FOR CONSTRUCTION

0 NOV 14. '12 FOR CONSTRUCTION K.J.YOON J.Y.LEE S.D.PARK

Rev. DATE DESCRIPTION PRPD. CHKD. APRD.
PURCHASER :

UCH-II POWER (PRIVATE) LIMITED, PAKISTAN

VENDOR :

HYUNDAI ENGINEERING CO,. LTD

SUB-VENDOR :
HYOSUNG GOODSPRINGS, INC.
PROJECT :

UCH II EXPANSION PROJECT

PREPARED BY DATE TITLE :

K.J.YOON NOV 14. '12

CHECKED BY DATE CEP OPERATION & MAINTENANCE MANUAL

J.Y.LEE NOV 14. '12

APPROVED BY DATE DOCUMENT NUMBER REV.

S.D.PARK NOV 14. '12 UCH2-M06-LC-78-0001 0

UCH2 EXPANSION PROJECT
HYUNDAI ENG

- CONTENTS -

SECTION I. PUMP INSTRUCTION MANUAL

1. DESCRIPTION
2. INSTALLATION
3. OPERATION
4. MAINTENANCE

SECTION II. REFFERENCE DOCUMENT & DRAWING

1. DISMANTLEMENT AND ASSEMBLY PROCEDURE

2. PUMP DATA SHEET.
3. PUMP PERFORMANCE CURVE
4. PUMP OUTLINE DRAWING
5. PUMP SECTIONAL DRAWING
6. P&I DIAGRAM
7. LUBRICANT LIST
8. COUPLING MANUAL
9. MECHANICAL SEAL DRAWING
10. PRESSURE GAUGE HOOK UP DRAWING
11. MOTOR SPECIFICATION

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HYOSUNG GOODSPRINGS INC.

UCH2 EXPANSION PROJECT
HYUNDAI ENG

SECTION I

PUMP INSTRUCTION MANUAL

for

CONDENSATE EXTRACTION PUMP

UCH2 EXPANSION PROJECT

HYUNDAI ENG

SERVICE NAME : CONDENSATE EXTRACTION PUMP

PUMP MODEL : VCP250/5
HGS ORDER No. : 1102343-001
PUMP ITEM NO. : 13LCB11/21AP001

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HYOSUNG GOODSPRINGS INC.

 Instruction, Operating, Maintenance Manual HGS VCP PUMP

SECTION I

INSTALLATION

OPERATING &

MAINTENANCE

MANUAL for PUMP

VCP250/5 (5 Stages)

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 Instruction, Operating, Maintenance Manual HGS VCP PUMP

INSTRUCTION MANUAL
FOR
HGS
TYPE VCP PUMPS

FOREWORD

This manual provides installation, operation an maintenance instructions for the HGS VCP PUMP(s)
described in Section one.
This manual outlines the general procedures that must be observed to ensure long, trouble free service.
However, it is assumed that plant personnel are familiar with the basic principles and tools involved
in the installation, care and service of a pump, Successful operation is dependent on careful study of
the manual and a well-planned maintenance program.
Should questions arise which are not specifically covered in this manual, please contact the nearest
HGS office or the dealer through whom the unit was purchased for additional infomation. All inquiries
should identify the applicable pump by type, size and serial number as given on the pump nameplate.

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 Instruction, Operating, Maintenance Manual HGS VCP PUMP

TABLE OF CONTENTS

No. TITLE PAGE

SECTION ONE PUMP DESCRIPTION 1/24

1.1 General 1/24

1.2 Design Data and Operating Conditions 1/25
1.3 Bowl Assembly and Related Components 1/24
1.4 Nozzle Head Assembly and Related Components 3/24
1.5 Suction Barrel 4/24
1.6 Driver 4/24
1.7 Lubrication 4/24
1.8 Environmental Considerations 4/24

SECTION TWO INSTALLATION 5/24

2.1 General 5/24

2.2 Shipping Arrangements 5/24
2.3 Equipment Required 5/24
2.4 Pump Handling Instructions 6/24
2.5 Unloading and Checking the Pump 7/24
2.6 Temporary Storage 7/24
2.7 Install Pump 8/24
2.8 Grout the Pump 9/24
2.9 Install Driver and Align Equipment 9/24
2.10 Connect Main Piping 11/24
2.11 Install Pressure Gages 11/24
2.12 Install Auxiliary Instruments, Piping and wiring 12/24
2.13 Assemble Coupling and Adjust Impeller 12/24
2.14 Set the Mechanical Seal 12/24
2.15 Removal of Unit 12/24
2.16 Preparation for Storage or Shipment 12/24
2.17 Mechanical Seal Instructions 13/24

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 Instruction, Operating, Maintenance Manual HGS VCP PUMP

TABLE OF CONTENTS (continued)

No. TITLE PAGE

SECTION THREE OPERATION 15/24

3.1 Operating Precautions 15/24

3.2 Preliminary Check 15/24
3.3 Starting 16/24
3.4 Opeating Check 17/24
3.5 Stopping 17/24

SECTION FOUR MAINTENANCE 18/24

4.1 General 18/24

4.2 Preventive Maintenance 18/24
4.3 Troubleshooting Chart 19/24
4.4 Pump Disassembly 20/24
4.5 Cleaning and Inspection 21/24
4.6 Pump Reassembly 22/24

page 0-6

HYOSUNG GOODSPRINGS
UCH2 EXPANSION PROJECT
HYUNDAI ENG

SECTION II

REFFERENCE DOCUMENT & DRAWING

1. DISMANTLEMENT AND ASSEMBLY PROCEDURE

2. PUMP DATA SHEET.
3. PUMP PERFORMANCE CURVE
4. PUMP OUTLINE DRAWING
5 PUMP SECTIONAL DRAWING
5.
6. P&I DIAGRAM
7. LUBRICANT LIST
8. COUPLING MANUAL
9. MECHANICAL SEAL DRAWING
10. PRESSURE GAUGE HOOK UP DRAWING
11. MOTOR SPECIFICATION

SERVICE NAME : CONDENSATE EXTRACTION PUMP

PUMP MODEL : VCP250/5
HGS ORDER No. : 1102343-001
PUMP ITEM NO. : 13LCB11/21AP001

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HYOSUNG GOODSPRINGS INC.

 Instruction, Operating, Maintenance Manual VCP PUMP

SECTION ONE - PUMP DESCRIPTION

1.1 GENERAL

The type of pump for which this manual is supplied is Type VCP, which is a vertical self-
lubricated pump consisting of a bowl assembly, a column shaft assembly, a driver-to-pump
coupling assembly, the shaft seal, the discharge head assembly, the suction barrel and the driver.
The VCP pumps provided for this contract will supply condensate to a dearator.

Paragraph 1.2, below lists the operating specifications; Paragraphs 1.3 through 1.7 provide a
detailed description of the pump and related equipment.

1.2 DESIGN DATA AND OPERATING CONDITIONS

Pump Size & Type VCP250/5

Serial Number 1102343-001
Service Condensate Extraction Pump
Liquid Pumped Condensate Water
Specific Gravity 1
Pump Temperature 39.5℃
Flow 635m3/h
Mi i
Minimum Flow
Fl 168m3/h
/ continuous
Total head 150m
NPSHre 3.1m Required.
Speed 1488 Rpm
Efficiency 78%
Power Required 390kw
Rotation (as viewed looking down on motor top) ClockWise
Impeller Lift 6 mm

1.3 BOWL ASSEMBLY

The bowl assembly is a eight-stage subassembly which includes the single-suction impeller
that is mounted on the pump shaft. Sleeve couplings connect the pump shaft with the section, of
column shaft and the head shaft which extends through the stuffing box area to support the shaft
seal rotating components, the pump half coupling(530).

1.3.1 Bowl Assembly

The major components of the bowl assembly are the pump shaft (167, 404), the double suction
impeller (176), the single-suction impeller(176-1), the suction bell(075), the first case(079),
the series case(078), the top case (076)

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 Instruction, Operating, Maintenance Manual VCP PUMP

The cases of the bowl assembly are fitted with case wear rings, two per impeller, and sleeve bearing
that support the pump shaft. The wear rings (201,201-1,201-2) and bearings (103 and 105) are
are press fitted and secured by set screws.

The first-stage impeller is driven by its key (676) and retained by a first-stage split ring (255) and
shaft nut(205). Each series impeller is driven by a key (676-1) and retained by a series-stage
split ring (256) and thrust collar (950). The stage split rings are each installed in a shaft groove
at the hub of a impeller and held by a thrust collar that is fastened to the impeller by socket head
cap screws with washers.

The join of suction bell to case and case to case joints are assembled by studs with washers
and nuts, with the series case O-rings (747-1) sealing the case-to-case joints.
Similary, the joint of top case (076) to column (382) is sealed by an O-ring (747-2) and
secured by hex. bolts with washers and nuts.

1.3.2 Shafts Assembly

The shaft assembly, which transmits driver torque to the pump shaft, consists of the shaft drive
shaft (404) and the coupling components between shaft(167) and the drive shaft(404)
The shafts run in plain bearings lubricated by the pump discharge.

The top shaft is threaded its top end(upside of thrust bearing) to receive the shaft nut (532)
of the driver-to-pump coupling.
The two shaft couplings between the drive shaft and pump shaft are of the split clamp ring type.
The split ring (402) for each coupling assembles over the mating shaft shoulders where it is
held by the coupling sleeve (401) which receives and transfers drive power through shaft
coupling keys (676-4 and 676-5). The coupling sleeves are located by coupling keys(676-5).

1.3.3 Adjusting position of pump rotor assembly and Pump Coupling Assembly

Pump coupling is a gear non-space coupling, and consists of the pump half(530) and
motor half(529).

The shaft nut(532) functions to set the element in running position (rotor assembly lift: 6mm)
After the adjustment is made, the pump half coupling, and driver half coupling are
connected to lock the adjusting nut in place and retain the setting.

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 Instruction, Operating, Maintenance Manual VCP PUMP

1.4 NOZZLE HEAD ASSEMBLY AND RELATED COMPONENTS

The nozzle head assembly consists of the discharge head (082), motor stool(083),the column(382),
and the mechnical seal(120) which supports the mechanical seal.

1.4.1 Discharge head

The Discharge Head (082), which provides a right angle elbow for the pump discharge flange,
mates with the suction barrel (072) to support the pump and bearing stool(083). motor stool's
top flange is connected with the driver, while the discharge head(082)'s bottom flange, sealed
with an O-Ring (747) and secured by hex. bolts, mates with the column (382) to receive
the pump discharge and support the columns components and bowl assembly. The Joint of
discharge Head-to-column, sealed by the O-ring(747-3) is fastened by hex. bolts
while, studs secure the driver.

1.4.2 Column

The column form an assembly which directs the pumped fluid to the discharge head. The column
(382) is assembled by means of hex. Bolts with washers and nuts. Includes a bearing
(317) of the same type and assembled in the same manner as the top case bearing. The joints
off series
i column
l tto h
head
d are sealed
l dbby O
O-rings(747-3)
i (747 3)

1.4.3 Shaft Seal

: Mechanical Seal Drawing = UCH2-M06-LC-89-0004

Leakage of pumped fluid is controlled by the mechanical seal(120).

The pump uses Flowserve Mechnical seal, consisting of a rotating sub-assembly
and a stationary sub assembly, The mechnical seal can be assembled as a unit to
facilitate installation in the pump.

The rotating subassembly consists of the shaft sleeve (1) which located by the drive collar (58)
and upon which is mounted the rotating face body (14) which houses the rotating face
(15). The rotating face body is located by the set screws (57,57-1); the drive collar
by the set screws(57, 57-1). O-rings (13,19,76) seal against leakage under the rotating
face body and shaft sleeve.

The stationary subassembly consists of the seal flange(11) within which are installed.
The bellows assembly consists the stationary face (14). The seal flange is installed over studs.

CAUTION : Remove setting blocks (103) prior to starting pump.

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 Instruction, Operating, Maintenance Manual VCP PUMP

1.5 SUCTION BARREL

The suction barrel(072) receives and supports the entire pump and driver assembly at the
sole Plate, The sole plate is located and retained by a foundation bolts.
The mating flanges of suction barrel (072) and discharge head (082) are sealed by O-ring
(747)

1.6 DRIVER

The pump driver is a synchronous vertical solid shaft motor rated 390 kW, 1488 RPM. The
driver requires 6300 volt. 50 Hz, 3-phase power. Rotation, viewed from top, is clockkwise.
For detailed description of the driver, refer to the driver manufacturer's documentation.

1.7 LUBRICATION
The type of arrangement show in outline drawing is commonly used for flushing the mechanical
seals in a condensate system in which the condenser, hotwell and suction manifold are under
vacumn and the pumps are connected to the suction manifold, with blow off from stuffing box piped
back to the suction side of the pumps. When the pumps are operating, the bearings are lubricated
by the liquid pumped and self-connection is used for flushing the mechanical seals. However,
when
h any off th
the pumps are idl
idle, th
the stuffing
t ffi b
box iis under
d vacumn and
d can pullll air
i iinto
t th
the system.
t
To avoid this condition, it is recommended that the customer inject condensate
maintaining positive pressure to keep air from entering the pumps.

1.8 ENVIRONMENTAL CONSIDERATIONS

Operating pumping equipment environmental requirements are consistent with normal indoor
conditions.

However, in event of high levels of HUMIDITY, then the motor lubrication oil reservoir should
be occasionally checked for water condensation, to be removed if present.

In event of high levels of DUST, then the motor lubrication oil, oil reservoir, motor vents, and
motor internals should be checked for dust contamination or excessive dust buildup, which must
be removed if present. This also applies after long term coal dust exposure.

Consult motor manufacturer's representative for any other environmental considerations.

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 Instruction, Operating, Maintenance Manual HGS VCP PUMP

SECTION TWO - INSTALLATION.

2.1 GENERAL

Pump installation includes unloading and checking the equipment, preparing the foundation,
installing and grouting the pump, installing the driver, connecting the piping and instruments,
adjusting the impeller, and installing the shaft seal. When installing the pump, refer to the Pump
Outline Drawing contained in Attachment.

The unit should be installed only experienced personnel, with care taken to handle equipment
safely and to prevent entry of foreign materials into the working parts of the pump.

It is recommended that the services of HGS Installation Supervisor be employed for

the installation and initial starting of HGS pump. Such service will ensure the
purchaser that the equipment is properly installed, and will provide an excellent opportunity for
the plant operator to receive special instructions relative to the unit.

2.2 SHIPPING ARRANGEMENTS.

The pumps will ship to the job site approximately as follows :

a) Driver and driver half coupling. The driver may ship by separate carrier.

b) Suction barrel. The suction barrel may ship ahead of the remanding pump components.

c) Bowl assembly, column shaft sections, columns and discharge head, complety assembled.
Mechanical seal will be installed in the nozzle head.

2.3 EQUIPMENT REQUIRED.

In additional to common millwright tools used in this type of work, the following should be
available at the job site when installing or removing the pump:

NOTE : These item are not provided by HGS unless specifically ordered.

1. A crane or derrick. Lifting equipment must be of sufficient strength to handle the entire
assembled suction barrel (072) and pump (excluding the driver) safely. and must be of
sufficient height to provide ample clearance for the pump components.
2. Shackles (clevis-and-pin type adapters), suitably sized, for attaching lifting lines to equipment
lifting lugs.
3. Lifting eye bolts with washers and nuts, for handling pump sections when lifting lugs are not
provided.

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 Instruction, Operating, Maintenance Manual HGS VCP PUMP

4. I - beams or H-beams, for supporting pump subassemblies at barrel top flange when it is
necessary to install or remove the pump in sections.
5. A lifting eye bolt, for handling any section of shaft separately. Each shaft has a tapped hole at
each end to receive a lifting eye bolt.
6. Steel blocks and wedges or shim packs (one per foundation bolt) of 2" minimum thickness, for
leveling pump assembly. Alternatively, (or in addition), Jockey bolts can be used
below the soleplate.
7. Grout mix, non-shrink type. Also sufficient lumber for building a wooden trough to contain
the grout, and sufficient oil paint for grout protective covering.

2.4 PUMP HANDLING INSTRUCTIONS.

IMPORTANT : The approximate weights of the major pump components are listed on Outline Pump
Drawing in Section Attachment.

2.4.1 Handling precautions

WARNING : DO NOT WORK UNDER A HEAVY SUSPENDED OBJECT UNLESS THERE IS A

POSITIVE SUPPORT UNDER IT TO PROTECT PERSONS SHOULD A HOIST OR
SINGLE FAIL.

CAUTION : Adjust lifting equipment so that the load hook is directly over the foundation axis
Watch for overhead obstruction.

CAUTION : Use care to prevent bumping, pushing or scraping of pump parts, especially the shafts
and other machined surface and fits.

I. When handling the pump or its components, always work carefully to prevent accident.

2. Be sure lifting devices are in good repair and are capable of safely handling the weights being
lifted.

3. Adjust lifting equipment so that the load hook is directly over the foundation axis. Watch for
overhead obstructions.

4. Use care to prevent bumping, pushing or scraping of pump parts, especially the shafts and
other machined surfaces and fits.

5. Prevent foreign materials or dirt from entering the working parts of the pump or driver.

IMPORTANT : The driver lifting points are designed for lifting the driver only.

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 Instruction, Operating, Maintenance Manual HGS VCP PUMP

2.4.2 It is important to handle the pump components safely during installation and maintenance. The
following procedure are suggested.

Shaft.- Each section of shaft is threaded at each end to receive a lifting eye bolt. When raising
shaft from a horizontal position , avoid dragging of shaft lower end.

Discharge head (082) : Use lifting lugs provided on the discharge head (082). The lifting
lugs on the discharge head (082) are including the suction barrel (072). Do not lift
discharge head (082) with driver attached.

Driver : Handle driver in accordance with the manufacturer's instructions; normally, lifting lugs
are provided, Detach the driver from the pump before lifting, as the driver lifting points are
designed for lifting points are designed for lifting the driver only.

Suction barrel (072).. In horizontal position, use padded slings. in vertical position, install
lifting eye bolts with washers and nuts in the flange bolt holes.
Use care to prevent damage to the sealing face of the barrel top flange.

Other components.- Crated assemblies or components can be handled with a fork lift of suitable
capacity. For uncrated components, use lifting lugs when provided. Otherwise, install eye bolts
with washers and nuts in the flange bolt holes, with lifting lines attached to the eye bolts. When
using this method, use care to avoid damaging the flange sealing faces.

2.5 UNLOADING AND CHECKING THE PUMP.

CAUTION : Be certain that forklifts do not puncture boxes or crates. Prevent damage to the pump,
driver and related components.

I. Before handling equipment, review the procedure of Paragraph 2.4. work safely to prevent
accidents.
2. After unloading, uncrate and/or unwrap all parts inspect carefully to be certain nothing was
damage during shipment. Check driver carefully to be sure there are no signs of oil leakage.
3. Inspect shipment against materials list or shipping papers to check for possible shortages.
4. If damage or shortage has occurred, immediately advise the carrier's claim department and
nearest HGS office.

2.6 TEMPORARY STORAGE

If pump is to be stored for some time prior to installation, replace protective covers or
wrappings during inspections and recreate the equipment, Store equipment in a dry and
protected location, and keep pump free of dirt and grit both internally and externally.

The flange covers should be kept tight and renewed if damaged; do not remove these cover until
ready to connect pump to the system piping.
Shafts, bearings, and other finished parts subject to attack by moisture should be inspected
occasionally, and the protective coating renewed if necessary.
As regards motor storage, refer to the motor manual.
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 Instruction, Operating, Maintenance Manual HGS VCP PUMP

2.7 INSTALL PUMP

1. For reference drawings see Attachment

2. If pump is disassembled, assemble the pump as directed in

the applicable procedures of paragraph 4.6

3. For reinstallation of a previously installed pump, proceed

as follows:
(a) Thoroughly clean barrel plate top surface and
mating pump flange, removing all dirt, burrs and
roughness that could interfere with proper placement
of the pump.

(b) Lift and install pump assembly on barrel to mate

to barrel plate, and secure the pump-to-barrel-plate
with washers and stud nuts. Proceed to
paragraph 2.9.

4. For original installation only, proceed as follow:

(a) Check that foundation plate is assembled to barrel; if

detached, inspect foundation plate for any interference
that could prevent accurate leveling of the pump and
assemble foundation plate to barrel

(b) To prepare for grouting; first of all, rough up the foundation

in the area that will fit with the foundation plate to assure a
good grout bond; then lift foundation plate as required
to clean underside surface, ensuring that surface is
free of all dirt, oil, grease or other foreign matter.

(c) Jockey bolt as necessary to level the foundation plate within

the recommended tolerance of .0005" per linear foot(up to .0025"max.
total) using top face of foundation plate mount surface for reference.

(d) Install the pump assembly on barrel plate to verify the

leveling, using driver mounting surface for reference.

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 Instruction, Operating, Maintenance Manual HGS VCP PUMP

IMPORTANT : Check that O-ring is inserted in barrel groove. If not, insert the O-ring
in barrel groove.

(e) With pump accurately leveled, install hold down nuts

on anchor bolt and secure them evenly and firmly (but not
tight), being certain pump remains leveled within the
recommended tolerance.

2.8 GROUT THE PUMP

A good grout job is essential to trouble-free installation. It is important that a non-shrink type
of grout be used. Ordinary cement, sand and water mixtures tend to shrink as the water
evaporates, often leaving the underside of the foundation plate insufficiently supported. It is
recommended that grouting be performed by a qualified grouting contractor.

1. Be certain that the unit is leveled within .0005" per linear foot
(up to .0025"max.total) with foundation anchor nuts secured evenly
but not tight.

2. Build a wooden around the outer of foundation to prevent the grout

3. Pour the grout, being certain that the grout fills all voids between the foundation
plate and the foundation pit, Allow several hours for the grout to settle,
then dress surplus grout on the outside.

4. After the grout has hardened, remove any accessible curbing, wedges or
blocks, tighten the foundation anchor nuts to their permanent position,
confirm that the pump is leveled within the recommended tolerance (0.005" per
linear foot up to .0025"max.total), and apply a good oil paint to prevent air and
moisture from coming in contact with the grout.

2.9 INSTALL DRIVER AND ALIGN EQUIPMENT

When installing driver to pump, certain alignment checks should be made to ensure successful
operation. Proceed as follows :

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 Instruction, Operating, Maintenance Manual HGS VCP PUMP

NOTE : Refer to the driver manufacturer's instruction manual for additional instructions my apply.

I. Before mounting the driver, check mounting flange dimensions to be certain driver will fir the
driver mount surface.
2. Support driver vertically, shaft facing down, and thoroughly clean the shaft and mounting
surfaces in preparation for checking alignment.
3. Check trueness of driver mounting face by attaching a dial indicator to the driver shaft, on an
expansion Perpendicular to the shaft centertine, and setting the dial indicator to contact with
the driver mounting face. Rotating the shaft while the readings, check:

a) Concentricity of the rabbet fit, which must be within 0.001" total indicator runout
(T.I.R.) per foot of rabbet diameter.

b) Squareness of mounting face, which must be perpendicular to the shaft within 0.0012"
T.I.R. per foot of bolt circle diameter.

4. Check trueness of driver shaft by mounting the dial indicator to the driver housing and setting
the dial indicator to contact the shaft. Rotating the shaft to take readings, check:

a) Runout of shaft circumference, which must not exceed 0.003"T.I.R.

b) Squareness of shaft face which must be parallel to the driver mounting face
within 0.002" T.I.R.

5. Install driver on pump and temporarily tighten the mounting fasteners.

6. Using a dial indicator mounted to the driver half coupling,rotate driver shaft to take
readings from the motor mounting flange inside diameter surface and adjust driver as
necessary to center driver shaft within 0.002" total indicator readout.
Tighten driver mounting fasteners.

7.Refer to the driver manufacturer's manual for driver operating instructions. If the driver is
presently operable, check driver for proper lubrication, make sure the driver-to-pump
coupling components are disconnected
then connect driver leads to power source and operate the driver momentarily to
check the driver shaft for correct rotation.
Viewed from the top, the shaft rotates correctly Clock Wise. If rotation is incorrect,
interchange two leads to establish correct rotation, Correct rotation established, disconnect
driver leads at power source and tag the leads with correct terminal identification.

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 Instruction, Operating, Maintenance Manual HGS VCP PUMP

2.10 CONNECT MAIN PIPING

With the pump grouted and firmly bolted to the foundation, the main piping should be connected
to the pump piping flanges. When installing piping, note the following:

1. Use pipe of ample size for length of line and the pressure involved. Allowed absolute
minimum of bends and fitting.

2. Install check valve, followed by gate valve, in event of power failure, and protects pump from
system backpressure. Reducer, if used in discharge line, should be fitted to discharge flange
preceding check valve and gate valve.

3. Suction piping must be as short and direct as possible, and never smaller than the suction
entrance to the pump. Where a long suction line can not be avoided, the pipe size should be
at least one and preferably two sizes larger than the suction entrance. Bends and elbows,
when required, should be of long radius type. Suction pipe must be kept free of air leaks, and
high point which will form air pockets must be avoided.

4. Permit no excessive strain on the pump suction and discharge flanges, pipe strains on the
pump can be a definite source of trouble, resulting in possible misalignment, overheated
bearings, excessive wear, vibration, and even broken shafts. Although the pump is designed
to withstand specified load, is generally advisable to minimize these forces by
supporting the piping independently of the pump. Provide hot lines with loops or expansion
joints to prevent strains on the pump caused by pipe expansion.

5. Be sure pipe-to-pump flange faces mate flush and parallel with bolt holes in alignment, and
eliminate any tendency for the piping to push toward or pull away from the pump. Never
force piping into position with flange bolts or use drifts to force alignment of bolt holes.

6. Be certain that piping and suction discharge cavities are thoroughly clean before connecting
pump to piping. This will prevent welding slag, pipe scale and other foreign material from
entering the pump and causing damage to the pump or the valves and equipment which
follow. Provide strainers or screens where required to prevent foreign materials from being
drawn into the pump suction inlet.

2.11 INSTALL PRESSURE GAUGE.

Pressure gages are the most effective direct check on the operation of a centrifugal pump; their
use is highly recommended, It is preferable that the discharge gage be placed at least five pipe
diameters away from the pump or other fittings such as elbows or valves.

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 Instruction, Operating, Maintenance Manual HGS VCP PUMP

2.12 INSTALL AUXILIARY INSTRUMENTS, PIPING AND WIRING

Install and connect any auxiliary instruments, piping and wiring as indicated on the Pump
Outline Drawing and P&ID in Attachment.

2.13 ASSEMBLE COUPLING AND ADJUST IMPELLER

1. Install the mechanical seal as directed in Paragraph 2.17.3. Do not yet set the seal or
engage its rotating components with the pump shaft.

2. With shaft nut(532) plate screwed onto top shaft, install the coupling
in the driver half coupling with the bolts.

3. While holding pump half coupling- against turning, rotate shaft nut until gap between faces of
adjusting nut and spacer is a little higher than the impeller lift setting specified in Paragraph 1.2
Use feeler gages.

4.Turn shaft nut(532) so bolt holes will line up with the nearest holes in the pump half
coupling, then rotate the driver shaft to align bolt holes of the coupling with those of the
shaft nut.

CAUTION : Before performing step 5, make sure that the mechanicalseal drive collar set screw are
disengaged from the shaft.

5. Insert two of the coupling bolts and tighten progressively until secure, thereby closing the gap
above the shaft nut(532) and raising the impeller to running position.

6. Insert the remaining coupling bolts and tighten all bolts securely.

CAUTION : With dial indicator mounted to pump housing, check that pump shaft runout below
coupling does not exceed 0.001" per inch of shaft diameter. Readjust driver if necessary, tighten driver
mounting bolts.

2.14 SET THE MECHANICAL SEAL

Set and lock the mechanical seal as directed in Paragraph 2.17.4. This completes the pump
installation

2.15 REMOVAL OF UNIT

Removal of unit, when necessary, generally is performed in the reverse order of installation. To
remove the pump inner assembly from the barrel, proceed as directed in Paragraph 4.4, Pump
Disassembly. To prepare the unit for storage or shipping. Refer to the following paragraph.

2.16 PREPARATION FOR STORAGE OR SHIPMENT

Unit should be stored or shipped in original as-shipped condition, protected against moisture,
dirt and physical damage. Prepare the pump for shipping or storage as follow:
* As regards motor storage, refer to the motor manual.

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 Instruction, Operating, Maintenance Manual HGS VCP PUMP

1. Remove auxiliary instruments such as gages and place in a separate container with other small
loose part. This container may be stored inside pump if desired.

2. Remove the mechanical seal and provide separate protective wrappping.

3. Block the shaft or shafts as necessary to eliminate shaft end float.

4. Coat exposed machined surfaces that are vulnerable to moisture with a suitable protective
compound.

5. Ensure pump is thoroughly dry, place desiccant inside unit, install suitable flange covers and
plug any smaller openings.

6. Install protective wrapping and create the unit or mount on skids as appropriate. Support the
bowl assembly adequately along its length.

7. Store equipment in dry and protected location, keeping pump free of dirt and grit both
internally and externally.

8. During storage, periodically inspect desiccant and other protective materials and renew as
necessary.

2.17 MECHANICAL SEAL INSTRUCTION

2.17.1 Disassembly

To remove the mechanical seals, proceed as follows:

1. Disengage the drive collar set screw(57) from the pump top shaft

2. Disconnect and remove the driver to pump coupling components.

3. Disconnect seal injection piping and drain piping from the seal flange.

4. Remove the seal flange stud nuts, install and engane the setting blocks (103) then take hold
of the shaft sleeve and seal flange to lift up and remove as unit the entire mechanical seal.

2.17.2 Cleaning and inspection of parts.

1. Discard all gaskets and O-rings removed during disassembly.

2. Solvent wash remaining parts and dry using filtered, dry compressed air or a clean, lint-free cloth

3. Inspect all parts for wear, corrosion or other damage indicative of replacement.

HYOSUNG GOODSPRINGS Page : 24/24

 Instruction, Operating, Maintenance Manual HGS VCP PUMP

4. Inspect the mechanical seal faces as follows:

a) Stationary face:If circular lines are visible on the lapped surfaces, return the face to the
factory for relapping. If edges on the I.D. or O.D. are chipped or nicked more than
1/32", replace the face.

b) Rotating face and rotating face body: If the lapped surfaces of the rotating face and
rotating face body have any nicks, burrs, scratches, heavy stains or discoloration's
return to the factory for relapping. If penetrations are more than 1/32", or fractured all
the way through, replace the components.

5. For further maintenance procedure, refer to seal manufacturer's literature

2.17.3 Installation

1. Reassemble the mechanical seal as directed in the manufacturer's instruction.

2. Install the mechanical seal in the pump to fit the shaft sleeve (1) over the pump top shaft
and seal flange assembly (11) over the studs. Install and fasten the stud nuts. Do not yet
engage the set screws (57) with the pump top shaft.

3. Connect seal injection and drain piping.

4. Set and lock the mechanical seal as directed in Paragraph 2.17.4.

2.17.4 Setting and locking the mechanical seal.

1. Replace the pump half coupling keys (676-2), pump half coupling (530) and adjusting nut
(57). Connect to the driver half coupling (529).

2. Adjust the impeller lift and connect the coupling components as directed in Paragraph 2.13

3. Referring to the mechanical seal assembly drawing in attachment, engage the set screws
(57) with the shaft sleeve (1) and set the shaft sleeve so that the distance between drive
collar (58) and seal flange assembly (11) is as show on the drawing.

4. Firmly tighten the set screws (57) to engage the pump top shaft(404).

CAUTION : Remove setting block (103) prior to starting pump.

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 Instruction, Operating, Maintenance Manual HGS VCP PUMP

SECTION THREE - OPERATION

3.1 OPERATING PRECAUTIONS

CAUTION
1. Operate the pump only within the design parameters specified in Paragraph 1.2.

2. To prevent possible damage to the pump, always be sure the suction valve and suction vent
valve are fully open during pump operation.

3. Do not operate pump for any extended period of time with discharge valve closed, as
insufficient flow will lead to pump overheating and greatly reduced pump life. If pump is
installed in a parallel system, operate only a sufficient number of pumps (at or near their
rated capacity) to maintain the desired total flow.

NOTE : In most case, recommended minimum and/Or intermittent minimum flow rates for the
pump are specified in Paragraph 1.2. If a minimum or intermittent minimum flow is
specified, do not operate the pump below the specified minimum and/or intermittent
minimum flow rate, and limit operation at the minimum/intermittent minimum flow rate to
one (1) hour per day for a hour per day for a total of 1000 hours.

4. Do not allow pump to run dry or break suction, as possible damage to the unit may occur.

5 .Pumped liquid must be free from excessive air or gas. The presence of excessive air or gas in
the liquid will result in a reduction in capacity and head which cannot be predicated with
accuracy, and may lead to excessive wear or damage of the unit.

6. HGS makes no guarantees against the erosive action of sand or abrasive material in
pumped liquid. Small amounts of abrasives will pass through the unit with slight immediate
effect, but it is only a question of time until continued operation under this condition will
damage the working parts of the pump.

IMPORTANT : Before initial start-up of a pump used in condesate service, clean the system

7. Perform the preliminary check of Paragraph 3.2 before initiating pump operating.

3.2 PRELIMINARY CHECK

1. Before starting the pumping operation, check the security of all bolting, piping and wiring

2. Check all gages, valves and instruments for proper working order.

3. Verify proper flow of condensate injection to the mechanical seal, (Refer to the P&ID drawing
in attachment for injection requirements).
HYOSUNG GOODSPRINGS Page : 36/24
 Instruction, Operating, Maintenance Manual HGS VCP PUMP

4. Check the driver and pump thrust bearing for proper lubrication.
Refer to the driver instruction manual for instructions regarding starting of the driver.

3.3 STARTING

CASE ONE - In this case the system is empty and no pumps are running. There is water in the
hotwell but not in the condensate pump casing (i.e. the condensate pump suction valve is
closed). Condenser vacumn pumps may or may not be running.

1. Perform the preliminary check of Paragraph 3.2

2. Close the discharge valve.

3. Open the suction and discharge vent valves.

4. Open the suction valve slowly. Make sure the pump is completely filled with water.

5. Crack open the discharge valve (5 to 10% open).

6. Once the discharge is fully primed, close the discharge vent valve. The suction vent must
remain open.

7. Energize the driver to start the pump. As soon as it is up to speed, open the discharge valve
slowly to prevent any abrupt changes in capacity.

CAUTION : Running the pump with discharge valve closed will lead to rapid overheating of the pump.

CASE TWO : In this case, the system is operating (i.e. one pump running and the standby pump
will be brought on line.

1. Perform the preliminary check of Paragraph 3.2

2. Open suction and discharge vent valves.

3. Open suction valve slowly. Make sure the pump is completely filled with water. (Pump must

4. Open the discharge valve fully.

5. Check whether the discharge is fully primed, the suction vent valve must remain open.

6. Energize the driver to start the pump.

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 Instruction, Operating, Maintenance Manual HGS VCP PUMP

3.4 OPERATING CHECK

As soon as possible after the pumping operation begins, repeat the applicable portions of the
checking procedure of Paragraphs 3.2. Other than monitoring of flows, pressures, temperatures
and driver and pump thrust bearing's lubrication, the pump should require no attention during
operation. In the event, symptoms of trouble occur, stop the pump and refer to the Trouble-Shooting
Chart, Paragraph 4.3.

3.5 STOPPING

To stop the pump, close the discharge valve and immediately deenergize the driver.

IMPORTANT : Do not stop the flow of cold condensate injection to the stuffing box when the pump is
idle, as to do so will allow air to enter the system

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 Instruction, Operating, Maintenance Manual HGS VCP PUMP

SECTION FOUR-MAINTENANCE

4.1 GENERAL

In general, any type of equipment must be maintained in good repair if it is to give satisfactory
and efficient service. HGS pumps are designed to operate for extended periods with a
minimum of regular maintenance, the frequency and scope of required maintenance depending
primarily on the conditions of service to which the pump is subjected.

Under normal circumstances, regular performance of the preventive maintenance tasks outlined
in Paragraph 4.2 will prevent costly breakdowns and detect most problems that may arise.
Periodic dismantling of the pump for inspection is no necessary unless there is reason to suspect
excessive wear or other internal damage. in the event a pump malfunction is suspected, refer to
the Troubleshooting Chart of Paragraph 4.3. If major maintenance is required, refer to the
procedures of Paragraphs 4.4 thru 4.6 For driver maintenance requirements, refer to the driver
manufacturer's instructions.

4.2 PREVENTIVE MAINTENANCE

Periodic testing or monitoring of critical pump performance factors, such as head, flow, driver
current, speed, temperatures, vibration levels, etc., is recommended to establish a reliable
data baseline for use in evaluating and projecting the pump's condition and in establishing
the maintenance requirements for its particular application. The scope and frequency of
periodic testing is primarily a matter of customer decision based on the severity of pump
operating conditions. In most cases the faithful measurement, recording, review and
extrapolation of periodic test results every few months will provide a sufficiently adequate
and reliable indication of pump condition that major maintenance, when needed, can be
scheduled and performed in a timely manner.

In additional to periodic testing, the following maintenance should be performed regularly:

1. Check tightness of the pump and driver mounting fasteners, which may loosen, and tighten
them as necessary.
2. Inspect all piping for evidence of leakage, loosening or other damage and repair as necessary.

3. When pump size permits, periodically rotate shaft by hand to check for free rotation. If
binding occurs, recheck pump alignment and impeller setting.
4. Refer to manufacturer's instructions for driver lubrication, periodic inspection and any other
schedule maintenance tasks to be performed.

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 Instruction, Operating, Maintenance Manual HGS VCP PUMP

4.3 TROUBLESHOOTING CHART

SYMPTOM PROBABLE CAUSE

1. No Discharge (a) Pump not primed (barrel empty).

(b) Pump not vented.
(c) Discharge valve closed.
(d) Wrong direction of rotation.
(e) Pump intake blocked or impeller completely
plugged.
(f) Suction valve closed.

2. Insufficient Pressure (a) Suction or discharge valve

or Flow closed.
(b) Impeller incorrectly set.
(c) Insufficient suction head.
Check for clogged suction line or screen.
(d) Impeller clogged.
(e) Suction vent valve not open
(f) Wrong direction of rotation
(g) System
y head too high
g
(h) Speed too low; Check drive input.
(i) Excessive air or gasses in liquid.
(j) Wear rings worn;
Impeller damaged.
(k) Air leak in suction or at stuffing box.

3. Reduced Output (a) Suction valve not fully open.

Following Period of (b) Insufficient suction head;
Satisfactory Check for clogged suction line or screen.
Operation (c) Suction vent valve not open.
(d) Excessive air or gasses in liquid.
(e) Air leak in suction or at stuffing box.

4. Excessive Power Consumption, (a) System head incorrect.

Noise or Vibration (b) Impeller drags (incorrect setting)
(c) Mechanical defects: sealShaft bent; Rotating element
binds: Excessive clearances;
Misalignment.
(d) Pump or driver mounting fasteners loose.
(e) Specific gravity or viscosity of pumped liquid is to high

HYOSUNG GOODSPRINGS Page : 43/24

 Instruction, Operating, Maintenance Manual HGS VCP PUMP

4.4 PUMP DISASSEMBLY

4.4.1 Disassembly of Pump (General)

1. Follow stopping procedure, Paragraph 3.5, and disconnect driver leads from power source.

2. Disconnect any auxiliary piping and wiring, including seal injection and drain piping, that
would interfere with disassembly.

3. Disengage the drive collar set screws (57-2) from the top shaft (404) in the mechanical seal.

4. Remove the driver half coupling bolts, remove the pump half coupling bolts,
detach and remove the driver, then remove the shaft nut(532)
and the pump half coupling (530).

NOTE: For further disassembly of the mechanical seal, refer to the manufacturer's literature.

5. Remove motor stool(083), and disconnect the main piping and aux. piping from discharge
head(082),and disconnect the discharge head(082) from the suction barrel(072)

6. With lift lines attached to lifting lugs on the discharge head(082), lift the pump assembly
bodyy slowlyy to verticallyy above the barrel(072)
( ) hole byy using
g the lifting
g lugs
g and shackles,
while lifting pump, adjust the chain block of the wiring rope so that pump assembly body
stands vertically as shown in Dismantlement and Assembly Procedure”.
Move pump to the maintenance area, and positioned it from vertical to horizontal position
as shown Dismantlement and Assembly Procedure”,

7. Remove discharge head(082) and column spool(382) from pump assembly.

8. Thread a lifting eye bolt into top shaft(404), and attach a lifting line. Disconnect top shaft(404) from
shaft coupling(401) and split ring(402), and remove top shaft(404)

9. Disassembly the pump bowl assembly as directed in the following paragraph 4.4.2.

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 Instruction, Operating, Maintenance Manual HGS VCP PUMP

4.4.2 Disassembly of Pump Bowl Assembly.

1. With the pump bowl assembly supported horizontally, disconnect and remove the top case
(076), fasteners, thrust collar (950), split ring (256), top stage impeller(176-1), and key(676-1).

NOTE : When the pump is reassembled , the cases, thrust collars, split rings and impellers must be
reinstalled in the same positions as when removed. Note that original factory parts are marked for
location and orientation to assure correct installation at reassembly.

2. Repeat the procedure of Step "I" to remove the series cases (078) and impeller components.
Support the pump shaft as needed at all time to prevent possible bearing damage.

3. Disconnect pump shaft (404) from shaft coupling (401) and remove pump shaft(404).

4. Repeat the procedure of Step "1" to remove the case (078,079) and impeller components.
Support the pump shaft as needed at all time to prevent possible bearing damage.

5. Disconnect and remove the suction bell (075) from the 1st stage case (079).

6.Examine the bowl assembly bearings (103,105 and 317) and wear rings(201,201-1,201-2)
for wear indicative of replacement as directed in Paragraph 4.5 If replacement of any of these
parts,, which are press-fitted,
p p , is required,
q , proceed
p as applicable.
pp

(a) To remove a bearing, remove the one or two set screws as applicable and them press
the bearing out of its housing.
(b) To remove a wear ring, remove the set screws and then use a suitable puller tool to
free the wearing.

4.5 CLEANING AND INSPECTION

1. Discard all gaskets and O-rings removed during disassembly.

2. Refer to Paragraph 4.5.1 for the diametrical running clearance specifications. Discard and
replace all excessively worn parts. Wear ring clearance can be restored by installing original
or oversized wear rings and, if necessary, turning down to size.

3. Solvent wash and use clean dry, filtered, compressed air to dry all remaining components.
Clean, lint free cloths may augment or substitute for the compressed air.

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 Instruction, Operating, Maintenance Manual HGS VCP PUMP

4. When parts are dry, inspect each part for wear, erosion, or corrosion, discard all parts worn,
eroded corroded sufficiently to damage pump operation. Provide replacement parts for all
parts discarded.

5. Repeat the cleaning and drying procedure of Step 3 for all original and replacement parts to
be reassembled.

4.5.1 Diametral Running Clearances.

The following diametral running clearances are factory tolerances for a new or rebuilt pump. For
maintenance purpose, it is recommended that pump running clearances not be allowed to exceed 150% of
the maximum values given.

FROM TO CLEARANCE

Shaft sleeve bottom (170) Suction bell Bearing (103) .004 ~ .006"

Shaft sleeve series (171-2) Bowl Bearing (317) .004 ~ .007"

Shaft sleeve, Column ((171-3)) Column Bearing

g ((317)) .004 ~ .007"

Shaft sleeve, M/Seal Housing(980) M/Seal Housing Bearing(106) .004 ~ .007"

Impeller (176) Wear Ring (201) .010 ~ .011"

Impeller (176-1) Wear Ring Eye Side (201-1) .010 ~ .011"

Impeller (176-1) Wear Ring Hub Side (201-2) .010 ~ .011"

4.6 PUMP REASSEMBLY

Assemble the pump bowl assembly, if disassembled, as directed in Paragraph 4.6.1 Complete the pump
assembly and installation as described in Paragraph 4.6.2

4.6.1 Reassembly of Pump Bowl Assembly

1. Replace any bearings (103,317,and 106) or wear rings (201,201-1,and 201-2) that have been
removed and check that all retaining screws are securely tightened. Note that the bearings
and wear rings are a press fit.

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 Instruction, Operating, Maintenance Manual HGS VCP PUMP

CAUTION : All impellers, split rings, thrust collars and pump cases must be replaced in same location and
orientation as originally installed. If new pump shaft, cases or impellers are to be installed, new split rings
must be used.

2. Slide pump shaft into the 1st stage case (079), Install the first-stage impeller key, impeller
(176), split ring (255) and Impeller nut (205) and shaft sleeve on pump shaft (167) and tighten
the impeller nut's set screw, providing shaft support as necessary to protect the case bearing.
The split ring(255) should be correctly oriented with its extended side toward the impeller.

NOTE: Lubrication of the pump shaft is recommended to ease installation of impellers. When installing
impeller on shaft, heating should not be required.

3. Install suction bell (075) on 1st stage case (079) ; assemble washers and nuts
on studs and torque the fasteners.

4. Install second-stage impeller key (676-1) and impeller (176-1), properly sized
split ring(256) and thrust collar (950), securing thrust collar to impeller using
screws with washers.

5. Install O-ring (747-1) and pump case (077,078) and secure with washers and nuts.

6. Repeat the operations of Steps 4 and 5 to complete the assembly of stages from 3 to 7. Each
of these stages consists of an impeller key (676-1), impeller (176-1), properly-sized
split ring (256), thrust collar (950), screws, and the applicable pump cases (077,078)
sealed with an O-ring (747-1) and fastened with stud, washers and nuts

12. Regarding nest procedure, proceed in the reverse order of disassembly while ensuring
the match marks are alighed. In addition, the following instructions must be observed.

(1) When replacing parts, check thoroughly before assembling.

(2) When reassembling each part, remove foreign matter in the tapped holes with
compressed air and check for defects or dirt on the flange surfaces and mating surfaces.
(3) Before reassembly, remove anti-rust agent, check for corrosion and damage.
(4) Generally, replace consumables (such as O-rings, rubber rings, washers,etc.) with
new one.

NOTE: Please refer to the "Dismantlement and Assembly Procedure"

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 Instruction, Operating, Maintenance Manual HGS VCP PUMP

4.6.2 Reassembly of Column and Head Components

1. Assemble the top shaft (404) to the pump shaft (167) as follows :

2. If removed, reinstall the press-fitted column bearings (317) in column (382)

3. Install 0-rings and support shaft as necessary to avoid bearing damage while installing
the column (382) to mate with the top case (176); then install and torque the hex. Bolt.

4. Install O-ring (747-3) in top column flange and carefully install the discharge head (082)
into position, using care to guide the top shaft (404) safely. Assemble and torque the
discharge head-to-column fasteners.

5. Assemble aux. piping (M/Seal external flushing line, blow-off line, seal drain line, etc)
on discharge head (082).

6. With lift lines attached to lifting lugs on the dicharge head (082), lift the pump and place
place the assembly over the barrel, and assembly and torque the nozzle head to barrel
fasteners.

7. Complete the pump installation as directed in the applicable portions of Paragraphs 2.9
thru 2.17,

NOTE: Please refer to the "Dismantlement and Assembly Procedure"

HYOSUNG GOODSPRINGS Page : 48/24

 DOC. NO. UCH2-M06-LC-77-0001
SPECIFICATION FOR MFG
PUMP DATA SHEET OF PUMP ESTIMATED
1 PROJECT UCH II EXPANSION PROJECT REV. APP'D BY CHK'D BY MADE BY
2 LOCATION PAKISTAN JOB NO - A FOR APPROVAL S.D.PARK J.Y.LEE K.J.YOON
3 ITEM NO. 13LCB11AP001,13LCB21AP001 ORDER NO 1102343-001 B FOR APPROVAL S.D.PARK J.Y.LEE K.J.YOON
4 PUMP TYPE VCP250/5 Q'TY 2 SETS C
5 SUPPLIER HGS MFG. HGS MOTOR ENGINE
DRIVER
6 SERVICE Condensate Extraction Pumps Q'TY 2 SETS
7 OPERATING CONDITIONS PERFORMANCE
8 LIQUID Condensate Water SPEED 1488 RPM DES. EFF. 78 %
9 CAPACITY 635.0 3
m /Hr NPSHre 3.1 m (@1st Impeller) SFT. POWER 332.6 kW
10 TOTAL HEAD 150 m B MATERIALS
11 DIF. 14.70 barg ASTM
12 PRESS DIS. 14.70 barg B CASING A216 Gr WCB or Eq.
13 SUC. 0.00 barg IMPELLER A743 Gr CA15 or Eq.
14 PUMPING TMP. 39.5 ℃ SHAFT A276 Tp 410 or Eq.
15 VAPOR PRESS NEG. barg B SHAFT SLEEVE A276 Tp 410 or Eq.
16 NPSH Avail. 4.98 m (@1st Impeller) B BASE PLATE A36 or Eq.
17 VISCOSITY - CP S.GRAVITY 1.000 BARREL A36 or Eq.
18 SIZE - mm CORR/EROS -
SOLID
19 CONTENT : - % CAUSED BY
20 CONSTRUCTIONS SEALING WATER YES NO
21 MOUNTING Foot Centerline Bracket INLET SIZE 1/2" RATING 300 LB
22 CASING Vertical Inline OUTLET SIZE N/A RATING N/A
23 SPLIT Axial Radial PRESS 1~2 barg Q'ty 11 ℓ/min
24 FLANGE BORE DIA. RATING FACING POSITION ELECTORIC MOTOR
25 SUCTION Ø400.0 mm ANSI 150LB RF SIDE MFR. HHI TYPE TE-FC
26 DISCHARGE Ø250.0 mm ANSI 300LB RF SIDE R.OUTPUT 390 kW NO.OF POLE 4
27 LENGTH OF BARREL (VERTICAL CAN PUMP) 4.6 m SYN.SPEED 1500 rpm INS.CLASS F
28 NO. OF STAGE 5 PHASE 3 Φ CYCLE 50 Hz
29 INSTALLATION INDOOR OUTDOOR VOLTAGE 6300 V B SPACE HEATER 1Ph,230V,200W
30 BASE PLATE COMMON SOLE ASSESSARIES
31 IMPELLER CLOSE OPEN SEMI-OPEN COUPL. SET YES NO BASE PLATE YES NO
32 LUBRICANT GREASE OIL WATER C. FLANGE YES NO ANCH. BOLT YES NO
33 COUPLING FLEXIBLE RIGID FLANGE FUNNEL YES NO GAUGE COCK YES NO
34 TRANSMISSION DIRECT V-BELT SUC.STRAINER YES NO PRESS.GAUGE YES NO
35 BRG. NO. THRUST Anti-friction RADIAL Journal APPENDED DRAWINGS
36 ROTATION VIEWD FROM DRIVER CW CCW PERFORMANCE UCH2-M06-LC-77-0002
37 TAPPED VENT DRAIN GAUGE CONN. OUTLINE DWG. UCH2-M06-LC-00-0001
38 OPENING 1" 1/2" 1/2" P&ID UCH2-M06-LC-01-0001
39 PACKING MECH. SEAL WEIGHTS (APPROX)
40 SHAFT SIZE - TYPE BSTFN PUMP 6,000 Kg Lbs
41 SEAL TURN - MODEL - BASE[PUMP] 420 Kg Lbs
42 MFG. KSM or Eq. DRIVER 3,040 Kg Lbs
43 SPARE PARTS REMARKS
44 1. Except Details specified on this Data Sheet,
45 all subjects including test shall be
46 performed in accordance with H.I STANDARD B
47
48
49
HYOSUNG GOODSPRINGS, INC.
CHARACTERISTIC CURVE Date : 2012/10/19

ITEM No. : 13LCB11AP001,13LCB21AP001 DOC. No. : UCH2-M06-LC-77-0002 Rev. 0

CUSTOMER : HYUNDAI ENGINEERING SERVICE : CONDENSATE EXTRACTION PUMP
HGS SER. No. : 1102343-001 MODEL : VCP250/5
3 -1
SPECIFIED ITEMS : 635.0 m /hr x 150 m x 1,487 min x 390 kW x 50 Hz x 4 Poles x 6,300 V
( LIQUID HANDLED = Condensate Water : = 1.00 kg/l : Temp. = 39.5 ℃ : Vis. = - cP )
REFERENCE DOCUMENT: UCH2-M06-LC-77-0001(CEP PUMP DATA SHEET)

6
peller Eye

5
4 NPSHre
NPSH req( m ) @ Imp

3
2
1
0
0 100 200 300 400 500 600 700 800 900 1,000
CAPACITY ( m3 / hr )

300 100

270 90

240 80
Pump Efficiency
Shut‐off Head:
210 193m=18.9barg
193m 18 9barg 70

EFFICIENCY ( % )
180 60
TOTAL HEAD (m)

150 50

Total Head
120 40

90 30
Design Flow= 635 m3/h

Max Flow= 762 m3/h

Min Flow= 168 m3/h

60 20

30 10

0 0
0 100 200 300 400 500 600 700 800 900 1,000
CAPACITY ( m3 / hr )

600
500 Pump Power Input

400
W)

BHP
SHAFT POWER ( kW

300
200 Rated BHP=
332.6kW
100
0
0 100 200 300 400 500 600 700 800 900 1,000
CAPACITY ( m3 / hr )

Issued By : DESIGN TEAM App'd By : S.D.PARK Chk'd By : J.Y.LEE Prep'd By : K.J.YOON

 JOB NO. : -

LUBRICANTS LIST PROJECT NAME : UCH II EXPANSION PROJECT

(VENDOR'S RECOMMENDATIONS)
DATE : 2012.6.29

10LCB11AP001
ITEM NO. ITEM NAME Condensate Extraction Pumps NO. OF SETS 2 VENDOR : HYOSUNG GOODSPRINGS
10LCB12AP001

INITIAL REPLACEMENT CHARGE MAKE-UP

GRADE LOCATION TO
NO SHELL CALTEX MOBIL ESSO CHARGE
(ISO or ASTM) BE USED
QUANTITY INTERVAL QUANTITY INTERVAL

Replacement from
PUMP
SHC 525 4 4 time to time
1 ISO VG No.46 - - - ~3 Month 1 Month BEARING
VG46 (LITER/SET) (LITER/SET) depending on the
HOUSING
state Oil

Alvania 390 390 GEAR

2 GREASE - - - ~3 Month - 4 Month
EP1 (g/SET) (g/SET) COUPLING
Gadus S2 434 130 MOTOR DE
3 GREASE - - - - - 4 Month
V100 2 (g/SET) (g/SET) BEARING
Gadus S2 668 200 MOTOR NDE
4 GREASE - - - - - 4 Month
V100 2 (g/SET) (g/SET) BEARING
GEAR COUPLINGS


MANUAL
(VERSION - 080205)

NARA CORPORATION
#1500-11, Dadae-Dong, Saha-ku, Pusan, Korea,
Tel : (051) 264-3100, Fax : (051) 264-3107
 - CONTENTS

1. STRUCTURE ․․․․․․․․․․․․․․․․․․․․․․․․․․ 1

2. INSTALLATION ․․․․․․․․․․․․․․․․․․․․․․․․․ 2

(1) ASSEMBLING

(2) DISASSEMBLING AND INSPECTION

(3) CENTERING

3. LUBRICATION ․․․․․․․․․․․․․․․․․․․․․․․․․ 4

(1) FEEDING

(2) RECOMMENDED LUBRICANTS AND QUANTITY

4. MAINTENANCE ․․․․․․․․․․․․․․․․․․․․․․․․․ 5

-------------------------------------------------------------------------------------------------------------
 1. STRUCTURE
NR Gear coupling consists of the internal spur gears in its sleeves and the external spur gears

with crowened teeth on its hubs, both of which are in mesh when assembled.

NARA GEAR COUPLINGS

1. Sleeve A

2. Sleeve B

3. Two hubs

4. Reamer bolts sets

5. Lubrication plugs

6. Side 0 Rings

7. Center 0 Ring

■ CROWNED HUB TEETH (Pitch diameter on a curve type)

Since these spur gears are so designed as to employ an involute

tooth profile and to have a special form on the top and bottom

lands of their teeth, taking account of the tilting and lubrication,

and equal speed rotation and smooth power transmission can be

obtained even when a little tiltings occur between the sleeves and

the hubs

-1-
 2. INSTALLATION
1. ASSEMBLING

(1) Ensure all parts are clean.

(2) Apply a light coat of grease to the 0 Rings and insert 0 Rings into grooves of sleeves.

(3) Place sleeves over shaft ends. Care should be taken not to damage 0 Rings.

(4) Install hub on their respective shafts with the longest hub end towards shaft end or to-

wards machine bearing depending on the type. Hub faces have to be flush with shaft end.

(5) Install units to be connected in place and check the spacing between hubs. See below

tabulation for correct hub spacing. (Table.1)

(6) Align the two shafts, check alignment using a dial gauge. (Fig.1) (Table.2)

(7) Coat hub and sleeve gearings with grease and slide sleeves over hubs.

(8) Insert reamer bolts into bolt holes of sleeve and sleeve or, sleeve and flange.

(9) Remove both lube plugs of one sleeve and add grease in sufficient amount to overflow

with lubricant holes in horizontal position. Re-install the 2 plugs.

(10) In case of doubt, please consult us.

2. DISASSEMBLING AND INSPECTION

(1) Remove bolts.

(2) Slide sleeves off hubs.

(3) Control gearing and sealing.

(4) Control alignment.

(5) In case of doubt, please consult us.

3. CENTERING

(1) SPACING BETWEEN HUBS AND ALLOWABLE ERROR

TABLE 1.

SIZE 112 125 140 160 180 200 224 250 280
GAP 8 8 8 10 10 10 12 12 14
-0.5 -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 -0.5
Δd
～ 2.0 ～ 2.5 ～ 2.5 ～ 3.0 ～ 3.0 ～ 3.0 ～ 4.0 ～ 4.0 ～ 4.5
SIZE 315 355 400 450 500 560 630 710 800
GAP 14 16 16 18 22 22 28 28 28
-0.5 -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 -0.5 -0.5
Δd
～ 5.5 ～ 5.5 ～ 6.5 ～ 5.0 ～ 6.0 ～ 6.5 ～ 8.0 ～ 8.5 ～ 9.5
SIZE 900 1000 -- -- -- -- -- -- --
GAP 32 32 -- -- -- -- -- -- --
-0.5 -0.5
Δd -- -- -- -- -- -- --
～10.5 ～12.0

-2-
(2) ALIGNMENT

TABLE. 2

ALIGNMENT ALIGNMENT
SIZE SIZE
ANGULAR OFF-SET ANGULAR OFF-SET

112 BELOW 0.05 BELOW 0.03 355 BELOW 0.21 BELOW 0.11

125 BELOW 0.06 BELOW 0.03 400 BELOW 0.24 BELOW 0.11

140 BELOW 0.06 BELOW 0.04 450 BELOW 0.25 BELOW 0.17

160 BELOW 0.08 BELOW 0.04 500 BELOW 0.29 BELOW 0.19

180 BELOW 0.09 BELOW 0.05 560 BELOW 0.33 BELOW 0.21

200 BELOW 0.10 BELOW 0.05 630 BELOW 0.39 BELOW 0.24

224 BELOW 0.12 BELOW 0.06 710 BELOW 0.45 BELOW 0.28

250 BELOW 0.14 BELOW 0.07 800 BELOW 0.50 BELOW 0.31

280 BELOW 0.16 BELOW 0.08 900 BELOW 0.58 BELOW 0.33

315 BELOW 0.19 BELOW 0.10 1000 BELOW 0.63 BELOW 0.35

Fig. 1

-3-
 3. LUBRICATION
1. FEEDING

(1) In the case of gear oil (Fig.2)

- Remove the two oil plugs, upper and lower, and feed the recommended oil through the

upper plug hole, until it flows out of the lower plug hole.

- After the feeding, screw in the plugs securely applying the sealing agent (as used in the

keyway portion) or sealing tape.

(2) In the case of grease (Fig.3)

- When assembling, pack the coupling sleeve and the coupling hub with the recommended

grease until their teeth become invisible, and after tightening the reamer bolts, add the

grease through the oil plug hole using a grease gun, etc.

FIG.3 HOW TO APPLY GREASE

FIG.2 HOW TO FEED OIL

2. RECOMMENDED LUBRICANTS AND QUANTITY

(1) Recommended lubricants

TABLE. 3

Makers Gear oil Grease

Esso Pen-o-led EP6 Pen-o-led EP 35

Shell Shell Macoma oil 82 Alvania EP grease 1

Caltex Meropa 680 Multifak EP 1

Mobil Mobil Compound GG Sovarex L O

-4-
(2) Lubricant quantity list

TABLE.4

NR-SSM NR-SEM NR-CCM NR-CEM NR-CAM

Size Grease Grease Size Grease Grease Grease
(gf) (gf) (kgf) (kgf) (kgf)
112 50 38 450 2.3 1.9
125 65 51 500 3.4 2.8
140 100 77 560 4.1 3.5
160 130 100 630 6.0 5.3
180 160 130 710 10.5 7.7
200 220 170 *** B L A N K ***
224 320 270
250 480 370
280 620 510
315 1000 810
355 1200 1000
400 1800 1440

SVM SVM

Size Grease UPPER Size Grease UPPER

(gf) LOWER (gf) LOWER

50 270
125 224
35 180
70 390
140 250
50 265
90 500
160 280
65 345
130 750
180 315
90 500
180 900
200 355
120 600

-5-
 4. MAINTENANCE
- After about 3 months of the initial operation, feed fresh oil or grease to the coupling

after thoroughly removing the old oil or old grease and abrasion particles from the inside of the

coupling by means of disassembly, and thereafter add or change the oil or grease using the

plug hole every 6 months (every 4000 hours).

(1) Remove both plugs of one sleeve.

(2) Position lube holes at horizontal and by means of a grease gun, force grease into one hole

until clean grease flows out of the opposite hole.

(3) Re-install the plugs.

-6-
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 AC INDUCTION MOTOR DATA SHEET
Model No.or RFQ No Item No. Rev. No. [ 4 ]
Project Name HYUNDAI ENG UCH II PROJECT(CEP) Project No. 20114995RMHF13 Quantity 2 sets
GENERAL SPECIFICATION PERFORMANCE DATA
Frame Size 4 355 Rated Output 1 390 kW
Type 3 HLE5 354-48V Number of Poles 1 4
4
Enclosure(Protection) TEFC ( IP 55 ) Rotor Type Squirrel Cage
Method of Cooling IC411 Starting Method* D.O.L
Rated Frequency 50 Hz Rated Voltage 6300 V
Number of Phases 3 Current Full Load 1 44.0 A
Insulation Class F B H Locked-rotor** 600 %
Temp. Rise at full load (by resistance method) Efficiency
at 1.0 S.F 34 70 deg.C 50% Load 95.0 %
Motor Location Indoor Outdoor 75% Load 95.3 %
Altitude Less than 1000 meter 100% Load 95.5 %
Relative Humidity Less than 90 % Power Factor(p.u)
Ambient Temp. 3 50 deg.C (Max.) 50% Load 1 0.76
4
Duty Type Continuous ( S1 ) 75% Load 1 0.82
Service Factor 1.0 100% Load 1 0.85
Mounting B3 B5 V1 Speed at Full Load 4 1487 r.p.m
Type Anti-friction Torque
Bearing DE/N-DE 1 6324C3 / 7322BDB Full Load 1 255.3 kg·m
Lubricant 3 Grease(Shell,Gadus S2 V100 3) Locked-rotor** 1 90 %
External Thrust Not applicable Breakdown** 200 %
Coupling Method Direct V-Belt Moment of Inertia (J)
Shaft Extension Single Double Load 1 6 kg·m²
Terminal Main Steel Cast Iron Motor 3 10.1 kg·m²
Box Aux. Yes No Sound Pressure Level (No-load & mean value at 1m from motor)
Rotation(Viewed from DE) 1 CW CCW BI-Direction 82 dB(A)
Application PUMP Vibration 1 2.3 mm/sec(r.m.s)
Area classification Non-Hazardous, Non-Seismic Permissible number of Cold 2 times
Type of Ex-Protection N/A consecutive starts Hot 1 time
Applicable Standard IEC,ISO Paint Munsell No. 7.5BG 6/1.5
ACCESSORIES SUBMITTAL DRAWING
2 1) Winding Temp. Detector(Pt 100 Ω,Dual,3Wire) : 1ea/Phase Outline Dimension Drawing \ Motor Weight(Approx.)
2 2) Bearing Temp. Detector(Pt 100 Ω,Dual,3Wire) : 1ea/Bearing V1 HM-086863 3040 kg
3) Space Heater : 1Phase, 230V, 200W
4) Vibration Sensor (CBT-420 : SHINKAWA) : 4ea/Motor
5) Jacking Bolt : 1set/Motor

REMARK

SPARE PARTS

Date DSND CHKD CHKD APPD

2012.08.20 J.K.Bae -- -- I.J.Kang

Note: Others not mentioned in this data sheet shall be in accordance with maker standard.
Above technical data are only design values and shall be guaranteed with tolerance of applicable standard.
Inspection and performance test shall be maker standard, if not mentioned.
* In case of Inverter-Fed Motor, performance data is based on sine wave tests.
** The data are based on rated voltage & frequency, and data are expressed as a percentage of full load value.
HHI W230-131-1 A4(210mm X 297mm)
PAINTING PROCEDURE FOR MOTOR
No. : P-20114995/Rev.0 1/4

1. SCOPE
This procedure defines the painting and rust prevention procedure at shop.
But non-ferrous metal will not be painted.

2. SURFACE PREPARATION
2.1 Oil, grease and crayon marks will be cleaned off with solvent solution.
2.2 Shot blast cleaning will be carried out in accordance with provision of
"The steel structure painting council's specification SSPC-SP10/NACE NO.2
blast cleaning(Near White)”.
2.3 The surface profile height is defined as distance between the tops of
the highest peak and lowest adjacent rough, measured in a direction
perpendicular to the mean surface height plane.
2.4 Surface to be coated will be cleaned and dried before coating is applied.
2.5 Rust, weld spatter, mill scale and other surface contaminants will be
removed by the power tools and shot blasting.
2.6 The compressed air used for nozzle blasting will be free from the liquid
water or oil. Adequate separators and driers will be used so as to get
rid of condensation.
2.7 In principle, shot or sand blasting will be done only when the weather
condition allow the surface to remain dry after blasting and coating
for several hours (Min.4 Hours).

3. PROCEDURE
3.1 Detail painting procedures refer to attached data sheet.
3.2 Painting conditions.
3.2.1 The metal temperature shall be minimum 3 deg. C above the dew point temperature.
Air temperature : 5 ~ 40 deg. C
Air relative humidity : less than 85%

3.3 Related conditions

No paintings shall be applied outdoor when it is foggy, rainy or excessive
wind. If chemical contamination occurs in paint it should be removed by
by washing with water or solvent before painting.
PAINTING PROCEDURE FOR MOTOR
No. : P-20114995/Rev.0 2/4

4. APPLICATION DETAILS
4.1 Preparation of paintings
Paintings should be prepared for application according to the instructions.
Individual components of multi-component paintings must be stirred before
mixing. If the thinner is required, only designated thinner should be used
and thinning rate may be adjusted according to the job condition.
4.2 Application method
4.2.1 Airless spray may be most effective in obtaining specified thickness at once.
4.2.2 Keep the spray gun at constant distance and perpendicular to the surfaces.
4.2.3 Brush or roller should not be used. Required thickness shall be achieved by applying
several coats at indoor. No outdoor painting shall be allowed.
4.3 Application work
4.3.1 Welding seams, corners and edges should always receive a stripe coat
before full coating in order to obtain adequate film built.
4.3.2 Bolt jointing surroundings and flange matching faces should be blanked
off or otherwise protected from painting unless otherwise accepted.
4.3.3 Special care should be taken to gain uniform thickness.
4.3.4 Each coat should be allowed enough to dry and interval between coats.
4.4 Cleaning of tools
The application tools and equipments should be cleaned with the thinner
immediately after use.

5. INSPECTION
Before painting, the surfaces shall be inspected as following items.
- Surface cleaning as per SSPC SP1
- Surface preparations as per SSPC-SP10/NACE No.2
- Environmental condition (Air temperature, Air relative humidity)
After painting, the surfaces shall be inspected visually for wrinkle, swelling
and other harmful defects. Also the dry film thickness shall be measured according to SSPC PA2.
If repair coating is required, applicable surfaces shall be arranged by sand
paper and re coated with the same paint. Also repairing shall be in compliance with paint manufacturer
recommendation.
PAINTING PROCEDURE FOR MOTOR
No. : P-20114995/Rev.0 3/4

6. COATING REPAIR
6.1 Defective paint work will be removed, and the surface re-prepared and
repainted according to the original specifications.
6.2 Damaged parts on the coated surface will be cleaned by power tool and
touch-up with the same coating system as applied initially.

7. STORAGE OF PAINT
The storage area should be well ventilated and protected from sparks, flame,
direct exposure to sun or excessive heat, preferably located in isolated room.
Storage place shall have a temperature ranging from 10 to 40 deg.C.
PAINTING PROCEDURE FOR MOTOR
No. : P-20114995/Rev.0 4/4

8. PAINTING SYSTEM
8.1 Item : Motor ( Include Platform)
8.2 Painting schedule

POLYURETHANE
First or External and Brand : Korethan Primer UP171
Prime coat. internal Maker : KOREA CHEMICAL CO., LTD
surface of motor Dry film thickness : 35 micro-meter
Coating time : After preparation
surface
Coating method : spray and/or brush

POLYURETHANE
Finish coat. External surface Brand : Korethan Enamel UT 6780
of motor Maker : KOREA CHEMICAL CO., LTD
Color : Munsell no. - 7.5 BG 6/1.5
Dry film thickness : 40 micro-meter
Coating method : spray and/or brush
Curing method : Self Curing
Total Dry film thickness Min. 75 micro-meter
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 SHEATHED RESISTANCE TEMPERATURE DETECTOR
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R222 : DOUBLE ELEMENT
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R221 : SINGLE ELEMENT
R222 : DOUBLE ELEMENT

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B General & Spring-Loaded 2 ”PT(Only available for Single Element)
F Explosion Proof 3 ”NPT(Only available for Single Element)
G Explosion Proof & Spring-Loaded *4 ”PF(Only available for Double Element)
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2 INCONEL 600
3 310SS 12th and 13th Characters
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6 321SS
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E9 4.8mm
F9 6.4mm
G9 8.0mm 15th Character
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CODE OPTIONS
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1 Accessories

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SAMPLE ORDERING NUMBER

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