TITLE: Cooling Water System.

Presentation by : PENY XYL

CONTENTS
• Open loop components & specification.
• Close loop components & specification.
• Operation process flow of open loop & close loop.
• Detailed assembly and dismantling procedure of open loop and Close loop
equipment.
• Maintenance of equipment.
 Functions.
 Cooling water system at XPXN hydro power project includes two loop such as : Open loop & close
loop.
 The open loop cooling water system is an open type. It uses the water from the tailrace and takes the
heat away from the closed loop cooling water system on the heat exchanger.
- Open loop are supply to shaft seal.
- The required water quantity of open loop cooling water system is about 883.1 m3/h.

 The close loop cooling water system is used to cool and removed the heat from air of generator and
from the lubricant parts such as turbine guide bearing, Lower guide bearings and Upper guide
bearing.
- The total water quantity of closed loop cooling water system is 755 m3/h.

Reference document No. :ZHF XPXN 0CW01 CAL 001-4

 Open loop components
1. Motor & Pump

2. Motorized Spherical valve

3. Backwash filter

4. Manual Operated Gate valve

5. Differential pressure switch

6. Check valve

7. Heat exchanger
 Specifications of Motor & pump.
Technical data
1. Pump
Type Centrifugal
Head 25 m
Capacity 994m3/h
NPSH 6.5 m
Speed 1480 rpm
Efficiency 76%
Motor.
Inlet size DN 350
Outlet size DN 350
Design pressure 1.0 MPa
2. Motor
Type Asynchronous
Output 110 Kw
Pump.
Voltage 380 V
Current 201 A
Frequency 50 Hz
Speed 1480 rpm
3. Total weight: 1623 Kg
 Components of Motor & pump

1. Pump Body
5
4
2. Impeller
8
6 3. Mechanical seal
3
7 3 4. Retaining ring
2
8 5. Motor
1
6. Pump cover
7. Impeller nut
8. Shaft
 Automatic Backwash filter specifications & Components
Motor 0.55 Kw Technical data
Protection class: IP55
Design flow 900m3/h
Reducer
Pressure gauge inlet Filtration accuracy 0.5 mm

Design pressure 1.0 MPa

Vent valve Test pressure 1.5 MPa/30 min

Inlet/outlet size DN400/DN400

Pressure gauge outlet
Sewage size DN100

Total power 0.6 kw

Power source AC400V/50Hz

Net weight 1290 Kg

Electric Sewage ball valve
Differential pressure switch Power 0.05 Kw
Protection class: IP55 Weight with water 1900 Kg
Motorized Spherical valve

The motor operated valves (MOV) is an important element of

the plant and pipe system. These valves are generally large
and are used for different applications such as pump discharge,
etc. The control valves operated by motor are often called on /
off valves since the motors serve to open or completely close
the valves in the pipes. For example, cooling water lines,
process piping where fluid control is not required, motor
operated valves can be used to completely allow or completely
stop the flow of fluid.
Power Source: There is three-phase AC;
the control line is 220v, 50HZ;
Remote control is 24V DC;
Power is 0.55 KW
Protection Class: IP65.
Components of Motorized Spherical valve

1. Motor
2.3. Spur gear
4. Worm
5. Worm gear
6. Output shaft
7.8 bevel gear
9.Travelling control apparatus
10. Middle gear
11. Opening indictor
12. Worm round grave
13. Crank
14. Torque control apparatus
15. Butterfly spring
 Heat exchanger Specifications & Components .
Guide rail
Movable board Technical data
Clamp bolt
Close loop Open loop

Medium water water

Flow 755 m3 900 m3

Symbol (Inlet/outlet) S1/S2 S4/S3

Design pressure 1.0 MPa 1.0 MPa

Test pressure 1.5 MPa 1.5 MPa

Work temperature(inlet/outlet) 36/31 26/30.2

Plate number 245

Thickness of core plate 0.6 mm

Heat exchanger area 172.19 m2

Heat transfer area 153.09 m2

Core plate
Fix board Net weight 3320 Kg

Weight with water 4316 kg

 Close loop components & specification.
1. Accumulator Tank (water tank) 8. Pressure switch
2. Motor & Pump 9. Temperature sensor
3. Motorized Spherical valve 10. Local temperature indication.

4. Manual Operated Gate valve

5. Check valve

6. Flow sensor

7. Pressure sensor
Accumulator Tank (water tank) specifications.
Technical data
Air 0.35 MPa
Design code ASHE CODE SECT.VIII DIV.1(2015 ED)

Color RAL 7035 Light grey

Volume 5 m3

Material SA-516m Gr.485

Height 40 cm Design pressure 1 MPa

Test pressure 1.5 MPa,30 min

Low 20 cm
Working medium Water + Compressor Air

Outlet size DN 350

Erection weight 2180 Kg

Operating weight 3880 Kg

Full of water weight 7180 Kg

Components of water tank.
1. Safety Valve
2. Pressure transmitter
3. Pressure gauge
4. Liquid level monitor,4 switch
5. Level gauge
6. Exhaust Valve
7. Air compensating device
Specifications of Motor & Pump.
Technical data
1. Pump
Type Centrifugal
Head 23.5 m
Capacity 791 m3/h
NPSH 6.0 m
Speed 1480 rpm
Efficiency 74%
Inlet size DN 300
Outlet size DN 300
Design pressure 1.0 MPa
2. Motor
Type Asynchronous
Output 75 Kw
Voltage 380 V
Current 139.6 A
Frequency 50 Hz
Speed 1480 rpm
3. Total weight: 945 Kg
 Water Flow 755 m3/h

31 ·c

Water outlet Temp .31 c

168 m3/h
4.59 m3/h

35.5 ·c
3 m3/h 31 ·c

540 m3/h
Water Flow 900 m3/h

34 ·c
31 ·c

32 m3/h
Water inlet Temp. 26 c Outlet Temp. 30 c
31 ·c 33.6 ·c

6.6 m3/h

Water inlet Temp. 36 c

33.4 ·c

5
1
Detailed assembly and dismantling procedure of open loop and
Close loop equipment.
Motor & Pump dismantling

1. Shut down the motor to prevent personal injury due to

unexpected startup.
2. Close all inlet and outlet vale and drain off the water
in the pipe.
3. Install the lifting device of motor and pump assembly.
4. Remove the pump inlet and outlet flange bolts.
5. Remove the pump foundation bolts.
6. Lifting of pump and motor using 3 chain blocks.
7. Use Hand Pallet to remove pump.
To lift the unit, reeve the ropes through the inlet and outlet necks
and motor lug, and make the two rope bear the force jointly and rise
slowly with cares to avoid overturning. prevent pump from
collision, and take protective measures if necessary.

Caution on pump lifting

1. Clear the debris within the target area;

2. Check the consistency of the lifting tools;
3. reeve the rope/hook through the lifting part according to the
requirement;
4. Check the reliability of the rope/hook, and the status of locking
tools;
5. raise up equipment from the ground to move it to the target
location slowly and evenly
6. Put down the equipment slowly
7. Take off the lifting tools till it is confirm that the equipment is
free from the risk of dumping.
 Disassembling process of motor & pump.
1. Remove the stud for connecting the pump body and pump
cover, lift the motor and the rotor parts to remove them from
the pump, which should be placed flat in a broad space to
facilitate the further step;
2. Remove the impeller nuts so as to remove the impeller,
and remove the key;
3. Remove the mechanical seal;
4. Remove the bolt between the pump cover and the motor
flange, then remove the pump cover;
5.Remove the retaining ring;
6. Remove the motor hood and fan (this step is part of the
motor disassembling)
7. Remove the front and back cover of the motor (this step is
part of the motor disassembling)

Remark: To replace the motor bearing, please use special

tools to disassemble them from the motor shaft.
 Assembling of motor & pump.

1. Check the components before performing the assembling;

2. It's necessary to clean the component prior to assembling of them;
3. In the assembling, pay attention of the seal s, and do not miss some small pieces,
such as keys, and retaining ring. Basically, they are assembled in the reverse order as
they are disassembled.
 Routine maintenance and inspection of Motor & pump.
1. wipe the rust and taints from the motor,
2. Check the fixing bolt(screws) and ground wire;
3. Check the bearing noise and lubrication during operation;
4. Unusual noise, Vibration, Temperature;
5. Leaks in pump or piping;
6. Mechanical seal (should be no leakage);
7. Add grease to pump anti-friction bearings.

Annual inspection of Motor & pump.

1. Visual check any damage to each part;
2. check the wear and tear of pump housing;
3. check the wear and tear of the impeller;
4. Check the radial clearance of the sealing ring due to wear and ;
5. Check the radial run-out of the pump shaft;
6. Check all part of the auxiliary piping and pipe;
7.Clean and check the wear and tear of the mechanical seal.
 Failure analysis and solution of Motor & pump.
Items problems Reason solutions
1. Air trapped in the pump housing, or insufficient 1. Go on priming or air removing.
pump priming. 2. Solve the air leakage by tightening the piping
2. Air leaking in suction piping bolts appropriately.
1 No or insufficient 3. Change the driver rotation direction
3. Wrong pump rotation direction
water output 4. Find out the reasons, and improve the speed
4. Too slow pump speed 5. Check the piping and re move any debris.
5. Clogging in bottom valve, piping or impeller
inlet.
1. Anchor bolt get loose, or the base is not grouted 1. Tighten the bolt, and temp the base
or sufficiently tamped 2. Straighten or replace the pump shaft
Excessive vibration 2. The shaft is bent 3. Replace the bearing
2 4. Disassemble to inspect or replace the seal ring
or noise 3. The bearing is damaged
or impeller
4. The seal ring and impeller abrade each other 5. Re-do the balancing test to the rotor
5. The rotor balance goes beyond the tolerance
1. Bearing broken 1. Replace the bearing
2. Over load 2. Select a motor of larger capacity or reduce the load
3. Check the fuse and switch contacts
3. Running with only two phases 4. Clean the oil taint and dust in the air duct
Motor over heating
3 or smoking 4. Motor air duct blockage 5. Take measures for cooling
5. Too high ambient temperature 6. Repair and maintain the stator winding in a
professional manner
6. Stator winding failure 7. Check the voltage of power at the input end of motor
7. Too low or too high supply voltage with a voltmeter
 1. The power is not connected 1. Check the switch, fuse, each pair of
2. stator winding fault contact and leads
4 The pump cannot
be started 3. Wrong winding of the control device 2. Check winding break, internal short
circuit
3. Correction of the wiring
1. Abrasion between the rotor or stator with 1. Check the internal cavity of the
Abnormal sound the insulation paper motor to find out if any part of the
5 during motor 2. Bearing damage or serious lack of insulation paper stretches out.
operation lubrication 2. Replace or clean the bearing, and
replace the grease.
1. Unqualified rotor balancing 1. Perform rotor balancing calibration
6 Motor vibration 2. The shaft is bent 2. Straighten or replace the shaft

1. Bearing damage 1. Replace the bearing

2. Poor quality of bearing grease or improper 2. Replace the grease, but the filling
filling volume should not exceed 70% of the
bearing volume
Bearing over 3. Excessive wear or deformation of the
7 heating bearing housing or shaft
3. Repair the worn part with embedding or
coating method
4. Motor end covers or bearing caps are not 4. Align the motor and covers or bearing
installed flush caps with the location holes, then tighten
bolt.
Motor Spherical valve
 ROUTINE MAINTENANCE

1. Check the correct valve position signaling on the control panel;

2. Check mounting bolts, nuts, washers and screws for damage and tightness.

3. Conduct external visual inspection of all external surfaces including paint finishes,
control knobs and valve stems.
4. Confirm hand wheel is operating correctly and that there is physical movement of
the valve.
5. Confirm local control works in both directions and check for an signs deterioration,
such as undue motor noise.
 Problems and Solutions.
Items Problems Reason Solutions

1. Check the power cords.

1. The power cord disconnect.
2. Fix the lines.
2. Control lines disengage.
1 Can’t be started 3. Remove the problem of
3. Travelling or the moment of force
the traveling and the
apparatus fail.
moment of force
apparatus

The rotational direction of the

The phase sequence of power source is Exchange two random
2 out haft doesn’t conform to the connected improperly power cords
stipulation

1. Stop operating and cool

1. The running time is too long
the electromotor
3 The motor overheat 2. Motor can not match with the electric
2. Check the necessary
actuator
3. One phase disengages condition.
3. Check the power cords.
Items Problems Reason Solutions

1. The actuator is over

loaded and the moment 1. Increase the setting
4 Motor stops during the operation. of force acts. moment of force.
2. The valve has a 2. Inspect the valve.
breakdown.

1.The traveling or the 1. Inspect the setting

moment of force apparatus moment of force
5
The motor still rotates or the light is not bright
though the valve is in the right position. has a break down. apparatus.
2. Traveling controller may 2. Readjust the traveling
not be adjusted properly. control apparatus.

1. Remote transmission
1. Inspect or change the
potentiometer has
potentiometer.
6 No position signal available. breakdown.
2. Tighten up the fixing
2. The fixing screw of the
screw of the
potentiometer gear gets potentiometer gear.
loosen.
 Automatic Backwash Filter dismantling for maintenance.

1. Removal of filters tank manhole flange bolts and open the cover.
2. Remove the filters locking bolts.
3. Remove the filter one by one.
 Daily maintenance of automatic filter
Project Inspection standard Check the cycle

Three months (can be based on the

If after completing a backwash,
The differential value of the filtered water quality is good or bad
differential pressure cannot fall below
differential pressure controller to extend or shorten the inspection
rated differential pressure value
period)

Oil the eye can see grease, such as no

The speed reducer lubrication grease Two months or work 300 hours
need filling grease

Control cabinet Dry, clean Once a week

Whether the connecting bolt A month

is loose
 Troubleshooting
Common problems The reason of causing The solution

Drain electric actuators can't Drain valves have larger dirt valve to
completely closed, and control the get stuck in, cause electric actuator Clean up the drain valve
ark of the light is not bright. torque

The main shaft in the drain valves are Axis compression flange bolt
Tighten the bolt
leaking looseness

Water filter differential pressure drain

Floc to block a mesh screen Clean the filter
frequent restart

Unscrew the interface on high

Differential pressure alarm signal not Differential pressure controller
pressure differential pressure
reset interface gasket too tight
controller
 Heat Exchanger Disassembly
1. Always release pressure and drain your heat exchanger before disassembly;
2. Measure and take note of the distance between the pressure plate and the frame plate (Measure value).
3. Remove outside bolts (leave 1,2,3,4).
4. Loosen bolts 1,2,3,4 slowly in diagonal pairs, alternating back and forth.
5. Slide the pressure plate along the guiding bar to open the unit.
6. To remove a plate, lift up gently and swing the bottom out.
 Heat Exchanger Reassembly
1. Before you reassemble and close your heat exchanger, it is important to ensure that all plates have been returned to
their original positon and are in the correct direction.
2. Check the plates and gaskets. It is important to make sure that the gaskets are on correctly and that there is no
debris in the unit.
3. Brush any debris off of the bolts, the carrying bar, and the guiding bar (we suggest the use of a wire brush) and then
apply a thin layer of grease).
4. Press the plates together. With the plates together, check again that the plates form a honeycomb pattern
5. Begin by tightening bolts 1,2,3,4 in diagonal pairs until you reach the desired Measure value. When tightening the
bolts, ensure that the frame plate and the pressure plate are always parallel and are not uneven.
6. Attach the remaining bolts
7. Measure the unit and check that the Measure value is the same as the measure marked on the front of the unit.
8. Check Measure A at the top, bottom, and middle of the unit.
 Preventive Maintenance Checklist
1. Confirm plate and frame units are tightened as recommended by the manufacturer
2. Visually check heat exchanger for leaks at the connection points to the heat exchanger as well as the body of the
heat exchanger. Insulation may be hiding small leaks so also check for areas of wet or water stained insulation.
3. Check the pressure gauges and thermometers for accuracy.
4. Wipe clean all painted parts and check surfaces for signs of damage.
5. The upper carrying bar and lower guiding bar should be coated with a lubricant to enable the plates to slide
smoothly.
6. If rollers are fitted to the follower, lubricate the bearings with light machine oil.
7. Check bolts and bars for rust and clean. Lightly coat threaded parts with molybdenum grease or a corrosion
inhibitor (ensure that no grease, etc. falls onto the plate gaskets.
 Problems and Solutions.
items
Symptom Possible cause(s) Remedy/ Solution

1. Heat transfer performance 1. The heat transfer surfaces get fouled. 1. Disassemble the Heat
has Decreased, 2. Fouling on the heat transfer surface is Exchanger and make the
2. The differential pressure making the plate gap narrow. heat transfer plates clean.
increases or the flow rate 3. The port holes and/or the heat Be sure to check if any
1 decreases. transfer surfaces are clogging. pipe connected to the
inlet and outlet of PHE are
clean.

Fluid is leaking to the outside 1. Sealing performance has decreased 1. After PHE internal pressure shall
be atmospheric pressure and tighten
from between heat transfer due to insufficient tightening
the plate pack sufficiently.
plates 2. Sealing performance has decreased However, do not tight shorter than
due to plate gasket deterioration. the minimum length.
2 3. The heat transfer plate arrangement is 2. Disassemble PHE and replace any
damaged plate gaskets to brand-new
incorrect.
one.
3. Disassemble PHE and heat transfer
plate arrangement shall be
corrected.
 Problems and Solutions.
4. Heat transfer plate has crack and/or 4. Disassemble PHE and replace
pin-hole due to corrosion etc. any damaged heat transfer plate to
brand-new one.

1. Gaskets fitted incorrectly 1. open the heat exchanger,

leak between
2. Gaskets are defective correct the installation of the
3 the heat
gaskets.
exchanger plates
2. open the heat exchanger and
and the frame
replace the gaskets
The mixture of hot Heat transfer plate has crack and/or pin- Disassemble PHE and replace any
side media and hole due to corrosion damaged heat transfer plate to
4 brand-new one
cold side media
has occurred