JINDAL INDIA THERMAL POWER LIMITED

INTEGRATED MANAGEMENT SYSTEM

DEPARTMENT: MECHANICAL MAINTENANCE
WORK INSTRUCTION TITLE: MAINTENANCE OF HFO FORWARDING PUMP
REV.NO : 00
JITPL/SMP/Mech/004 DATE:1.10.2014
PAGE 1 of 7
1. PURPOSE

: MAINTENANCE OF HFO FORWARDING PUMP

2. SCOPE

: HFO FORWARDING PUMP

3. REFERENCE

: JITPL/SMP/Mech/004

Prepared By:

Checked By:

Reviewed By:

Approved By:

NAME:

NAME:

NAME:

NAME:

DESIGNATION:

DESIGNATION:

DESIGNATION:

DESIGNATION:

SIGNATURE:

SIGNATURE:

SIGNATURE:

SIGNATURE:

JINDAL INDIA THERMAL POWER LIMITED

INTEGRATED MANAGEMENT SYSTEM
DEPARTMENT: MECHANICAL MAINTENANCE
WORK INSTRUCTION TITLE: MAINTENANCE OF HFO FORWARDING PUMP
REV.NO : 00
JITPL/SMP/Mech/004 DATE:1.10.2014
PAGE 2 of 7
AMENDMENT HISTORY
Sl
no.
1

Amendment Description
a. Inclusion of new hazard controls
b. Version change

Current Ver.
No.
00

Current
Rev.No
00

Issue Date
15.10.2013

JINDAL INDIA THERMAL POWER LIMITED

INTEGRATED MANAGEMENT SYSTEM
DEPARTMENT: MECHANICAL MAINTENANCE
WORK INSTRUCTION TITLE: MAINTENANCE OF HFO FORWARDING PUMP
REV.NO : 00
JITPL/SMP/Mech/004 DATE:1.10.2014
PAGE 3 of 7

GENERAL SPECIFICATION OF HFO FORWARDING PUMP

MAKE

ALEKTON SCREW PUMPSCHENNAI

MODEL

DH600-1600-2SJ

SI NO

12096825/26/28/29

DIFF PRESSURE

30 BAR

FLOW

980 L/MIN

VISCOCITY

180-380 CST

SPEED

1450 RPM

BKW

58.6 KW

JINDAL INDIA THERMAL POWER LIMITED

INTEGRATED MANAGEMENT SYSTEM
DEPARTMENT: MECHANICAL MAINTENANCE
WORK INSTRUCTION TITLE: MAINTENANCE OF HFO FORWARDING PUMP
REV.NO : 00
JITPL/SMP/Mech/004 DATE:1.10.2014
PAGE 4 of 7
1. DEFINITION: Applicable for HFO FORWARDING PUMP of all the units, PTW-Permit To Work
2. WORK INSTRUCTIONS:
1.
2.
3.
4.
5.
6.
7.
8.

Check
Check
Check
Check
Check
Check
Check
Check

(ROU-5.1) (NROU-6.1,6.2)

pump suction & discharge pressure

filters condition.
coupling guard & coupling bolts.
mechanical seal condition.
oil seal condition.
Pump & motor foundation bolt condition.
oil level in view glass.
pump & motor alignment.

HFO FORWARDING PUMPS MAINTENANCE PROCEDURES:1. Isolate power supply.

2. Close the suction & discharge valve.
3. Open the drain valve & Drain the oil in line.
4. Open all connecting lines in pump.
5. Open the coupling guard.
6. De-couple Pump & motor.
7. Open Pump suction & discharge flange bolts
8. Remove pump DE side circlet and open the seal box.
9. Remove mechanical seal.
10. Take out bearing from seal box casing.
11. Check bearing housing condition of seal box condition.
12. Open pump PRV & foundation bolts.
13. Remove NDE side pump cover.
14. Remove Pump screw shaft.
15. Check shaft & bush condition.
16. Ensure proper clearance between shaft and bush. Replace both shaft and bush if
required.
17. Replace bearing and mechanical seal if required.
18. Check shaft run out. If found ok then install.
19. Install NDE side cover.
20. Install rotary seal in shaft. Install stationary seal in seal box.
21. Install bearing in bearing housing. (If Greasing required do it.)
22. Install mechanical seal.
23. Fit Seal box cover in pump casing.
24. Install PRV & tighten the bolts.
25. Install suction & discharge line & tighten the bolts.
26. Install all connecting pipe line & view glass in pump.
27. Install pump foundation bolts & tighten the bolts.
28. Install pump & motor coupling.
29. Check pump & motor alignment and install coupling guard.

JINDAL INDIA THERMAL POWER LIMITED

INTEGRATED MANAGEMENT SYSTEM
DEPARTMENT: MECHANICAL MAINTENANCE
WORK INSTRUCTION TITLE: MAINTENANCE OF HFO FORWARDING PUMP
REV.NO : 00
JITPL/SMP/Mech/004 DATE:1.10.2014
PAGE 5 of 7
4. QUALITY CHECKS
All the parameters, activities are maintained within
4. CHECKS BEFORE RELEASE OF PERMIT:
All Tools, materials and manpower are removed.

Clean the maintenance area properly.

Ensure safety protection cover / guards are fitted in its position.

5. RE-COMMISSIONING PROCEDURE:
Return PTW.

1.0
2.0
3.0
4.0
5.0

Normalize isolations after release of PTW

RESPONSIBILITY Mechanical Engineers
MAN POWER REQUIRED: 1 engineer, 1 Technicians, 2 Helper, 2 Rigger.
DURATION: 8 hrs.
OTHER DEPARTMENT TO BE INTIMATED: (Main Plant Operation /Electrical.)
DETAILS OF HAZARD INVOLVE:

1. Fall/ Slip due to oily surface.

2. Fire.
3. Failure of lifting tools & tackles.
4. Exposure to high noise.
5. Contact with hot surface.
6.

6.0

Exposure to process liquid.

SAFETY PRECAUTION REQUIRED:

1. Keep the fire extinguishers ready within reachable limit for any exigency.

JINDAL INDIA THERMAL POWER LIMITED

INTEGRATED MANAGEMENT SYSTEM
DEPARTMENT: MECHANICAL MAINTENANCE
WORK INSTRUCTION TITLE: MAINTENANCE OF HFO FORWARDING PUMP
REV.NO : 00
JITPL/SMP/Mech/004 DATE:1.10.2014
PAGE 6 of 7
2. Ceramic hand gloves to be used while handling thrust collar / hot surface.
3. Ensure use of periodically tested proper lifting tools & tackles.
4. Use of earplug is mandatory along with other general PPEs.
5. Ensure good housekeeping of maintenance bay.
Put barricade tapes around the equipment under maintenance
7. 0 PERMIT TYPE: Permit To Work Order.
8.0 PERMIT APPROVING AUTHORITY: Shift- In-Charge (Main Control Room)
9.0 TOOLS REQUIRED:SL. NO.

TYPE OF THE TOOL

SPECIFICATION

QUANTITY

Spanner

18~32mm

1 Nos

Hammer

4lb

1 Nos

Allen key set

Chisel

Tool box set

Screw driver

12mm

1 Nos

Pipe wrench

12

1 Nos

10

Slide wrench

12

1 Nos

10.0 MATERIALS REQUIRED:SL. NO.

TYPE OF THE MATERIAL
1
Oil Gasket

1 Nos

1 Nos
1 Nos

QUANTITY
01 mtr

JINDAL INDIA THERMAL POWER LIMITED

INTEGRATED MANAGEMENT SYSTEM
DEPARTMENT: MECHANICAL MAINTENANCE
WORK INSTRUCTION TITLE: MAINTENANCE OF HFO FORWARDING PUMP
REV.NO : 00
JITPL/SMP/Mech/004 DATE:1.10.2014
PAGE 7 of 7
2
3
4

RTV paste
WD-40
Cotton west

01 no`s
01nos
01kg

11. FREQUENCY OF MAINTENANCE: Annual Outage / In case of failures / when required.

12 .CHECKS BEFORE RELEASE OF PERMIT:
All Tools & materials and manpower are removed.

Clean the maintenance area properly.

Ensure safety protection cover / guards are fitted in its position.

13 .RE-COMMISSIONING PROCEDURE:
Return PTW
Normalize isolations after release of PTW