DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

DG HP Boiler Water Supply Pump

DG 型高压锅炉给水泵

Installation and Operation Instruction

安装使用说明书
Client ：PEOPLE ELE.APPLIANCES GROUP CHINA

Drawed:
编制：陈红霞
Checked:
校对：龚绍海
Reviewed:
审核：王艳蕊

Nuclear Pump Co., LtdShenyang Brower Works Gro up

沈阳鼓风机集团核电泵业有限公司

~ 1 / 26~
 DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

目录 
I. Foreword .......................................................................................................................................................... 3
II. Structural Description ..................................................................................................................................... 3
III. Auxiliary Equipment ..................................................................................................................................... 4
IV. Disassembly of Pump .................................................................................................................................... 4
V. Inspection and Maintenance of the Pump ....................................................................................................... 6
VI. Assembly of the Pump .................................................................................................................................. 9
VII. Installation Description ...............................................................................................................................11
VIII. Start, Stop and Operation of the Pump ..................................................................................................... 12
IX. Analysis and Processing of Fault ................................................................................................................ 14
一、前 言 ..................................................................................................................................................... 16
二、结构说明 ................................................................................................................................................... 16
三、辅助设备 ................................................................................................................................................... 18
四、泵的拆卸 ................................................................................................................................................... 18
五、泵的检修 ................................................................................................................................................... 20
六、泵的装配 ................................................................................................................................................... 21
七、安装说明 ................................................................................................................................................... 22
八、泵的启停及运行 ....................................................................................................................................... 23
九、故障的分析及处理 ................................................................................................................................... 25
十、相关文件 ................................................................................................................................................... 26

~ 2 / 26~
 DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

I. Foreword

This installation and operation instruction is suitable for DG HP boiler water supply
pump.
Boiler water supply pump is the main auxiliaries in the thermal power plant. To ensure
that the water supply pump can operate stably and safely and that the unit can generate stably
and fully，personnel responsible for installation, inspection, maintenance and operation must be
familiar with this instruction and carefully read the technical documents and drawings supplied
by manufacturer，and need to make record for the operation, inspection, maintenance and
accident at any time, as main basis for analyzing and processing problem.

II. Structural Description

DG water supply pump is a sectional multistage centrifugal pump with single casing and
designed to operate under HP and high temperature, for product structure see drawing:
1. Stator Part:
It is mainly consist of such parts as bearing, head cover, intake section, middle section,
guide vane, discharge section and tail-hood, which are coupled with stretching bolts. The suction
inlet of the intake section and discharge outlet of the discharge section are vertically upward，
static sealing surfaces of the intake section, middle section and discharge section of the pump
are sealed by metallic surfaces and O-ring is used as auxiliary seal. The sealing surfaces must be
protected carefully during assembly and disassembly of water supply pump.
2. Rotor Part:
Rotor part is closely related to integral structure of the pump, stability of operation and
product performance. Rotor of DG water supply pump is composed of impeller, balance disk,
dentiform gasket and locknut. Entire rotor is supported by slide bearings at both ends of pump.
Impeller and shaft have two forms, the sliding fit positioned separately, and static fit.
3. Balance Mechanism:
Axial thrust of rotor is balanced by balance disk, and with thrust bearing used to endure
residual axial force resulting from working condition change，a balance pipe is installed between
balance chamber and suction pipe.
4. Bearing Part:
Rotor of the water pump is supported by two sliding bearings located in the bearing
body and provided with Michell thrust bearing at axial direction. To ensure good lubrication of

~ 3 / 26~
 DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

sliding bearing and thrust bearing, the bearing is used with forced lubrication and the lub-oil is
supplied by oil supply system. Oil supply system could use either the thin oil station or
hydraulic coupling. Bush centering can be adjusted by setting screw on the bearing body to
make rotor always located in the center position.

III. Auxiliary Equipment

1. Motor
DG HP boiler water supply pump is equipped with motor, which adopts the forced
lubrication due to larger power。
Lubrication system refers to the pipeline diagram.
2. Coupling Pump is driven by motor through elastic coupling，and also can be
equipped with gear coupling, diaphragm coupling and fluid coupling etc. upon user request.
Prime mover is driven by electric motor. Watching from motor end, pump is clockwise rotation.
3. Measuring Meter
To monitor the safety and operation of the pump，appropriate quantity of instruments
should be installed，details see testing points diagram.
4. Filter
1）If the water supply pump is used with mechanical seal and with filter, it should be
cleaned frequently，particularly at the beginning of putting into service, switchover cleaning
interval could be extended gradually from two hours according to blocked situation of filter
gauze.
2）Filter gauze before inlet of water supply pump should be cleaned periodically，
especially in the early days of putting into operation，which is even more important. Differential
pressure transducer could be installed as necessary for monitoring.

IV. Disassembly of Pump

1. Preparations before Disassembly

（1）To prepare the site and tools required for pump disassembly, e.g. dial indicator
(with magnetic seat), micrometer, caliper and ……etc.
（2）Tackle block should be provided for hoisting large component if there is no lifting

~ 4 / 26~
 DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

equipment.
（3）To remove the piping of the cooling water system.
（4）To remove the piping of the lub-oil system，and to drain off the oil in the oil cooler.
（5）To remove pump warming valve, inlet water drain valve, recirculation valve and
check valve.
（6）To remove pressure gauge pipe, balance pipe, inlet gauze filter and out pump
mantle.
Quality Requirements:
（1）Oil pipe nozzle should be sealed to prevent impurities from falling in
（2）Gasket, nuts, bolts, removed pipes and accessories should be kept properly.
2. Coupling Disassembly and Center Recheck
（1）To remove coupling housing and sleeve.
（2）To recheck coupling center and make record.
（3）To push the rotor to drive side and measure end face clearance of the coupling.
Quality Requirements:
（1）To note the original mark of the coupling during disassembling and reassembly
should be carried out according to this mark.
（2）Allowable error of coupling center：surface deviation≤0.05mm and circle deviation
≤0.08mm.
3. Thrust Clearance Measurement
To measure the thrust clearance and record.
Quality Requirements:
（1）To make record, convenient for calculation of axial distribution.
（2）Thrust clearance. Backwards（free side is about 0.4 mm）.
4. Bush Disassembly and Raising Shaft Test
（1）To remove bearing cover, and to recheck the journal raise at two journals with dial
indicator.
（2）To test raising shaft and to check the concentricity of rotor and stator.
Quality Requirements:
Raise of the journal should make the both ends of the shaft simultaneous raise upwards,
scales shown on the dial indicator should be about equivalence.
5. Disassembly of Balancer, measurement of the total axial movement of the rotor
（1）To open the bearing cover of free side，and to measure the clearances between the
front and end side of the thrust bearing.

~ 5 / 26~
 DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

（2）To loosen tail-hood bolts and to remove the tail-hood.

（3）To use bracket to support the shaft to prevent rotor from drooping and pressing on
the wear part.
（4）To measure the distance from shaft sleeve locknut to shaft end with depth rule，then
remove shaft end sleeve, shaft sleeve, compression ring, sealing ring and balance disk etc.
（5）To loosen the stretching bolts on the balance sleeve and to remove balance sleeve.
（6）To install balance disk（not install the balance sleeve）and shaft sleeve, and to tighten
the shaft sleeve locknut to original position.
（7）To measure the total axial movement（accident axial movement），total axial
movement refers to general drawing.
（8）Shaft sleeve, balance disk and other parts can be removed after measurement
6. Disassembly of Pump Body
（1）To measure the distance between intake section and discharge section and check the
inclination of the casing before disassembly.
（2）To remove eight stretching bolts and to lift away the discharge section.
（3）To disassemble guide vane of final stage, adjusting sleeve, final stage impeller,
middle section, guide vane, impeller and spacer sleeve (if any), and to disassemble step by
step.
（4）To displace the intake section backwards and draw out coupling.
（5）To disassembly the bearing body at LP side, and draw out from suction side.
Quality Requirements:
（1）Casing deviation＜0.10mm.
（2）Washer and nut of the stretching bolt should be replaced to original position.
（3）Pay attention not to impact on the shaft when lifting discharge section.
（4）All disassembled parts and components should be wiped out and marked，coated
with rust-preventive oil, placed on the appointed location. Do not knock against and scratch
the sealing surface, especially those of middle section.

V. Inspection and Maintenance of the Pump

1. Inspection and Maintenance of the Coupling

（1）To check the perfection of the diaphragm of the diaphragm coupling.
（2）To check the centering of the pump and the prime mover before disassembly of the
pump, and to make original record.
2. Inspection and Maintenance of the Bearing

~ 6 / 26~
 DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

（1）Whether the bearing babbit has crack, scale, pore and heavy wear.
（2）Journal is smooth without scar.
（3）Trust bush contact is required to be equal, two points at least per cm2 are contacted.
3. Inspection and Maintenance of Balancer
Balance drum, balance sleeve (diameter clearance at small journal of the balance drum is
0.4mm and diameter clearance at external circle is 0.45 mm）, thrust working surface should
be smooth without groove mark. If groove mark is deep, it should be grinded，but to ensure
that axial and radial clearances are not changed，replace if no way to ensure.
4. Inspection and Maintenance of Stator Part
（1）Allowable error of grooves non-concentricity (run out）at intake section, middle
section and discharge section is 0.06 mm.
（2）Allowable error of non-parallelism at end faces of intake section, mid section and
discharge section is 0.04 mm.
（3）Maximal clearance of the stator part groove is 0.08 mm, otherwise processing is
necessary.
（4）The junction surfaces of the middle section should be smooth and even, without
groove mark, and checked by color method. The contact ratio should be above 80%，axial
connection is not interrupted.
（5）Allowable error of non-concentricity (run out) at internal and external circles of the
guide vane is 0.04 mm.
（6）Allowable error of non-parallelism at end faces of guide vane is less than or equal to
0.04 mm.
（7）Copper nail, if any, the height should have compression allowance of 0.5 mm.
（8）Allowable error of non-concentricity (run out) at sealing ring groove of the first
stage and next stage to internal and external circle is 0.025 mm, allowable error of run out
from end face to circle is 0.016 mm.
（9）Allowable error of non-concentricity (run out) at guide vane sleeve to internal and
external circle is 0.025 mm.
（10）O-ring, if being found aged during inspection and maintenance, should be
replaced.
5. Inspection and Maintenance of Rotor
（1）After pump disassembled, if finding that the shaft has one of the following
circumstances, user should consider to replace the shaft.
a. Crack is found on the shaft surface，particularly at balance disk, which may cause shaft

~ 7 / 26~
 DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

fatigue fracture under the action of alternating load.

b. There is deep groove mark scoured by high-speed water flow on the shaft surface，
particularly in keyway.
（2）Run out of shaft to journal should be less than 0.03 mm.
（3）To check the worn situation of the impeller sealing ring，if worn depth is not bigger,
special mould on the lathe can be used to expand against the impeller to repair the worn
position, and make allowable error of non-concentricity (run out) from the impeller sealing
ring to the inner bore within 0.025 mm，allowable error of non-parallelism at both end faces is
0.016 mm，clearance of sealing pair after repaired could be not more 1.3 times than that given.
（4）Static Balance of Impeller
To ensure stable operation of the rotor，impeller balancing is a very important link，
allowable error of unbalanced weight on max impeller diameter is 3~5g，cover plate
thickness of impeller after unbalanced weight removed should be not less than 2/3 of original
ones，the part to be cut should be smooth transition to disk. No static balance test on new
water supply pump installed would be performed, because dynamic balance has been done in
the manufacturer.
（5）Trial Installation of Rotor
Allowable error of run out at impeller sealing ring and guide vane sleeve to bearing is
0.05 mm.
Allowable error of run out at balance disk end face and balance external circle to bearing
is 0.04 mm.
Allowable error of run out at retaining sleeve and shaft sleeve to bearing is 0.05 mm.
It is not permitted that the run out of the rotor is eliminated by such method as
off-grinding shrunk-on component end face. It is prohibited to add spacer between end faces
of shrunk-on component to adjust the center distance of the water outlet on the impeller. After
dynamic balance of the rotor, no transposition or replacement is permitted for any one of the
parts, if replacement is required, dynamic balance must be done again.
（6）Inspection and Maintenance of the Shaft Seal Device.
1）Tight hydrostatic test above 0.8Mpa on the head-hood and tail-hood liners should be
performed，to check if there is leakage at the fit position.（combined with head-hood and
tail-hood）
2）For the worn depth of shaft sleeve external circle more than 0.3 mm or surface rough
and uneven, new shaft sleeve should be replaced.

~ 8 / 26~
 DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

VI. Assembly of the Pump

1. Preparations before Assembly

1）To check the list of all parts, and the parts should be placed by classification according
to the assembly sequence.
2）To recheck if the every overhauled part is good.
3）To prepare the gasket and O-ring ready for replacement.
4）Final cleaning for each part is carried out, especially the junction surface of middle
section and end face of shrunk-on part should be came into notice.
5）Special tools are prepared ready.
2. Assembly of Pump Body
1）Pay attention to the outlet center location of the first stage impeller, an orientation
piece should be prepared according to drawing and insert it in the first stage impeller outlet,
push the rotor to the locating piece until contact with side of intake section. At the place flushed
with end face of the head-hood, use the marking pin to mark a line on the external circle of the
shaft, ready for check of water port centering after balancer assembled and axial position of
impeller in the stator.
2）Pay attention to the alignment of guide vane anti-rotating pin, height is proper.
3）Tightening steps of the stretching bolt: the stretching bolt should maintain appropriate
fastening force，insufficient force may cause leakage on junction surface of middle section，
excessive force may cause distortion of the junction surface on stator.
a. Pre-tightening running-in of the stretching bolt
Use the socket wrench to tighten all stretching bolts by several times according to
symmetric sequences, fastening force is not too much.
Measure the distance between end face of intake section and end face of discharge
section，length error in four directions should be within 0.1 mm. If the allowable error is
exceeded, tighten partial stretching bolts to ensure it.
After tightened, the stretching bolts, nuts and gaskets should be stamped respectively
with “1, 2 and 3……”, seated by Number. Four stretching bolts that are perpendicular each
other would be left. The other stretching bolts are loosened completely, then use wrench
(without socket) to retighten these bolts, the moment is 40kg/m approx, and then loosen
completely the four unloosened bolts. Same as the above, tighten the four stretching bolts. The
plane of tightening nut of discharge section and the circle flushed with nutφ90 on which the
“O”position marks are stamped.
b. Tighten the stretching bolts

~ 9 / 26~
 DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

In accordance with the tightening sequence as pre-tightening, tighten a turn of nuts of

each of eight stretching bolts to make it flushed with the “O” position on the plane of discharge
section.
Measure the distance between intake section end face and discharge section end face,
length error at four directions should be less than 0.1 mm，if exceed the allowable error, can
tighten the nuts in a small range to ensure it.
4）Measure the axial movement
Size of thrust clearance should take the impeller guide vane outlet centering as final.
Generally, the movement to inlet side is more 0.5 mm than that to outlet side as
appropriate.
3. Adjust Rotor Center
Adjust the radial position of rotor in stator, also called as adjusting center, is the most
pivotal overhaul process of the water pump，it should be performed according to the following
methods.
1）To use the prefabricated locating mould，by means of balance sleeve, and to raise the
shaft at discharge end to the center position for locating.
2）At intake section, stretch hand into the inlet of intake section to measure the sealing
ring clearance on the first stage，by the aid of this clearance, install the bearing at LP end and
centering.
3）To check the run-out of the balance sleeve, allowable error is 0.05 mm.
4）First to install the tail-hood, bearing and lower bush of the discharge end, the locating
mould is not moved, use micrometer to make main shaft raised 0.01~0.02 mm a little，then
remove the tail-hood at discharge end together with bearing body, take out the locating mould.
5）To assemble the rotor part，make tight nut reach to small installation position.
6）To reassemble the tail-hood at discharge end and lower bush of the bearing.
7）The dial indicator indicates to at the inside 80 mm of the two bushes center，at the
same time put the lower bush in to make it reach to the specified value and even at both sides of
the bush.
4. Assembly of the Bearing
1) To measure the bush clearance.
2) To measure the fastening force of the bush.

~ 10 / 26~
 DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

VII. Installation Description

Water pump foundation is not only to support the dynamic and static loads of the water
pump and should consider to absorb the thermal state acting force of the pipe also，the
foundation of the water pump is generally the heavy rebar concrete structure，no light structure
is permitted，should sufficiently note the rigidity, pump seat to foundation should have firm
connection.
And should ensure the grouting quality，make the lower part of the pump seat embedded
tightly into the concrete foundation，foundation frequency should be more 20% than the
frequency range of the water pump at least.
1. Foundation is poured with cement，in accordance with drawing reserve the foundation
bolts holes positions for the corollary equipment such as pump seat and motor etc..
2. Fabricate two frames as best by use of I-steel, motor and pump frame bracings depend
that the centerline from which is deviated or not.
3. After centerline aligned，pump and motor are placed in position.
4. First align the pump, and then axial and transversal, standard is 0.03~0.05 mm/m.
5. The wedges and shim plates are welded on the frame，wedges are not more than three
pieces.
6. Both sides of the pump seat are grouted to 50 mm from pump foot plane to increase
the rigidity and quality of the pump seat.
7. The acting force and acting moment of intake and discharge piping of the water supply
pump to the pump refers to the joint installation drawing.
Piping should be not rigid，may add U-pipe and extension pipe section to increase the
flexibility of the piping.
8. To reduce the vaporization of the pump, elevation of downcomer mains is lower
2.5—3m than shell of deaerator as appropriate, balance backwater is introduced into
deaerator，piping length from the deaerated water tank to inlet of the water supply pump
should be short as possible，selection of pipe size should be proper.
9. Intake pipe slope of the water supply pump should be located in the reverse direction
of the water flow to ensure that the air in the pipe is able to be smoothly discharged into the
deaerator, if the slope of the piping is not tally with the above requirement, venting point
should be provided at dead space.
10. Vessel and piping must be cleaned, wiped out and purged before pump running.
11. After completion of pump installation，rotate the rotor by barring to determine no
blocking phenomenon.

~ 11 / 26~
 DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

12. Tightness test for suction and discharge piping of the lubrication system should be
carried out，the pressure is respectively 0.5Mpa and 1.5Mpa.
13. Tighten the nut for securing the discharge section to pump seat and then loosen the
nut to make it keep the vertical clearance 0.03~0.04 mm，and tighten the nut after the pump is
sufficiently heated.

VIII. Start, Stop and Operation of the Pump

1. Start of the pump

1）Heat the pump
Reasonable heating pump is one of the most important start sequences of water supply
pump，which could use positive heating or negative heating, using positive heating pump, i.e.
water comes from deaerator into pump through suction pipe and discharges through orifices at
the lower part of the discharge section of the pump. Using the negative heating pump, i.e. the
water from the pressure mains comes into pump through orifices at the lower part of the
discharge section of the pump and return to deaerator from suction pipe of the pump, in
addition, the water is drained off at the lower part of the intake section also.
a）Temperature difference of the casing from top to bottom is ≦15℃.
b）Temperature difference between top temperature of casing and water supplied
temperature is＜10～20℃.
c）Deviation from top to bottom of the pump to motor coupling is 0.05 mm.
The three items above take the value specified for deviation from top to the bottom of the
coupling as prevailing，temperature rise speed of the heat pump is usually 1～2℃/min.
2）To check cooling water pressure and temperature rise ( standard refers to the previous
description) and the cooling pipe should be opened completely.
3）To check the intake pressure and temperature rise of pump, intake pressure is not less
than 1.13 times of vaporization pressure at this temperature.
4）Overall electric part has been completed，various instruments are installed, auxiliary
oil pump interlock has been put into service，oil circulation has been initiated, assay of oil
quality is qualified，oil level is normal，oil pressure before bearing is 0.05~0.1Mpa，cooling
water and enclosed flushing water is put into normal.
Stop the pump immediately after speed determined for startup of water supply，record the
coasting operation time，and observe the abnormal situation in the operation of the pump.
6）If the coasting operation time is not less than 50s，water supply pump can be started

~ 12 / 26~
 DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

formally，if coupler is equipped，could operate at 700 rpm approx, check the operation of the
pump，then adjust the scoop tube position and slowly increase the speed of the water pump.
2. Maintenance during operation
1）Check intake pressure，the intake pressure is not less than 1.13 times of vaporization
pressure.
2）Check discharge pressure
3）Check balance pressure（generally, not more than intake pressure 0.3Mpa）.
4）Oil return temperature of the bearing is not more than 70℃.
5）Difference of cooling water intake and drainage temperatures is not more than 10℃.
6）Note to check the oil level and oil quality in the oil tank.
7）Management for the water supply pump must be strengthened, make operating journal
record，establish the regular vibration metering and abnormal situation vibration metering
files，swing value at vertical direction of rotor at bearing is not more than 0.06 mm，vibration
value at horizontal direction is not more than 0.08 mm， the cause should be checked and
analyzed if the vibration value exceeds those specified above.
8）When main machine is in load shedding，pressure in the deaerator falls down and cause
water pump vaporized often，require：
a）Deaerator should be provided with automatic water level and pressure regulator.
b）Deaerator should be provided with sufficient and reliable backup steam source
0.8~1.3Mpa.
c）Makeup water of the deaerator，recovery of the condensate and water level of the
makeup water for which the large extent of regulation is not permitted, and should slowly
carry out.
d）When the deaerator during operation is required to operate at reduction of pressure due
to requirement of the system，water temperature falling gradient is 1~2℃/min and close the
vent valve of the deaerator.
3. Stop
1) Close the outlet gate valve of the pump，ensure the min flow when closing, the system
should act at min water flow specified.
2) It should be ensured that coupler or auxiliary oil pump is started automatically.
3) Close the motor, check that the revolution is slowly reduced or not，rotor of the water
pump should not be stopped suddenly.
4) After rotor of the pump unit stopped，close the auxiliary oil pump and cooling water
system.

~ 13 / 26~
 DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

IX. Analysis and Processing of Fault

Fault Cause Troubleshooting

1.No water from pump 1. Water pressure in the intake
after operation ， no pipe is less than vaporization
pressure displayed on pressure at temperature
pressure gauge specified.
2. Rotation of pump is wrong
2. Insufficient effluent 1. Same as 1 above
and pressure of water 2. Gauze filters of impeller
pump during operation passageway and intake pipe
are blocked
3. Air present in intake pipe and
pump, not vented
4. Dynamic and static
clearances worn seriously,
exceeded allowable value
5. Clearance of balancer
exceeds the value specified
3. Motor overload 1. Flow of pump is more than
the value specified
2. Dynamic and static parts of
the pump is ground
Check and take measures ，
increase intake pressure,
Correct rotation
Check and eliminate it,
Check intake pipe and pump，
vent air off，clean or replace
gauze filter
Disassemble for check，ensure
requirements on drawings and
repair.
Check by flow meter，regulate
outlet valve, readjust rotor
center to achieve flexible
rotation ， reasonable heating
pump.

4. Pump with vibration 1. Heat pump unreasonable

(1) Vibration peak value 2.Nonconcentricity of pump to Adjust pump and motor to
is gradually increased motor C o n c e n t r i c i t y. P e r f o r m
and not disappeared 3. Static balance of impeller static balance for impeller
is out-of-tolerance and dynamic balance for rotor
4. Dynamic balance of rotor is again. Readjust rotor center of
out-of-tolerance pump. Properly adjust and
5. Dynamic and static parts reduce the pipe acting force.
of pump are ground
6. Piping gives acting force
to pump to make pump
displaced
(2) Vibration peak value
sometimes big 1.Dynamic and static Disassemble as best, minimize
sometimes small, clearances of pump are larger dynamic/static clearances.
sometimes disappeared 2. External interference，such as Eliminate external interference
piping or system vibration as possible, reduce the
possibility of resonance.
(3) Horizontal vibration 1.Nonconcentricity of pump to
value of coupling and motor coupling
bush 2. Rubber ring size of the Verify the coupling center,
（2# bush）is larger coupling is out-of-tolerance Replace coupling rubber ring,
3. Bush is ground Check bush grinding situation

~ 14 / 26~
 DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

X、Documents related to installation and commissioning：

1、General drawing and parts list (Annex 1)

2、Piping drawing (Annex 2)
3、PID drawing and parts list(Annex 3)
4、Outline drawing(Annex4)

~ 15 / 26~
 DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

一、前 言

本安装使用说明书适用于 DG 型高压锅炉给水泵。
锅炉给水泵是火电厂中的主要辅机。为了保证给水泵能安全稳定运行，
保证机组的稳发、满发，安装、检修和运行人员，必须通晓本说明书，认
真阅读制造厂提供的技术文件和图纸，同时需要随时做好运行、检修和事
故记录，作为分析和处理问题的主要依据。

二、结构说明

DG 型给水泵是单壳体节段式多级离心泵。设计在高压高温下运行，其
产品构造见图：
1、定子部份：
主要由轴承、首盖、进水段、中段、导叶、出水段、尾盖等零件用拉
紧螺栓联接而成。进水段的吸入口、出水段的吐出口均垂直向上，泵的进
水段、中段、出水段的静止密封面是靠金属面密封，同时有 O 形密封圈作
为辅助密封。在拆装给水泵时对其密封面必须仔细保护。
2、转子部分：
转子部件对泵的整体结构、运行的稳定性及产品性能都有着密切联系。
DG 型给水泵转子由叶轮、平衡盘、齿形垫、锁紧螺母等件组成。整个转子
由泵两端的滑动轴承来支承。叶轮与轴有滑配合单独定位和静配合两种形
式。
3、平衡机构：
转子的轴向推力用平衡盘来平衡。且带有止推轴承，用于承受由于工
况变化而产生的残余轴向力，在平衡室体和吸水管之间装有平衡管。
4、轴承部分：
水泵转子依靠位于轴承体内的两个滑动轴承来支承，轴向设有瓦块式
推力轴承。为了保证滑动轴承和止推轴承的良好润滑，轴承采用强制润滑，
润滑油由供油系统供给。供油系统可采用稀油站或液力偶合器两种。轴瓦
调心可用轴承体上的调节螺钉进行调整，使转子始终位于中心位置。

~ 16 / 26~
DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

~ 17 / 26~
 DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

三、辅助设备

1、电机
DG 型高压锅炉给水泵配用电机由于功率较大一般采用强制润滑方式。
润滑系统见管路图。
2、联轴器 泵通过弹性联轴器由电机驱动，也可根据用户需要配带齿轮联轴器，
膜片联轴器，液力偶合器。原动机采用动机驱动。从电机端看，泵为顺时针方向旋转。
3、测量仪表
为了监督泵的安全，运行，安装适量仪表，具体详见测点图。
4、过滤器
1）给水泵若采用机械密封且有过滤器时，要经常进行清洗，特别投入初期，切换
清洗间隔可根据滤网堵塞情况由两个小时而逐渐加长。
2）给水泵入口前滤网，也应定期清理，特别在运投初期，显得更为重要。必要时
可装差压传感器监测。

四、泵的拆卸

1、拆前准备工作
（1）准备为拆卸泵所必须的场地和工具如千分表（有磁力座）、千分尺、卡尺……。
（2）当没有起吊设备时，需准备为起吊大型零部件用的滑车组。
（3）拆去冷却水系统管路。
（4）拆去润滑油系统管路，放掉冷油器内存油。
（5）拆去暖泵门，入口放水门，再循环门，出口逆止门。
（6）拆去压力表管、平衡管、入口滤网、泵罩。
质量要求为：
（1）油管管口要封好，以免咋质掉入。
（2）垫片、螺母、螺栓、拆下管路及附件应妥善保管。
2、联轴器解体及复检中心
（1）拆下联轴器罩及联轴器外套。
（2）复检联轴器中心，做好记录。
（3）将转子推向传动侧，测量联轴器端面间隙。
质量要求为：
（1）解体时注意联轴器的原始记号。组装时按此记号组装。
（2）联轴器中心允差：面偏差≤0.05mm，圆偏差≤0.08mm。
3、测量推力间隙

~ 18 / 26~
DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

测量推力间隙，做好记录。
质量要求：
（1）做好记录，便于计算轴向分配。
（2）推力间隙。向后（自由侧约 0.4mm）。
4、轴瓦解体、抬轴试验
（1）拆下轴承盖，在两个轴颈处用千分表复查轴颈抬量。
（2）抬轴试验，检查转子与静子的同心性。
质量要求为：
轴颈的抬量，应该使轴的两端同时向上扬起，千分表所指示的格数应大致相等。

5、平衡装置解体、测量转子的总窜量
（1）打开自由侧轴承盖，测量止推轴承前后间隙。
（2）松掉尾盖螺栓拆下尾盖。
（3）用支架将轴顶住，以防转子下垂压在磨损件上。
（4）用深度尺测量轴套锁紧螺母到轴头的距离，然后拆下轴端套，轴套，压紧环，
密封胶圈，平衡盘等。
（5）松掉平衡套压盖螺栓，拆下平衡套。
（6）装上平衡盘（不装平衡套）和轴套，拧紧轴套锁紧螺母到原来的位置。
（7）测量总窜量（事故窜量），总窜量见总图。
（8）测量后即可拆下轴套，平衡盘等件。
6、解体泵体
（1）解体前要测量进水段与出水段之间的距离，检查壳体的偏斜。
（2）拆卸 8 个拉紧螺栓，并吊走出水段。
（3）拆卸末级导叶、调整套，末级叶轮，中段，导叶，叶轮，挡套（如果有）……
进行逐级分解。
（4）将进水段向后移位，拔联轴器。
（5）拆卸低压侧的轴承体，从吸入侧抽轴。
质量要求为：
（1）壳体偏斜＜0.10mm。
（2）拉紧螺栓的垫圈和螺母应按原来位置戴好。
（3）吊出水段时注意勿碰伤轴。
（4）拆下来的各部零件擦试干净，做好记号，涂以防锈油，应放在指定地点。各
密封面，特别是中段密封面切勿磕碰，擦伤。

~ 19 / 26~
 DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

五、泵的检修

1、联轴器检修
（1）检查膜片联轴器膜片的完好性。
（2）在拆泵以前要检查泵与原动机的对中情况，并做好原始记录。
2、轴承检修
（1）轴承钨金有无裂纹、脱胎、气孔及严重磨损。
（2）轴颈光滑无伤痕。
（3）推力瓦块接触要求均匀，每平方厘米上至少有两点接触。
3、平衡装置检修
平衡鼓、平衡套、
（平衡鼓小轴径处直径间隙为 0.4mm，外圆处直径间隙为 0.45mm）
止推工作端面应光滑无沟痕，如沟痕过深应进行磨修，但要保证轴向径向间隙不变，无
法保证时要进行更换。
4、定子部件检修
（1）进水段、中段、出水段各止口不同心（跳动）允差 0.06mm。
（2）进水段、中段、出水段各端面不平行允差 0.04mm。
（3）定子部件止口的最大间隙为 0.08mm，否则须进行处理。
（4）各中段结合面应平整光洁，无径向沟痕，用颜色法检查接触率应在 80%以上，
轴向应连接不断线。
（5）导叶内外圆止口不同心（跳动）允差 0.04mm。
（6）导叶端面的不平行允差≤0.04mm。
（7）若有紫铜钉则高度 h 应留 0.5mm 压缩余量。
（8）第一级及次级密封环止口对其内圆的不同心（跳动）允差 0.025mm，端面对
圆的跳动允差 0.016mm。
（9）导叶套外圆对其内圆的不同心（跳动）允差 0.025mm。
（10）O 形密封圈检修时如发现有老化现象要进行更换。
5、转子检修
（1）泵解体后发现轴有下例情况之一者请用户应考虑更换轴。
a、轴表面发现裂纹，尤其在平衡盘处因裂纹在交变载荷作用下造成轴疲劳断裂。
b、轴表面有被高速水流冲刷而出现较深的沟痕，尤其在健槽处。
（2）轴对两轴颈处的跳动应小于 0.03mm。
（3）检查叶轮密封环的磨损情况，如磨损深度不大，可在车床上用专用胎具胀住
叶轮内孔，把磨损的部位修好。使叶轮密封环处对内孔的不同心（跳动）允差 0.025mm，
两端面平行度允差 0.016mm，修复后密封副间隙不得大于给出间隙的 1.3 倍。
（4）叶轮静平衡

~ 20 / 26~
 DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

为了保证转子稳定运行，叶轮找平衡是非常重要的一个环节，叶轮最大直径上的不
平衡重量允差 3~5 克，叶轮去掉不平衡重量后其盖板厚度不应小于原盖板厚度的 2/3，
切削部分应与圆盘圆滑过渡。新安装的给水泵，因厂家已找过动平衡，可不再进行静平
衡校验。
（5）转子试装
叶轮密封环和导叶套处对轴承处跳动允差 0.05mm。
平衡盘端面和平衡盘外圆对轴承处跳动允差 0.04mm。
挡套，轴套处对轴承处跳动允差 0.05mm。
不允许用偏研套装零件端面的办法来消除转子的跳动，严禁在套装零件端面之间加
垫片，来调整叶轮的出水口中心距离。转子动平衡后，不准零件换位或更换其某一个零
件。如要更换，必须重新进行动平衡。
（6）轴封装置检修。
1）首尾盖衬套进行 0.8Mpa 以上密封性水压试验，检验配合位置有无渗漏。（与首
尾盖组合）
2）轴套外圆圆周磨损深度超过 0.3mm，或表面粗糙不平都应更换新轴套。

六、泵的装配

1、装配前的准备工作
1）清点全部零件，并按照装配次序将零件进行分类排放。
2）再次检查每个经过检修的零件是否良好。
3）准备好待更换的密封垫片及 O 形圈。
4）将每个零件进行最后清理，尤其中段结合面和套装零件的端面应特别引起注意。
5）专用工具准备就绪。
2、泵体组装
1）注意首级叶轮出口中心定位，需按图准备一块定位片将其插入首级叶轮的出口，
把转子推至定位片与进水段侧面接触为止，在与首盖端面齐平的地方。用划针在轴外圆
上划线，以备平衡装置组装后检查水口对中情况和叶轮在定子中的轴向位置。
2）注意导叶防转销对正，高度适当。
3）拉紧螺栓的紧固步骤：拉紧螺栓应保证适当的紧力，紧力不够会造成中段结合
面的渗漏，紧力过大会造成定子结合面变形。
a、拉紧螺栓予紧把合
用加有套管的搬手。按对称的次序分几次将所有拉紧螺栓拧紧，紧力不宜过大。
测量进水段端面及出水段端面之间的距离，在四个方向上长度误差应在 0.1mm 以
内。如果超差可通过拧紧部分拉紧螺栓来保证。

~ 21 / 26~
 DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

紧好后将拉紧螺栓与螺母及垫片分别打上“1、2、3……”标记。对号入座。留下
四根互相垂直的拉紧螺栓。将其它拉紧螺栓完全松开，再用搬手（不加套管），将这些
拉紧螺栓重新拧紧，力距为 40 公斤米左右再将没有松开的四根拉紧螺栓完全松开。同
样再将这四根拉紧螺栓拧紧。在出水段拧紧螺母的平面及螺母φ90 的圆周上对齐打出
“O”位标记。
b、紧固拉紧螺栓
按予紧时的紧固顺序。将 8 个拉紧螺栓螺母都拧一周，使其与出水段平面上的 O 位
置对齐。
测量进水段端面及出水段端面之间的距离在四个方向上的长度误差应小于 0.1mm，
如果超差可在较小范围内拧紧螺母来保证。
4）测量总窜量
推力间隙的大小应以叶轮导叶出水口对中为准。
一般向入口侧窜量比向出口侧窜量大 0.5mm 为宜。
3、调整转子中心
调整转子在定子中的径向位置也称调中心是水泵最关键的检修工艺，按以下方法进
行。
1）利用予先制作好的定位胎，借助平衡套，把出水端的轴抬到中心位置，进行定
位。
2）在进水端，伸手入进水段入口测量第一级密封环间隙，借助于这间隙把低压端
轴承装好，且定心。
3）检查平衡套端面跳动，允差 0.05mm。
4）把出水端尾盖和轴承及下瓦先装上，定位胎不动，用千分尺检查主轴使之略抬
高 0.01~0.02mm，然后把出水端尾盖，连同轴承体一齐拆下，取出定位胎。

5）组装转子部件，使紧固螺母达到小装位置。
6）复装出水端尾盖及轴承下瓦。
7）将百分表分别指在两轴瓦中心内侧 80mm 处，同时放入下瓦使其达到规定值，
并使轴瓦两侧均匀。
4、轴承组装
1)测量轴瓦间隙。
2)测量轴瓦紧力。

七、安装说明

水泵基础不仅承受水泵动荷载和静荷载还需考虑吸收管道的热态作用力，水泵基础

~ 22 / 26~
 DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

一般应用重型钢筋混凝土结构，不允许采用轻型结构，要充分注意刚度，泵座与基础要
有牢固的连接。
并需保证灌浆质量，使泵座下部紧紧嵌入混凝土基础内，基础频率应超出给水泵的
频率范围至少 20%。
1、基础用水泥浇好，根据图纸留出泵座，电机等配套设备的地脚螺钉孔位置。
2、最好用工字型钢做成两个框架，电机、泵框架拉线看中心线是否有偏差。
3、中心线找好后，泵、电机就位。
4、先找泵水平，再进行轴向找平和横向找平，标准为 0.03~0.05mm/米。
5、把楔铁，垫铁全部焊在框架上，楔铁不超过三块。
6、将泵座的两侧灌浆至泵脚平面处 50mm，以增加泵座的刚性及质量。
7、给水泵进水和出水管道对水泵的作用力和作用力距可参考合装图。
管道不要太硬，可以加 U 形管、伸管节等措施来增加管道柔性。
8、为了减少泵的汽化，下水母管标高比除氧器外壳低 2.5—3 米为宜，平衡回水引
入除氧器，由除氧水箱到给水泵入口管长度应尽量减短，管径选择应适当。
9、给水泵进水管坡度应处于与水流逆向，以保证管道中空气能顺利排到除氧器，
如管道坡度不符合上述要求，则死角处必须加放气点。
10、泵在运转前必须清理，擦试，吹洗容器和管路。
11、泵安装完成后，要盘动转子保证没有卡住现象。
12、润滑系统的吐出吸入管路进行密封试验，其密封试验压力分别 0.5Mpa 和
1.5Mpa。
13 、 拧 紧 将 出 水 段 固 定 于 泵 座 的 螺 母 ， 然 后 松 开 螺 母 使 之 保 留 垂 直 间 隙
0.03~0.04mm，待充分暖泵后，再紧固该螺母。

八、泵的启停及运行

1、泵的启动
1）暖泵
合理暖泵是给水泵最重要的启动程序之一，可采用正暖或倒暖，采用正暖泵即除氧
器来水经泵吸入口管进入泵内，并经泵吐出段下部节流孔放水。采用倒暖泵即由压力母
管来水经泵吐出段下部节流孔进入泵内，由泵吸入口管返回除氧器，另外在进水段下部
也放水。
a）壳体上下温差≦15℃.
b）壳体上部温度与给水温差＜10～20℃.
c）泵与电机联轴器上下偏差 0.05mm.
三者以联轴器上下偏差规定值为主，暖泵温升速度一般应为 1～2℃/分。

~ 23 / 26~
DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

2）检查冷却水压力及温升（标准见前述）并将冷却管全部开放。
3）检查泵进水的压力和温度，进水压力不低于该温度下汽化压力的 1.13 倍。
4）电气部分已全部完工，各种仪表全部装好，辅助油泵联动已投，已进行油循环，
油质化验合格，油位正常，轴承前的油压力为 0.05~0.1Mpa，冷却水、密封冲洗水投入
正常。
启动给水泵定速后迅速停泵，记录惰走时间，并观察泵的运转异常情况。
6）如果惰走时间不小于 50 秒，可正式起动给水泵，配有偶合器时，可在 700 转/
分左右运转，检查泵的运转情况，然后调整勺管位置慢慢增加水泵的转速。
2、运转中的维护
1）检查进水压力，进水压力不低于汽化压力的 1.13 倍。
2）检查出水压力
3）检查平衡压力（一般不高于进水压力 0.3Mpa）。
4）轴承回油温度不超过 70℃。
5）冷却水进水和排水温度之差不大于 10℃。
6）注意检查油箱中的油位，油质。
7）必须加强给水泵的管理，做好运行日志记录，建立定期测振和异常情况测振档
案，轴承处转子的垂直方向振动值不大于 0.06mm，水平方向振动值不大于 0.08mm，振
动值超过时应检查分析原因。
8）主机甩负荷时，除氧器压力下降，经常引起水泵汽化，要求：
a）除氧器应有水位自动调节和压力自动调整器。
b）除氧器应有 0.8~1.3Mpa 充足而可靠的备用汽源。
c）除氧器补充水，凝结水回收，补水的水位调整等都不允许幅度太大，应缓慢进
行。
d）除氧器运行中因系统需要降压运行时，水温下降的梯度为 1~2℃/分并关闭除氧
器放气门。
3、停机
1)关闭泵出口闸阀，关闭时应确保最小流量系统在规定的最小水量时起作用。
2)偶合器或辅助油泵应确保自动起动。
3)关闭电机、看转数是否慢慢下降，水泵转子不应突然停住。
4)当泵机组转子停止转动后，关闭辅助油泵，关闭冷却水系统。

~ 24 / 26~
 DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

九、故障的分析及处理

故 障 现 象 原 因 消 除 方 法
1、水泵运转后不出 1、进水管中水的压力低于 检查并采取措施，提高进
水，压力表不显示压 规定温度下的汽化压力 水压力
力 2、水泵的转动方向错误 改正转动方向
2、工作过程中水泵 1、同上第一条 检查并设法消除
出水及压力不足。 2、叶轮流道及进水管的过 检查进水管及泵，放净空
滤网被堵 气，清洗或更换滤网
3、进水管及泵内有空气没
有放出
4、动静间隙磨大，超过允 解体检查，保证图纸要求
许值 并修复之。
5、平衡装置的间隙超过规
定值
3、电机过载 1、水泵流量大于规定值 用流量计检查，调节出口
阀门
2、泵动、静部分研磨 重新调转子中心达到转动
灵活，合理暖泵
4、泵振动 1、暖泵不合理 合理暖泵
（1）振动峰值逐渐 2、泵与电机不同心 调整泵与电机使其同心
增加永不消失 3、叶轮静平衡超差 重新找叶轮静平衡
4、转子动平衡超差 重新找转子动平衡
5、泵的动静部分研磨 重新调泵转子中心
6、管路给泵有作用力使泵 适当调减管道作用力
移位

1、泵的动静间隙过大 最好解体，缩小动静间隙。
（2）振动峰值时大
2、外界干扰，如管路或者 尽量消除外界干扰，减少
时小，有时会消失
系统振动 共振的可能

校验联轴器中心
（3）联轴器、轴瓦 1、泵与电机联轴器不同心
更换联轴器胶圈
（2#瓦）水平振动值 2、联轴器胶圈尺寸超差
3、轴瓦有研磨情况 检查轴瓦研磨情况
偏大

~ 25 / 26~
DG 型高压锅炉给水泵安装使用说明书 Installation and Operation Manual of DG HP Boiler Water Supply Pump A0 版

十、相关文件

1、总图及明细表(附件1)
2、管路图（附件2）
3、PID图及明细表（附件3）
4、外形图（附件4）

~ 26 / 26~