Wartsila India Ltd.

PREPARED BY : MECH PLANT SMP BOILER FEED PUMP APPROVED BY : PPM AT STERLITE THERMAL ISSUED BY : PPM POWER DIVISION DATE :
PURPOSE SCOPE RESPONSIBILITY INPUT / TOOLS Hand gloves Mechanical tool box kit Dial Gauge Lifting and Hydraulic Tools : Record : : : BFP Major Overhaul CPP Mechanical Maintenance Engineer

Operations & Maintenance PAGE DOC. NO. EDITION REVISION : : 496024P01 :0 :0

OUTPUT PROCEDURE Make JSA

Take the Work Permit Clean the equipment Drain Water and Oil from BFP Remove the instrument probe Remove the all pipe connections Decouple the high speed coupling

Safety Precaution Required

1. Keep the fire extinguishers ready 2. Drain hot water from BFP suction strainer & from pump drain line completely. 3. Ceramic hand gloves to be used while handling any hot surface. 4. Ensure use of periodically tested proper lifting tools & tackles. 5. Ensure good housekeeping. Put barricade tapes around the equipment under maintenance T & P INCLUDING SPECIAL ONES 1. Tool box containing normal T & P for mechanical technician. 2. Special tools, tackles and spanners. 3. Alignment fixtures / Laser alignment kit.. 4. Bolt heating device. 5. Device to remove thrust collar.

Wartsila India Ltd. PREPARED BY : MECH PLANT SMP BOILER FEED PUMP APPROVED BY : PPM AT STERLITE THERMAL ISSUED BY : PPM POWER DIVISION DATE :
6. Fixtures for cartridge removal and insertion. OUTPUT : Record

Operations & Maintenance PAGE DOC. NO. EDITION REVISION : : 496024P01 :0 :0

ISOLATION PROCEDURE 1. 2. 3. 4. 5. 6. DC supply of control panel made OFF. Rack-out and lock breaker. Close suction and discharge valve All drains and vents to be opened. Isolating valves of re-circulation valve to be kept closed. AOP module to be made off and locked.

WORK INSTRUCTION PROCEDURE A) Cartridge removal 1. Remove instrumentation. 2. Remove oil and water pipe lines that will create hindrance. 3. Remove DE and NDE radial and thrust bearings and bearing housing. 4. Remove both ends mechanical seals. 5. Remove both ends cooling water jackets and suction covers. 6. Remove discharge cover bolts. 7. Assemble BFP cartridge removing fixtures. 8. Remove cartridge.. Thread in of pump cartridge. 1. Thorough cleaning of barrel. 2. Fix cartridge thread in fixture with pump cartridge. 3. Insert the cartridge in barrel with new O-ring and back up ring. Care is to be taken to avoid the damage of stand threads. 4. Fix discharge cover, tighten all bolts and ensure using 0.02mm feeler gauge. 5. Assemble balancing device, assemble suction cover, cooling water jackets, bearing brackets, bearings, Check and set floats. Mechanical seal to be assemble after completion of balancing device assembly. 6. Do alignment and couple pump? Fix coupling guard 7. Fix piping and instrumentation. 8. Start AOP, check oil flow, pressure etc. 9. Charge cooling & seal water and check flow, pressure etc. 10. Run pump, record parameters and vibration. 11. Release pump for normal operation

C) Servicing of mechanical seals of BFP

1. 2. 3. 4.

Remove instrumentation. Remove DE & NDE side bearings and bearing housing. Lock mechanical seal gland plate with sleeve and form a cartridge unit. Remove mechanical seal.

Wartsila India Ltd. PREPARED BY : MECH PLANT SMP BOILER FEED PUMP APPROVED BY : PPM AT STERLITE THERMAL ISSUED BY : PPM POWER DIVISION DATE :
5. 6. 7. 8. 9. 10.

Operations & Maintenance PAGE DOC. NO. EDITION REVISION : : 496024P01 :0 :0

Dismantle mechanical seal and inspect its individual components. Check the working surface of seals. If required replace the seal ring pair. Assemble seal and form a cartridge unit. Fix cartridge in position and remove locking arrangement. Fix both ends bearings & instrumentations. Hand over pump for normal operation.

QUALITY All the parameters, activities are maintained within prescribed limit. Any deviation from the norm is recorded and corrective action is taken according

ENVIRONMENT OHSAS Not applicable. Ensure PPE, Helmet, adequate lighting near the work place. Ensure the lifting tools are in adequate condition. Ensure proper earthing of the equipment / area of work as the case may be. Ensure healthiness & safety of the entire activities with respect electrical system.

RECORDS WIN /SIL/4/F/05