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INSTRUCTION MANUAL
FOR
CARGO PUMPING SYSTEM

MESSRS. NAMURA SHIPBUILDING CO., LTD.

HULL NO. 286

REV. DA. TE DESCRIPTION CHECKED BY DRAWN BY

APPROVED BY
ORDER NO.
APPROVED BY
MODEL , KV400,RX I ,etc.

CHECKED BY
DATE JAN. 09, 2007 IL

D RAW.NO. TIF - 0701 09-6 REV. ' DRAWN BY

!~c~
SHlnKO IN:D.LTD.
5-7-21, Ohzu, Minami-ku, Hiroshima, Japan
TEL : ( 082 ) 508 - 1000 FAX : ( 082 ) 508 - 1020
 MESSRS. NAMURA SHIPBUILDING CO., LTD.
HULL NO. 286

INDEX

NO. SERVICE NAME MODEL PAGE

1
CARGO OIL PUMP KV400 81 -1 -1 5

2 CARGO OIL PUMP TURBINE RX 1 87-1 -28

3 BALL~sT PUMP cV450 82-1 -1 5

4 CARGO OIL STRIPPING PUMP KPH200 9 6A- I -8

5 REMOTE CONTROL SYSTEM FOR CARCO OIL STRIPPING PUMP

KSC65 97-1 -7

SHmKO IIVo. L To.

 INSTRUCTION MANUAL FOR CENTRIFUGAL PUMP (KV)

This instruction manual describes construction, operation, maintenance,

disassembling, assembling, etc. of model KV pump.

CONTENTS
Page
CHAPTER I CONSTRUCTION . . . . . . 81-2
2. Pump casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5. Pump stuffingboxseal . . . . . . . . . . . . . . . . . . . . . . . 3
6. Bulkhead stuffing box and intermediate shaft . . . . . . . . 3
wlth gear coupling
7. Steam cleaning device . . . . . . . . . . . . . . . . . . . . . 3

CHAPTER 2 CAUTION FOR INSTALLATION AND PIPlNG . . . . . . . 8 1 4

l . Place of installation and foundation . . . . . . . . . . . . . . . . . 4
2. Finishingofpumpmounting seat . . . . . . . . . . . . . . . . . . . 4
3. Caution for piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4. Suction piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

6. Permissible deformation ofbellows . . . . . . . . . . . . . . . . . 5

7. Fitting offloating shaft complete . . . . . . . . . . . . . . . . . . 5

CHAPTER 3 OPERATION . . . . . . . . . . . . . . . 81-6

1 . Check before operation . . . . . . . . 6
2. Starting . . . . . . . . . . . . . . . . . . 6
3. Stopping . . . . . . . . . . . . . . . . . . 6

CHAPTER 4 MAlNTENANCE . . . . . . . . . . . . . . 81-7

1 . Caution during operation . . . . . . . . . 7
2. Ban bearing . . . . . . . . . . . . . . . . . . 7
3. Mechanical seal . . . . . . . . . . . . . . . 7
4. Gear coupling . . . . . . . . . . . . . . . . 8
5. Bulkhead stuffingbox . . . . . . . . . . . 8
6. Maintenance check list . . . . . . . . . . . 9
7. Lubricants . . . . . . . , . . . . . . . . . . . 9
8. Standstill . . . . . . . . . . . . . . . . . . . 9

CHAPTER 5 STANDARD CLEARANCE AND LIMIT OF USE . . . 81-10

CHAPTER 6 DISASSEMBLlNG AND ASSEMBLlNG . . . . . . 81-11
1 . Disassembling . . . . . . . . 1 1
2. Assembling . . . . . . . . . . 12
CHAPTER 7 TROUBLE SHOOTlNG AND REMEDIES . . . . . . 81-13

CHAPTER 8 REPLACEMENT PARTS . . . . . 81-15

C~!D I suINKomlo.LTo.
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 CHAPTER
1 CONSTRUCTION

1 . GENERAL
The model KV pump is of a vertical single-stage double-suction centrifugal type, and
the pump and driver are connected with the flexible couplings through an intermediate
shaft and a bulkhead stuffing box, the construction being simple for ease ofhandling,
overhauling and caretaking.

Fig. I .1
2. PUMP CASING
The volute casing is split into two halves
along a vertical plane containing the axis. o
34
Since the volute casing is of double-volute
20
type the radial thrust on the impeller is 9 7

almost balanced. 3 53 ldj

l

Also since the suction and discharge nozzles 3 54 54

are provided on the rear half casing, the 48 1

rotating element can be taken out by re- 27

moving the front half casing (2) without 38

disturbing the suction and discharge pipings. 2 \

A vent to be connected with the stripping Lt L 11t

or priming line and an air valve are provided t

1t
,l t,
l

on the volute casing. /

L // ll
1\
/
\
16
3. IMPELLER 19 /
The impeller (16) is of the double-suction 7

type and hydraulically balanced. It is so 18

54
1le
designed as to improve pump efficiency and 372
2

suction performance. Moreover, the im- 57

2
3
peller is statically and dinamically balanced. 35 7
7
14

4. BEARING 10
The rotating element is supported by ball
bearings on both sides of the pump casing.
The 6300 type ball bearing is fitted in the
REa. FOR IPUMP AEa. FOR pUMP

solid inner case (14) with the split type PART NO.
NAME OF PART
PART NO.
NAME OF PART
bearing housing and can be taken out to- 1
VOLUTE CASING 1
38 MOUTH RING 2
gether with the rotating element if the cap
of the bearing housing (7) is removed.
2 VOLUTE COVER 1
48.1 FLINGEA 1

3 PUMP BED 1
48.2 FLINGER 1

(1) The ball bearing (34) at the coupling end

7-1 BEAR ING HOUSING 1
54A MECHAN ICAL SEAL 1 SET
is secured in the housing by pressing its
7-2 BEARING HOUSING 1
54B MECHANICAL SEAL 1 SET
outer race by means of the cover (9).
9 8EARING COVER 1
57 PACK ING R ING 1

This serves to support the weight of the

10 BEARING COVER 1 70- 1 SNAP RING 1
rotating element.
141 BEARING INNER CASE 1
70-2 SPLIT RING 1 SET
(2) The ball bearing (35) at the bottom end 1 42 BEARING INNER CASE 1
70-3 SNAP RING 1

is not fixed axially in view of the thermal

16 IMPELLER 1 1 46-1 MECHA. SEAL COVER 1

expansion of the shaft (1 8).

18 iMPELLER SHAFT 1 46-2 MECHA. SEAL COVER 1

(3) Grease is used as lubricant for the ball 19 IMPELLER KEY 353 BEAA ING NUT 1

bearing.
20 COUPLING KEY 11 1 354 BEAR ING WASHER 1

27 IMPELLER NUT 37 2 PACK ING R ING 1

34 BALL BEARING 1

35 BALL BEARING 1

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5. PUMP STUFFING BOX SEAL Fig. I .3

The stuffing box is so designed as to furnish the

mechanical seal exclusively. Therefore there is
no leakage of the liquid pumped and no air leaks ~~:~~~]
f ~I~~'
into the pump. r ,ZI
~T I

Moreover, the operation is very simple since no a25

[
adjustment for the stuffing box during operation a]6 ,08

is required. 128

a21

Mechanical seal 101 42c

Unbalanced type mechanical seal is fitted and 111 l

lal
138
flushed by pressure liquid led through the clearance 149

between the impeller and the mouth ring.

,t] ,04
DECX
lo?
Fig. I .2 tog
D~~Z~~l
a:9
438
MECHAN I CAL SEAL da5

131
F LUSH I NG aQI

WATER PIPE 1
409

IF
,t5
a,o
2 A]o
al3

5 dt2
lo-

t 3 ,31
"I
5 '12 129
4
5
5
105

aa8
~~@
5 4lg
,3]
6 ,], lll I

lll A

Itl I

7
.'= \~
Close-up view of 421
mechanical seal
4:o

5lh 1 F LOAT I NG SEAT CARBON

542 PACKINC RING RUBBER
543 PAC K I NG RUBBER
51 h4 SEAL R INC STA I N LESS STE E L PART NO.
R EQ. FOR PUMP
PART NO.
REa. FOR PUMP

NAME OF PART NAME OF PART

545 PACKING RING RUBBER
401 BEARING SUPPORT 1
423B HUB 1

546 SPR I NG STA IN LESS STE E L

STOPPER RING & SET SCREW 402 BEARING CASE 1
424 COUPLING BOLT & NUT
51 h7 STAIN LESS STEE L 403 BEARING CASE 1
425 PACKING RING 1

404 BEARING COVER 1

426 PACKING RING 1

For upper mechanical seal, A is attached, e.g. 54A-1 405 STUFFING BOX 1
427 PACKING RING 2
FLOATlNG SEAT, and for lower one, e,g, 54B-1, 406 GLAND 1
428 PACKING RING 1

407 FLINGER 1
429 PACKING RING 2
408 COVER & PACKING 1 SET 430 COVER & PACKING 1 SET
409 DISTANCE RING l 431 INTERMEDIATE SHAFT 1

6. BULKHEAD STUFFING BOX & INTERMEDIATE 410 DISTANCE RINC 1

432 F LOATING SHAFT 1

SHAFT WITH GEAR COUPLING (Standard) 41 1 BALL BEAR ING 1

433 COUPLING KEY 4
A stuffing box is provided where the intermediate 41 2 BALL BEARINC 1
434 SNAP RING 1

shaft passes through the bulkhead to prevent the 413 LANTERN R ING 1
435 BELLOWS 1

414 PACKING RING 1

436 SEAT PACK ,NG 1

gas in the pump room coming into the engine room.

415 GLAND PACK ING 2 437 SEAT PACK I NG 1

If non-standard arrangement is fitted, it will be

416 SLEEVE 1
438 SPACER 1

shown later. 417 SLEEVE 1

43g DOUBLING PLATE 1

418A S LE EV E 1
440 PLUG 1

7. STEAM CLEANlNG DEVICE (Option) 418B SLEEVE 1

441 BEAA ING NUT 1

The device is provided on the pump to clean the 419 COUPLING FLANGE 1
442 BEARING NUT 1

420 COUPLING FLANGE 1

443 BEAA ING WASHE R 1

mechanical seal and the mouth ring for pumping 421HUB 1

444 BEAR INC WASHE R 1

very high viscosity cargoes. 422 HUB 1

423A HUB 1

cg SnINKO INIO.LTO.
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 CHAPTER 2 CAUTION FOR
IN STALLATIONAND PIPING

In order to prevent occurrence of vibration and noise and to operate the pump over long
periods with best efficiency and safety the following points must be observed at the time
of installation and piping.

1 . PLACE OF INSTALLATION & FOUNDATION4 SUCTION PIPING

(1) Size of the place of installation must be chosen The piping on the suction side affects pump effi-
in view of the pump disassembly and inspection. ciency to a great degree and to avoid troubles
A space necessary for disassembly is shown in the arising there from the following points must be
outside drawing. noted.
(2) The foundation must be strong enough to absorb (1) No air pocket must be formed in the piping.
pump vibration and to resist deformation against (2) A11 fittings in the piping must be perfectly
long use. tightened to prevent air invasion.

(3) The pump is placed on its foundation. The (3) Care must be taken to prevent air leakage th-
driver with its bed is placed on its foundation rough glands of all valves in piping.
with the bearing support (401) complete fast-
(4) The suction piping must be thoroughly cleansed
ened at the bottom of the driver's bed.
so that pipe scale, welding beads and other
In this case confirm that the drstance "E" shown
foreign matter do not remain, otherwise seizure
in the outside drawing, between the end faces of
and other troubles may result.
the coupling halves on the pump shaft end and
the intermediate shaft bottom end must be as
shown in the drawing. The permissible error of
5 ALIGNMENT
Table 2.1 and 2.2 show permissible errors in ali-
this distance * ''',,
is :t2mm. (Refer to Fig. 2.2).
gnment when the pump and driver are connected
through the intermediate shaft.
2. FINISHING OF PUMP MOUNTING SEAT When installations of the pump and driver have
Chockliners must be welded on the foundation been finished it is necessary to check the alignment
place just under the pump foundation bolt holes
and if the errors exceed those shown in Tables 2.1
and their faces must be planed so that they lie in
and 2.2 adjustment is needed. This work is also
a perfect plane. When the foundation bolts are necessary when pipings for them have been finished.
tightened leaving gaps between the liner faces and
When the alignment has been completed set the
pump bed, deformation may be given to the pump driver's bed and the pump bed on their foundation
and besides vibration may result.
by driving the dowel pins.

3. CAUTION FOR PIPING Table 2J Between driver & intermediate shaft

Deformation given to the pump by outside force Parallel misalignment A Angular misalignment B
due to incorrect piping causes not only vibration at coupling (mm) at coupling (mm)
but also pump troubles. Therefore, the pipe flanges Below O . 2 Below 0.2
(Between centers)
connecting with the suction and discharge nozzles
must be correctly matched. Be sure to avoid the
cases shown in Fig. 2.1 otherwise the pump may Table 2.2 Between intermediate shaft & pump
receive unreasonable force. Nor must the pump Parallel misalignment A Angular misalignment B
be directly given deformation due to the total at coupling (mm) at coupling (mm)
weight of piping and thermal expansion. Below 0.4 Below 0.4
(Between centers)
Fig. 2.1

PIPING PUMP

Angular Parallel Flange faces

misalignment misalignment do not touch

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5 .1 Between driver and intermediate shaft 5 .2 Between intermediate shaft and pump
(1) Measurement ofparallel misalignment (1) Measurement of parallel and angular mis-
As shown in Fig. 2.2, fix a dial indicator on alignments
the coupling at the intermediate shaft upper As shown in Fig. 2.2, fix dial indicators on the
end for the alignment so that its spindle rests temporary shaft to be provided for the ali-
on the periphery of the coupling on the driver. gnment so that their spindles rest on the peri-
Give one complete turn at the same time to phery and the face of the coupling half on the
both coupling halves on the driver and the intermediateshaft. Give one complete turn
intermediate shaft and read the difference at the same time to both coupling halves on
between the maximum and minimum readings the pump and intermediate shaft and read the
on the indicator. difference between the maxirnum and mini-
(2) Measurement of angular misalignment mum readings on the indicators.
In the same way as above, give one complete
turn to both coupling halves at the same time 6. PERMISSIBLE DEFORMATION OF BELLOWS
measure the gap between the coupling faces WHEN FITTED
(e.g. at each 90 deg.) using a feeler gauge, and (1) Elongation or contract in vertical direction
read the difference between the maximum i 10 mm.
and minimum measurements. (2) Angle deviation (Refer to Fig. 2.3) 5 deg.
(3) Perpendicular deviation (Refer to Fig.2.4) :!:8mm,
Fig. 2.2
Driver
Fig. 2.3 Fig. 2,4
~ ~
't~
50

it, 'll
tl
FEELER GAUGE t,l
~1: ~r l

Parallel
F
m isa I ignment
m is~

i8

A
1
7. FITTING OF FLOATING SHAFT
(LOWER INTERMEDIATE SHAFT)
It is strictly prohibited to fit the floating shaft
(432) upside-down due to an abnormal thrust
BE L LOWS force is given to the pump bearing. It is therefore
A lar
Angu special attention should be paid for that the floating
misalignment
m i sa
shaft with the coupling marked with "C" is to be
fitted up and the other side marked with "PC"
"~~ down.

E
TEMPORARY SHAFT

Pump

g SnINKO IND.LTO.
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 3 O'PERATION
CHAPTER

1
CHECK BEFORE OPERATION (2) Close the discharge valve completely and open
When operating for the first time after installation the suction valve fully.
or overhaul and assembly, it is necessary to do as (a) When the liquid level in the cargo tank is
follows.
above the pump the liquid flows into the
(1) Take off dust preventing tape placed on the pump casing by gravity, so open the air vent
part where the pump shaft passes through and valve on top of the volute casing to draw the
take care so that no foreign matter enters the air in the pump and close it when the liquid
clearance around the shaft. begins to flow out of it.
(2) Give some oil to the mechanical seal. (Refer (b) When the liquid level in the tank is below the
to "MECHANICAL SEAL") pump draw the air in the pump and suction
(3) Give a few turns to the coupling by a turning line through the gas vent on the volute casing
bar and see if it turns normally. by means of stripping pump or some other
(4) Confirm if the rotation direction of the driver extracting devices so that liquid can fill the
is correct. pump inside. In this case keep the air vent
valve closed so that no air can enter the pump
(5) Confirm if the grease in the bearing housing casing. Never neglect priming the pump.
and the oil in the gear coupling, if fitted, is
(3) Start the driver gently and increase its speed
within the specified amount.
gradually .
(6) Confirm if the driver is ready for the operation.
(4) When the discharge pressure has risen reasona-
blly, open the discharge valve gradually and
2 . STARTlNG
fully .
(1) If the steam cleaning device for high viscosity
cargoes is provided for cleaning the mechanical
seal and mouth ring and if the last cargo un- 3. STOPPING
(1) Close the discharge valve.
10aded by the pump was so, open the steam
inlet valve provided on the device to clear the (2) Stop the driver.
said parts before starting the pump and keep (3) If the steam cleaning device is fitted and the
the valve closed during the operation of the liquid pumped was high viscosity cargo, open
pump. Refer to Fig. 3.1 . the steam inlet valve on the device and clean
the mechanical seal and mouth ring for about
Fi9. 3.1
1 O minutes to prevent from sticking the said
STEAM parts under normal temperature.

In case stop valve

is opened
STEAM
C LEAN I NG
' r~- -~J
DEVICE
( Fitted on
PUMP
L--~-l CASING
IN LET STEAM Itr---~l pump body)
(Steam press.
2-3kglcm2 g)

Liquid being handled

I n case stop valve

is closed

IL~
Pl I I I I J

Fl - l-el
1'~~-

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g SHINKO INO.LTD.
 4 MAINTENANCE
CHAPTER

In order to eliminate pump troubles, to minimize parts consumption and repair and to
maintain best efficiency over long periods the operator must aim at perfect maintenance
of the pump.

1 . CAUTION DURING OPERATION (7) With lowering of the liquid level in the tank
(1) Never throttle the suction valve in any case suction pressure approaches the vapor pressure
during operation otherwise troubles may occur of liquid and vapor develops in the suction
due to dry operation. line and pump suction and, moreover, air is
(2) Never operate the pump for over 3 minutes sucked through the suction bell-mouth until
with discharge valve completely closed. When punrping ability decreases to such extent that
discharge stops.
a centrifugal pump is operated without dis-
charge, most of the power changes into heat In order to prevent this, vapor and gas coming
and as a result temperature of the liquid in the into the pump inside must be drawn through
pump casing rises to the boiling point causing that vent on the casing by means of stripping
seizure of the interior of the pump and accident pump or some other extracting devices.
may occur, especially when dangerous liquids (8) When cavitation occurs even though the pump
are pumped. speed becomes minimum, discharge mut be
(3) Never operate the pump with dry condition. decreased by throttling the discharge valve.
If this remedy is ineffective stop the pump.
(4) Except that the driver is with the constant
speed like electric motor, keep the discharge
2. BALL BEARING
valve open in full and it is desirable to adjust
(1) In consideration of lubricating ability of the
discharge flow by changing speeds. The adjust-
grease and running clearance of the bearing
ment of discharge flow by the degree of dis-
due to thermal expansion and liquid tempe-
charge valve opening is not recommendable rature pumped, the bearing temperature is so
because of loss of driving energy. designed as to stand up to 90'C.
(5) When operating more than 2 pumps in parallel However from viewpoint of service life it is
be sure to keep the discharge pressure of each desirable to keep it below 75'C.
pump always equal. If the speed of some pump (2) For the lubrication of ball bearing grease is used.
decreases during operation and its shut-off The recommendable grease and the interval of re-
pressure drops below the discharge pressure placement grease are shown in Table 4,1 and 4.2.
of the remaining pumps, it is operated with
zero flow even though its discharge valve is (3) For supplying grease for the bottom ball bearing,
opened and thus the result will be the same as take the grease drain plug away.
mentioned in (2) before in this chapter.
In such a case try to make the speed of the 3. MECHANICAL SEAL
pump in question same as those of the remaining (1) Cautions before starting and during standstill
pumps, and if this is impossible stop that pump Care must be taken so that no dust enters part
(a) in Fig. 4.1 .
immediately.
Pouring lubricating oil in (a), when the pump is
(6) When operating the pump at the rated speed
at a standstill, wiD prevent dust from sticking.
with the discharge valve open in full available
If dust accumulates here and sticks hard seal
NPSH decreases as the liquid level in the tank
ring (54-4) may stick and sliding face (S) can
lowers and finally discharge becomes zero not be tightened. When the pump is delivered,
due to cavitation.
a strip of cloth tape is put over the gap around
In such a case pumping ability can be restored
the impeller shaft to prevent foreign matter
if discharge is decreased, so for the reason from invading.
mentioned above lower the speed without
throttling the discharge valve as the liquid level (2) Check of flushing
in the tank drops. The mechanical seal may be considered to be
working perfectly if there is no heating near
the sliding parts and no abnormal noise.

g SuINKO INiD.LTO.
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 Fig. 4.1

(a) ll

(s)
plug B plug A

I'
Q)
~'1~
Rernove/ \~e move
vl / ~
Q)
~o
L-
c~,

-C
u
OJ)V1
:= I- (b) Fill oil through an oil plug hole on the
•- to
J=
Cl)~~ coupling by using pistol oiler till the oil
::, o
- ,= begins to fiow out from the other oil plug
LLY-
hole on the opposite side.

(3) Leaking from mechanical seal

Coupl i ng
Under normal operational conditions there is o- r n g
no leakage, but in case there is a leakage of Air gaP
over 30cc/h there must be some trouble inside, ~ea r o
Dverflow (]so vG4so-s80)
so a remedy Inust be taken as early as possible.
(4) Heating of sliding parts and abnormal noise.
Insufficient flushing to the sliding face causes
abnormal wear down of the carbon due to O-ring
heating and dry contact. If flushing Coup I i ng o e r

temperature rises to more than 10~C above

the liquid temperature being pumped, it is (c
(c) After filling
After fillin the oil ut
the oil, puttwo
twoluplugs
s back toto
back
necessary to trace the cause and remove it. the coupling with Teflon seal tape on them.
When operated under the condition of dry Apply several turns to the shaft so that
contact, abnormal sliding noise may occur. the oil may reach the interior of the
coupling. If too much oil is filled,
4. GEAR COUPLING (Standard) excessive oil may leak from the key way
(1) Misalignment between pump and driver but this is acceptable because necessary
Since the gear coupling has sel~alignment oil is kept in the coupling.
action to some extent, small misalignment
within the permissible values shown in Table 5. BULKHEAD STUFFING BOX (Standard)
2.1 and 2.2 can be absorbed. (1) When operating for the first time after
However the excessive misalignment causes repacking the stuffing box tighten once the
too much slip between the teeth and as a result gland firmly before starting, then loosen the
wear becolnes excessive, vibration occurs and gland nuts to such extent that the coupling can
the coupling may be damaged. be turned lightly by turning bar.
(2) Lubrication (2) Supply grease to the gland packing for
Lubrication oil has a very important function in lubricating and to keep gas-tightness between
reducing friction and wear and in hydraulically the pump room and engine room.
distributing contact pressure on the gear The recommendable greases and the interval of
flanks by forming oil film in the gap between replacement grease are shown in Table 4.1 and
the m . 4.2.
The recommendable oils and the interval of (3) Start the pump and adjust the gland nuts
replacement oil are shown in Tables 4.1 and gradually and evenly. If the gland is tightened
4.2. suddenly or too much or unevenly there may be
(3) Filling lubricant oil a danger of seizure of overheating.
(a) Remove two oil plugs. (4) If the packing becomes deteriorated the
tightness can not be kept no matter how much
the gland is tightened.
In such case renew the packing.

c )
g St,lNKO IND.LTO.
6. MAINTENANCE CHECK LIST
Maintenance and check for the followings can extend a life of the pump.
Item Inspection procedure Remedy in case of trouble

Check every time if there is any Stop pump immediately and check suction
Suction pressure
abnormal pressure drop line .

In the case of above ambient temperature

Bearing temperature Check and record every tilne. plus 40~C or above 85~C, stop pump and
eliminate cause.

Check oil in gear c'oupling every time

Lubricating oil Supply oil if necessary.
through oil hole on it.

If abnormal noise or overheating occurs,

Ball bearing Check abnormal noise every time. stop pump and eliminate cause, and renew
ball bearing if necessary.

Check leakage, heating, noise every

Mechanical seal Stop pump and remove cause.
time.

Vibration Check vibration every tilne. Check alignment.

7. LUBRICANTS
(1) Replacement of lubrication Table 4.1
The replacement of the lubricants is based on
deterioration or contamination of the lubricants Replacement
being used. However, Table 4.1 shows Location After initial start Normal o peration

recommendable replacement.
(2) Lubricants Within 3 months
Ball bearing Every year
NLGI No. 2(National Lubricating Grease
Institute) for grease for the ball bearing on the Every 6 months

pump and intermediate shaft and for its stuffing

Gear Coupling ,,

box, and for the gear coupling, ISO VG 460- Every operation Every o peration

Bulkhead stuffing box.

680 gear oil are recommendable. The brand
names of the lubricants equivalent to the
recolnmendable ones are shown in Table 4.2.
(3) Grease amount
Pump model KV 300 KV 350 KV 400 KV 450-3 KV 450-4 KV 500-2
Pump upper side bearing (g) 70 70 110 150 270 330
Pump lower side bearing (g) 50 50 70 llO 150 210
Intermediate shaft upper side bearing (g)

70 70 110 150 270 330

Intermediate shaft lower side bearing (g)

70 70 110 150 270 330

Bulkhead stuffing box (g) 240 240 280 300 360 400
(4) Gear oil amount
Pump model KV 300 KV 350 KV 400 KV 450-3 KV 450-4 KV 500-2
Turbine side gear coupling (cc) 180 180 270 480 550 700
Intermediate shaft side gear
130 130 170 280 380 410
coupling (cc)
Pump side gear coupling (cc) 130 130 170 280 380 410
8. STANDSTILL
When there is a fear of freezing, drain the pump conrpletely after stopping. In case of a long standstill, clean each
sliding part thoroughly and apply rust preventive where necessary.

cg SHINKO INb.Llb.
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 Table 4.2
Gre85e (NLGI N0.2) ( ;ear Oi] (rso VG 680)

Name of Com pany

IDEMITSU KOSAN DAPHNE EPONEX EP2 DAPnNE SUPER GEAR OIL 680

BEACON EP2 LISTAN EP2

EXXON SPARTAN EP 680

MOBIL UX 2 MOBIL PLEX 47

R/!OBIL OIL MOBIL GEAR 634 OR 636

NIPPON OIL EPINOC GREASE AP2 BONNOCK M 680

CALTEX OIL MULTIFAK EP2 ~IEROPA LUBRICANT 680

JOMO LISONIX GREASE EP2 REDUCTLJS 68,I

MITSUBISHI OIL DIAMOND MIJLTIPURPOS N0.2 D[AMOND GEAR LUBE SP 680

CULF OIL C.ULF CROWN GREASE N0.2 GL!LF EP LUBRICANT HD680

BP OIL BP ENERCREASE MM-F.P-2 BP ENERCOL GR-XP 680

TEXACO OIL MULTIPA K NO.2 TEXACO MEROPA 68Q

CASTROL St•HEEROL AP2 OR EPL2

CASTROL ALPflA SP 680

COSMO OIL COSMO C•REASI~ DAINAMAX N0.2

COS*MO GEAR SE 680

ALVANIA GREASE N0.2 ALVANIA CREASE EP2

SHOWA SHELL OIL OMALA OIL 680

GENERAL S P GEAROL 680

GENERAL OIL GEMICO GREASE MP-2

ELF
EPEXA 2 = EPONA Z680
CHEVRON DURA-LITH GRF.ASE EP2 , NL GEAR COMPOUNl] 680 ** EP680

CLEARANCE AND LIMIT USE

5 STANDARD
CHAPTER OF

The bigger the clearance between impeller and mouth ring becomes, the more the counter-
flow from discharge side to suction side becomes, and consequently pump capacity de-
creases.

Unit :
Table 5.1 mm
New parts Limit of use

Name of part Model Standard Length b b

clearance a
a Upper seal Lower seal Upper seal Lower seal

KV 300 O. 3 15.9 15.9 1 13 13

Im p eller
c3 ~3
350 o. 3 3 15.9 15.9 1 13 13
and
mouth ring 400 o. 3 3 15.9 15.9 1 13 13

450-3 o. 3 8 15.9 l 5. 9 1 13 13
Floating b
seat of 45 O-4 o. 3 8 16.5 1 5. 9 1 13.5 13
m echanical
seal 500-2 o. 3 8 35 16.5 1 32 13.5

C J
g SHINKO INO.LTD.
 CHAPTER AND ASSEMBLING
6 DISASSEMBLlNG

1 . DISASSEMBLING Fig. 6.1

In order to replace impeller, ball bearing, mouth
ring, etc., disassembling of pump is carried out as 1 34
1
20
folbws.
7
9
3 53 td 1

l .1 Removal ofvolute cover 354 54

(1) Remove the sealing pipe for the mechanical seal. 4 1

27
(2) Loosen the nut for the mechanical seal cover _'1~1'1
3B
(146) until the mechanical seal cover moves 2
/
I// l' / ~\
and touches the flinger (48). L \ \ Ll

(3) Remove the volute cover nuts and move the ,l j~

t
t l

volute cover (2) forward by using the two ' l ll l'

lifting b olts. L~

16 /

l9 __.l
1.2 Removal ofrotating element 70
5dB
(1) Remove the coupling bolts. 18 Id
2
37 2
(2) Remove the bearing housing cap after removing 2
57
3
the nuts fastening the cap. 35 7
70
(3) Take out the rotating elements together with 14
2
the bearing inner case (14), bearing covers 10

(9 & I O), bali bearing, etc. with paying attention

to the mouth ring (38) and mechanical seal. 1 .4 Removal ofmechanical seal
Since the mechanical seal for this pump has a
l .3 Removal ofball bearing large spring compression allowance and force,
(1) For the upper bearing, remove the coupling the special tool provided must be used for re-
after removing the snap ring (70-1). moving the mechanical seal and ball bearing
Remove the bearing cover (9). from the shaft.
Make straight the rotation preventing piece on (1) As shown in Fig. 6.2 hold the tool in such
the washer (354) which is bent into one of the a way that the spring force does not act upon
slots along the bearing nut (353) periphery and the flinger (48), and maintain not to transmit
remove the bearing nut. directly to the mechanical seal the shock pro-
(2) For the lower bearing remove the bearing duced when the ball bearing is removed.
cover (1 O) and the snap ring (70-3).
(2) Remove the ball bearing and flinger from
(3) Compress the mechanical seal spring by using the shaft.
the special tool provided as shown in Fig. 6.2 (3) Loosen the special tool bolts to reduce the
and also mentioned in "Removal of mecha- spring force and remove the special tool as
nical seal". shown in Fig. 6.3 .
(4) Since the ball bearing is pushed lightly onto (4) Remove the mechanical seal from the shaft.
the shaft, it can be removed with the inner
case by using puller.
Fi9. 6.2 Fig. 6.3
SPECIAL TOO L ISUPPLIED)
COVER~ 2-"5cm
BALL BEARING

SPR I NC

STO PP E R RtNG SET SCR EW SEAL RINC LOAT I NG SEAT

FLING R

gD SuINKO INlo.L70.
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 1.5 Removal ofimpeller (2) Take care not to injure sliding face and "O"
The impeller ~shaft _diameter where the impeller ring by hitting or scoring.
(16) is fitted is the largest and gets smaller to-
(3) When fitting be sure to apply lubricating oil
ward either end. to "O" ring .
Fixing the impeller is by the impeller nut (27)
at the upper side and by the split ring (70-2) at
(4) Referring to Fig. 6.2 the floating seat (54-1)
the lower side. (carbon) must be inserted by hand until it
(1) Remove the setscrews on the impeller nut touches bottom of the cover (146) firmly
taking care not to injure sliding face.
(27) and remove the impeller nut after re-
moving the ball bearing, the flinger and the (5) Place the stopper ring (54-7) against the shaft
mechanical seal. shoulder which forms fitting base and tighten
it by the setscrew.
(2) Remove the impeller from the shaft.
However, if it is difficult to remove the im- (6) Confirm the winding direction of the spring
peller from the shaft, warm the hub of the if it is suitable for the rotation direction of
impeller slightly to ease working. the pump. Refer to Fig. 6.4.
(7) Fit rotating elements of the mechanical seal
2. ASSEMBLING and the cover (146) onto the shaft.
Assembling can be carried out by reversing order
(8) Afterward, apply the special tool and compress
of disassembling and attention must be paid to
the spring evenly as shown in Fig. 6.2.
the followings.
(1) Clean each part thoroughly to remove rust (9) Fit the flinger and the ball bearing onto the
and scale, and be sure there are not injury and shaft, Ieaving the special tool as it is as shown
burr in fitting parts. in Fig. 6.2 to compress the spring until the
rotor is settled in the volute casing.
(2) Assemble fitting parts according to match
marks if any. (10) After settling the rotor in the volute casing
remove the special tool.
(3) Turn nuts for rotating parts securely and fix
anti-rotation device without fail.
Fi9. 6.4
(4) Be sure to thoroughly cleanse the ball bearing
with pure kerosene taking care to keep off
dust and foreign matter.
STOPPER RING STOPPER RING
2.1 Alignment SEAL R ING SEAL RING
Alignment is to be confirmed if it is within
/

the specified limit shown in Tables 2.1 and 2.2 l l

in "ALIGNMENT" . R ight-hand Left-hand

winding winding
2.2 Assembly ofmechanical seal
Use the special tool for assembling the me- IMPELLER SHAFT IMPELLER
chanical seal as shown in Fig. 6.2 and 6.3.
(1) Sliding face, "O" ring and "O" ring groove
must be claned with leadless gasoline and
wiped with soft cloth taking care to keep
off dust and other foreign matter.

SmNKO INO.LTD.
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 CHAPTER 7TROUBLE
SHOOTING AND
REMEDIES

Pump can perform satisfactory function if properly handled and maintained.

Should trouble occurs speedy remedies must be found for it. Table 7.1 shows commonest
causes of trouble and suggested remedies.

Table 7.1

Troubles Causes Remedies

1. Pump not completely or insufficiently 1. Prime once more,

filled with liquid.
2. Much air leakage in suction line. 2, Check suction line.
3. Air pocket in suction line. 3. Check suction line,
4. Suction lift too high. 4. Check by suction gauge on suction side.
Pump cannot discharge
5. Wrong direction of rotation. 5. Check,
6. Suction strainer and suction line 6. Check interior of suction line,
clogged.
7. Speed too low. 7. Check by tachometer.
8. Impeller clogged. 8. Check pump interior.

1. Air leakage. l. Check suction line and stuffing box,

2. Speed too low. 2. Check by tachometer.
3. Discharge head too high. 3. Check by discharge gauge.
4. Suction lift too high. 4. Check by suction gauge.
5. Suction pipe bell-mouth not sufficiently 5. Check.
submerged.
Insufficient discharge 6. Suction strainer and suction line clogged. 6, Check interior of suction line.
7. Impeller clogged. 7. Check pump interior.
8. Wrong direction of rotation. 8, Check.
9. Excessive clearance between impeller 9. Replace mouth ring by new one.
and mouth ring.
1 O. Cavitation due to high liquid tempe- 1 O. Check design.
rature or excessive viscosity of liquid.

1. Pump not sufficiently fmed with liquid 1. Prime sufficiently.

Pump discharges liquid
2, Air pocket in suction line. 2. Check piping and if wrong correct it,
after starting, but soon
3. Much air leaks into suction line. 3. Check suction side.
fails to discharge
4. Air leaks through stuffing box . 4. Check if mechanical seal is incorrectly
fitted or carbon is broken,

1. Speed too high (Power frequency too 1. Lower speed. (Frequency)

high.)
2. Impeller touches mouth ring, 2. Check state of installation and
alignment.
3. Rotating elements touch stationary 3. Replace shaft by new one.
Prime mover overload element due to bent shaft.
4. Casing deformed. 4. Check if undue force is given
by piping.
5. Liquid specific gravity or viscosity is 5. Check design.
greater than designed one.
6. Voltage too low (Constant input, but 6. Check power source,
increase in current) in case of electric
motor driven.

g SuINKO INb.LTo.
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 Troubles Causes Remdeies

1. Grease is too little. 1. Supply grease up to specified level.

2. Grease is too much. 2. Remove grease till specified level.
3. Grease has improper consistency or 3. Replace old grease with specified
it is deteriorated. new grease,
4. Misalignment is great. 4. CorTect alignment of pump and driver.
Overheating of bearing
5. Shaft is bent. 5. Replace with new shaft.
6. Injury or too much wear in ball 6. Replace with new ball bearings.
bearing.
7. Too much thrust force. 7. Check if impeller is clogged and if
clearance between mouth ring and
impeller becomes too much, and
correct them if any.

1. Injury in balls or rolling face.

Abnormal noise in 2. Too much clearance due to abnormal
Replace with new ball bearing.
ball bearing we ar .
3. Abnormal wear in retainer.

1. Misalignment. 1. Check alignment of pump and driver.

2. Shaft bent. 2. Renew shaft.
3. Impeller partially clogged with foreign 3. Check pump interior.
matter.
4. Incorrect installation. 4. Check state of installation.
5. Weak foundation. 5. Measure vibration up and down, right
Vibration in pump and left around pump's mounting on
foundation, if vibration is too great
reinforce foundation.
6. Suction and discharge pipings not 6. Refer to "CAUTIONS FOR PIPING'*,
sufficiently secured. and give necessary support.
7. Rotating elements touch stationary 7. Check pump alignment and bending of
elements. shaft.

1. Injury or excessive wear down in 1. Remove mechanical seal cover and

rubbing faces. check rubbing faces.
2. Foreign matter in rubbing faces. 2. Ditto.
3. Insufficient tightening of mechanical 3. Check if cover bolts are evenly
seal cover. tightened.
Leakage in mechanical 4. Break down of "O" ring. 4. Check "O" rings for stationary and
seal rotary rings.
5. Insufficient tightening of setscrew of 5. Tighten sufficiently setscrew.
stopper ring (54-7).
6. Injury or wear down of part of shaft 6. Replace with new shaft.
where rotary ring's "O" ring (54-5)
contacts.
7. Scale sticks in groove for "O" rmg 7. Disassemble and remove scale
(54-5), causing rotary ring to stick completely.
and rubbing faces to open.

1. Flushing is insufficient. 1. Check if flushing pipe is clogged.

Heating of mechanical
seal (Sometimes
accompanied by abnormal 2. Pump operated dry. 2. Stop pump immediately.
noise)

c J
g SHINKO INO.LTb.
 PART S
CHAPTER 8 REPLACEMENT

When ordering replacement parts, include the following information.

1 . Ship's name

2. Shipbuilder and hull number

3 . Service and model of the pump
4. Parts' numbers and names shown in this instruction manual

PART NO. NAME OF PART R EQ.

PREssuRE GAUGE 71 Io PUMP SUCTION 1

71 1 1
PUMP DISCHARGE 1

UJ
tD
:)

(g

UJ
cc
:)
Cl)
U)
UJ
o:
CL

7221 PUMP CASING 1 set

TH ER MO-SW I TCH
( If fitted,
7221 .1 1 INSTALL THREAD 1

7222 PUMP BEARING COUP. SIDE

1 set

7222-1 1 INSTALL THREAD 1

7223 PUMP BEARING END SIDE1 set

I 7223.1 1 INSTALL THREAD 1
o
h
~ 7226 BULKHEAD STUFFING BOX
1 set
co
7221 -1 1
o
~:
7226.1 1 INSTALL THREAD 1

7222.1 1 a:
UJ
7223-1 1
I
7226-1 1 F
7221
7222
7223
7225

g SHINKO INO.LTD.
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 INSTRUCTION MANUAL
FORTURBlNERX

This instruction manual describes construction, caution for installation

and piping, operation, maintenance, etc.
As the life of turbine depends extremely on the correct installation and
handling and suitable maintenance, it is recommendable to carry out
them according to this manual.

CONTENTS
Page
CHAPTER 1 CONSTRUCTION , . , . . . . . . . . . . .87- 2
1 . General , 2
2. Exhaust casing . . . . . , . . . . . 2
3. Rotor disc . . . . . . . 2
4. Governorvalve . , . . . . . . . , , 2
5. Gland seal . . . , , . . . . . . . . . 2
6. Speed regulating governor 3
7. Emergency trip device , . . , . .
8. Lubrication system . 3

CHAPTER 2CAUTION FOR INSTALLATION AND PIPlNG . . . . . , , .87- 4

1 . Place ofinstallation and foundation . . . 4
2. Finishing ofturbine mounting seat . . 4
4
4. Alignment . . . , . , . . . . . . . , 4

CHAPTER 3OPERATION . . . . , . , . . . . , . . . . . , . .87_ 5

1. Check before operation . . . . . . . 5
2. Starting . . , . , . . . , . . . . , . .
3. Operation at various speeds 5
4, Stopping . , . , , . . , . , . . . . , . . 6
5. Emergency stopping . . . . . 6
6, Resetting of emergency trip , . . 6

CHAPTER 4MAlNTENANCE . .87. 7

l . Maintenance check list for during operation .
2. Adjustment for accessories and emergency trip . . . 8
3 . Maintenance check list for regular inspection . . . . . ... 9
4. Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . 10

CHAPTER 5STANDARD CLEARANCE AND LIMIT OF USE. 87-1 1

CHAPTER 6DISASSEMBLlNG AND ASSEMBLlNG . . 87-1 2

1. Disassembling . . . . . . . . 12
2. Assembling . 14

CHAPTER 7TROUBLE SHOOTlNG AND REMEDIES . 87-1 5

CHAPTER 8REPLACEMENT PARTS . 87-1 8

C~g I snINKolNb.LTo.
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 CHAPTER 1CONSTRUCTION

l . GENERAL 4. GOVERNOR VALVE

The model RX steam turbine is a vertical Curtis The governor valve is double seat type to prevent
single stage with a reduction gear unit. unbalance by the effect of steam pressure and also
Its construction is simple, strong and compact and acts as an emergency stop valve so that this valve
the safety device and the governing device are closses to stop the turbine when emergency trip
composed of simple mechanism. devices work.

2. EXHAUST CASING 5. GLAND SEAL

The exhaust casing is solid construction with an The turbine gland is provided with labyrinth pack-
axial flow exhaust steam bore to lead steam flow ing.
smoothly to the exhaust steam piping for saving
steam consumption.

3. ROTOR DISC
The rotor disc is provided on the turbine shaft end
by shrinkage fit. The pinion and shaft are solid
construction and teeth faces are grinded or shaved
in order to operate in good effrciency and silently.
The outer circumference of rotor disc is provided
with blads in two raws, and shroud rings are pro-
vided on the blads to prevent steam leakage.

Fig. I ,1 Fig. I .2

WITH UG8GOVERNOR
TURBtNE SHAFT
BLADE
EXHAUST CASING
ROTOR DISC
~
LABYRINTH PACKING

f= [

C
rl
~- ~
Illl
ll
,
~
~ ~1J

~ ,
/
GOVERNOR VALVE
J
WITH PGDGOVERNOR

c~g SHINKO IND.LTD.

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6.
SPEED REGULATING COVERNOR Fig. I .3
For the speed regulating governor, Woodward governor
is adopted and installed on the top of the reduction gear
casing, driven by a gear at the output shaft end.
The speed regulations are as follows. SPEED GOVERNOR
Momentary :!: 9%

Steady state ~1%

7. EMERGENCY TRIP DEVICE
For the purpose of safe turbine operation, the following
emergency trips are provided. They actuate automatically
the governor valve, which is directly closed by linkage, MAIN
thus turbine is stopped. Lo pUMP
Overspeed trip 1 13-1 1 5% of rated speed
Low L.O. pressure trip 0.5 kg/cm2g or below
High back pressure trip I .5 kg/cm2g r~:hr"~
Local hand trip Manual
Remote stop Electric or pneumatic ~~::
source

In case of driving pump, if the followings are provided .. _. __

their standard set values are as below to stop the turbine. ~~~r~'~., ~~~~~ _._

Pump
Pump casing trip
overpressure overheat
1 10%80 C trip
ofrated dis.opress,
. ,, ' dl iL :
Bulkhead
Pump bearing overheatstuffing
trip 800C (900C box
for cargo ~ f ~" '
oil pump)
8 Oo C
overheat trip

8. LUBRICATION SYSTEM
Forced lubrication system by turbine driven L.O. pump is adopted.
Namely, after L.O. pressure is adjusted at I .0-1.5 kg/cm2 g by adjusting valve, the L.O. is supplied to bearings,
reduction gear, etc. through the L.O. cooler and strainer. And a part of L.O. is sent to solenoid valve, trip servo-
motor and actuates as control oil for various emergency trip devices. For the safe operation of turbine a motor-
driven priming L.O. pump is provided. Unless the pressure in the L.O. Iine reaches 0.2-0.3 kg/cm2g the inter-
lock acts so that the turbine does not start even though the main steam valve is opened.

Fig. I .4

To triP deviCe P.S. FOR LOW LOP.S. FOR PRIM. LO PR ESS.

BEARINGS t
PRESS. TR IP LO PUMP GAUGE
,, ll
OIL JET FOR RE- i jOLn~~:E~:~/D VALVE
DUCTION GEARING ~~
O L JET FOR GO-
VERNOR DAIVING
GEARING
OIL JET FOR MAIN
LO PUMP DR IVING
GEARING
~
LO STRAINER

t
PRESS. CHECK PRIM.
AD J U ST I N G VALVE LO PUMP
VALVE LO PUMP COCHECK
LO COOLER MAIN
L/'L~ ji~iE~~] VALVE
COOLINGWATER J [Ill] CHECK
~ VALVE LO TANK

cg SHINKO INb.LTb.
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 CHAPTER 2CAUTION
FORIN STALLATIONAND PIPlNG
In order to prevent occurence of vibration and noise (b) Use of bellows type expansion joint
and to operate the turbine over long periods with best Bellows joint is used in many cases. On the
efficiency and safety the following points must be exhaust piping, the amount of elongation is
observed at the time of installation and piping. small due to low temperature but outside
force acting on the turbine is very great due
1 . PLACE OF INSTALLATION & FOUNDATION to large bore of piping. Therefore, be sure
(1) Size of the place of installation must be chosen to provide supports where necessary.
in view of the turbine disassembly and inspection. (2) Give consideration also to the movement of the
A space necessary for disassembly is shown in steam inlet and exhaust flanges themselves on
the outside drawing.
the turbine under operation due to thermal
(2) The foundation must be strong enough to absorb expansion of the turbine itself.
vibration of the turbine and to resist deformation
against long use. 3.4 Drain separator, drain traps and drain valves
Special attention should be given not to send
2. FINISHING OF TURBINE MOUNTING SEAT drain to the turbine because most causes of
(1) Chockliners must be welded on the foundation turbine troubles are by the drain.
plate just under foundation bolt holes of the (1) Drain separator with drain trap for saturated
turbine baseplate and their faces must be planed steam
by a surface plate so that the turbine lies on a In order to remove the drain in the inlet steam
perfect plane. be sure to provide a sufficient drain separator
(2) When the foundation bolts are tightened leaving as near as possible to the turbine, with a drain
gaps between the liner faces and the turbine trap.
baseplate, deformation may be given to the (2) Drain trap for superheated steam and saturated
turbine and besides vibration may result. st e am
Provide drain traps at the low point of piping,
3. PIPING expansion joint, upright pipe and the piping
Deformation given to the turbine by outside force end to remove drain in inlet steam.
due to incorrect piping causes not only vibration (3) Drain valves
but also turbine troubles. Therefore the followings Provide a drain valve each above 1 5 mm of
must be considered. bore just before the steam in]et valve and above
(a) Matching piping flanges to turbine flanges. 40 mm of bore just after the steam exhaust valve
(b) Fitting support to bear piping dead weight. respectively to remove drain from the piping
(c) Avoiding effect of thermal expansion ofpipings. before starting the turbine.
(d) Prevention of drain in pipings to turbine.
3.5 Others
3.1 Matching pipe flanges to turbine flanges (1) Branch from main steam pipe
The pipe flanges connecting with the steam inlet Take the branch from the top of the main
and exhaust flanges of the turbine must be co- steam pipe and avoid the drain collection in
rrectly matched. case a bend is provided. In case drain collects
in the piping be sure to provide a drain trap.
3.2 Fitting support and hanger (2) Flushing piping
Provide supports and hangers to bear piping dead
Before connecting the piping to the turbine be
weight so that no bad effect caused by the piping
sure to do flushing so that no foreign matters
dead weight will be given to the turbine.
such as dust, pipe scales, etc. do not enter the
3.3 Effect ofthermal expansion of piping turbine.
(1) Thermal stress occurs when the pipe expands (3) Special attention should be given to that pipe
and contracts due to change of steam tempera- scales, welding beads, etc. may clog the drain
ture and thus outside force is given to the trap especially at the initial operation after
turbine flanges, disturbing the alignment. installation or repair of the turbine or the
In order to absorb the expansion ofpiping and piping.
decrease the outside force actingon the turbine,
the following 2 methods are considered. 4 ALIGNMENT
(a) Use ofelasticity ofpipe Refer to "ALIGNMENT" shown in the instruction
Provide 90'-bends, U-bends and double manual for the driven machine.
U-bends to absorb the thermal expansion of
the steam inlet piping.

C )
g snINKO INO.LTO.
 3 OPERATION
CHAPTER

1 . CHECK BEFORE OPERATION

(1) Confirm if the driven machine is ready for so much steam as to start the turbine.
starting. Unless pulling the starting lever, if fitted, the
(2) Check by opening the drain valve or removing govemor does not function and the governor
the plug if water is in the oil tank, Woodward valve remains closed. Moreover, unless L.O. pre-
governor, the L.O. cooler or the oil strainer. ssure is above 0.3 kg/cm2g by operating the
(3) Check the oil level in the oil tank and the gover- Priming L.O. pump, the L.O. interlock acts and
nor. the governor valve can not be opened.
(4) Check oil in the gear couplingbetween the turbine 2. STARTING
and driven machine by removing the plugs on (1) Open the steam inlet valve gradually and start
the gear coupling. the turbine. Then keep its speed at 100 to 200
Supply of oil to the gear coupling is from the rpm to warm up the turbine for 25 minutes.
plugs. (2) During that time check if there is no abnormal
(5) Start the priming L.O, pump and confirm oil pre- noise or vibration in the turbine and the redu-
ssure reaches above 0.3 kg/cm2 g. ction gear.
In case any abnormal state is felt, stop the
(6) Pass cooling water to the L.O. cooler, turbine immediately and trace the cause.
(cooling water is adjusted by throttling the (3) Close each drain valve on making sure that the
cooling water outlet valve so that temperature
of the L.o. supplied is kept between 20 and drain has been completely discharged from
45'C during operation of the turbine.) each portion.
(7) Confirm all relating equipments, such as con- (4) Trip the turbine by operating the hand trip
denser cooling water pump, condensate pump, knob to confirm that the governor valve closes
etc. are ready for starting the turbine. immediately.
(8) Open fully the drain valves on the drain se- (5) After sufficient warm up, open the steam inlet
parator, the governor valve, the exhaust casing valve further and gradually and raise the speed
and the pipings and also on the pipings before up to the rated revolutions in about 5 minutes.
the steam inlet valve and after the exhaust (6) When the governor is used t~or the first time,
valve. draw out air in the govemor oil by opening
(9) Open the exhaust valve fully. the needle valve on the governor and adjust
(10) Turn the turbine together with the driven ma- the needle valve as described in the manual
chine several revolutions by the turning bar to ofWoodward Governor.
confirm smooth turning. (7) Confirm if the emergency trip mechanism
(11) Set all trips on reset condition by the reset knob actuates surely always at the time of starting.
on the trip casing. Refer to Fig. 3.1. Also at the first operation after inspection or
long standstill, confirm the actuation of over-
(12) Set the governor at the minimum speed by speed trip at the specifiedspeed.
turning the adjusting knob counterclockwise
and fully. (8) When testing the overspeed trip for the turbi[]e,
(13) Supply the sealing steam to the turbine gland the pump must be disconnected and the test must
be to the turbine only in order to avoid dry ru-
as follows ; (In case ofthe exlraust is vacuum). nning of mechanical seal fitted on the pump.
Open the sealing steam valve gradually till the
sealing steam begins to slightly leak from the 3. OPERATION AT VARIOUS SPEEDS
turbine gland where the turbine shaft pases (1) For remote control
through. (The sealing steam pressure as an idea In the control room, operate the speed control
is 0.1 - 0.8 kglcm2 g. ) switch.
(14) Open the steam inlet valve slightly to warm- For speed increase, turn the switch clockwise,
up the turbine. and vice versa.
Pull the starting lever, if fitted, (2) For local control
to open the governor valve to supply a just suffi- For speed increase, turn the manual adjusting
cient steam to the turbine for its warm-up, not knob clockwise, and vice versa.

9 1 SHIN!KOIN!O.LTO.
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 4. STOPPING 5. EMERGENCY STOPPING
(1) Decrease the turbine speed gradually. (1) Local stopping
(2) Close the steam inlet valve. Push the hand trip knob provided on the trip
Also stopping is possible when the remote stop casing on the reduction grear casing so that
or the hand trip on the turbine is actuated. the spindle moves downward and the governor
valve closes through actuation of the trip me-
(3) When speed decreases and oil pressure falls chanism and the turbine stops as shown in Fig.
below 0.45 kg/cm2g the priming L.O. pump 3.1 and 3.2.
starts automatically, keeping oil pressure above
0.3 kg/crn2g. (2) Remote stopping
Push the remote stop switch provided in the
(4) Stop the cooling water to the L.O. cooler. remote control room so that the trip mechanism
(5) When the turbine has stopped, close the exhaust actuates to close the governor valve to stop the
valve and open all drain valves on the turbine to turbine as shown in Fig. 3.1 and 3.2.
discharge drain completely.

(6) Keep the priming L.O. pump is in operation 6. RESETTING OF EMERGENCY TRIP
Before resetting emergency trip, be sure to make
for more than 5 minutes after stopping the
the following conditions.
turbine. After stopping the priming L.O. pump,
(a) The driven machine is at the minimum load,
confrrm that the turbine bearing temperature
e.g. the pump discharge valve is fully closed.
does not rise above 80'C.
(b) The governor speed setting is at the minimum
speed.
(c) The turbine steam inlet valve is fully closed.

Fig. 3,1 Fig. 3.2

RUNNING CONDITiON TRIP CONDITION

WITH UG 8 GOVERNOR SPEED SETTE R WITH UG 8 GOVERNOR
SPEED
O SWITCH REIMOTE STOP
ADJUST. MOTOR
O
o
Gov. LEVER
o
close I '
GOV & EMERG TRIP
STOP VALVE SERVO- LOCAL
MOTOR = CONT.PAN E L
TACHOMETER
o ~] RECEIVER
In et
stea m
~ To nozzle Oo
O~~ Q
~~!: ELECTRIC
SOU RC E

P.S. FOR
LO TR IP
HAND R ESET \'
TRIP KNOBKNOB P S. FOR
PRIM
LO PUMP
Press. oil P.S. FOR
BACK PRESS.
TRIP
o
SOL. VA LVE To LO tank
(DE-ENERGIZED)

~ TRANSMITTER
TACHOMETER
OVER SPEED~
TRIP
TRIP LEVER
~ -~
WITHPGDGOVERNOR WITH PGDGOVERNOR

c J
g SuINKO INO.LTO.
 CHAPTER 4 MAINTENANCE
In order to eliminate turbine troubles, to minimize parts consumption and repair and to
maintain best efficiency over long periods the operator must aim at perfect maintenance
of the turbine.

1 . MAINTENANCE CHECK LIST FOR DURlNG OPERATION

Maintenance and check for the followings can extend a life of the turbine.

Item Inspection procedure Remedy in case of trouble

Inlet steam pressure and temperature before governor valve
Kcep constant as much as possible and record periodically.

Chcck everyday. 2 Keep between I and 1.5 kg/cm g and rccord periodically. Refer tO"TROUBLE SHOOTlNG & REMEDIES ".

L.O. pressure

Chcck everyday. Keep between 20 and 45~C and record periodically.

L.O. temperature at L.O. cooler outlet

Discharge drain periodically by opening drain valve on drain separator and piping.
Drain in steam into turbine Check everyday.

Refer to "TROUBLE SHOOTlNG & REMEDIES ".

Vibration and noise Check everyday.

Turn its handle several times once a week to clean filter plate.

Oil strainer

Air in L.O. cooler and strainer

Draw out by vent valve or plug.

Check everyday by oil level gauge tbr oil tank and by sight glass for governor, and oil leakage from gear coupling.
Supply oil. Refer to "LUBRICANTS".
Oil level in oil tank, governor and gear coupling

In case of high vacuum (more than 600mmHg) , reduce the cooling water (S.W.) flow or driving steam pressure of ejector to keep the exilaust vacuum between design pressure and 600mlnH~,

Check everyday and record periodically. (Exhaust pressure never exceeds 600mmHg-V)

Keep its switch in automatic operation always.

Priming L.O. pump

When testing the overspeed trip for the turbine, the pump must be disconnected and the test must be to the turbine only in order to avoid dry ru- ' nning of mechanical seal fitted on the pump.
Conrrrm at every initial starting of turbine if they work surely and smoothly.

All trip devices

Steam leakage from turbine gland Refer to "TROUBLE SHOOTlNG & REMEDIES ".

Check everyday.

Refer to "TROUBLE SHOOTlNG & REMEDIES ".

Bearing temperature Check everyday and record periodically.

Corrosion protective piece on L.O. cooler Corrosion protective piece (if fitted, the piece is shown in the spare list as its spare) is to be checked every 3 months and replaced if any.

g I SHINKOINlb.LTO.
C )
 2. ADJUSTMENT FOR ACCESSORIES & 2.4 Electric tachometer
EMERGENCY TRIP Turn the adjusting screw inside the adjusting
As all parts of the turbine have been adjusted at nut at the back of the tachometer to adjust
the shop trial, it is important to avoid unnecessary the reading.
readjustment. Clockwise turn of the adjusting screw increases
However, if readjustment is required proceed as the reading and vice versa.
follows ; The tachometer pointer must be at zero point
2.1 Speed governor (Woodward governor) when the turbine is at a standstill. Otherwise,
Refer to the separate instruction manual of adjust by means of the zero point adjusting
Woodward governor. screw in the center of the tachometer front.
However, the adjustment of the interior is 2.5 Mechanical overspeed trip
very complicated and, therefore, must be done
( I ) Remove the trip casing on the reduction gear
by expert.
casing and remove from this opening the split
Never open the sealed governor part for the pin for locking the trip ring and trip spindle
adjustment. of the overspeed trip.
2.2 L.O. pressure adjusting valve (Refer to Fig. 4.1) Then draw out the trip spindle and spring from
Remove the plug and turn the adjusting screw the trip ring by screw driver.
to adjust lubricating oil pressure between 1.0 The adjusting liner is provided at the back of
and 1.5 kg/cm2 g. the spring in order to change as desired its
Clockwise turne of the adjusting screw increases compressive load. By changing the thickness
L.O, pressure and vice versa. of this liner the overspeed trip actuating revo-
Fig. 4.1 lutions can be changed. Every increase of
0.5 mm in thickness of this liner means about
65rpm rise in revolutions of the overspeed
P LU G trip and vice versa. Refer to Fig. 4.3.

AD JU ST I NG (2) When testing the overspeed trip for the turbine,

SC R EW the pump must be disconnected and the test n:lust
i

~ SPR ING be to the turbine only in order to avoid drv ru-

nning of mechanical seal fitted on the pump.
ADJUSTING
VALVE BODY
Fig. 4.3
ADJUSTING
VALVE

2.3 Sentinel valve (Refer to Fig. 4.2) TRIP CASI NG

Remove the cap and turn the adjusting screw
to adjust the valve actuating pressure specified i
l

in the drawing. Clockwise turn of the adjusting

R EDUCTION
screw increases the valve actuating pressure GEAR CASING
and vice versa.

Fig. 4.2

ADJUSTING
SC R EW

LOCK NUT
SPR I NG
OVERSPEED
I:
j':

VALVE BODY TRIP

ADJUSTING
RING
OVERSPEED TRIP
CLOSE-UP
VALVE SEAT
TRIP SPINDLE
TRIP WEIGHT

ADJUSTING LINER
SPR I NG

C J
g snINKO INO.LTO.
2.6 Electric overspeed trip
( I ) Adjust so that the actuating revolutions becomes 1 12 - 1 1 3% of the rated revolutions by tuming the
adjusting screw at the head of the overspeed trip relay contained in the relay box.
Clockwise turn of the adjusting screw increases the revolutions and vice versa.
The adjusting range is between -5 and +1% of the preset revolutions.
(2) when testing the overspeed trip for the turbine, the pump must be disconnected and the test must be to
the tuFbine only in oFder to avoid dry running of mechanical seal fitted on the pump,

2.7 Pressure switCh (Refer tO Fig. 4.4 and 4.5)

Remove the plug and turn the adjusting screw clockwlse to decrease the actuating pressure and vice versa.
For differential pressure adjustment, clockwise turn of the differential pressure adjusting screw widens
pressure difference and vice versa.
Fig. 4.4 Fig. 4.5

DIFFERENTIAL
ADJUSTING P LU G P R ESSU R E P LU G ADJUSTING
SCR EW ADJUSTING SCREW
SC R EW

L ~ ~~~_ _

2.8 Thermo-switch for overheat trip(If fitted)

An adjusting stem each for the contractor and the temperature reading is provided at the center of the
front face and on the side respectively.

3. MAINTENANCE CHECK LIST FOR REGUIAR INSPECTION

It is recommendable to perform the regular inspection to avoid accidental troubles.

3.1 Inspection every 3 months

Item Procedure and inspection Item Procedure and inspection

Emergency trip device Confirrn wear and damage on

Labyrinth labyrinth packing and steam guard.
packing and Suitable clearance between shaft
steam guard and labyrinth packing is shown in
standard clearance table.
Clean cooler interior and cooling tubes.

L.O. cooler

Confirm wear and damage on

bearing. Suitable clearance is shown
3.2 Inspection every year in clearance table.
No adjustment is required for radial
bearing when fitting as they are
Procedure and inspection Bearing metai
Item
machined• fine.
Thrust bearing clearance is adjusted
Check blades and nozzles for erosion, with adjusting liner and its relating
corrosion, damage and sticking scale. position is subject to clearance
Turbine blade
(Scale on blades causes vibration, between moving blades and nozzles.
and nozzle
abnormal steam thrust and insu-
fficient output) Confirm wear and rust on teeth
faces. Ifthere is any indication of
Check valve and valve seat for Reduction gear
Governor valve, rust immediately find cause and
its seat and
erosion, corrosion and wear. take proper measure.
Check valve stem and guide bush for
parts
wear. Check clearance between casing
Main L.O. pump and pumping gear and also axial
Dynamic balance Dynamic balance to be carried clearance.
for turbine rotor if rotor is damaged or repaired.

cg snINKO INIO.LTO.
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 4 LUBRICANTS 4.2 Lubricants
4.1 Replacement of lubricating oil ISO VG 68 (International Standard Organi-
The replacement interval of the lubricating oil zation) for lubricating oil for the bearing,
is based on deterioration or contamination of the reduction gear and the Woodward gover-
L.O. being used. nor and ISO VG 460-VG680 for Gear
However Table 4.1 shows recommendable Oi] for the gear coupling are recommendable.
interval of the replacement. The brand names of the oils equivalent to
the recommendable one are shown in Table
4.2.
Table 4.1

Replacement
Location
After initial Norm al
start operation
L.O. tank Within 3 months Every I year

Woodward If ,l
governor

Gear coupling ll Every 6 months

Table 4.2

Name of company Lubricating oil Gear oil

BP BP ENERGOL THB68,77 BP ENERGOL GR-XP680,GR-EP680
CASTROL PERFECTO T68 CASTROL ALPHA SP680
COSMO OIL COSMO TURBINE SUPER68 COSMO GEAR SE680
EXXON TERESS068 SPARTAN EP680
IDEMITSU KOSAN DAPHNE TURBlNE OIL68 SUPER GEAR OIL680
KYODO OIL RIX TURBINE OIL 68 KYOSEKI ES GEAR G680,M680
HITSUBISHI OIL TURBINE OIL68, DIAMOND MARINE68 DIAMOND GEAR LUBE SP680
MOB I L MOBIL DTE OIL HEAVY MOBIL DTE OIL HEAVY MEDlUM MOBIL GEAR636

NIPPON OIL CALTEX OIL FBK68 REGAL OIL R & O 68 BONNOCK SP680 MEROPA LUBRICANT 680

SHELL OIL TURBO OIL T68 SHELL OMARA OIL680

SHOWA SHELL OILTURBO OIL T68,J-H OIL68 OMARA OIL680
TEXACO OIL REGAL OIL R & O 68 TEXACO MEROPA 680

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g SHINKO INO.LTO.
 CLEARANCE AND
CHAPTER 5STANDARD LIMIT OF USE
Fig. 5.1

17

1C_6

15 13 ,. 14 L-A 11

B
13

13 o (~)

l* F~ l l I

~,,

D ETAI L-A

(~)

{ t

DETA IL-B
L-B

Table 5.l Unit

ru : mm
NO. l 2 3 4 5 6 7 8 9

RXO o. 15-0.2
Standard 0.15-
clearance RX1 0.2
0.3-0.35 0.2-0.3 0.45-0.55 0.25-0.35 0.25-0.30
0.2~-
RX2-2
0.25
0.3-0.35 0.15-0.2

RXO 0.23
Limit of
RX1 0.23 0.38 0.4 0.65 0.45 0.4
use
RXZ-2 0.28 0.38 0.23 t

NO. lO ll 12 13 14 15 16 17 Backlash

Standard 0.28-0.63
0.25-0.30 0.20-0.50 0.20-0.25 2.2~2.8 (0.22-0.5D
clearance
Limit of
0.4 0.65 0.35 1.5-3.5
use
The figures shown in Table 5.1 are for RX O , RX I . RX 2-2 ."Backlash" for RX O.
And the figure in ( ) shows Backlash of Model RX O only.

SHlnKO InD.LTD.
C )
 ANDASSEMBLING
CHAPTER 6 DISASSEMBLING

1 . DISASSEMBLING l .2 Disassembling ofexhaust casing

1.1 General caution (1) Remove the lagging on the casing.
(1) Proceed with the work in good order by re- ('_) Remove the piece provided on the exhaust
ferring to the assembly drawing and thoroughly piping for disassembling.
understanding the construction.
(3) Remove the tightening bolts and taper bolts
(2) When removina* the fixing or fitting faces use on the casing fiange.
lifting bolts provided on them.
(4) Separate the casing from the steam chest by
(3) When removing the rotating element, be careful lifting bolts on the casing flange.
to avoid damage on,the sliding faces, the journals
and machiried faces. (5) Remove the casing vertically and axially from
the steam chest.
(4) When removing the rotating parts from the This removal of the casing should be done
shaft, remove them carefully after removing carefully otherwise the casing may hit and
the rotation preventing device. damage the rotor.
(5) In order to avoid mistake in assembling, mark
suitable match marks as much as possible when
disassembling.

Fig. 6.1

MOVING BLADE
ADE ADE
~ EXHAUST CASING
_-- EXH Ncz / MAII Top

STATIONARY BLADE NCZZLE

r : :~=E,~ t MAIN LO PUMP

c TOP COVER
STEAM CHEST
EST ING AFT EAR VER

GEAR
G E,~ WHEE L
LABYRINTH PACKING
r~
TURBINE SHAFT
REDUCTION GEAR
CASING

.J

BOTTOM COVER OUT

OUTPUT SHAFT

c~ SHINKO IND.LTD.
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1.3 Disassembling of steam chest 1 .6 Opening of governor valve (Refer to Fig. 6.2)
(1) Disassembling of the steam chest should be (1) Remove the linkage betWeen the governor
carried out after disassembling of the exhaust valve and the governor.
casing mentioned before. (2) Put the "Governor valve spring holding tool"
(2) Remove the bolts and taper bolts tightening to the threaded holes on both sides of the
the front and rear halves of the steam chest. valve stem passing through the governor valve
(3) Separate the front half of the chest from the casing cover and screw down its nut so that the
spring coils touches closely.
rear half by lifting bolts on its vertical flange.

(4) Remove the front half of the steam chest. (3) Remove the bearing holder at the rod end of
This removing of the steam chest should be the valve stem frorn the valve stem after re-
done carefully otherwise the rotating element, moving the split pin on the side and securing
the moving and the stationary blades may be the valve stem.
damaged. (4 ) Remove the tightening bolts and taper bolts
from the governor valve casing flange.
1 .4 Disassembling of reduction gear casing cover
(5) Remove the cover vertically without bending
(1) Remove the thermometers on the reduction
or injuring the valve stem.
gear casing.
(6) Screw 2 jack bolts of the governor valve seat
(2) Remove the reduction gear casing top cover
pulling tool to the valve seat.
and the front half of the bottom cover.
Fix the holding plate to the casing by the
(3) Remove the piping, wiring, etc. disturbing jack bolts.
the disassembling. Refer to Fig. 6.3.
(4) Remove a bolt joinning the front half of the (7) Tighten the nuts of the jack bolts as to pull
L.O, pump casing flange and reduction gear out the valve seat from the casing.
casing cover.
(8) After removing the valve guide of the gover-
(5) Separate the reduction gear casing cover from nor valve take out the governor valve toward
its casing by using the lifting bolts on the the valve stem. (If the governor valve is an
flange.
assembled one, remove the stop ring on the
(6) Pull the cover horinzontally. valve after removing the strainer and disassem-
ble the valve before taking it out.)
1.5 Opening of turbine rotor and reduction gear
(1) Disassemble the exhaust casing, the steam
chest and the reduction gear casing cover in
accordance with I .2, I .3 and 1.4 ofthis chapter.

(2) Using eyebolt into the hole on the turbine

shaft end, put wire rope from the crane.

(3) Just lift up the turbine rotor a little gently

and draw it forward while taking care so as
to avoid contact between the moving blads
and nozzles, and labyrinth packing.

(4) Using eyebolt into the hole on the output

shaft end, put wire rope from the crane.
(5) Just lift up the gear wheel a little gently and
draw it forward while taking care so as to
avoid damage.

Gg snINKO INlb.LTo.
c )
 Fig. 6.2 Fig. 6.3

WITH UG8 GOVERNOR BEARING COV E R HOLDER

e
VALVE
STEM

VALVE
STEM
i~ VALVE
JACK BOL
BOLT

!!i,l i,ij,1,
GUIDE
J HOLDING
~•Til, PLATE
VALVE
1

VALVE
SEAT
GOVERNOR VALVE
CASING PAC Kl NG
AC Kl NG

WITH PGD GOVERNOR STRAINER

RAINER

~~
~:i-
i

r~

~
i:1 !il! I

J
-~
'J~' ~
1
~
L*

2 ASSEMBLING
Assembling can be carried out by reversing order (8) Clean thoroughly various bolts and nuts on the
of disassembling and attention must be paid to the Steam side and apply seizure preventive (e.g.

follovving: Graphite) on them.

(1) Clean each part thoroughly with kerosene to (9) Before assembling apply seizure preventive (e.g.
remove dust and foreign matter and correct if Graphite) on the sliding portion of the governor
injury is found. valve and on the valve and on the valve stem.
(2) Turn nuts for rotating parts securely and fix (10) Assemble the positioning liners. split pins, set
anti-rotation device without fail. screws, spring washers, etc. of each part in the
(3) Assemble fitting parts according to match same state as before. Never t~orget caulking
where necessary.
marks ifany. (1 1) Check the clearance of each part in accordance
(4) Before assembling apply sufficient lubricating with the clearance table.
oil to the bearing portion and gear teeth. (12) Check the backlash of gear teeth.
(5) Be careful to avoid one-sided tightening of
bolts. (13) Confirm that the position ofthe oil spray for the
(6) Before assembling confirm that no dust and reduction gear, the L.O. pump driving gear
and the speed governor driving gear.
foreign matter exist inside the turbine casing, (14) Confirm alignment (Refer to "r:\;'STALLATION
governor valve casing, reduction gear casing
and oil tank. AND PIPPING).
(7) Clean all the joint faces and fitting faces and (15) Confirm the smooth turning ofthe rotor.
apply heat resisting liquid packing (e.g. Hermetic) (16) When testing the overspeed trip for the turbine,
on the steam side and oil-proof liquid packing the pump must be disconnected and the test must
(e.g. Three Bond) on the oil side. be to the turbine only in order to avoid dry ru-
nning of mechanical seal fitted on the pump.

Cg SHINKOIN!O LTO
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 CHAPTER 7TROUBLE
SHOOTlNG AND
REMEDIES

Turbines can perform satisfactory function if properly handled and maintened.

Should trouble occurs speedy remedies must be found for it. Table 7.1 shows commonest
causes of trouble and suggested remedies.

Table 7.1

Troubles Causes Remed ies

l. Incorrect assembly. 1. Check axial parallelism between shaft

and bearing and correct.
Check taper land of oil groove of
thrust bearing and correct or replace.

2. Abnormal misaJignment between 2. Correct it within permissible value.

turbine and driven machine. (Refer to "INSTALLATION AND
PIPING" and "ALIGNMENT".
3. Air, water or foreign matter mixed in 3. Refer to "Insufficient L.O. sup p ly
oil. and pressure ,, mentioned later in this
Table 7.1.

Overheating of bearing 4. Incorrect selection of oil in oil tank. 4. Replace oil with correct one.
(Refer to "LUBRICANTS")

5. Shortage of oil in oil tank and of 5. Refer to "Insufficient L.O. supply and
oil supply and of oil pressure by main pressure mentioned later in this
,,

L.O. pump. Table 7. l.

6. Vibratio n. 6. Refer to "Vibration ,,

mentioned later
in this Table 7.1.

7. Deterioration or pollution of L.O. 7. Replace oil.

8. High temperature of L.O. supplied by 8. Refer to "High temperature of L.O.

main L.O. pump. supplied by main L.O. pump ,,

mentioned later in this Table 7. 1.

1. Shortage of oil in oil tank. 1. Add oil.

2. Abnormai condition of main L.O. 2. Check clearance between shaft and

pump. bearing of main L.O. pump and correct
it by replacing bearing if necessary.
Check axial thrust clearance between
pumping gear and bearing of main L.O.
pump and replace bearing if necessary.
Insufficient L.O. supply
and pressure 3. Abnormal oil escape from L.O. 3. Increase oil pressure by adjusting valve.
pressure adjusting valve. (Refer to "ADJUSTMENT FOR
ACCESSORIES AND EMERGENCY
TRIP")

4. Air mixed in oil. 4. Draw air from oil strainer and L.O.
cooler by plug or vent valve.
Repair part from where air invades
into oil.

gl St,!lNKO INO.LTO.
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 Troubles Causes Remedies

5. Water mixed in oil. 5. Draw water from oil tank, oil strainer
and L.O. cooler by plug or drain valve.
Check and repair cooling tube of L.O.
cooler if necessary.
Insufficient L.O. sup ply
Check steam leakage from turbine
and pressure gland into reduction gear casing and
replace labyrinth packing if necessary.

6. Foreign matter in oil. 6. Clean oil strainer by turning handle on

oil strainer.

1. Foulling ofcooling tube of L.O. 1. Clean cooling tube of L.O. cooler.

cooler.

2. Insufficient cooling water flow 2. Increase cooling water by openin*

to L.O. cooler. cooling water inlet and outlet vaives
for L.O. cooler and keep L.O.
o
High temperature of L.O. temperature between 20 and 45 C
supplied by main L.O. pump suitable for correct bearing temperature.

3. Abnormal operation of L.O. 3. Repair to work correctly.

temperature control valve, if fitted.

4. High temperature of coolmg water 4. Decrease cooling water temperature.

to L.O. cooler.

1. Excess ofsealmg steam supply 1. Adjust sealing steam adjusting valve

(In case of exhaust steam is provided on this line.
vacuum)

2. Excess of clearance between shaft 2. Replace with new packing.

Steam leakage from turbine and labyrinth packing.
gland

1. Damage of bearing. 1. Check bearing and replace if necessary.

2. Abnorrnalmisalignment between 2. Correct it within permissible value.

turbine and generator. (Refer to "INSTALLATION AND
PIPlNG" and "ALIGNMENT")

3. Excess of bearing clearance. 3. Replace bearing.

4. Unbalance ofshaft due to damage 4. Check and correct or replace with

Vibration of blades or shrouds or bending great consideration and dinamically
of shaft. rebalance.

5. Abnormal contact between shaft 5. Correct or replace labyrinth packing.

and labyrinth packing.

6. Thermal deformation of shaft or 6. Check and correct.

casing due to insufficient warming Warm-up sufficiently and turn turbine
up or turning or excessive outside manually and sufficiently.
force, Iike incorrect piping.

C J
g SHINKO INO.LTD.
 Troubles Causes Remedies

7. Accumlated drain in exhaust casing 7. Discharge drain by drain valve or plug.

and drain in inlet steam. Clean drain separator and drain trap.

Vibration 8. Abnormal teeth contact of reduction 8. Check and correct.

gear and driving gear of main L.O.
pump and speed governor.

l. Abnormal contact or damage of teeth l. Check and correct parallel between

of pinion and gear wheel, driving gear pinion and gear wheel, and driving
of main L.O. pump and governor. gears.
Correct teeth by shaving or grinding
Noise machine, etc.

2. Insufficient oil spray to teeth of 2. Clean oil spray to teeth.

pinion, gear wheel or driving gear
of main L.O. pump and governor.

1. Sticking in movement of governor 1. Check and correct to move smoothly

valve, valve stem and valve guide. or replace.

2. Wear or sticking ofjoints and 2. Correct to move smoothly or replace.

pins of linkage.

Hunting in operation and

3. Incorrectselection of oil in 3. Replace with correct oil.
difficulty of speed control
caused by turbine itself govemor. (Refer to "LUBRICANTS")

4. Deterioration or pollution of L.O. 4. Replace oil.

in governor.

5. Incorrect operation ofgovernor. 5. Refer to manual of Woodward

governor.

g SuINKO INO.LTO.
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 CHAPTER 8 REPLACEMENT PARTS

This chapter introduces replacement parts information for the turbine RX.
When ordering replacement parts, include the following information:

1 . Ship's name

2. Shipbuilder and hull number

3. Service and model of the turbine

4. Parts' numbers and names shown in the parts lists

1 440 ~ 1 oo 1

1414 \ l( 7008-1 4. 7065-7

1 461 ,
1 402

1521 ~
/ 7008-1 . 7065-1

7008-2 7065-1 ~ 7008-3

1 089, 1 093
231 7
1 087 ~-~~~ t~r, ~
231 5
1 460, 1 520 ll
1 050 L // 1712
//~2115
1 002 /
1 003 l~ _~/ 7128
2 1 08
1012
2101
1 020
1015 " ~.,
2 1 07

2119
2 1 24
7 1 29
2113 =~~ 21 1 6
7 1 26
2 1 20
1401 21 25
1 430
// 7053-27
2117
2114
L~:
7 1 27

2118
1 432
~
1433 /

C J
g SuINKO INO.LTO.
PART NO. NAME OF PART REQ. PART NO. NAME OF PART REQ.

1 Ool EXHAUST CASI NG 1 set 2113 BEARING METAL 1 set

1 002 STEAM CHEST 1 set 2114 BEARING METAL 1 set

1 003 PACKI NG CASE 1 set 21 1 5

BEARING METAL 1 set

1 ol 2 LABYR INTH PACKI NG 2 sets 2116 BEARING METAL 1 set

1 O1 5
STEAM GUARD 1 set 2117 TH RUST METAL 1 set

1 020 SPRING 8 2118 TH R UST M ETAL 1 set

1 050 NOZZLE 1 or 2 2119 THRUST METAL 1 set

1 087 STATIONARY B, SEAT 1 or 2 2120 TH RUST M ETAL 1 set

1 089 STATIONARY BLADE 1 set or 2 sets 2124 OIL GUARD 1 set

1 093 SHROUD 1 set or 2 sets 2125 OIL GUARD 1 set

1 40 1
TURBINE SHAFT 1
231 5 TACHOMETER ROTOR 1 set

1 402 ROTOR DISC 1 231 7 TACHOMETE R TRANS. 1 set

1 41 4 KEY 1
7008-1 CAP SCREW
1 430 TH R UST CO LLAR 1
7008-2 CAP SCREW
1 432 BALANCE WEIGHT 1 7008-3 CAP SCREW
1 433 TRIP SHAFT 1 7 008- 1 4 CAP SCREW
1 440 NUT 1
7053-27 KEY 1

1 460 Ist MOVING BLADE 1 set 7065-1 SPRING WASH ER

1 461 2nd MOVING BLADE 1 set 7065-7 SPRING WASHER
1 520 SHROUD 1 set 7 1 26 TH E RM OM ETE R 1

1 521 SHROUD 1 set 7127 TH E RM OM ETE R 1

1712 DRIVING GEAR 1 7 1 28

THERMOMETER 1

2101 REDC. GEAR CASING 1 set 7 1 29 THERMOMETER 1

2107 WHEEL 1

2 1 08 WHEEL SHAFT 1

g SulNIKO INlb.L7b.
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 COVERNOR VALVE

1 340 -
7061-29, 7051 -16 --••-•-~__
'~\\'
1 337
1317
1 341 =-- \
\ \\\\ 1 730 1 753 706 1 -32,
1 304
6101. 7055-22 \
\.

1302 \_
\\ \\ \ \\ \+
7051-10

1 752
1 305 __
1 306 7074-1 O
1 330 --- 1 331
1301 -__ 1 333
1 335
__~~ 1 322
~~/~~~~ ___/ 7074-1 2 ~ _~_/-

=.~ - 1203 =1 7074-2 /

/
\•;
\\-.

/
/
/ ~'l
7008-24 /

PART NO. NAME OF PART * R E O. PART NO. NAME OF PART R EO.

1 203 STE AMSTRAINER 1 1 7 30

GOVERNOR
LEVER 1

1 301 GOVERNOR V. CASING 1

1752 HOLDER 1

1 302 GOVERNOR V. COVER 1 1 753 BUSH 2

lrl•,,,,~~ SPRING ~ - ,~-1 1
1 304 6101 STUD
1 305 BUSH 7008-24 CAP SCREW
1 306 STEM 1 7051 -1 O SNAPRtNG 2

1317 SPR t NG HOLDER 1 705 1 -1 6 SNAPRING 2

1 322 GOVERNOR
VALVE 1
7055-22 NUT
1 330 P LU G 1 7 06 1 -29 PIN 1

1 331 GOVERNOR
V. LtNER 1 IL 1 706 1 -32 PIN 1

1 332 GUtDE 7074-2 GASKET PACKI NG 1

1 333 GUIDE 1 7074- I O GASKET PACKtNG 1

1 334 BUSH 1 7074-1 1 GAS CET PACK,NC 1

1 335 BUSH 1 7074-1 2 GASKET PACKING 1

1 337 8USH 1

1 340 BALL BEARING 1

1341 LINER 1

c J
g SuINKO INO.LTO.
 TR,P SERVO -MOTOR PART NO. NAME OF PART RE(L
FOR UG 8 GOVERNOR 1 721 LINK 1

1 724 CONNECTiNG BAR 1

1721
C 1 830 ASSEM B LY 1 set
7061-33, 7051 -6 1 830 CYLINDER 1

1831 COV E R 1

>
J 1832 BUSH 1

m
~;
4750-2 1 835 PISTON 1
LU
(1)
1 841
1 7 24 co 1 836 SPINDLE 1

7061 -41 , 7051 -9

4750-1
a: 1 837 ROD END 1
o
1 837 H 1 84 1
NEEDLE BEARING 1
o
~:
1 836 1 842 SPR I NG 1
o
> 1 843 SPR I NG 1
3870-5 a:
UJ
co
1 832 rL
3870-5 OIL SEAL 2
a: 7051 -9
1 83 1 H SNAP RING 2

7072-1 8
7057-7 U-NUT 1

706 1 -4 1 PIN 1
1 830
n' li,i[,
7072- 1 8 SEAT PACKI NG 1
1 835
li 4750-1 BALL JOINT (L-TYPE) 1

7057-7
l i,
47 50- 2 BALL JOtNT ( L-TYPE) 1

li 1 843
705 1 -6 SNAP RING 2
1 842
7061 -33 PIN 1

1 755 ROD END 1

FOR PGD GOVERNOR 1 758 BALL BEARING 1

C 1 830 ASSEMBLY 1 set

1 830 CYLINDER 1

1 831 COV E R 1

1 837~. >
Joo 1 832 BUSH 1
1 84 1 ,..

7061 -41 , 7051 -9 :l ~~

UJ
co
1 835 P I STON 1

1 836 \. co 1 836 SPINDLE 1

3870 5 \ a:
1 832 lll I~
1 755
o
1 837 ROD END 1

1 83 1 l _JL\~::JJJl' ' 7072-1 8

7061 -33,705 1 -1 7 H
1 758 o 1841 NEEDLE BEARING 1

:~

I ~~,rH o 1 842 SPRING 1

1 830 T[
>
1 835
I 1,Il l ll
a:
UJ
1 843 SPRING 1

co
7057-7 CL 3870-5 OIL SEAL 2
1 843' :c
1 842
.l
h
7051 *9 SNAP RING 2
7057-7 U-NUT 1

7 061 -41 PIN 1

7 072-1 8 SEAT PACKtNG 1

7051-17 SNAP RING 2

7 06 1 -33 PIN 1

g SlllINKO INb.LTO.
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 PART NO. NAME OF PART R EO.
MAINL.O. PUMP
1 703 DRIVING SHAFT 1

1 705 SPACER 1

1 709 BALL BEARING 1

1710 BALL BEARING 1

~1~~ L'I~~~~Gd~ E RNOR COY~LING_ 1

8001 1 7 1:~ ;;~ijN~~n~bLLI~GGEAR 1

2054 C2051 ASSEMBLY 1 set

7057-9 2051 CASING~ ~~~~~ 1

3870-7 2053 DRIVING SHAFT 1

2064 _ __ __2._054 FO L LOW_ I N G SHA FT 1

2061 2055 DRIVING GEAR 1

set
7057-8
> 2057 FOLLOWING GEAR 1
set
2063 J
co 2051}~91 BEA R I NG
1711
2051 ~ - BEARING METAL 1 set

2059
3530- 1
3540-1
UJ
co
cl'
206,~__
2060
2055 2062 BEARING METAL 1 set
1 709 CL
7053-21 ~
1 703 D 2063 BUSH 1

2057
1 705 2064 BUSH 1

2060 d
1710 J 3870-7 OIL SEAL 1

7053-22
2129 z- 3870- I o Ol L SEAL 1
3870- I o -+
2062
7053- 1 8
~
7 05 3-2 1
KEY 1

2053
1713 7053-22 KEY 1

2 1 30
l. ~ 7053-23 KEY 1

7053-23
7057-8 U-NUT 1

7057- 1 2 7057-9 U-NUT 1

7057-1 2 U-NUT 1

21 29 DRIVING GEAR 1

2130 FOLLOWING GEAR 1

3530-1 BEARING NUT 1

3 540- 1 BEARING WASHER 1

7053- 1 8 KEY 1

800 1 SPEED GOVERNOR 1

c J
g SuINKO INO.LTO.
 PART NO. NAME OF PART R EO.
TRIP DEVICE
1 434 O.S.T. WEIGHT 1 set
1 436 SPR I NG 1

1 450 ADJUSTING LINER 1

1 605 TRIP LEVER 1

1 608 SPR I NG 1
1911 1 91 o
1 922 C 1901 ASS EM B LY 1 set

1921 ---
3870-6 1 901 CAS I N G 1

1914 1 902 COV E R 1

1 907 ~ 1 902
1 91 2 1 903 COV E R 1
1 903
1 905 1 905 BUSH 1

4020-2
1913
/ 1 90 1

>
1 906
1 907
BUSH
BUSH
1

1920 ~ JtD
7057-15 - ~
1 908 SPINDLE 1

3870-8
UJ
co
1 909 SPINDLE 1

co
1 906 1910 GRIP 1

UJ
1911 GRIP 1
o
1 908 >
UJ
1912 SPRING 1

1 923 1913 SPR I NG 1

D
'L
1 605
tC
1914 SPRING 1

1 909 1 608
h 1 920 LINER 1
7061 -30, 7051 -1
1 450 ll
1921 LEVER 1

1 436 ll
i 1922 FULCRUM BOLT 1

1434 \\ ~\
l~
'!'f

3870-6 OI L SEAL 1

\ \
3870-8
4020-2
OtL SEAL
B E L LOWS
1

7057-1 5 U-NUT 1

1923 BRACKET 1

7051-1 SNAP RING 2

7061 -30 PIN 1

cg SulNIKO INIO.LTb.
C )
 L . O.
COOLER PART NO. NAME OF PART R EO.

7 30 1 ASSEM B LY 1
set
7301-6 l; 730 1 -5 / / 7301-9B ~~ 7301 -3

730 1 -2 INLET HEAD 1

730 1 -3
RETURN
HEAD 1

730 1 -4 TUBE SHEET 1

730 1 -5 TUBE SHEET 1

7301 -6 COOLtNG TUBE

7301-9A GASKET 1

7301 -9B GASKET 1

7301 - 1 1 STU D &NUT

7301 -1 2 BOLT &NUT
7801 ASSEMBLY 1
set
L.O. P R ESS. ADJUSTINC V.
7801 -1 CASING 1

780 1 -2
VALVE 1

780 1 -3 ADJUSTIN G SCR EW 1

7801 -4 SPRING 1

7801 -5 P LU G 1

780 1 -6
GASKET 1

L.O. +\ \
781 1 ASSEM8LY 1 se t

781 1-3 FILTER 1

set
781 1 -8
\ 781 1 -6 SPINDLE 1

781 1 -7
HANDLE 1

781 1 -8 PACKING 1 set

781 1 -9 AIR PLUG 1

781 1-1 O DRAINPLUG 1

ll

PRIM. L.O. PUMP ( I f fitted ) _~_ 8301 _~~ 830 1 -~ 8301 ~_~= 8301 830 1 8301 83 o 1
8301 ASSEMBLY 1 se t

8301 -5 8301 -6
ROTOR 1
set

8ALL BEARING BALL BEARING 11

8301 -7
830 1 -9
8301 - 1 6 --8301 - 1 5

FAN 1

8301 - 1 1 IMPELLER FAN COVER 1

8301 - 1 3 1

8301 - 1 5
CRIMP TERMtNAL 3
8301 - 1 6 TERMINAL BOX OIL SEAL 1

8301 - 1 8 1

cg SHINKO INO.LTO.
C J
 PRIM. L.O, PUMP (If fitted)
PART NO. NAME OF PART R EQ.

8302 ASSEMBLY 1 set

8302-1 CAS I N G 1

8302-2 CASING COVER 1

8302-3 DRIVING SHAFT 1

8302-4 FOLLOWtNG SHAFT 1

8302-5
PUMPING GEAR 1 set
8302'-6

8302-7
PUMPING GEAR 1 set
8302-8
8302-9
8302- I O
BEARING METAL 1 set

>
J
ao
8302-1 1
:~
8302-1 2
BEARING METAL 1 set
UJ
8302-20 -___ co
co
..,\.- BUSH
8302- 1 3 1

8302-1 oL
:~ 8302- 1 4 BUSH 1
3 1 80-2 l, 7 053-32
:)

3 1 90*2 8302-21 o* 8302- 1 5 SPACER 1

d
8302-1 9 8302-1 8 J 8302-1 6 ADJUSTING LINER 1

7 008-62 // /~~/'/ 3530-3 l/'/ I l 8302-1 7

8302-1 5 ~ 8302-1 7 BALL BEARING 1

oc
8302-3 tL 8302- 1 8 BEARING COVER 1

8302- 1 9 COUPLING
l
1

8302-9 17053-33
8302-4 8302-20 COUPLING 1

8302-1 O
8302*21 OI L SEAL 1
8302-7 8302-5
7053-34
3 1 80-2 COUPLING BOLT & NUT 4 sets
8302-6
/ 3 1 90-2 COUPLING
RING 4
8302-8
8302-1 2,// ~ ll 8302-1 1
8302- 1 3 3530-3 NUT
BEARING 1

8302-1 4 \8302-1 6 7008-62 BO LT 2

7057-1 7 7057-1 6 7053-32 KEY 1

8302-2 7053-33 KEY 1

7053-34 KEY 1

7057-1 6 U-NUT 1

1
7057-1 7 U-NUT
KEY ON MOTOR SHAFT 1

MOTOR 1 set

ROTOR AXIAL MOV . DETECT. (If fitted)

HEAD ASSEMBLY c 1 980 ASSEMBLY 1 set

> 1 980 CASING 1

J
:o
1 984 E LEM E NT 1 set
BALANCE WEIGHT :~
~UJcl)

Ocod :~~
1 998 BRACKET 1

1 984
l

l I ~ I•lli~L
\
Jo
~
1 980
f~ ~ XI
I

Hh OUJ

J - -- I ~~ l ~J - J-~

QCo

,
l

-TJ

PINt~ ~ll
l

SET SCREW
__C. ~_~/
/
'LL
1 998

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 SENTINEL VALVE PART NO. NAME OF PART RE(l
1
> 741 1 ASS E M B L Y set
741 1 -10
J
co
~
741 1 -9 SPRING 1

UJ
741 1 -9 co
co
741 1 -1 o CAP 1

li UJ
li
>
J
>
J
uJ
Z
H
zuJ
co

231 5 TACHOMETER
R OTO R 1

E LECTRIC TACHOMETER 23 1 7 TACHO.TRANSMITTER 1

23 1 8
TACHOMETER RECEIVER 1

2325 TACHOM E TE RECEtVER

R 1
{' !
FOR CONTROL ROOM
23 1 5 701 0-37 S ETSC R EW 1

701 0-37
23 1 8 / 23 1 7
2325 _ Jj

7451 ASSEMBLY 1
set
SOLENOID VALVE 7451 -3 SLEEVE 1

> 7451 -4 SPOOL 1

J
745 1 -3 f' 7451-4 7451-10

Co
~ 745 1 -6 SPOOL SPR IN G 1

UJ
co 7451 -7 O- RING 6
/ co
7451 -8
uJ
745 1 -8 PUSHBUTTON 1
7451~7
>
7451.6 J J J 7451 -1 o SOLENOID COI L 1

Tl >
D
o
zUJ
J
o
U)

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 PREssuR E SWITCH PART NO. NAME OF PART R EQ.

7161 LOW L O PRESS. TRIP 1 set

I 7 1 63 LOW L.O. PRESS. ALARM 1 set

o PUMP DIS. OVER PRESS.
h 7 1 74 1 set
~ TRIP
co 7181 HIGH BACK PRESS. ALARM
1 set
UJ
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:)
co
U)
UJ
oC
~

7 1 78 ASSEM B LY 1 set
PREssuRE SWITCH
I 7 1 78-1 PRIM L.O.PUMP 1 set
7178 1 7178 2 7178-3 7178 o
h 7 1 78.2 L.O. PRESS. INTERLOCK 1 set
~
(D 7 1 78.3 HIGH BACK PRESS. TRIP 1 set
~~1 r~ --1 ~--l r~~~L----1 r --1 r--il I I t I : I I l i I
UJ
oC
D
(1)
CD
~ uJ
oC
'L

LtM IT SWITCH 8454 OVERSPEED TRIP 1

I 8458 EMERGENCY TRIP 1

o
H
I
~r~1 ~ ~
Cl)

H
~
@ J

7101 tN LET STEAM 1

PR ESSURE GAUGE 7 1 02 CHEST STEAM 1

UJ 7 1 04
EXHAUST STEAM 1

o
:) 7 1 05
GLAND STEAM 1

o 7 1 08 L.O. 1
UJ
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:)
(D
7110 PUMP SUCTION 1

(1)
UJ
a:
7111 PUMP DISCHARGE 1

(L
l

7 1 26 TURBINE
UPPER SHAFT
SIDE
1

THERMOMETER TURBINE SHAFT

7127 LOWER SIDE
1

FOR L.O. COOLER FOR TURBINE 7 1 28 WHEEL SHAFT 1

UPPER SIDE
7 1 29 WHEEL SHAFT 1
LOWER SI DE
a: 7 1 30 L.O. COOLER 1
uJ L.O. INLET SIDE
h
UJ 7131 L.O. COOLER 1
:~ L.O. OUTLET SIDE
O
~
CC
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 TH E RMO-SWI TCH PART NO. NAME OF PART R EO.
( tf fitted,
7 230 TURB,NF_ SHAFT 1 sot
UPPER StDE
7230-1 1 ,NSTALL THREAD 1

7231 TURBINE SHAFT 1 set

LOWER SIDE
7231*1 1 ,NSTALL THREAO 1

:E
7232 WHEEL SHAFT
UPPER SIDE
1 set

u
h 7232- 1 1 ,NSTALL THREAD 1

7230- 1 1 ~
U' 7233 WHEEL SHAFT LOWER S,DE
1 set
7231 -1 1 O
:~ 7233- 1 1 tNSTALL THREAD 1
7232- 1 1 a:
7233- 1 1 w
I
7230 h
7231
7232
7233

PART NO. NAME OF PART REQ.

QUICK EXHAUST VALVE 7481.1 BODY 1

7481-2 VALVE BODY 1

74 1-7 748 1 -3 DISC VALVE 1

7481-6 7481-2 7481-3 LU 7481-5 CHECK VALVE SEAT 1

748 1 - 5
748 , -9 >
J
748 1 - 1 748 1 -8
7481~ CHECK VAKVE 1

IN EXH . H
(o
748 1 -7 SPRING 1

FROM 1~_L TO OIL TANK :D

VALVE SEAT
MAiN LO PUMP ~ 748 1 -8 1

~ 748 1 -9 VALVE SEAT GASKET 1

~'
g
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D
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TO TRIP SERVO-MOTOR

C J
g SHINKO INO.LTO.
 INSTRUCTION MANUAL FOR DRAIN SEPARATOR
FOR CARGO PUMP TURBINE

1 . Purpose for Drain Separator

(1 ) The Drain Separator is intended to remove the drain in the steam coming into the
Steam Turbine to prevent not only a decrease of the Steam Turbine's performance
but also damages of the moving blades and the bearing metals.
(2) This Drain Sep~rator is so constructed that the steam coming, into the Drain
Sep~rator circles in it and the Drain in the steam is gathered to the outer circle
inside the Drain Separator and drained.

2. Installation of Drain Separator and Pipings

A special attention is to be given for the installation of the Drain Separator and its

(1 ) The Drain S~parator is installed as low as possible to easily remove the Drain,and
also near to the Steam Turbine.
(2) The Drain Separator is securely fixed on its flat foundation with the bolts of M20,
(3) The insulation is so constructed that the insulation is made thick enough to prevent
as far as possible the steam in the Drain Separator becomes drain by radiation from
the outside surrace of the Drain Separator.
(4) The piping between the Drain Separator and the steam pipe is so connected that
unreasonable force and moment do not effect as far as possible.
(5) Special attention and consideration are sufriciently paid for the pipe supports and
the hangers not to give bad efrect for,the pipings,

3. Opefation Manual
If the drain in the steam comes into the Steam Turbine it becomes th cause for several
troubles.
Therefore the drainage is to be carried out sutficiently before starting the Steam
Turbine as follows;

(1 ) Warmihg up the steam pipings betwe~n the Boiler and the Drain Separator is
' sufficiently carried out by gradually opening the drain by - pass valve till no drain
comes out from the drain by - pass valve. ,
(2).After'confirming no drain coming out from the drain by - pass valve, the drain by -
pass valve is blosed and then the valve fitted on the Drain Trap Line is opened.
(3) After sutficiently warming up th~ St~ani Turbine, the Steam Turbine is stared.
(4) Dufing operating the Steam Turbine, no drain in the steam being supplied fs
confirmed by opening the drain by - pa~s valve on the Drain Separator.

C~ I srnNKo IND. LTD.

c)
 INSTRUCTION MANUAL FOR CENTRIFUGAL PUMP (CV)

This instruction manual describes construction, operation, maintenance,

disassembling and assembling, etc. of model CV pump.

CONTENTS
Page
CHAPTER I CONSTRUCTION . . . . . . 82 - 2
2. Pump casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5. Pumpstuffingboxseal . . . . . . . . . . . . . . . . . . . . . . . . 3
6. Bulkhead stuffing box and intermediate shaft
with gear coupling . . . . . . . . . . . . . . . . . . . . . . . . 3

CHAPTER 2 CAUTION FOR INSTALLATION AND PIPlNG . . . . . . . 82 - 4

1. Place of installation and foundation . , . . , . . . . . 4
2. Finishing ofpump mounting seat . . . . . . . . . . . . 4
3. Caution for piping . . . . . . . . . . . . . . . . . . . . . 4
4. Suction piping . . . . . . . . . . . . . . . . . . . . . . . . 4
5. Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6. Permissible deformation ofbellows . . . . . . . . . . 5
7. Fitting offloating shaft . . . . . . . . . . . . . . . . . . 5

CHAPTER 3 OPERATION . . . . . . . . . . . . . . . 82 - 6
l . Check before operation . . . . . . . . . . 6
2. Starting . . . . . . . . . . . . . . . . . . . . 6
3. Stopping . . . . . . . . . . . . . . . . . . . . 6

CHAPTER 4 MAlNTENANCE . . . . . . . . . . . . . . 82 - 7
1 . Caution during operation . . . . . . . . . . 7
2. Ball bearing . . . . . . . . . . . . . . . . . . . 7

CHAPTER 5 STANDARD CLEARANCE AND LIMIT OF USE . . . . . 82 -10

CHAPTER 6 DISASSEMBLlNG AND ASSEMBLlNG . . . . . . . 82 -11

1 . Disassembling . . . . . . . . . . . . . . . . . . . . . . . . . 1 1
2. Assembling . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

CHAPTER 7 TROUBLE SHOOTlNG AND REMEDIES . . . . 82 -13

CHAPTER 8 REPLACEMENT PARTS . . . 82 -15

9 1 SHINKOINb.LTO.
C)
 CHAPTER 1CONSTRUCTION

1 . GENERAL
The model CV pump is of a vertical single-stage double-suction centrifugal type, and
the pump and driver are connected with the flexible couplings through an intermediate
shaft and a bulkhead stuffing box, the construction being simple for ease of handling,
overhauling and caretaking.

2.ThePUMP CASING Fi9. I .1

volute casing is split into two halves
along a vertical plane containing the axis.
70
Since the suction and discharge nozzles 1 34

20
are provided on the rear half casing, the 7
9
rotating element can be taken out by re- 1

ld,8
353
moving the front half casing (2) without 1

35d 54A
disturbing the suction and discharge pipings. 4 1
1

A vent to be connected with the stripping

27
or priming line and an air valve are provided
38
on the volute casing. /
/ \\ lh

2
,~ ~
,
/
,
l ~LLI

3. IMPELLER a, ,1
ll
The impeller(16) is of the double-suction l ,
,

type and hydraulically balanced. It is so 1t L

\ ,, , / /
,

\
/
designed as to improve pump efficiency and /
16
~~ ll /
,,

suction performance. Moreover, the im-

peller is statically and dinamically balanced.
19

/ 54B

t8
L~~~ 48
4. BEARING 372

The rotating element is supported by ball 57 3

7
bearings on both sides of the pump casing. 35

The 6300 type ball bearing is fitted in the

solid inner case (14) with the split type 10

bearing housing (7) and can be taken out

together with the rotating element if the
cap of the bearing housing (7) is removed.
R EO. FOR PUMP

(1) The ball bearing (34) at the coupling end

R EO. FOR PUMP
PAR T NO. PART NO.
NAME OF PART NAME OF PART
is secured in the housing by pressing its
1
VOLUTE CASING 1
38 MOUTH RING 2
outer race by means of the cover(9).
This serves to support the weight of the 2 VOLUTE COVER 1 48-1 FLINGER 1

rotating element . 3 PUMP BED 1 48.2 FLINGER 1

7- 1
BEARING HOUSING 1
54A MECHAN ICAL SEAL 1 SET
(2) The ball bearing(35) at the bottom end
is not fixed axially in view of the thermal
7.2 BEARING HOUSING 1 54 B MECHAN ICAL SEAL 1 SET

expansion of the shaft (1 8). 9 BEARING COVER 1

57 PACK ING R ING 1

10 BEARING COVER 1 70-1 SNAP RING 1

(3) Grease is used as lubricant for the ball

141 BEARING INNER CASE 1
70-2 SPLIT RING ISET
bearing.
1 42 BEARiNG INNER CASE 1
70-3 SNAP RING 1

16 IMPELLER 1 1 46- 1
MECHA. SEAL COVER 1

18 IMPELLER SHAFT 1 1 46.2 MECHA. SEAL COVER 1

19 IMPELLER KEY 1
353 BEAR ING NUT 1

20 COUPLING KEY 1
354 BEAR ING WASH ER 1

27 IMPELLER NUT 1 37 2 PACKING A ING 1

34 BALL BEARING 1

35 BALL BEAR ING 1

c J
g SNINKO INO.LTD.
5. PUMP STUFFING BOX SEAL Fig. 1.3
The stuffing box is so designed as to furnish the
mechanical seal exclusively. Therefore there is
~~~~~!l
no leakage of the liquid pumped and no air leaks f _:~~!=
into the pump. 125
r
Moreover, the operation is very simple since no l

'16
adjustment for the stuffing box during operation
12e
is required. IZ1

Mechanical seal 401

426 I
411 l
Unblanced type mechanical seal is fitted and flushed 441

'38 j
by pressure liquid led from discharge side. a4:

,II lo4
OHCX

Fi9. I .2 ,02
40, t~Z~~]
13g
a95
,]s
52
1 31
,oT

403
5 ~~
1 lp
,15
~)
4l9
5 Ito

4 It2
lOO

13t
14,

12g
412

5
l05

1:3
~~@ 1!a A

5 ,T,
139
6 ,8, ,1,

7' ll, l

5 A
7
(?1 ,3a

Close-up view of 430

lzo
mechanical seai

541 F LOATING SEAT CARBON

542 PACKING RING RUBBER
5lh3 PAC K I N G RUBBER
544 SEAL R ING STA I N LESS STEE L PART NO.
R Ea. FOR pUMP
PART NO.
REa. FOR PUM

NAME OF PAAT NAME OF PART

545 PACKING RING RUBBER
SPR I NG
401 BEARING SUFPORT 1
423B HU8 1

546 STA I N LESS STEE L

STOPPER R ING & SET SCREW 402 BEARING CASE 1
424 COUPLING BOLT & NUT
5lh7 STAI N LESS STE E L
403 BEAR ING CASE 1
425 PACK ING R ING 1

404 BEARING COVER 1

426 PACKING R ING 1

For upper mechanical seal, A is attached, e.g. 54A-1 405 STUFFING BOX 1
427 PACKING RING 2
FLOATlNG SEAT, and tor lower one, e.g. 54B-1. 4 06 GL~ND 1
428 PACKING R ING 1

407 FLINGER 1 429 PACKING R ING 2

408 COVER & PACKING 1 SET 430 COVER & PACKING ISET
6. BULKHEAD STUFFING BOX & INTERMEDIATE409 DISTANCE RING 1 431 INTEAMEDIATE SHAFT 1

SHAFT WITH GEAR COUPLING (Standard) 410 DISTANCE RING 1

432 FLOATING SHAFT 1

A stuffimg box is provided where the intermediate 41 1 BALL BEAAING 1

433 COUPLtNG KEY 4
412 BALL BEARfNG 1
434 SNAP RING 1

shaft passes through the bulkhead to prevent the

413 LANTERN RING 1
435 BELLOWS 1

gas in the pump room coming into the engine room. 414 PACKING RfNG 1
436 SEAT PACK ING 1

If non-standard arrangement is fitted, it will be 415 G LAND PACK ING 2 437 SEAT PACK I NG 1

shown later. 416 SLEEVE 1

438 SPACER 1

417 SLEEVE 1 439 DOUBLING PLATE 1

418A SLEEVE 1 440 PLUG 1

418B SLEEVE 1 441 BEAR ING NUT 1

4l9 COUPLING FLANGE 1

442 BEAR ING NUT 1

4 20 COUPLiNG FLANGE 1
443 BEAR ING WASHE R 1

HUB
42 1 1
444 BEAR ING WASHER 1

422HUB 1

423A HUB 1

c!D SuINKO INO.LTO.

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 2 CAUTIONFORIN STALLATIONANDPIPING
CHAPTER

In order to prevent occurrence of vibration and noise and to operate the pump over long
periods with best efficiency and safety the following points must be observed at the time
of installation and piping.

l . PLACE OF INSTALLATION & FOUNDATION4 SUCTION PIPING

(1) Size of the place of installation must be chosen The piping on the suction side affects pump effi-
in view of the pump disassembly and inspection. ciency to a great degree and to avoid troubles
A space necessary for disassembly is shown in the arising there from the following points must be
outside drawing. noted.
(2) The foundation must be strong enough to absorb (1) No air pocket must be formed in the piping.
pump vibration and to resist deformation against (2) All fittings in the piping must be perfectly
10ng use. tightened to prevent air invasion.

(3) The pump is placed on its foundation. The (3) Care must be taken to prevent air leakage th-
driver with its bed is placed on its foundation rough glands of all valves in piping.
with the bearing support ( 401 ) complete fast-
(4) The suction piping must be thoroughly cleansed
ened at the bottom of the driver's bed.
so that pipe scale, welding beads and other
In this case, confirm that the distance "E" shown
foreign matter do not remain, otherwise seizure
in the outside drawing, between the end faces of
and other troubles may result.
the coupling halves on the pump shaft end and
the intermediate shaft bottom end must be as
shown in the drawing. The permissible error of
5 ALIGNMENT
Tables 2.1 and 2.2 show permissible errors in ali-
this distance "E" is :t2mm. (Refer to Fig. 2.2).
gument when the pump and driver are connected
through the intermediate shaft.
2. FINISHING OF PUMP MOUNTING SEAT When installations of the pump and driver have
Chockliners must be welded on the foundation been finished it is necessary to check the alignment
place just under the pump foundation bolt holes
and if the errors exceed those shown in Tables 2.1
and their faces must be planed so that they lie in
and 2.2 adjustment is needed. This work is also
a perfect plane. When the foundation bolts are necessary when pipings for them have been finished.
tightened leaving gaps between the liner faces and
When the alignment has been completed set the
pump bed, deformation may be given to the pump driver's bed and the pump bed on their foundation
and besides vibration may result.
by driving the dowel pins.

3. CAUTION FOR PIPING Table 2,1 Between driver & intermediate shatt
Deformation given to the pump by outside force
Paranet misangnment A Angutar misalignrnent B
due to incorrect piping causes not only vibration at coupling (mm) at coupling (mm)
but also pump troubles. Therefore, the pipe flanges Below O . 2
(Between centers) Below 0.2
connecting with the suction and discharge nozzles
must be correctly matched. Be sure to avoid the
cases shown in Fig. 2.1 otherwise the pump may Table 2.2 Between intermediate shaft & pump
receive unreasonable force. Nor must the pump Parallel misalignment A Angular misalignment B
be directly given deformation due to the total at coupling (mm) at coupling (mm)
weight of piping and thermal expansion. Below 0.4 Below 0.4
(Between centers)
Fig. 2.1

PIPING PUMP

Angular Parallel F Iange faces

misalignment m isa I ign ment do not touch

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g suINKO INO.LTO.
5.1 Between driver and intermediate shaft 5 .2 Between intermediate shaft and pump
(1) Measurement of parallel misalignment (1) Measurement of paranel and angular mis-
As shown in Fig. 2.2, fix a dial indicator on alignments
the coupling at the intermediate shaft upper As shown in Fig. 2.2, fix dial indicators on the
end for the alignment so that its spindle rests temporary shaft to be provided for the ali-
on the periphery of the coupling on the driver. gnment so that their spindles rest on the peri-
Give one complete turn at the same time to phery and the face of the coupling half on the
both coupling halves on the driver and the intermediate shaft. Give one complete turn
intermedaite shaft and read the difference at the same time to both coupling halves on
between the maximum and minimum readings the pump and intermediate shaft and read the
on the indicator. difference between the maximum and mini-
(2) Measurement of angular misalignment mum readings on the indicators.
In the same way as above, give one complete
turn to both coupling halves at the same time 6. PERMISSIBLE DEFORMATION OF BELOWS
measure the gap between the coupling faces WHEN FITTED
(e.g. at each 90 deg.) using a feeler gauge, and (1) Elongation or contract in vertical direction
:!:lO mm.
read the difference between the maximum
and minimum measurements. (2) Angle deviation (Refer to Fig. 2.3) 5 deg.

(3) Perpendicular deviation (Refer to Fig. 2.4)

Fig. 2.2
:!:8 mm.
Driver
Fi9. 2.3 Fi9. 2.4
~ ~
,,,
50

FEELER GAUGE li
'It,
ll tl
~] ~r
Parallel
misalignment
mi:

~8

A
/
[

7. FITTING OF FLOATING SHAFT

(LOWER INTERMEDIATE SHAFT)
It is strictly prohibited to fit the floating shaft
BE L LOWS ( 432 ) upside-down due to an abnormal thrust
Angu I ar force is given to the pump bearing. It is therefore
m isa I ignment
m i$ special attention should be paid for that the floating
shaft with the coupling marked with "C" is to be
B~c fitted up and the other side marked with "PC"
down.

E
TEMPORARY SHAFT

Pum p

g SuINKO INO.LTD.
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 CHAPTER 3OPERATION

1 . CHECK BEFORE OPERATION 2. STARTING

When operating for the first time after installation (1) Close the discharge valve completely and open
or overhaul and assembly, it is necessary to do as the suction valve fully.
foilows. (a) When the liquid level at the suction side is
(1) Take off dust preventing tape placed on the above the pump the liquid flows into the
part where the pump shaft passes through and pump casing by gravity, so open the air vent
take care so that no foreign matter enters the valve on top of the volute casing to draw the
clearance around the shaft. air in the pump and close it when the liquid
begins to flow out of it.
(2) Give some oil to the mechanical seal. (Refer
to " MECHANICAL SEAL") (b) When the liquid level at the suction side is
(3) Give a few turns to the coupling by a turning below the pump draw the air in the pump and
bar and see if it turns normally. suction line through the gas vent on the volute
casing by means of stripping pump or some
(4) Confirm if the rotation direction of the driver
other extracting devices so that liquid can fill
is correct.
the pump inside. In this case keep the air vent
(5) Confirm if the grease in the bearing housing valve closed so that no air can enter the pump
and the oil in the gear coupling, if fitted, is casing. Never neglect priming the pump.
within the specified amount.
(2) Start the driver gently and increase its speed
(6) Confirm if the driver is ready for the operation. gradually .

(3) When the discharge pressure has risen reasona-

blly, open the discharge valve gradually and
fully .

3. STOPPING
(1) Close the discharge valve.
(2) Stop the driver.

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 4 MAINTENANCE
CHAPTER

In order to eliminate pump troubles, to minimize parts consumption and repair and to
maintain best efficiency over long periods the operator must aim at perfect maintenance
of the pump.

1 . CAUTION DURING OPERATION (7) With lowering of the liquid level at suction side
(1) Never throttle the suction valve in any case suction pressure approaches the vapor pressure
during operation otherwise troubles may occur of liquid and vapor develops in the suction
due to dry operation. line and pump suction inlet and, moreover,
(2) Never operate the pump for over 3 minutes air is sucked through the suction bell-mouth
with discharge valve completely closed. When until pumping ability decreases to such extent
that discharge stops.
a centrifugal pump is operated without dis-
charge, most of the power changes into heat In order to prevent this, vapor and air coming
and as a result temperature of the liquid in the into the pump inside must be drawn through
pump casing rises to the boiling point causing the vent on the casing by means of stipping
seizure of the interior of the pump and accident pump or some other extracting devices.

may occur. (8) When cavitation occurs even though the pump
(3) Never operate the pump with dry condition. speed becomes minimum, discharge must be
decreased by throttling the discharge valve.
(4) Except that the driver is with the constant If this remedy is ineffective stop the pump.
speed like electric motor, keep the discharge
valve open in full and it is desirable to adjust
2. BALL BEARING
discharge flow by changing speeds. The adjust- (1) In consideration of lubricating ability of the
ment of discharge flow by the degree of dis- grease and running clearance of the bearing
charge valve opening is not recommendable due to thermal expansion and liquid tempe-
because of loss of driving energy.
rature pumped, the bearing temperature is so
(5) When operating more than 2 pumps in parallel designed as to stand up to 900C.
be sure to keep the discharge pressure of each However from viewpotnt 6f service life it is
pump always equal. If the speed of some pump desirable to keep it below 750C.
decreases during operation and its shut-off (2) For the lubrication of ball bearing grease is used.
pressure drops below the discharge pressure The recommendable grease and the interval of
of the remaining pumps, it is operated wlth replacement grease are shown in Tables 4.1 and
zero flow even though its discharge valve is 4.2.
opened and thus the result will be the same as
mentioned in (2) before in this chapter. (3) For supplying grease for the bottom ball bearing,
take the grease drain plug away.
In such a case try to make the speed of the
pump in question same as those of the remain-
ing pumps, and if this is impossible stop that 3. MECHANICAL SEAL
pump immediately. (1) Cautions before starting and during standstill
Care must be taken so that no dust enters part(a)
(6) When operating the pump at the rated speed
in Fig. 4.1 .
and with the discharge valve open in full avai-
Pouring lubricating oil in (a), when the pump
lable NPSH decreases as the liquid level at the
is at a standstill , will prevent dust from sticking.
suction side lowers and finally discharge becomes
If dust accumulates here and sticks hard seal
zero due to cavitation.
ring (544) may stick and sliding face (S) can
In such a case pumping ability can be restored
not be tightened. When the pump is delivered,
if discharge is decreased, so for the reason
a strip of cloth tape is put over the gap around
mentioned above lower the speed without
the impeller shaft to prevent foreign matter
throttling the discharge valve as the liquid level
from invading.
at the suction side drops.

g SnINKO INlo.LTb.
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 Fig. 4.1

(a)
11
l

(~) ~~~ ~~~~ T i J / ~fjiUg A_

[i)lug ~

Q) ci
~ e m o v el \:~emove~
>
L/~ r~
r
/ I LJ+- ---

ELo
U
t/~

(b) Fill oil through an oil plug hole on the

T)
EL c] coupling by using pistol oiler till the oil
~)

Ll
begins to flow out from the other oil plug
hole on the opposite side.

(3) Leaking from mechanical seal

Co u i) I i ng
Under normal operational conditions there is O-ring
A I ,' ga p
no leakage, but in case there is a leakage of
over 30cc/h there must be some trouble inside, Ov e "' f t ow Gear oi
( so vc}4so-~80)
so a remedy must be taken as early as possible.
(4) Heating of sliding parts and abnormal noise.
Insufficient flushing to the sliding face causes
abnormal wear down of the carbon due to O rin~
heating and dry contact. If flushing CouJling o 'i e r

temperature rises to more than 10~C above

the liquid temperature being pumped, it is (C) After filling
After fillin the oil ut
the oil, puttwo
twoluplugs
s back
backtoto
C
necessary to trace the cause and remove it. the coupling with Teflon seal tape on them.
When operated under the condition of dry Apply several turns to the shaft so that
contact, abnormal sliding noise may occur. the oil may reach the interior of the
coupling. If too much oil is filled,
4. GEAR COUPLING (Standard) excessive oil may leak from the key way
(1) Misalignment between pump and driver but this is acceptable because necessary
Since the gear coupling has sel~alignment oil is kept in the coupling.
action to some extent, small misalignment
within the permissible values shown in Table 5. BULKHEAD STUFFING BOX (Standard)
2.1 and 2.2 can be absorbed. (1) When operating for the first time after
However the excessive misalignment causes repacking the stuffimg box tighten once the
t,oo much slip between the teeth and as a result gland firmly before starting, then loosen the
wear becomes excessive, vibration occurs and gland nuts to such extent that the coupling can
the coupling may be damaged. be turned lightly by turning bar.
(2) Lubrication (2) Supply grease to the gland packing for
Lubrication oil has a very important function in lubricating and to keep gas-tightness between
reducing friction and wear and in hydraulically the pump room and engine room.
distributing contact pressure on the gear The recommendable greases and the interval of
flanks by forming oil film in the gap between replacement grease are shown in Table 4.1 and
them. 4.2.
The recommendable oils and the interval of (3) Start the pump and adjust the gland nuts
replacement oil are shown in Tables 4.1 and gradually and evenly. If the gland is tightened
4.2. suddenly or too much or unevenly there may be
(3) Filling lubricant oil a danger of seizure of overheating.
(a) Remove two oil plugs. (4) If the packing becomes deteriorated the
tightness can not be kept no matter how much
the gland is tightened.
In such case renew the packing.

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g SuINKO INO.LTO.
6. MAINTENANCE CHECK LIST
Maintenance and check for the followings can extend a life of the pump.
Item Inspection procedure Remedy in case of trouble

Check every tinre if there is any Stop pump immediately and check suction
Suction pressure
abnormal pressure drop line .

In the case of above ambient temperature

Bearing temperature Check and record every time. plus 40~C or above 85~C, stop pump and
eliminate cause.

Check oil in gear coupling every time

Lubricating oil Supply oil if necessary.
through oil hole on it.

If abnormal noise or overheating occurs,

Ball bearing Check abnormal noise every time. stop pump and eliminate cause, and renew
ball bearing if necessary.

Check leakage, heating, noise every

Mechanical seal t ilne .
Stop pump and remove cause.

Vibration Check vibration every time. Check alignment.

7. LUBRICANTS
(D Replacement oflubrication Table 4.1
The replacement of the lubricants is based on
deterioration or contamination of the lubricants Replacement
being used. However, Table 4.1 shows Location After initial start Normal o peration

recommendable replacement.
(2) Lubricants Within 3 months
Ball bearing Every year
NLGI No. 2(National Lubricating Grease
Institute) for grease for the ball bearing on the Every 6 months

pump and intermediate shaft and for its stuffing

Gear Coupling ,,

box, and for the gear coupling, ISO VG 460- Every o peration Every o peration

Bulkhead stuffing box.

680 gear oil are recommendable. The brand
names of the lubrjcants equivalent to the
recornmendable ones are shown in Table 4.2.
(3) Grease amount
Pump model cV 350 CV 400-2 Cv 450 cV 500-2
Pump upper side bearing (g) 50 50 110 150
Pwnp lower side bearing (g) 30 30 70 110
Intermediate shaft upper side bearing(g)

70 70 110 150
Intermediate shaft lower side bearing (g)

70 70 110 150

Bulkhead stuffing box (g) 240 240 280 300

(4) Gear oil amount
Pump model cV 350 CV 400-2 CV 450 CV 500-2
Turbine side gear coupling (cc) 180 180 180 310
Intermediate shaft side gear cou pling(cc)

130 130 130 190

Pump side gear coupling (cc) 130 130 130 190

8. STANDSTILL
When there is a fear of freezing, drain the pump completely after stopping. In case of a long standstill, clean each
sliding part thoroughly and apply rust preventive where necessary.

g SHINKO INb.LTO.
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 Table 4.2
Crcase (*NLGI N0.2) Gear Oil (fSO VC 680)
~lame of compan,_'

IDEMITSU KOSAN DAPHNE EPONEX EP2 DAPtiNE SUPER CEAR O[L 680

BEACON EP2 LISTAN EP2

Dxxorl SPARTAN EP 680

MOBIL VX 2 MOBIL PLEX 47

MOBIL OIL MOBIL CBAR 634 OR 636

NIPPO~' O]L EPINOC GREASE AP2 BONNOCK M 680

CALTEX OIL MLfLTIFAK EP2 MEROPA LUBRICAr,T 680

JoMo LISONIX GREAS!~ EP2 REDUCTUS 680

MITSUB[SHI OIL DIAMOND MULTIPURPOS N0.2l][AMOND GEAR LUBE SP 680

GULF OIL CULF CROWN GREASE NO 2 CLILF EP LUBRICANT HD680

BP OIL BP ENERGREASE MM-EP-2 BP ENERGOL CR-XP 680

TEXACO OIL MLfLTIFAK N0.2 TEXACO MEROPA 6~O

CASTROL SPHEEROL AP2 OR EPL2 CASTROL ALPtlA SP 680

COSMO OIL COSMO C•REASE DAINAMAX N0.2

COSMO CEAR SE 68(]

ALVANIA GREASE N0.2 AL1/A*NIA CREASE EP2

SHOWA SHELL OIL O~IALA OIL 680

GENERAL SP CEAROL 680

GENERAL OrL GEMICO GREASE MP-2

ELF EPEXA 2 EPONA Z680

CHEVRON DURA-LITH GREASE EP2 ~L GEAR COMPOUND 680 or EP680

AND LIMIT OFUSE

5 STANDARD CLEARANCE
CHAPTER

The bigger the clearance between impeller and mouth ring becomes, the more the counter-
flow from discharge side to suction side becomes, and consequently pump capacity de-
creases.

Unit :
Table 5.1 mm
New parts Limit of use
Name of parts Model S t and ard
clearance a
Length b a b

Im peller el d~~L 15.9 13

an d a CV 350 0.35 1.5
mouth ring
400-2 0.35 15.9 1.5 13

450 0.40 15.9 1.5 13

Floating seat
of
rb ! 5 OO*2 0.40 15.9 1.5 13
mechanical seal

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 AND AssEMBLING
6 DISASSEMBLING
CHAPTER

1.
DISASSEMBLING Fig. 6.1

In order to replace impeller, ban bearing, mouth

ring, etc., disassembling of pump is carried out as
follows.

1 .1 Removal ofvolute cover

(1) Remove the sealing pipe for the mechanical seal.

(2) Loosen the nut for the mechanical seal cover

(146) until the mechanical seal cover moves
and touches the flinger (48).

(3) Remove the volute cover nuts and move the

volute cover (2) forward by using the two I I \ \ \\

lifting bolts.
L1

l .2 Removal ofrotating element

(1) Remove the coupling bolts.
(2) Remove the bearing housing cap after removing
the nuts fastening the cap.

(3) Take out the rotating elements together with

the bearing inner case (14), bearing covers
(9 & I O), ball bearing, etc. with paying attention
to the mouth ring (38) and mechanical seal. 1 .4 Removal ofmechanical seal
Since the mechanical seal for this pump has a
l.3 Removal ofball bearing large spring compression allowance and force,
(1) For the upper bearing, remove the coupling the special tool provided must be used for re-
after removing the snap ring (70-1). moving the mechanical seal and ball bearing
Remove the bearing cover (9). from the shaft.
Make straight the rotation preventing piece on (1) As shown in Fig. 6.2 hold the tool in such
the washer (354) which is bent into one of the a way that the spring force does not act upon
slots along the bearing nut (353) periphery and the flinger (48), and maintain not to transmit
remove the bearing nut. directly to the mechanical seal the shock pro-
(2) For the lower bearing remove the bearing duced when the ball bearing is removed.
cover (1 O) and the snap dng (70-3). (2) Remove the ball bearing and flinger from
(3) Compress the mechanical seal spring by using the shaft .

the special tool provided as shown in Fig. 6.2 (3) Loosen the special tool bolts to reduce the
and also mentioned m "Removal of mecha spdng force and remove the special tool as
nical seal". shown in Fig. 6.3 .
(4) Since the ball bearing is pushed lightly onto (4) Remove the mechanical seal from the shaft.
the shaft, it can be removed wlth the inner
case by using puller.
Fi9' 6,2 Fig. 6.3
SPEC,AL TOOL ,SUPPL,ED,
~ '."=" ' - 5cnl
BALL BEARINC

SPRINO

STOPPE R,NG ET SEAL SCREW RtNGFLOATfNG SEAT

FLING R

g snINKO INO.LTO.
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 l .5 Removal ofimpeller (2) Take care not to injure sliding face and "O"
The impeller shaft diameter where the impeller ring by hitting or scoring.
(16) is fitted is the largest and gets smaller to-
(3) When fitting be sure to apply lubricating oil
ward either end. to "O" ring .
Fixing the impeller is by the impeller nut (27)
at the upper side and by the split ring (70-2) at
(4) Referring to Fig. 6.2 the floating seat (54-1)
the lower side. (carbon) must be inserted by hand until it
(1) Remove the setscrews on the impeller nut touches bottom of the cover (146) firmly
taking care not to injure sliding face.
(27) and remove the impeller nut after re-
moving the ball bearing, the flinger and the (5) Place the stopper ring (54-7) against the shaft
mechanical seal. shoulder which forms fitting base and tighten
it by th*e setscrew.
(2) Remove the impeller from the shaft.
However, if it is difficult to remove the im- (6) Confirm the winding direction of the spring
peller from the shaft, warm the hub of the if it is suitable for the rotation direction of
impeller slightly to ease working. the pump. Refer to Fig. 6.4.
(7) Fit rotating elements of the mechanical seal
2. ASSEMBLING and the cover (146) onto the shaft.
Assembling can be carried out by reversing order
(8) Afterward, apply the special tool and compress
of disassemblirrg and attention must be paid to
the spring evenly as shown in Fig. 6.2.
the followings.
(1) Clean each part thoroughly to remove rust (9) Fit the flinger and the ball bearing onto the
and scale, and be sure there are not injury and shaft, Ieaving the special tool as it is as shown
burr in fitting parts. in Fig. 6.2 to compress the spring until the
rotor is settled in the volute casing.
(2) Assemble fitting parts according to match
marks if any. (lO) After settling the rotor in the volute casing
(3) Turn nuts for rotating parts securely and fix remove the special tool.
anti-rotation device without fail.
Fig. 6.4
(4) Be sure to thoroughly cleanse the ball bearing
with pure kerosene taking care to keep off
dust and foreign matter.
STOPPER RING STOPPER RING
2.1 Alignment SEAL RING SEAL R ING
Aligument is to be confirmed if it is within
/
the specified limit shown in Tables 2.1 and 2.2 l l

in " ALIGNMENT" .
Right-hand L eft -ha nd
winding winding
2.2 Assembly of mechanical seal
Use the special tool for assembling the me- IMPELLER SHAFT IMPELLER
chanical seal as shown in Fig. 6.2 and 6.3.
(1) Slidmg face "O" rmg and "O" ring groove
must be claned with leadless gasoline and
wiped with soft cloth taking care to keep
off dust and other foreign matter.

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 CHAPTER 7TROUBLE
SHOOTING AND
REMEDIES
Pump can perform satisfactory function if properly handled and maintained.
Should trouble occurs speedy remedies must be found for it. Table 7.1 shows commonest
causes of trouble and suggested remedies.

Table 7.1

Troubles Causes Remedies

1. Pump not completely or insufficiently 1. Prirne once more,
filled with liquid.
2. Much air leakage in suction line. 2. Check suction line.
3. Air pocket in suction line. 3. Check suction line.
4. Suction lift too high. 4, Check by suction gauge on suction side.
Pump cannot discharge 5. Wrong direction of rotation. 5. Check.
6. Suction strainer and suction line 6. Check interior of suction line.
clogged.
7. Speed too low. 7. Check by tachometer.
8. Impeller clogged, 8. Check pump interior.

1, Air leakage. 1. Check suction line and stuffing box,

2. Speed too low. 2. Check by tachometer.
3. Discharge head too high. 3. Check by discharge gauge.
4. Suction lift too high. 4. Check by suction gauge.
5, Suction pipe bell-mouth not sufficiently 5. Check.
Insufficient discharge submerged ,
6. Suction strainer and suction line clogged. 6. Check interior of suction line.
7. Impeller clogged. 7. Check pump interior.
8. Wrong direction of rotation. 8. Check.
9. Excessive clearance between impeller 9. Replace mouth ring by new one.
and mouth ring.

1. Pump not sufficiently filled with liquid 1. Prime sufficiently.

Pump discharges liquid
2. Air pocket in suction line. 2. Check piping and if wrong correct it.
after starting, but soon
fails to discharge
3. Much air leaks into suction line. 3. Check suction side.
4. Air leaks through stuffing box. 4. Check if mechanical seal is incorrectly
fitted or carbon is broken.

1. Speed too high (Power frequency too 1. Lower speed, (Frequency)

high)
2. Impeller touches mouth ring. 2. Check state of installation and
alignment.
3.Rotating elements touch stationary 3. Replace shaft by new one.
Prime mover overload
element due to bent shaft.
4. Casing deformed. 4. Check if undue force is given by piping.
5. Voltage too low (Constant input, but 5. Check power source,
increase in current) in case of electric
motor driven.

g SHINKO INO.LTb.
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 Troubles C auses Remedies

1. Grease is too little. 1. Supply grease.

2. Grease is too much. 2. Remove grease.
3. Grease has improper consistency or 3. Replace grease with specified new one.
it is deteriorated.
4. Misalignment is great. 4. Correct alignment of pump and driver.
5. Shaft is bent. 5. Replace with new shaft.
Overheating of bearing
6. Injury or too much wear in ball 6. Replace with new ball bearings.
bear ing.
7. Too much thrust force. 7. Check if impeller is clogged and if
clearance between mouth ring and
impeller becomes too much, and
correct them if any.

1. Injury in balls or rolling face.

Abnormal noise in 2. Too much clearance due to abnormal Replace with new ball bearing.
ball bearing wear.
3. Abnormal wear in retainer.

1. Misalignment. 1. Check alignment of pump and driver.

2. Shaft bent. 2. Renew shaft.
3. Impeller partially clogged with foreign 3. Check pump interior.
matter.
4. Incorrect installation. 4. Check state of installation.
5. Weak foundation. 5. Measure vibration up and down, right
Vibration in pump and lieft around pump's mounting on
foundation, if vibration is too great
reinforce foundation.
6. Suction and discharge pipings not 6. Refer to "CAUTIONS FOR PIPING",
sufficiently secured. and give necessary support.
7. Rotating elements touch stationary 7. Check pump alignment and bending of
elements. sh af t.

1. Injury or excessive wear down in 1. Remove mechanical seal cover and

rubbing faces. check rubbing faces.
2. Foreign matter in rubbing faces. 2. Ditto.
3. Insufficient tightening of mechanical 3. Check if cover bolts are evenly
seal cover. tightened.
4. Break down of "O" ring. 4. Check "O" rings for stationary and
Leakage in mechanical rotary rings.
seal s. Insufficient tightening of setscrew for 5. Tighten sufficiently setscrew.
stopper ring (54.7).
6. Injury or wear down of part of shaft 6. Replace with new shaft.
contacts.
7. Scale sticks in groove for "O" rmg 7. Disassemble and remove scale
(54-5), causing rotary ring to stick com pletely.
and rubbing faces to open.

1. Flushing is insufficient. 1. Check if flushing pipe is clogged.

Heating of mechanical
seal (Sometimes 2. Pump operated dry. 2. Stop pump immediately.
accompanied by abnormal
noise)

C J
g SuINKO INO.LTO.
 CHAPTER 8 REPLACEMENT
PARTS

When ordering replacement parts, include the following information.

1 . Ship's name

2 . Shipbuilder and hull number

3 . Service and model of the pump
4. Parts' numbers and names shown in this instruction manual

PREssuRE GAUGE PART NO. NAME OF PART R EQ.

71 IO PUMP SUCTICN 1

71 1 1
l
PUMP DISCHARGE 1

l
UJ
cg
::)

o
LU
a:
:D
U'
Q8
LU
c::

If
t
l

TH ERMO-SW,TCH
7 22 1 PUMP CASING 1 set

( tf fitted) 7221 .1 1 INSTALL THREAD 1

7222 PUMP BEARING COUP. SIDE

1 set

ll
7222- 1 1 INSTALL THREAD 1

7223 PUMP BEARING END StDE 1 set

!:
o 7223.1 1 INSTALL THREAD 1

H
~ 7226 BULKHEAD STU FFING BCX
1 set
t Cl]
7221 -1 1
I 7222_1 1 o 7226.1 1 INSTALL THREAD 1

2
~c
7223.1 1 uJ
:E
7225-1 1
H
7221
7 222
7 223
l
7226

,~5- l

g SNINKO IND.LTD.
C )
 MANUAL OF
INSTRUCTION PISTONPUMP (KPH )
STEAM DRIVEN

This instruction manual describes construction, installation , operation,

maintenance, disassembling, assembling and trouble shooting and remedies
of model KPH pump.

CONTENTS

Page
CHAPTER 1 CONSTRUCTION . . . . . • 96A- 2
1. General . . . . . . .
.2
2. Steam cylinder
.2
3. Steam chest . . .
.2
4. Liquid cylinder
.2
5. Valve box . . . . .
.2
6. Pump Valve . . . .
.2
CHAPTER 2 CAUTION FOR INSTALLATION AND
PIPING . . . 96A-3
l. Place of installation and foundat i on 3
2. Finishing of pump mounting seat . . . .
3. Cautions for piping . . . . . . 3
4. Suction piping . . . . . . . . . . . 4

CHAPTER 3OPERATION . . . 9 6A- S

1. Preparation for operation

.S
2. Starting and
3. Stopping . . .
running . . . .
.S
4. Caution . . . . S

CHAPTER 4MAINTENANCE AND INSPECTION • • • • 96A-6

l. Maintenance . . . . . . . . . . .
... 6
2. Normal inspection . . . . . .... 6
3. Lubricating oil . . .. .. . ... 6
S DISASSEMBLlNG AND
CHAPTER ASSEMBLlNG . 96A-7

l. Disassembling 7
2. Assembling .. . 7

6 TROUBLE
CHAPTER SHOOTING
ANDREMED I ES . 96A-8

SUPPLEMENTATION
ADJUSTMENT OF • PISTON
• • • • • •, 96A-9
STRO

Cg I snlNIKolNo.LTo.
C)
 CHAPTER lCONSTRUCTION

l . GENERAL
The model KPH pump is a steam driven direct action p u mp of the worthington
t ype .

Fig. 1.l
2. STEAM CYLINDER '~~ (,1,
l 69

The steam cylinder block has 75 ~)

2 cylinders. 4
8 20

3. STEAM CHEST 32 ' 24

35
The steam chest block has 76
2 cylinders and distributes 74 171

steam to the steam cylinder. T70 28

36 30

4. LIQUID CYLlNDER 43 47
210 45
The liquid cylinder block has 191 48
2 cylinders which are provided 204 26
with liners(14) . 2oe 171

207 77
/~~
~/256 ~ 202
s. VALVE BOX Ill

~'i~ 203 73
(1) The top and bottom valve boxes .J 70
are cast separately and connect- ~~~20sA
.~ ~f",E ~,,1

.~/14 ~,~~ 11 ,

ed together on both sides by 201

\Jl
connecting pieces. 208

(2) Both boxes are identical in

construction and dimensions, PART l PAR
AEQ NO REQ NO
NAME OF PARTFOP NArnE OF PART FOR I
and each contains suction NO. PUMP NO. puedP

chamber, suction valve chamber,, l

STEAM CYLINOER l
76 STEAM PtSTON ROD2SETS
GLANO PACX,NG
LIQU,O PISTON ROO GLANO PACXING
and discharge valve chamber. 4 STEAM CHEST l
77 2SETS
8 STEAM CHEST LINER 2 169 VALVE ROO TOP GLANO2
(3) The suction valve chamber is VALVE ROO 80TTOM
ll LfQUID CYLtNOER l l 70 2
divided into two chambers, GLANO
14 LIQUID CYLtNOER LINER 2 171 PISTou ROO GLANO 4
each of which is open to the
20 STEAM PtSTON 2SETS
liquid cylinder.
23 STEAM P,STON R,NG 4
(4) Of both connecting pieces, one
24 STEAM PfSTOW ROD 2 191 VALVE BOX 2
serves as suction passage and
26 LtQUIO PISTON ROO 2 201 SUCTION VALVE SEAT8
the other as discharge passage,
28 FRONT COLUMN l
202 DELtVERY VALVE SEAT8
with suction and discharge
30 BACK COLUMN 2 203 SUCTtON VALVE GUARD8
openings respectively.
32 PtSTON VALVE 2 204 DELIVERY VALVE GUARD8
35 PtSTON VALVE RING 8 205 VALVE 16
6. PUMP VALVE 3G VALVE ROO 2 205A VALVE DISC 16
Both suction and discharge valves 43 ROCKtNG LEVER SPINOLE
2 206 VALVE SPRING 16
are of the flat type. 45 ROCKING LEVER 2 207 VALVE STEM 8
The suction valve is fixed by pull- 47 CROSSHEAO 2 208 YA~ VALVE SETSCREW 8
ing from the bottom by means of 48 CROSSHEAO PIN 2 210 JACK 80LT 8
setscrew stay(208) and the dis- 7o UQUID PISTOfl 2SETS
charge valve is fixed by pressing 73 UQU,O P,STON Rt~3 4 241 ESCAPE VALVE OOX l
from the valve box cover by means 74 VALVe RCO 80TTOM
2 SETS 243 VALVE 1
of jack boltC210) . GLANO PACKI~3
75 VALVE aoO TOP 2SETS ~6 SPRt~G l
GLANO PACXlrG

g I snINKOINO.LTD.
C )
 CHAPTER 2 CAUTIONS FOR INSTALLATION AND PIPING

In order to prevent occurrence of vibration and noise and to operate the pump
over long periods with best efficiency and safety the following points~ must
be observed at the time of installation and piping.

l. PLACE OF INSTALLATIO\1 AND FOVNDATION

(1) Size of the place of installation must be chosen in view of the purnp's
disassembly and inspection. Space necessarY for disassembly is shown
in the outside drawing.
(2) The foundation must be strong enough to absorb pump's vibration and to
resist deformation against long use.

2. FINISHING OF PUMP MOUNTING SEAT

Chockliners must be welded on the foundation plate just under the puJnp'S
foundation bolt holes and their faces must be planed using a surface
plate so that they lie in a perfect plane. When the foundation bolts
are tightened leaving gaps between the liner faces and liquid cylinder,
deformation may be given to the pump and besides vibration may result.
The same precaution is necessary in the case of fixing the steam cylinder
to the bulkhead if any, for if fitted incorrectly pump alignment will be
disturbed and premature wear of sliding faces and other trouble will occur.

3. CAUTIONS FOR PIPING

Deformation given to the pump bY outside force due to incorrect piping
causes not only vibration but also pump troubles. Therefore, the pipe
flanges connecting with the suction and discharge nozzles must be
correctly matched. Be sure to avoid the cases shown in Fig. 2.l
otherwise the pump may receive unreasonable force. Nor must the pump be
directly given deformation due to the total weight of piping and thermal
expan s ion .

Fig. 2.1

P ip in g P ump

Angular Para I I e l Flange faces

misalignment mi sa I i gnment do not touch

g I SHINKOINO.LTD.
c)
 4. SUCTION PIPING
The piping on the suction side affects pump efficiency to a great
degree and to avoid troubles arising therefrom the following points
must be noted.

(1) No air pocket must be formed in the piping.

(2) All fittings in the piping must be perfectly tightened to prevent air
invas ion .

(3) Care must be taken to prevent air leakage through glands of all valves
in the piping.
(4) The suction piping must be thoroughly cleansed so that pipe scale,
welding beads and other foreign matter do not remain, otherwise
seizure and other troubles may result.

cg SHINKO INO.LTO.
C)
 CHAPTER 3 OPERATION

1. PREPARATION FOR OPERATION

(1) Open each drain valve, exhaust valve, suction and discharge valve.
(2) Pour oil where required.
(3) Keep bolts and nuts perfectly tight.

2. STARTING AND RUNNING

(1) Warm up the steam cylinder by opening the steam valve a little.
(2) The pump will begin starting if the steam valve is opened further
gradual I y .
(3) Wllen drain stops completely, close the drain valve.
(4) Open the test valve provided on the valve box cover and expel air
inside completely.
(5) Open the steam valve gradually until the steam pressure reaches
required pressure at required revolutions, and begin operation if no
abnormal point is seen in the condition of running.
(6) When steam or liquid leaks excessively from the glands, tighten the
glands further and keep a tiny amount of liquid leaking from the pump
gl ands .

(7) In case the extent of steam valve opening is kept constant during the
operation the revolutions will rise or fall in accordance with the
variation of the liquid end pressure, but the operation must be carried
out at the rated revolutions by adjusting the extent of steam valve
opening. In case the speed exceeds 12S"', of the rated revolutions there
will be a fear of abnormal wear in the steam cylinder and piston rings.

3. STOPPING
(1) Close the steam valve.
(2) Open the drain valve to draw out the drain.
(3) After the pump stops, close the exhaust valve, suction and discharge
valves .
(4) Before stopping supply a small amount of oil and give attention to
the means of preventing rust.

4. CAUTIONS
In case that the pump works as cargo oil stripping pump, a special
attention is to be given to the followings;
It may happen that discharge pressure of the pump is suddenly reduced
due to an oil level in the cargo tank becomes lower and then gases and
air come into the suction pipe, resulting that the pump speed becomes
higher, the pump stroke length becomes shorter and shorter and finally
the pump stops. Under the circumstances mentioned above, the pump does
not work satisfactorily with its capability but also it cames abnormal
wear out of the steam cylinder quickly.
In case that gases and air mixtured in the cargo come into the pump,
it is recomlnendable to operate the pump with a reduced speed, Iess than
a half of the rated speed, and, if remote control devices are fitted,
10cal operation is preferable due to a difficulty of delicate control
by the remote control devices.
SfJlINKO INO.LTO.
C )
 AN D INSPECTION
4 MAINTENANCE
CHAPTER

1. MAINTENANCE
(1) Since the service life of the pump depends greatly upon whether main-
tenance is good or not, it is important to observe what this booklet
explains and. not to make mistakes in handling.
(2) When stopping the pump, keep each moving part in good condition, and
where rusting is feared apply rust preventing oil.
(3) When stopping over long periods, open the steam cylinder and steam
chest and remove the drain completely, and apply mineral oil on the
inner surfaces after cleaning the interior. However this oil must be
wiped off cleanly before using the pump again. The same proceduse is
also applicable to the liquid cylinder.

2. NORMAL INSPECTION
(1) During operation it is necessary to inspect from time to time the status
of lubrication and the bolts and nuts which tend to loosen, especially
the cap nuts for the pump valve setscrew stay at the bottom of the
valve box and lock nuts need attention so that they do not drop off
during operation.
(2) It is desirable to inspect at least once a year the parts invisible
from outside such as steam piston, Iiquid piston and pump valves, even
though no trouble occurs during operation. Too much time and cost
will be needed when the cylinder walls are found to have been injured
due to the unexpectedly great wear or breakdown of piston rings.
(3) It is imperative to inspect the pump valves once a year after overhaul-
ing the valve box. Especially, the valve discs made of synthetic resin
should be replaced by spare ones when they are enlarged or deparated by
reason of the weardown of the central holes.

3. LUBRICATING OIL Table 4.l

For the lubrication for NAJVIE OP COMPANY LUBRICATING OIL
the crossstand and cross- BRITISH PETROLEUVI BP ENERGOL THB68,77
head pin, oil of ISO VG68
(International Standard CASTRO L PERFECTO T68
Organization) is used. CO~dO OIL COSMO TURBINE SUPER 68
The brand names of oil ESSO STANDARD VACUUM TRESSO 68
which is equivalent to
ISO VG68 are shown in the GULP OIL GULF HARMONY 68
right table. IDEMITSU KOSAN DAPHNI TUEBINE OIL N0.68
KYODO OIL RIX68 TUEBINE OIL
DIANOND MARINE68 TURBINE OIL68
NITSUBISH:1 OIL
MOBIL DTE OIL HEA~ MOBIL DTE OIL HEAVY MEDIUVl
MOBIL OIL
PBK 68 REGAL OIL ReO 68
NIPPON OIL, CALTEX OIL
SHOWA SHELL OIL TURBO T OIL68
TEXACO OIL REAGAL OIL E (R~O)

c J
g SHINKO INO.LTO.
 CHAP TE R5 AN D ASSEMBLING
DISASSEMBLING

l. DISASSEMBLING
Disassembling of the pump in case of replacing the parts with spares,
maintenance and repair work will be done by following orders.
(1) Remove all accessories.
(2) Disconnect valve rod from valve rod link and remove valve rod link.
(3) Remove lever spindle nut and take off each lever spindle and at the
same time remove rocking lever.
(4) After drawing out bolt on the crosshead, disconnect stearn piston rod
from crosshead.
(S) Remove steam cylinder cover, Ioosen gland, and after fitting eye-bolt
to top end of piston rod, Iift. piston rod together with piston.
(6) Remove crosshead from liquid piston rod by turning it.
(7) Remove gland for liquid cylinder and then remove liquid cylinder cover.
(8) Fit eye-bolt to top of liquid piston rod and lift piston rod together
with piston.
(9) Loosen glands for steam chest.
(10) Remove steam chest covers.
C11) Take out piston valve.
(12) After removing cotter, split pin and nut from piston rod, draw piston
from piston rod.
(13) Remove cap nut from valve adjusting screw loosen screw remove valve
box cover nuts, and remove cover.
(14) Take out discharge valve.
(lS) Remove cap nut from suction valve setscrew stay at valve box bottom
and take out suction valve.

2. ASSEMBLING
Assembling can be carried out by reversing order of disassembling and
attention must be paid to the fo 1 Iowing .

Cl) The fitting parts should be assembled in accordance with matching

marks if any.
(2) At assembling care should be taken so that no undue f o rce is given to
fitting parts.
(3) Care should be taken so that al l bolts, nut s , screws and pins are
securely fixed.

g SHINKO INO.LTD.
C)
 CHAPTER 6TROUBLE SHOOTrNG AND REMEDI'*S

Pump scan perform satisfactory function if properly handled and maintained.

trouble occur speedy remedies must be found for it.
Shou I d Table 6.l
shows commonest causes of trouble and suggested remedies.

Table 6.l
Troub I e s Caus e s Remidies

(1) Ste~tm too muc~h. (1) Jump at start ot~ stroke is mostly
cCluscd b), tOo much s~te(Im, so trace
and eliminate caus~e.
Too much vibra (2) Liquid temperature too high. (~) 11'hen liquid temperature it;_- too
tion ~ noise high, jump and noise will re_sult,
so it must be reduced.
(3) Air leak~~ge. (3) Examine gland, pipe fitting etc. ,
and make them t;~ompletely airtight.

Speed too high. In reL:lproc~tlng pumps, increas.~e in

spGed tends to caus~e long stroking
Piston strikes
cylinder covers
and as a result piston strikes~ cyl-
inder covers, so decrease spced by
throttling steam valve.

(1) Foreign matter lodges in valve. (1) Remove valve box cover and examine
Decrease in valve and put it in good ordcr.
pump discharge (2) Piston ring LYorn or damaged. C2) Dismantle and examine. Renew rlng
if necessary.

(1) Gland not enough tightened. (1) Tighten gland properly.

Too much leak
from stut~fing (2) Packing deteriorated. (2) Renew packlng
box (3) Pis~ton rod worn. (3) Renew piston rod.

Damage by over (1) Incorrect alignment. (1) Correct alignment.

heat (2) Invasion of foreign matter. (2) Prevent invasion of dust and sand.

Slide valve adjustment is not Dlsconnect valve rod and link, then
Both stroke correc t . adjust valve position by turning valve
lengths are not rod. However, adjustmcnt of right-
equa l hand stroke length is adJusted by
left-hand valve rod.

Steam or/and liquid piston rings are

not in good condition. too closely, sliding resistance
Small vibration Increases, causing often vibratio.n,
especially at low speed. In such
case, remove piston rings and examine
them.

c J
g SHINKO INO.LIO.
 SUPPLEMENTATIONAD JU STMENT
OFPISTONSTROKE
The adjustment of the piston stroke is made as follows in case of that the cylinder top or bottom is knocked under
the rated operation (the rated discharge pressure, the rated suction head, the rated exhaust steam pressure and the
rated number of stroke).

A) For "H" and lost motion

The pump was adjusted and set at the shop
test so that the pistons move in the middle of
whole stroke under the rated operation.
Therefore if something happens on board the l,

ship, Iike that the piston knocks the steam

VALVEROb
l
cylinder top or bottom under the rated LOCK NUT
operation, it is necessary to confirm first as
AD JUST I NG
follows that the adjusted value marked at the ~~
NUT~ I
::r
~
shop test is being kept as it was.
LOST MOTloN l

L = 3~m ,

1) To confirm "H" between the valve rod

AD JUST I NG
and the valve rod joint is correct and
NUTC
same as that set at the shop test. ~~~
SPLIT PIN
("H" was adjusted at the shop test and has
been marked on the side of front column VALVE ROD
P,No. 28) Jo I NT

If "H" is incorrect compared with one

marked on the front column, it is adjusted
by moving the adjusting nuts.
(When reassembling after overhauling,
"H" is to be adjusted and set the original
one which has been marked on the front
column.)
2) To confirm the lost Motion L=3mm is being kept. If L of 3mm is not being kept, it is adjusted by moving

the adjusting nut (A) and set by the lock nut.

B) For adjustment for piston stroke

If the piston stroke in operation is unsuitable even though the A) mentioned before is confirmed corrrect, the

adjustment is carried out as follows;

1 ) Relation between piston and piston valve

a) To change the left side piston stroke is made by moving the right side piston valve up or down.
b) To change the right side piston stroke is made by moving the left side piston valve up or down.

!~c~ SW~~'uSSrui;::~:i:S,:::~S'
SHlnKO InD.LTb. , > * *, ;#="+. * + * ' ' ' "' '*** '* '
cl
 2 ) Adjustment for piston stroke
A necessity for the adjustment to get a suitable piston stroke is confirmed under the rated operation
otherwise the piston stroke under other operation conditions is different.
a) In case of the left side piston moves partially up and down at lower position (like the piston knocks
the cylinder bottom) : It is so adjusted that the lock nut on the right side valve rod is loosened and
the adJustlng nuts (A)(B) are screwed In to make "H" small, resulting that the piston stroke range is
moved upwards as a whole.
However, the lost motion L=3mm is to be still kept.

b) In case of the left side piston moves partially up and down at upper position (like the piston knocks
the cylinder top) : It is so adjusted that "H" becomes big.
However, the lost motion L=3mm is to be still kept.

c) In case of the right side piston moves partially up and down at lower position (like the piston knocks
the cylinder bottom) : It is so adjusted that the lock nut on the left side valve rod is loosened and the
adJustlng nuts (A)(B) are loosened to make "H" big, resulting that the piston stroke range is moved
upwards as a whole.
However, the lost motion L=3mm is to be still kept.

d) In case of the right side piston moves partially up and down at upper position (like the piston knocks
the cylinder top) : It is so adjusted that "H" becomes small.

However the lost motlon L=3mm is to be still kept.

e) After the adjustment the "H" is to be set with the lock nut and the split pin.

C) References
l) In operation on board the ship, the piston knocks the cylinder top or bottom sometimes.
However, almost of these abnormal operations are caused by too low discharge pressure or too low
exhaust sieam pressure or the both, which makes too small reaction power to stop the piston at dead
points of the top and the bottom of the piston stroke.
Therefore , it is absolutely necessry to confirm a necessity for the adjustment of the piston stroke before

hand at the rated operation.

2) It is impossible, for example, to only adjust the piston stroke shortened towards downwards in case of
the piston knocks the cylinder bottom.
Therefore, in this case, do not shorten the piston stroke towards downwards but adjust the piston stroke

moving wholly upwards.

c~~
SHIN!KO IN:D.LTD.
C]
 INSTRUCTION MANUALREMOTE
OF CONTROL SYSTEM
PUMP (KSC 65-lOO)
FOR STEAM DRIVEN PISTON

This Instruction Manual describes the construction , operation and type of

service of each equipment of KSC 65 - lOO .

CONTENTS
Page

CHAPTER 1GENERAL
''e'''O
, e , e O , t e l , , , t ,

CHAPTER 2CONSTRUCTION
ANDPLACE OFINSTALLATION
o t 97~2 , , , e , o

CHAPTER 3OPERATION , , e , , , e , , , , , , , , ,

1. Stroke number control 3

2. Stroke counter 3

' e ' ' ' ' , 97-4 4

CHAPTER 4TYPE OFSERVICE OF
EACHEQUIPMENT e e e e

l. Stroke transmi tter

2. Stroke converter . 4
3. S troke counter . 4

CHAPTER 5TROUBLE
SHOOTING
A ND REMEDIES o , , e , ,
e 97~6
, e

~~ 1 sHINIKOlnD.a:~i~!' ' '

C)
 l GENERAL
CHAPTER

KSC 65 - 100 is a system which controls the reciprocating stroke number

(hereinaf ter called ffstroke number") of the reciprocating pump (herein-
after called "pump") from the cargo control console provided in the cargo
control room of the tanker and at the same time monitors pump operation.
Generally, the cargo control console is provided with a speed setter to
control stroke number and a stroke counter.

2 CONSTRUCTION
CHAPTER (Refer to
ANDPLACEOF INSTALLATION Fig . 3.1)

l . Steam Control Valve (1)

Th i s is installed on the s t eam inlet pipe in the pump room and regulates
s t eam supply .

2 . Stroke Transmitter (7)

This is mounted on the pump and counts pump stroke number .

3. Stroke Converter (8)

This is installed in the englne room an d outputs signals to the stroke

counter
4 . S troke Counter (9)

This is installed on the cargo control console and indicates pump

stroke number .

5. Speed Setter (5)

Thi s is installed on the cargo control console, and operates t^h.e

s t eam control valve and regulates pump stoke number

c~ Sl~NKO IHD.LTO.
c)
 CHAPTER 3 OPERATION (Refer to Fig. 3 . I )

l . Regulating the stroke number

The steam supply is controlled by adjusting the opening of the steam

control valve provided in the pump room, which can be done by changing
pneumatic signals within the range of 0.2 to I .O kg/cm2 by the
speed setter provided in the cargo control console.

2. Indicating the pump stroke number

2.1 The stroke transmitter provided on the pump counts the punrp
stroke number, and supplies air to the stroke converter or
dischargeS the air out. By repeating these actions, the transmitter
outputs a pneumatic signal to the stroke converter provided in the
englne room.
2.2 Pneumatic signal from the stroke transmitter is converted into
an electric signal by the stroke converter provided in the engine
room and then the electric signal is outputted to the stroke
counter
2.3 An electric signal from the stroke converter is converted into
stroke number by the stroke counter provided on the cargo control
console and then the stroke number is digital-indicated on the
stroke counter.

Flg. 3.l
5 9
CARCOCONTROL ROOM RUN. tN D.
ELEC SOURCE
LA"IP C=_ J,-_D_PY_C_!!1_.2_5_W2
.(AC ,COINOV Of 2001~~fl
AIR
_j~~~~~l
Cd~O
(6~7 kg/cm2]
.. - --1 l

O~2k TO 1.0k I

-t
5;*l

t,,CNl

i
r!;TIT7r;~ITl r;~T;~Tr!~;;:71
PUMP ROOM ENGINE ROOM
~]
xt
Ul
>,Ll

Pl
!,I
Ai F~ I

te~7 ~glcm2, I

STEAM 6A 8
l

EXHAUST AtR
1 4k (6N7 k9/cm2] t

i l

-J
7
STR I PPING
PUMP

c~ SHINKOiN:Bl.E:T~l. ~i~~~~~~~
C )
 EQUIPMENT
4 TYPEOF SERVICEANDADJUSTMENT OF EACH
CHAPTER

l . Stroke Transmitter
The three-way air valve is employed as the stroke transmitter.
Vertical movements of the pumpfs valve rod changes over the air
passage in the stroke transmitter. When the valve rod is in the
the upward stroke, air pressure is outputted to the stroke converter.
When the valve rod is in the downward stroke, air is discharged
through the exhaust port of stroke transmitter, and air pressure is
removed. Thus, the stroke transmitter ,repeats the above actions
corresponding to the pump stroke number, by which a pneumatic *-ignal
is made and outputted to the stroke converter.

2 . Stroke Converter

The stroke converter converts air pressure signals outputted from the
stroke transmitter into an electric signal and outputs it to the
stroke counter on the cargo control console.
The pressure switch is preset to be ON when air pressure reaches 1.1
kglcm2
When confirming the preset value, set the supply air pressure through
the filter regulator(6A) (pressure reducing valve) mounted on the
pump to 1.1 kglcm2
Then force the roller of the stroke transmitter in and confirm that the
operation indicating lamp provided on the head of the stroke converter
goes ON.
If not, adjust the setting by the pressure setting screw on the head of
the stroke converter until the lamp goes ON.
After confirmation, regulate supply air pressure to I .4 kg/cm through
the filter regulator.

3 . Stroke Counter (Refer to Fig. 4.1)

3.l The stroke counter calculates a value per minute inversely in the
cycle of electric signals outputted from the stroke converter and
digital-indicates the results on the stroke counter.

3.2 Confirm as foll ows and adjust if necessary .

(1) Press the power switch (5) .

(2) While pressing the push button (9), confirm that the meter (1)
indicates 30 rpm.
When adjustuent is necessary, while pressing the push button
(9), adjust the volume (8) by uslng a screw driver .

c~ SHINKO IND.LTD.
c)
 (3) While pressing the push button (ll) to confirm operating
indication, confirm that the meter indicates 5 rpm.
If adjustment is necessary, while pressing the push button
(ll), adjust the volume (6) by using a screw driver.
(4) When the optional overstroke indicator is provided, while
pressing the push button (lO)p confirm that the meter (1)
indicates 40 rpm.
If adjustment is necessary9 while pressing the push button
(10), adjust the volume (7) by using a screw driver.
(5) After the above adjustment (3) or (4), press the push button
( 12) .

3 . 3 Others
(1) The stroke number counting operation of the stroke transmitter
installed on the pump can be confirmed by the flickering lamp
( 13) .

(2)standard
Theone. external terminal to indicate operation
ON/OFF of the contact to indicate operation can be confirmed by
the lamp (2).
(3) The external ternrinal to indicate overstroke (14) is optional.
On theoperation
overstroke unitcanwith thisbydevice,
be confirmed the lamp (3). ONIOFF •of the
3.4 Stopping the Pump and Stroke Counter
For twenty (20) s~conds after the pump stops, the stroke counter
indicates the stroke number which have been made before the punrp
stops, and after that, it indicates O rpm which means the pump is
not running .
When no signals from the stroke converter are outputted to the
stroke counter for more than twent~ (20) seconds,' the stroke
counter indicates O rpm to show that the pump is not running.
As the circuit of the stoke counter has been designed not to
indicate 3 rpm or less, the pump is in a waiting state for twenty
(20) seconds (3rpm), and during this period if no signals are
inputted by the stroke converter tihe stoke number is judged to be
less than 3 rpm and the circuit is reset and O ~pm is indicated.

Fig . 4.l ~•ig. 4.2 ELECTRIC WtRtNG DiAGRA,R

rl~~I str::::1:lTrt: ~r I COINT o L l
~>
STRtPPING PUMP STROJ'~ couNTLn
STROKE COUNTER C @ stroke converter

L~I- GND
4
I,1 PUT
@A
@B~z ,:
15
1tt I r'
P2taND' - It"I ll" I l
T1 Wl~~'1
INPuT P,
GND P2
1 +1 2V
@c ,~ PD"'iaV' II:I l tlav p3

6
IFI-O 13 @ @A OIJTPUTf t,

12
C @ 8~J
+ o UT
OulrpuTt~,

2
N'~s
UI-
PUT
@ @ zo

'uNO e l 1 Au~ e ~~~ 11

C C ~ ACa~~V
3 @ o
Act ta,lOOv F

10 18 C
a2av ~
o --
7 C
t lav S :

f-CJIJL-~ Ov @
e l o "'Tn
g
8 @
,aJIN 4 @ 8 n uN :Olb,

5
lI g•199alql ,uco,uu
C

D ALM
c
:O•l

: ELECT,NC WIRE FOR $troke CaRVerter

~~~
SHINKOinD•LT~!• i~~~~~~~i~~~
CJ
 SHOOTING
CHAPTER 5TROUBLE ANDREMEDIES

This system can perform satisfactory function if properl y handled and

maintained. In case any trouble should occur, it should be remedied
at once.
The following table shows the conunonest causes of trouble and suggested
remedies .

Trouble Possible Causes Remedies

Stroke l
e Power wlrlng is not connected ,
l
, Connect wiring to
counter does terminal (18) at t he
not indicate back of stroke counter e

2, Power is not ON e
2, Switch ON power switch
(5) of stroke counter ,

3 o Wrong wlrlng connection between 3 , Correct the connection

stroke converter and stroke between terminal codes
counter , P2 and P3 or Pl and P3,
Ref er to Fig . 4 2 e e

During l
, Pressure setting of strokeconverter l , Set pressure switch sO
o peration , is impro per . that it wi I l be ON at
1 kg/cm
indication l
, e
of stroke Ref er to 2 Chapter 4
, ,

counter
is always O 2, Stroke transmitter is not 2, Check the operation .
operating properly . Ref er tO l Chapter 4
, ,

3 e Air pressure of stroke 3 e Adjust air pressure so

transmitter is insuf f icient , as to be more than l , 4
kg/cm with f ilter
( 6A )
regulator ,

4 , Wrong wiring connection between 4 , Correct the connections

stroke converter and stroke of terminal codes Pl an
counter , P2 ,

Ref er to Fig . 4 2 , e

c~ SHm,(O INBl.LTD.
C)
 Trouble Possible Causes Remedies

During l. Push but.ton (12) f or measurement l. Press the push button e

o per.ation ~ is not pressed .
l

indication
of stroke
counter
is always 5

Operation 1 -e
Pumpstroke number is less l. Make pump stroke number
indicating than 5 rpm. more than 5 rpm.
l amp does
not goes ON 2. Stroke counter setting is . not 2. Set stroke counter to
proper . 5 rpm .
Ref er to 3.2 (3)
Chapter 4.

c~ SHIN:KO IN:D.LTD.
C~
Back to Top Page

SHIN:XiOlno. L70.
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