaskets of equal thickness as those removed from the assembly and recorded in step 4.5.6.
j i
4.9.3 APPLY light coat of approved Jubricant to gaskets.
l l
1 1
4.9.4 INSTALL gaskets onto head and align holes for studs.
4.9.5 LIFT body and POSITION drive end with head such that rotation arrows are pointed in same direction.
]
'4.9.6 ASSEMBLE body-to-head rabbet and ENSURE that rotation arrows are pointed in same direction.
,J 4.9.7 INSTALL nuts and TIGHTEN in a criss-cross pattern.
4.9.8 To provide support during reassembly, PLACE blocking under body at idle and drive ends.
4.9.9 INSTALL packing gland assembly (without the packing) into I
head and INSTALL, but do not tighten, gland nuts.
4.9.10 INSTALL inner drive-end bearing cap, gasket, and seal ring onto head.
4.9.11 INSTALL one outer drive-end bearing cap capscrew through head and into gasket and inner bearing cap.
4.10 Installation of Rotor and Shaft Assembly 4.10.1 With sling around the rotor, LIFT and LEVEL rotor and shaft L
assembly.
l
!O Level of use ser 3sk dsy wh MP728.1 Rev.5 Generar
+J A,
m.
t, 26 af 45 l
5
l 1~
1 C A UTIO N Use extreme care not to dent or cause burrs or damage parts while assembling.
4.10.2 INSERT drive end into body as far as possible such that drive end of shaft is temporarily supported by the body.
4.10.3 PLACE shaft extension over drive end of shaft.
4.10.4 ATTACII sling onto shaft extension.
4.10.5 INSERT shaft into body until rotor contacts drive-end cone.
4.10.6 To provide temporary support,13 LOCK idle end of shaft.
4.11 Reassembly of Pump Idle End 4.11.1 ATTACH packing gland assembly (without the packing)into head and INSTALL, but do not tighten, gland nuts.
(o 4.11.2 INSTALL idle-end inner bearing cap, gasket, and seal ring onto head.
1 4.11.3 INSTALL one idle-end outer bearing cap capscrew through head and into gasket and inner bearing cap.
4.11.4 Refer To Attachment 5 and OI3TAIN replacement body gaskets j
of equal thickness to those removed and recorded in step 4.3.22.
j 4.11.5 APPLY light coat of approved lubricant to gaskets.
l 4.11.6 INSTALL gaskets onto head and align holes for studs.
4.11.7 LIFT and POSITION idle-end head for assembly onto shaft.
4.11.8 INSERT shaft extension through head and onto shaft.
4.11.9 SLIDE head toward body and TRANSFER blocking from shaft to shaft extension.
1 O
MP 728.1 v
Level of Use STOP THINK ACT' REVIEW Rev.5 General 270f45
4 C A UTIO N Use care during assembly not to damage the gaskets or seals.
4.11.10 ASSEMBLF. head with body and ADJUST blocking beneath body as nee:sary to facilitate installation.
4.11.11 ENSURE rotation arrows are pointed in same direction.
4,11.12 INSTALL nuts.
4.11.13. Using a criss-cross pattern, evenly TIGHTEN nuts and DRAW head and body together.
4.11.14 REMOVE all blocking and shaft extension.
NOTE
% permit mounting feet at both ends to align with each other and the mountin g surface, all head-to-body nuts and base mounting bolts will be Q
loosenec and the assembly allowed to assume the same plane.
V 4.11.15 CLEAN mounting feet and flat work surface beneath feet.
4.11.16 LOOSEN, but do not remove, all head-to-body nuts and base mounting bolts.
4.11.17 VERIFY all feet are resting flat on mounting work surface.
4.11.18 TIGHTEN head-to-body nuts in criss-cross pattern.
j 4.12 Installation of Pump Bearings NOTE Each bearing assembly must be kept as a unit since the individual parts are i
matched and should not be changed with parts from' other bearings.
j 4.12.1 CENTER shaft at drive end as follows:
L i
I MP 728.1
-i
^
Level of Use 5{ 'ip%
]; sac f 'REVi$NRev.5 NK" General
.s j
- q 28 of 45
l i.
1 a.
PUSH shaft at idle end toward drive end and SLIDE rotor
.[
taper surface against cone taper.
b.
If necessary to support shaft and maintain shaft centered, INSERT non-metallic spacers between idle-end shaft and bearing housing.
C A UTIO N l
Do not exceed 250*F during application of heat to bearing races.
'i NOTE i
A heavy weighted object should be placed against shaft at idle end to prevent movement during bearing assembly.
l 4.12.2 Using an induction heater, HEAT drive-end bearing inner race to 200 E 4.12.3 DEMAGNETIZE bearing.
4.12.4 INSTALL heated inner race onto shaft until seated against shaft shoulder.
4.12.5 PLACE bearing seating tool over shaft and against inner race.
4.12.6 Using a mallet, TAP seating tool and ENSURE inner race is firmly seated against shaft shoulder.
4.12.7 INSTALL outer bearing race and center spacer.
)
4.12.8 ASSEMBLE outer inner race of bearing assembly.
4.12.9 Using a mallet and seating tool, TAP assembled bearing and ENSURE proper seating.
4.12.10 INSTALL bearing pin into bearing housing.
l 4.12.11 INSTALL lockwasher and shaft nut and TIGHTEN nut.
l L
4.12.12 ALIGN lockwasher tab with notch in shaft nut, but do not bend.
1 l!O b
d
[
MP 728.1 jv Level of Use
- syor ~*THlNid~ [hCT
' REVIEW Rev.5 l
General r
l' %
fE r*
j 29 of 45
~. _,
l i
1 4.12.13 - INSTALL and TIGHTEN herc head plug into bearing housing to
- s capture bearing pin.
4.12.14 BLOCK idle-end shaft.
4.12.15 From drive end, PUSH shaft toward idle end and SLIDE rotor I
taper surface against cone taper.
l 4.12.16 ADJUST idle-end blocking to permit bearing assembly.
C A UTIO N f
Do not exceed 250 F during application of heat to bearing races.
NOTE A heavy weighted object should be placed against shaft at drive end to prevent movement during bearing assembly.
l i
p 4.12.17 Using an induction heater, HEAT idle-end bearing inner race to i
V 200'E 4.12.18 DEMAGNETIZE bearing.
4.12.19 INSTALL heated inner race onto shaft until seated againsi shaft I
shoulder.
4.12.20 INSTALL bearing seating tool over shaft against inner race.
4.12.21 Using a mallet, TAP seating tool and ENSURE inner race is firmly seated against shaft shoulder.
4.12.22 INSTALL outer bearing race and center spacer.
4.12.23 ASSEMBLE inner race of bearing assembly.
4.12.24 Using a mallet and seating tool, TAP assembled bearing and ENSURE proper seating.
4.12.25 INSTALL lockwasher and shaft nut and TIGHTEN nut.
i A
~
MP 728.1 lOV Level of Use
' stOP" "THINK 7 ACT"' ' REVIEW Rev. 5 General
- a
- 4 30 0f 45
1 l-
- 3 4.12.26 ALIGN lockwasher tab with notch in shaft nut, but do not bend -
t lQ tab.
I 4.12.27 CHECK rotor and shaft assembly free end clearance within pump as follows:
ASSEMBLE outer bearing cap, gasket (without shims), and a.
through capscrews.
b.
TIGHTEN capscrews.
l l
c.
SLIDE shaft toward drive end until rotor is seated against cone and rubbing is felt.
d.
Using feeler gage, MEASURE distance between idle-end bearing cap and bearing housing as shown in Figure 1.
I c.
RECORD as reading'(E) on Attachment 5.
f.
SLIDE shaft toward drive end until rotor is seated against i
cone and rubbing is felt.
g.
MEASURE distance between idle-end bearing cap and O
bearing housing.
4 b
l h.
RECORD as reading (F) on Attachment 5.
i i.
CALCULATE free end travel, (F)-(E)=(G) and RECORD on Attachment 5.
I' j.
COMPARE calculated free end travel with Attachment 2.
NOTE 1.
To increase total free end travel, gasket (s) must be added between the head and body.
2.
To decrease total free end travel, gasket (s) must be added between j
the head and cone.
l 4.12.28 IE free end travel is not within allowable limits, CONSULT Engineering or FLS for disposition.
i /^')
MP 726.1 v
Level of Use Tropr '%8R' ' 4ACT'
' REVIEW Rev. 5 Generai V3
- 's 31 of 45
i n
i C
NOTE To centralize rotor within pump casing in lengthwise direction, shims must f
be added at the idle end.
i J
l 4.12.29 WHEN free end travel is within limits, CENTER the rotor axially within pump casing as follows:
a.
Refer To Attachment 5 and DETERMINE shim pack.
l thickness by adding previously established reading (E) plus l
l one half calculation (G) from step 4.12.27.i.
i I
l b.
ASSEMBLE shim pack.
c.
RECORD shim thickness to be installed on Attachment 5.
4.12.30 BEND lockwasher tabs into shaft nuts at both ends.
i I
j 4.12.31 Using through bolts, ASSEMBLE the following idle-end bearing l
cap components:
a.
Outer bearing cap I
b.
Gasket c.
Shims (Step 4.12.29) d.
Head e.
Seal ring l
f.
O-ring i
[
g.
Inner bearing cap 4.12.32 TIGHTEN idle-end through bolts.
4.12.33 INSTALL remaining capscrews on idle-end bearing cap.
4.12.34 Using through bolts, ASSEMBLE drive-end bearing caps:
1 a.
Outer bearing cap i[ rov '9hiNk
~
^
MP 728.1
,V Level of Use i CT/
REVIEN Rev. 5
(
General.
.s p3 j
~:
32 0f 45 i
I
_ _. ~. _ _ _ _.. _. -
l 1.
- s b.
Gasket I
.I l
c.
Head I
d.
Seal ring e.
Gasket f.
Inner bearing cap 4.12.35 TIGHTEN drive-end through bolts.
l
\\
4.12.36 INSTALL remaining capscrews on idle-end bearing cap.
j l
4.12.37 ROTATE shaft in direction of arrows and ENSURE pump shaft turns freely.
L
(
4.13 Bearing Lubrication i
4.13.1 CHECK oillevel.
4.13.2 Refer to MP 791.0 (Att),"Off Gas (324)" and LUBRICATE pump.
i
! V.
4.14 Stuffing Box Packing Replacement l
NOTE i
This pump is equipped with similar stuffing boxes at both idle and drive
)
ends of the shaft. Instructions for packing replacement are applicable for both ends.
l l
4.14.1 IE pump is being reassembled after disassembly, Go To Step 4.14.7.
4.14.2 REMOVE water slinger and spring from shaft.
l 4.14.3 REMOVE gland nuts holding gland assembly to head.
4.14.4 REMOVE two nuts holding gland halves together and DISASSEMBLE gland.
i j
e A
f Level of Use ng7op
'7; sing: ' dy 'gevisyr hip m
- gey, General m,
y.
e q
33 0f 45 l
...~
L' W
.)
STOP WARNING STOP Packing rings contained within the stuffing box and replacement packing shall be considered asbestos product and must he handled per 1
i
.U1 WC 1," Control of Asbestos Containing Materials."
4.14.5 REMOVE packing from stuffing box.
NOTE The count on each side of the lantern gland is important to correctly align the lantern gland during reassembly.
4.14.6 COUNT number of remaining packing rings removed from stuffing box and RECORD on Attachment 5.
4.14.7 Thoroughly CLEAN stuffing box.
4.14.8 LUBRICATE inside diameter of packing rings with approved dry film lubricant.
4.14.9 PACK pump.
4.14.10 ASSEMBLE gland halves and SLIDE gland flush against packing and onto studs protruding from head.
1 4.14.11 INSTALL and TIGHTEN gland to head nuts evenly and finger tight.
NOTE Controlled leakage through packinj; rings during service is necessary and leakage rate will be established by tightening gland nuts after maintenance is complete.
4.15 System Connection 4.15.1 TRANSFER pump to mounting base.
4.15.2 INSTALL bolts loosely into mounting base of pump.
e t
M MP 728.1 Level of Use STOP= 'YhiP TAC F 'hdVi5/I Rev. 5 General
^
7 s e3 34 of 45 s
m.e
I f
! 'C 4.15.3 CONNECT suction, discharge, and auxiliary piping to pump.
l l
4.15.4 INSTALL drain plugs and unloader to heads and body.
4.15.5 Manually ROTATE pump shaft in direction of arrows for at least one full turn and VERIFY no binding exists.
NOTE
- contains previously assembled shim sizes and locations.
I i
4.15.6 Refer To C MP 710A,". Horizontal Shaft Alignment" and ALIGN l drive motor and reduction gear drive shafts to the following criteria:
i l
Ceupling gap of 0.250 'ach nominal (range is 0.063 to 0.500 l
inch).
j i
Angular (face) alignment within 0.002 inch TIR.
=
Parallel (diameter) alignment within 0.004 inch TIR.
[
4.15.7 REPEAT step 4.15.6 for pump and reduction gear drive shafts.
4.15.8 CONNECT gearbox to pump and drive unit.
j I
4.15.9 REQUEST Operations to prepare and start the system.
NOTE l
Leakage through shaft packing is acceptable at this time.
l i
4.15.10 CHECK all joints and seals for leaks.
4.15.11 MONITOR and ADJUST shaft packing !eak rate as follows:
a.
ALLOW pump to run for 10 minutes with steady leakage from stuffing box.
- b. TIGHTEN gland nuts evenly one flat at a time.
t t
O-MP 728.1 4
Level of Use yov 34 fcf yypyy Rev. 5 l
General 2
en 1
3 m,
35 0f 45 l
l i
l
- m c.
REPEAT Step 4.15.11 at 10 minute intervals until leakage
(,.
rate of 45 to 60 drops per minute is achieved.
4.15.12 Refer To MP 790.45, " Vibration Monitoring and Predictive Maintenance Program" and MONITOR pump and system for vibration.
4.15.13 REQUEST Engineering to check speed of pump shaft rotation 1
with rated speed listed on nameplate as necessary.
,m A J' f)
U Level of Us9 sToi>
"THINK ACT ' ' R$ VIEW U
Rev. 5 Generat 36 of 45
j..
I.
l'
- 5. REVIEW AND SIGN-OFF
{
9,
'l 5.1 The review and sign-off of this procedure is satisfied by the review and
- i sign-off of Attachment 5 and the AWO.
j l
- 6. REFERENCES l
i l-6.1 NUSCo Accident Prevention Manual Rev. 5 l
6.2 Vendor Manuals i
i 6.2.1 25202-526-002A,"CL 3002 Main Condenser Hogger l
Instruction Manual", Bulletin No. 406-D, Installation and i
Operation, Nash Vacuum Pumps CL Series, Coppight 1966, Shop Order B-75092 -
i 6.3 Administrative Procedures 6.3.1 U1 WC 1," Unit 1 Work Control Process" l
I 6.3.2 CC 1," Control of Chemical Cons'umable Products" 6.3.3 WC 8," Control and Calibration of Measuring and Test Equipment" l
6.4 Maintenance Procedures j
6.4.1 C MP710A," Horizontal Shaft Alignment" l
l 6.4.2 MP 790.45," Vibration Monitoring and Predictive Maintenance Program" q
6.4.3 MP 732.4 " Main Condenser Vacuum Pump Speed Reducer j
Maintenance" 6.4.4 MP 791.0," Plant Component Lubrication" Revision 1 l
- 7.
SUMMARY
OF CHANGES 7.1 Updated references as a result of Biennial Review.
7.2 Modified procedure to standardize format for M&TE.
i-4 i
A lO
?
b Level of Use "sToF THINK" A
^
MP 728.1 L
General g'
y, j ~
T die 'R,EVIEW Rev. 5 v
- 4 e'-
37 of 45
m -..
I i
V i
7.3 Incorporated interim changes 1 and 2 as follows:
1 Change 1 added Applicability section to procedure to include local ID M2-12 for vacuum pump.
j Change 1 deleted reference to MP 720.8," Pump / Fan Driver Alignment and Coupling" and added C MP 710A, " Horizontal Shaft Alignment."
l I
l Change 1 updated references for U1 WC 1," Work Control j
i Process" and CC 1, " Control of Chemical Consumable Products."
i Change 2 removed lubricant types and quantities and added l
reference to MP 791.0, " Plant Component Lubrication."
I i
l l
i l
l l
l-l O lV j
l l
l I'
l l
l l
i l
l I
i h
r t.
lt A
r,.
MP 728.1 Level of Use
'stop" ~%d' '~cACJ' 'SEVISET s
l Rev 5 General px C;
W P%
330f45
l l
l,"
CL3002 Cross Section and Perts List
,r-~s (Sheet 1 of 1) 102 lil 10 2 175
,1, 1,
131 l
l l
l
'd f
g' #
131 I
N j
11 8 P
7
- i i
/
134 134 164 f
! q;i l; ;
- s f;
115 d
l 178 g.c End End l
3
[
1{N
'N.
r- -
f
-\\
l16 I'
I dk
)
'sj 168 l
)\\
hyg'
{
Q "'j
\\
/
14 2 s
K2 11 2 l
l b'
Item # Item Name item # Item Name item # Item Name 101 Body 117 Bearing Cap-Outer, Idle End 134 Gasket-Bearing Cap 102 11ead 118 Bearing Cap-Inner, Idle End 142 Seal Ring 104 Cone-Drive End 119 Bearing-Drive End 155 Lockwasher l
105 Cone-Idle End 120 Bearing-Idle End 164 Set of Shims j
110 Rotor 125 Shaft Nut 168A O-Ring 111 Shaft 127 Rotor Key 175 Gasket-Cone 112 Gland 128 Packing 178 Vent Cap j
115 Bearing Cap-Outer, Drive End 131 Slinger 116 Bearing Cap-Inner, Drive End 132 Gasket-Body 4
t I
i MP 728.1 Level of Use General
~
ACT' REVIEW STOP' THINK Rev. 5 i
39 or 45
.-.=-.. - -
I Pump Information (Sheet 1 of 1)
%J Model Compressant Free End Nominal Qty. of Nominal Qty of Flow Rate Travel (inch)
Body Gaskets Cone Gaskets (GPM)
(0.010" thk. paper)
(0.010" thk. paper)
I.E.
D.E.
I.E.
D.E.
3002 40 0.070 - 0.140 8
6 1
1 l
Steel Rotor 3002 40 0.105 - 0.210 8
6 1
1 i
Bronze Rotor (m
iV l
6 l
l l
l L
l od Level of Use 1 shb " i p s ' " % c V h N EVI f
ev.5 General P 's
- q
- - 'k 40 of 45
~..
l.
l.
o..
i.' '
Top View Schematic -- Shim Location (Sheet 1 of 1) l V l
.Back i
r 9
r u
Drive Pump Left Motor Right 2t J
Gearbox Shim Location (Typical)
Front l
Pump Gearbox Drive Motor l
Left Right Left Right Left -
Right Front Back
^j
%J t
l 4
l l
1 l
.k g
- ^
f._
MP 728.1
_'T.HIN,K ~^d: t..,
,9 AC,T",
v.A.,._,
Level of Use STOP' R,EVIEW Rev.5 7 s General
<v %s
>e M.
9"e e'?%
s 41or45 s
+
I l,"
Approximate Weights for CL3002 (Sheet 1 of1)
I Approximate Weights Item #
Item Name Weights (Pounds) 101 Body 1180 102 Head 712 l
104 Cone, Drive End 110 105 Cone, Idle End 110 110 Rotor 1090 I
111 Shaft 425 1
\\
l 119 Bearing, Drive End 15 120 Bearing, Idle End 15 I
l Total Pump 4800 1
l l
l~
i I
b i
s 4
MP 728.1 l J Level of Use stoV~ ' WINK 5 CT
' REVIEW' Rev. 5 l
General e
1 e,.
420r45
l ',-
Pump Inspection Record (Sheet 1 of 3)
U AWO No.
Pump Local ID Step Function Performed Initials NA 1
No.
1 1
4.1.2.c.
Record number of shims Record total thickness of shims l
4.1.2.h.
Record reading (A) l 4.1.2.k.
Record reading (B) 4.1.2.1.
Calculate and Record:
(C)=(B)-(A)=
4.3.23 Record number of gaskets Record total thickness of gaskets 4.3.25 Record Cumber of total packing rings Before lantern gland
'p After lantern gland
'D 4.5.7 Record number of gaskets Record total thickness of gaskets 4.5.9 Before lantern gland After lantern gland Record number of total packing rings 4.7.1.g.
Record number of gaskets (idle end)
Record number of gaskets (drive end) 4.7.3.c.
Record reading (D) 4.7.4.a.
Record rotor large diameter Record rotor small diameter Record cone large diameter Record cone small diameter l
l l
l O
MP 728.1
- v Level of Use
STOP THINK '
e ACF ^NEVIEW Rev.5 Generai
/ 4 Ii 43 0r45
l,' '
Pump Inspection Record n
(Sheet 2 of 3) ty Step No.
Function Performed Initials NA 4.7.4.c.
Record rotor large diameter Record rotor small diameter Record cone large diameter Record cone small diameter 4.7.4.d.
Calculate and record stock removal for Idle End(IE) and Drive End(DE):
Cone
- Small diameter before machining (IE)
Small diameter after machining l
- Stock removal (SR) =
i
- Small diameter before machining (DE)
- Small diameter after machining f3 Stock removal (SR) =
(;
\\
l Rotor Large diameter after machining (IE)
- Large diameter before machining Stock removal (SR) =
a Large diameter after machining (DE)
- Large diameter before machining Stock removal (SR) =
Total (IE)= Cone (IE)+ Rotor (IE)=
Total (DE)= Cone (DE)+ Rotor (DE)=
4.7.4.e.
Calculate and record additional gasket thickness:
i Thickness (IE)= (Total (IE)/.006)x.021=
Thickness (IE)= (Total (DE)/.006)x.021=
'O MP 728.1 sToV ~ Mid RAcT
^ REVi$%I v
Level of Use 4
Rev. 5 General r
x x
44 or 45
.