Sei sulla pagina 1di 33

DOC. NO.

JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 1 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

PREPARED BY :
__________________________________________ __________________
DM/MI (AME / GTE) DATE

REVIEWED BY (PEER) :
________________________________________ __________________
NDB/AR (Sr. Machinery Staff Supervisor / AUM) DATE

APPROVED BY :
________________________________________ __________________
OMQ (Maintenance Manager) DATE

CHANGE RECORD

S. # REV. # DATE PAGE # SECTION DESCRIPTION OF CHANGE

DISTRIBUTION

1. DAHARKI LAN
2. FIELD MAINTENANCE OFFICE
3. MAXIMO

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 2 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

Table of Contents
1. INTRODUCTION ...................................................................................................................................... 4
1.1 Purpose & Scope ................................................................................................................................... 4
1.2 Definitions / Abbreviations ................................................................................................................... 4
2. EQUIPMENT SPECIFICATIONS ............................................................................................................. 5
2.1 General Information .............................................................................................................................. 5
2.2 Gear Box ............................................................................................................................................... 5
2.3 Table of Weight .................................................................................................................................... 6
2.4 Blinds List ............................................................................................................................................. 6
3. HEALTH & SAFETY ................................................................................................................................ 6
3.1 Associated Hazards ............................................................................................................................... 6
3.2 Safety Precautions ................................................................................................................................. 6
3.3 PPE's ..................................................................................................................................................... 6
3.4 Special Instructions ............................................................................................................................... 7
3.5 Environmental Impact ........................................................................................................................... 7
3.6 OHIH ..................................................................................................................................................... 7
4. PREPARATIONS ....................................................................................................................................... 7
4.1 Pre Planning Activities.......................................................................................................................... 7
4.1.1 Work Permits / Authorizations .................................................................................................... 7
4.1.2 Manpower Requirement ............................................................................................................... 8
4.1.3 Material Requirement .................................................................................................................. 8
4.1.4 Tools Requirement ..................................................................................................................... 10
4.1.5 Measuring Tools ........................................................................................................................ 10
4.1.6 Equipment Requirement ............................................................................................................ 10
4.1.7 Miscellaneous Requirement ....................................................................................................... 11
4.1.8 Other Requirement ..................................................................................................................... 11
4.1.9 WPS / PQR requirement ............................................................................................................ 12
4.1.10 General ....................................................................................................................................... 12
5 PROCEDURE ........................................................................................................................................... 12
5.1 Complete Overhauling Procedure ....................................................................................................... 12
5.1.1 Disassembly ............................................................................................................................... 12
5.1.2 Inspection & Checks .................................................................................................................. 18
5.1.3 Assembly.................................................................................................................................... 18
5.1.4 Mechanical Seal assembly ......................................................................................................... 24
5.2 Lube oil pump overhauling (auxiliary) ............................................................................................... 28
5.2.1 Disassembly ............................................................................................................................... 28
5.2.2 Inspection & Checks .................................................................................................................. 28
5.2.3 Assembly.................................................................................................................................... 28
5.3 Gear Box Overhauling ........................................................................................................................ 28
5.3.1 Disassembly ............................................................................................................................... 28
5.3.2 Inspection & Checks .................................................................................................................. 29
5.3.3 Assembly.................................................................................................................................... 29
5.4 Machinery Surveillance/ Preventive Maintenance Plan ..................................................................... 30
5.5 Activity Bar Chart ............................................................................................................................... 30
PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 3 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

5.6 Quality Assurance Plan ....................................................................................................................... 30


5.6.1 Allowable Tolerances ................................................................................................................ 30
5.6.2 Runout & Axial Float ................................................................................................................. 31
5.6.3 Clearance List ............................................................................................................................ 31
5.6.4 Gear Box Clearances .................................................................................................................. 32
5.7 Technical Details / Special Conditions ............................................................................................... 32
6 FINISHING THE JOB .............................................................................................................................. 32
7 RECORDS ................................................................................................................................................ 32
8 ATTACHMENTS ..................................................................................................................................... 32
9 REFERENCES.......................................................................................................................................... 33

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 4 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

1. INTRODUCTION
1.1 Purpose & Scope
The purpose of this procedure is to ensure that Process Safety and Risk Management goals for protecting
Health, Safety and Environment are met by providing comprehensive job plan for routine & non routine tasks
/ jobs carried out by maintenance on P-202G, safety critical equipment, and to ensure that the contents of
this procedure are current, complete, under stood and are followed for safe, correct and quality work.
Further, the scope of this procedure is to provide hands on knowledge to area maintenance technicians, AME
/ AMS and ASH about P-202G (Carbamate Recycle Pump 'G') inspection & other routine preventive /
predictive maintenance checks and repairs.

1.2 Definitions / Abbreviations

1. ASH Area Section Head


2. AME Area Maintenance Engineer
3. AMS Area Maintenance Supervisor
4. PE Planning Engineer
5. MSE Machine Shop Engineer
6. FSE Fabrication Shop Engineer
7. MPE Motor Pool Engineer
8. LFCE Local Fabrication Cell Engineer
9. PJE Project Engineer
10. IE Inspection Engineer
11. MTSE Mechanical Technical Services Engineer
12. GL Group Leader
13. SFGL Shops Facility Group Leader
14. ISGL Inspection Services Group Leader
15. MSGL Machinery Services Group Leader
16. SA Safety Advisor
17. MM Maintenance Manager
18. EM Engineering Manager
19. JSA Job Safety Analysis
20. MSDS Material Safety Data Sheet
21. PPE Personnel Protective Equipment
22. PSRM Process Safety Risk Management
23. CMMS Computerized Maintenance Management System
24. NA Not Applicable

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 5 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

2. EQUIPMENT SPECIFICATIONS
2.1 General Information

Tag # P – 202G
Equipment Carbamate Recycle pump
Make Ebara Corporation Japan
Serial # RU 10512 – 01
Type Centrifugal (Horizontal)
Model 125 x 100 SSP 6 GM
Inlet pressure 300 psi
Inlet temperature 212 0F
Discharge pressure 2660 psi
Discharge temperature 212 0F
Pump (RPM) 6576
Motor (RPM) 1488
Motor Weight 6000 kg
Type of service Carbamate Recycle Pump
Number of impellers Six (06)
HP 780 KW (1045 HP)
Coupling type (Gear box to Motor) Metastream Tsks – 0750 - 0177 - 1800
Coupling type (Gear box to Pump) Metastream Tsks – 0180 - 0137 - 1850

2.2 Gear Box

Equipment Gear box (P – 202 G)


Make Ebara Corporation Japan
Serial # RU 10512 – 02
Model GBH 28
Input Shaft (RPM) 1488 1/min
Output Shat (RPM) 6576 1/min
Weight (with oil) 8820 N (900 kg)
Gear Ratio 4.419
Oil Capacity (Turbine 32) 400 LTR
Coupling (Gear box to Motor) Metastream TSKA –0750-0177-1800

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 6 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

2.3 Table of Weight

Component Weight (lbs)


Weight of pump 1850

2.4 Blinds List

S. # Blind Description & Location Size (in) / Rating Quantity

1 Blind on suction line 5” 300 psi 01 ea


2 Blind on discharge line 5” 3000 psi 01 ea

3. HEALTH & SAFETY


3.1 Associated Hazards
1. Carbamate splash.
2. Over head loads.
3. Pinch points.
4. Air hose pipe coupling failures.
5. Gear box fall and pump fall.

3.2 Safety Precautions


1. Work permit should be taken before starting any job.
2. Use certified rigging equipment.
3. Proper size slings should be used (1/2” minimum).
4. Keep walk way clear to avoid tripping hazard and cordon off the area.
5. Insure overhead crane load tested as per plan.
6. During the removal and installation of pump rotor unauthorized person should not be allowed to
enter the working area and area should be cordon off.
3.3 PPE's
1. Mandatory PPE's.
2. Comfo gas mask, Full-face mask.
3. Splash Goggle

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 7 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

3.4 Special Instructions


1. Ensure lock out / tag out is done
2. All rigging activities should be carried out under the supervision of ECPL supervisor/lead
technician.
3. Hold a five minutes safety talk before starting the job.
4. Ensure system is completely isolated.
5. Be very cautious since system contain hot Carbamate Solution
6 Store all parts and fasteners in to the separate containers after cleaning and tagging them.

3.5 Environmental Impact


1. MSDS available for Carbamate Solution

3.6 OHIH
Individuals working at this pump should be fit for work and have no health issues. Moreover, necessary
precautions are to be taken to maintain minimum standards of occupational health & industrial hygiene.

4. PREPARATIONS

4.1 Pre Planning Activities

4.1.1 Work Permits / Authorizations

S. # Type of Permit Required

1 Cold (Overhead Crane operation permit) Y

2 Hot Y

3 Electrical -

4 Instrument -

5 Radiography -

6 Confined Space Entry -

7 Vehicle Entry Y

8 Excavation & Civil Work -

9 Lifting Over Process Equipment -

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 8 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

4.1.2 Manpower Requirement

S. # Craft ECPL Contract


1 Field Machinists 04 02
2 Pipe Fitter 02 01
3 Scaffolders - -
4 Crane Operator / Fork Lifter Operator 01 -
5 Welder 01 -
6 Fabricator - -
7 Riggers 01 -
8 Insulator - -
9 Carpenter - -
10 Mason - -
11 USL - 02

4.1.3 Material Requirement

S. # Stock # Part Description Part # Quantity


1 132-140-006 Bearing Metal P. # 052 02

4 132-140-025 Element For Filter (no.13) P. # RU10512-01 02

5 132-140-030 Gasket 75X 61 P. # 117-1 06

6 132-140-032 Gasket 26 X 14 P. # 117-6 10

7 132-140-033 Gasket 26 X 14 P. # 117-6 01

8 132-140-034 Gasket 30 X 18 P. # 117-7 02

9 132-140-036 Gasket 206 X 191 P. # 117-7 02

10 132-140-050 Liner Ring 1ST P. # 107-1 01

11 132-140-052 Liner Ring P. # 107-2 05

12 132-140-060 O-Ring Bearing P. # 115-1 03

13 132-140-062 O-Ring Seal P. # 115-2 02

14 132-140-070 Rotor Assy Complete Rotor Assy Complete 01

15 132-140-080 Thrust Shoe P. # 062-2 12

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 9 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

Main Lube Oil Pump Parts


1 132-140-106 Bearing P. # 052-1 01 ea

2 132-140-108 Bearing P. # 052-2 01 ea


3 132-140-110 Bearing P. # 52-3 01 ea

4 132-140-112 Bearing P. # 052-4 01 ea

5 132-140-116 Drive Shaft P. # 036 01 ea

6 132-140-118 Drive Shaft P. # 035 01 ea


7 132-140-130 Pump Gear P. # 028 01 ea

Mechanical Seal Parts


1 132-140-220 Seal Mechanical Seiko Co , Type 100/90-BV28-YM 02 ea

2 132-140-250 O-Ring P. # 14 02 ea
3 132-140-252 O-Ring P. # 7 02 ea

4 132-140-254 O-Ring P. # 11 02 ea
5 132-140-260 Packing floating P. # 393505-100 02 ea

6 132-140-270 Ring Comp P. # 43-420936 02 ea

7 132-140-272 Rotary Seat P. # 04-457334 02 ea

8 132-140-280 Sleeve For Seal P. # 53-420937 02 ea


9 132-140-282 Seal Face P. # 24-420787 02 ea

Gear Box Parts


1 134-130-006 Bearing Low Speed Shaft P. # 052-01 , 052-02 01 ea
2 134-130-008 Bearing Low Speed Shaft P. # 052-02 01 ea

3 134-130-010 Bearing High Speed Shaft P. # 052-03 , 052-04 01 ea

4 134-130-012 Bearing High Speed Shaft P. # 052-03 , 052-04 01 ea

Couplings
1 134-130-020 Coupling Lube Pump P. # 142 01 st
2 132-140-010 Coupling Gear Box To Motor Type. TSKS-0750-0177-1800 01 st

3 132-140-012 Coupling Gear Box To Pump Type TSKS- 0180-0137-1850 01 t

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 10 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

4.1.4 Tools Requirement

S. # Tools Size Quantity


1 Tool Box - 01
2 Torque wrench 600' lb ¾ / 1” DR 01
3 Sling 1” X 6’ 02
4 Sling ¾” X 5’ 02
5 Strap 3 Ton 02
6 Socket head 50 mm 01
7 Ratched ¾” drive 01
8 Impact wrench 1” drive 01
9 Shackle 1” 04
10 Hammer 10 Lbs 01
11 Chain Block 5 ton + 10 ton 02 + 01
12 Bearing Puller (Plate Type) 14” 01
13 Bearing Puller (Three leg) 10” 01
14 Ellen Key 17 mm + 13 mm 01+01
15 Special Tool kit at mechanical shack - 01

4.1.5 Measuring Tools


S. # Tools Size Quantity
1 Dial Vernier 12” 01
2 OD Micrometer 0 – 6” 01
3 OD Micrometer 6 – 12” 01
4 ID Micrometer 2 – 40” 01
5 Magnet Base 6” 01
6 Dial Indicator Set - 01
7 Feeler Gauge 6” 01

4.1.6 Equipment Requirement


S. # Equipment Size Quantity
1 Welding Machine - 01
2 Fire Proof Gloves - 01 pr
3 Grinder 4“ 01
4 Overhead Crane (HC 04) 08 on 01

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 11 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

4.1.7 Miscellaneous Requirement

S. # Equipment Size Quantity


1 Wooden Boxes 1’ X 2’ 06 ea

2 Ply Wooden Sheet 4’ X 8’ 03 ea

3 Wooden Block 6” X 4’ 04 ea

4 Wooden V- Block 2’ x 2’ x 2’ 04ea

5 Coarse Cloth - 120 yd

6 WD – 40 - 10 cn

7 Cotton Gloves - 50 pr

8 Anti Seize Compound - 02 cn

9 Grease # 33 - 02 ea

10 RTV Gasket Maker - 10 ea

11 Emery Paper – 0 - 15 ea

12 Teflon Tape - 10 ro

13 Wire Brush - 04 ea

13 Hosiery Cloth - 02 g

4.1.8 Other Requirement

S. # Description & Location Quantity


1 Flood Lights from north & south side 04 ea.

2 Hand Light 12V 04 ea.

3 Fork Lifter with long forks. 01 ea

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 12 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

4.1.9 WPS / PQR requirement


1. WPS to be made available in case of any welding job on pump. PQR to be obtained from
inspection against the said WPS.

4.1.10 General
1. The pump has six impellers (six stages).
2. Impellers are arranged in two groups of three impellers each. We can name these groups as the
LP side and the HP side. These two groups are arranged in series such that the discharge of LP
side goes into the suction of HP side.
3. Casing is vertically split.
4. Balancing is achieved party by placing the impellers in two groups in opposite direction and partly
by a balancing line connecting the first impeller suction to fourth impeller suction.
5. There are two mechanical seals, one on each side.
6. The seal is a cartridge type, balanced mechanical seal made by Tanken.
7. There are two journal (liner) bearings, one on each side, and one thrust bearing.
8. The pump & gearbox, and gearbox & motor are coupled with Flexibox (Metastream) flexible
couplings.

5 PROCEDURE
5.1 Complete Overhauling Procedure
1. Obtain Work Permit.
2. Ensure Lock out / Tag out system (manually try out through local On / Off switch).
3. Ensure the pump is fully depressurized / de-energized & flushed.

5.1.1 Disassembly
1. Open the suction and discharge line flanges.
2. Open the balance line flanges.
3. Dismantle bearing oil inlet/outlet piping.
4. Dismantle seal water piping.
5. Remove the coupling bolts.
6. Take alignment reading.
7. Check bearing radial clearances by lifting method.
8. Check axial float of the rotor (with bearings).

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 13 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

9. Open the bearing cover (053 fig – 1) and then open the top covers of the bearing casing from
both sides (051 – 1 & 051 – 2 fig – 1).

10. Take out the liner bearing which is in two halves.


11. Take out the thrust shoes (062-2 fig-1) along with the rocker plate (062-4 fig-1) and levering
plate (062-3 fig-1).

Thrust disk

Upper half of
the liner bearing
Thrust bearings

12. Remove the lower portion of the bearing housing.


13. Remove the thrust disk nut (128-2 fig-1), thrust disk (062-1 fig-1) and key (039-6 fig-1).
14. Remove the thrust side bracket (044-2 fig-1). Coupling side bracket (044-1 fig-1) will be used for
placing the pump vertically.

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 14 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

15. Remove the fastening bolts of the mechanical seal cover (016 fig-1).
16. Draw out the mechanical seals.

17. Install the bearings and bearing housings back.


18. Remove the bolts of the pump pedestal.
19. Remove the pump from the base plate.
20. Relocate the pump to workshop.
21. Check axial bump of the rotor (without bearings).
22. Place the pump in vertical position with suction casing on the lower side on a skid.

Discharge
casing
Suction
casing

Pump Skid

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 15 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

23. Take out the stuffing box (008-2 fig-1).

Stuffing box

Balance
cover/intermediate
casing

Discharge
casing

24. Remove the fastening bolts (120 fig-1) of the casing after opening the fastening nuts (128-1 fig-1)
of the casing using impact wrench. These bolts include right handed screw and left handed screw,
The left handed screw has grooves on each end and the bolt which has no groove is the right
handed screw.

Impact wrench

Fastening/Tie rod
Bolts

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 16 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

25. Draw out the Balance cover/intermediate casing (015 fig-1) using overhead crane.

Balance
cover/intermediate
casing

26. Draw out the balance sleeve (078 fig-1) from the shaft.

Balance sleeve

27. Draw out the impeller (021-4 fig-1). If it is hard to pull out the impeller, knock the impeller lightly
with a wooden hammer and pull out cautiously not to scar the shaft. Components often stick to
the shaft very hard after the pump has been operating for long hours. In such a case, apply WD-
40. If this method does not work, heat the outside of the stuck part cautiously and uniformly, not
PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 17 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

to exceed 200 0C, and it will be easier to pull out. In this case the shaft must be kept cold. Avoid
heating the shaft under any circumstances.

Balance 4th stage


sleeve impeller

Diaphragm Guide
casing vane

28. Remove the split ring of the 4th stage impeller (021-4fig-1) and take out the impeller.

29. Take out the guide vane (022-3 fig-1) between 4th and 5th stage.

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 18 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

30. Take out the diaphragm casing and then remove the 5th stage impeller (021-5 fig-1) and guide
vane between 5th and 6th stage. Diaphragm casings are dowelled with the guide vanes.
31. Repeat the above process to take out the diaphragm casing, the 6th stage impeller (021-6 fig-1)
and guide vane between 6th stage impeller and discharge casing.
32. Pull out the middle/discharge casing (003 fig-1) and draw out the center sleeve (087 fig-1) by the
same way as in the case of the impeller.
33. Remove the guide vane (022-2 fig-1) and 3rd stage impeller (021-3 fig-1) by the same process as in
the case of the balance cover.
34. Repeat the above mentioned process at each stage.
35. While disassembling, pay serious attention to the machined surfaces of the casing as well as those
of the rotating elements.
36. The pump should not be transported in disassembled, condition. The parts must be assembled,
even temporarily, into one assembly for transportation.
5.1.2 Inspection & Checks
1. Cleaning and Inspection of all parts.
2. DPT of various parts like Rotor / Sleeve / Wear Rings etc if required.
3. Check all dimensions such as Rotor / Sleeve / Wear Rings / Mechanical Seal / Shaft run out and
compare with recommended values.
5.1.3 Assembly
1. Assembly should be carried out approximately in the reverse order of disassembly.
2. For Tolerances and clearances, refer to the Tolerances chart.
3. Check for any radial eccentricity, run out, deformations in all 3 casings (003,005,015 fig-1). Also
check the axial flatness of the faces.
4. Prepare sheet packing, O-rings, and gaskets in advance.
5. Place the suction sleeve (043-1 fig-1) and first stage impeller (021-1 fig-1) on the shaft.

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 19 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

6. Start the assembly by bolting the coupling side bracket (044-1 fig-1) with the suction casing.
7. Place the suction casing on a skid and insert impeller mounted shaft in it.

Shaft placed inside suction casing

8. Place the Gasket (117-1 fig-1) on the suction casing. During the whole assembly, ensure proper
seating of the elastomers before placing each casing/diaphragm.
9. Place the guide vane (022-1 fig-1) on the 1st stage impeller between 1st and 2nd stage.

Guide vane

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 20 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

10. Place the diaphragm casing on the guide vane (022-1 fig-1) and repeat the above 2 steps to
assemble the first 3 stages of the pump. Remember to mark all the diaphragm casings against the
position of dowel hole in the relative guide vane.

Dowel
position
markings

11. Place the center sleeve (087 fig-1) and middle/discharge casing (003 fig-1).

Middle/Discharge
Casing

12. Repeat the above mentioned steps to stack the rotor components up to 4th stage impeller.
13. Place the balance sleeve (078 fig-1) and balance cover/intermediate casing (015 fig-1).

4th stage
impeller

Balance sleeve

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 21 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

14. Place the neck bushing rotary piece (082-2 fig-1).

Neck
bushing

Holes for
Stuffing
box bolts Balance cover/
intermediate
casing

15. Screw in the bolts/tie rods while confirming that the suction casing leg, the discharge casing leg and
the balance cover leg are placed on the same plane. This can be ensured by bolting the pump
casings temporarily to flat bars. Ensure the flatness of these bars by putting them on a milling
machine.

Flat bars

Casing bolts /
Tie rods

16. Check the axial float after tightening the bolts by hand.
PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 22 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

17. Casing fastening bolts/ tie rods should be tightened at a torque of 600-Kg f-m symmetrically and
carefully so that all the bolts are tightened uniformly. Impact wrench may be used for rough
tightening but carefully ensure the suitable torque value using torque wrenches.
I a
k
b Tightening Sequence
j c a–g–j–d–l–f–c–i–b–h–k-e

i d

h e
g f

18. Place the pump horizontally on a skid.


19. Place the stuffing boxes (008-1,2 fig-1).

Stuffing
box

20. Place the thrust side bracket (044-2 fig-1).

Thrust side
Bracket

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 23 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

21. Place bearing oil deflectors and attach the lower halves of the bearing housings with the pump.

Lower half
of bearing
housing

Bearing oil
deflector seal

22. Axial Bump: Before the installation of bearings, check the axial bump of the rotor. Recommended
value is 6 mm. This value will be obtained only after the final torqueing of the fastening bolts.
During stacking of individual components, axial bump value of 6 mm may not be obtained due to
the fact that gaskets are not pressed yet and shaft has to be lifted up for installation of split rings.

23. Axial Centering: Center the rotor with axial bump being 50% on the drive end side and 50% on
the thrust end side. Adjust the size of thrust disk spacer to achieve this.

24. In this process, try not to influence the shaft with weight.
25. Insert the split ring retainer but don’t install the mechanical seal.
26. Install the bearing case lower half.
27. Carry out radial shaft centering as given below:

a. Set a dial gauge near the stuffing box where the circumference of the shaft can be measured.
b. Set the dial gauge to 0 with the shaft down
c. Then, read the dial gauge with the shaft all the way up and record the reading as A.
d. Install the lower half of the bearing in the bearing case.
e. Raise the shaft from zero position with a value of 0.5 to 0.6 time the reading A (fig-2).
f. In this state position the bearing case so that the clearances of the wearing parts matches at
both sides and hold it with knock pin (dowel pin) in that position.

28. Remove the bearing case again and install the mechanical seal (III fig-1) with sleeve (042 fig-1) and
cover (016 fig-1). See section 5.1.4 for mechanical seal assembly.

1. Make sure that the seal is properly locked with the set plates and sleeve collar is locked
on the shaft.

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 24 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

2. While shifting the pump to area, use wooden lugs to place the pump on for prevention of
sudden jerks to seal faces.

29. Install the bearing case lower half in position, with deflector (093 fig-1) set in the shaft.
30. Tighten set screw to hold the deflector in position after the thrust disk clearance has been
adjusted.
31. Set thrust disk in place accurately, where the axial clearance between the impellers and the
stationary parts will be equal to OP side and TH side.
32. Install the sleeve bearing and close the bearing upper half.
33. Check the clearances between sleeves and mechanical seal bushes by a thickness gauge to the
matched at any radial direction.
34. Assemble the bearings by the preceding method.
35. After fixing the thrust shoe, check the face of the disk, pressing the shaft toward the pump inside. If
the disk is out of its right position by 0.025 mm or more at the outside diameter, check the
condition of the disk and the locating ring.
36. Fill the thrust bearing housing and the sleeve metal with a small quantity of fresh oil
37. Install the upper half of the bearing housing.
38. Fix the assembled pump on the base, and turn the shaft by hand.
39. Finally fix the piping and turn the rotor by hand to check whether or not it turns smoothly.

5.1.4 Mechanical Seal assembly


Mechanical seal of P-202G is stock item and available both in cartridge form and by parts in the
warehouse. While assembling the mechanical seal, certain critical consideration should be taken into
account to avoid any mishap.

1. Carefully verify the critical dimensions of the seal components. A drawing of mechanical seal with
highlighted critical dimensions is provided in Attachment # P-202G/5.

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 25 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

2. Inspect all the reused components (springs, pins etc.) properly. Do not use loose or bent dowel pins.
3. Inspect all the elastomer seating surfaces carefully for burs or scratches.
4. Ensure proper cleaning of all the components.
5. Use silicon oil for placement of all the elastomers.
6. Start the assembly by placing the bore sleeve (9) in the Flange housing. ( May be found fitted already)

Seal Flange

Groove
Bore sleeve for O ring

7. Insert the O ring (11) in the flange.


8. Assemble the stationary face by placing the springs (2) and pins (10) in the holes using silicon oil.

9. Place the compression ring (4) and floating packings (5) on the springs using silicon oil.

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 26 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

10. Place the stationary face (6B, 6D) into the flange housing. Match mark the position of spring pins
(10) on bore sleeve and on the stationery face to ensure proper insertion.

Match
marking

11. Place the rotary face (8) on the shaft sleeve (13).

12. Insert the shaft sleeve into the bore sleeve carefully by placing the flange on the table. Lift the flange
up to ensure mating of the sealing faces and then invert the whole assembly.

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 27 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

13. Put the set plates/Seal buttons (15). Make sure the right set plate is being placed in the seal as it is
very important in adjustment of the seal tension. “TH” is engraved on the thrust side set
plate and similarly, “CP” is engraved on the coupling side set plate.

Identify if
it is TH or
CP side
button

14. Fix the drive collar on the shaft sleeve by tightening the set screws.

15. Make sure that the sleeve ends are properly flushed with the rotary face.

Flushed/
Levelled
faces

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 28 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

5.2 Lube oil pump overhauling (auxiliary)


5.2.1 Disassembly
1. Close both suction and delivery valves in pipeline. Remove prime mover from pump shaft.
Slacken off gland studs (18), remove gland from gland cover (7).
2. Using the forcing screws (15) provided, break the joint between the inspection cover (8) and the
pump body (4). Remove inspection cover (8), and examine inspection cover bush (6) for
excessive wear or damage. Replace if necessary.
3. Withdraw the outer rotor (1). The rotor shaft (11) complete with inner rotor (2) will now pass
through the gland cover (7).
4. Remove gland cover (7) from body (4), by means of forcing screws (15) provided. Examine gland
cover bush (5) for wear and replace if necessary.
5. To remove the liner (3) from the pump body (4), draw the liner (3) from the body (4) with a
plate and draw bolt.

5.2.2 Inspection & Checks


1. Cleaning and Inspection of all parts.
2. DPT of various parts like shaft and bush bearings etc if required.
3. Check all dimensions such as shaft / bush bearings / mechanical seal / shaft run out and compare
with recommended values.

5.2.3 Assembly
1. The assembly should be carried out in the reverse order to that outlined for dismantling. When a
new inner rotor (2) is fitted care should be taken to ensure that it is fitted in the correct position
on the shaft (11) to ensure correct end clearances are allowed between the faces of the inner
rotor (2) and the end covers. ie. (Equal clearances between faces of rotor and gland and
inspection cover faces).
2. When fitting a new pump body liner (3) use the parallel pin (12) at the base of the pump body (4)
as a guide to locate the liner (3) correctly in the body (4).
3. Before remaking the body / cover joints, the machined surfaces of the body and covers should be
thoroughly cleaned of old jointing.
4. A thin coating of new jointing should be applied by brush. It is important that the cover joints be
made with material of no greater thickness than that given by the jointing composition, otherwise
excessive Volumetric Slip will result.
5.3 Gear Box Overhauling

5.3.1 Disassembly
1. Remove the all instrument & electrically probs.
2. Remove the oil outlet / inlet flanges bolts of oil pump
PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 29 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

3. Remove the inboard / outboard coupling spool piece with matching mark.
4. Remove the top inspection window.
5. Remove the coupling hub of inboard / outboard side.
6. Remove the high speed inboard / outboard bearing cover.
7. Remove the main lube oil pump with matching mark & remove low speed out board bearing
cover.
8. Remove the all casing bolts and dowels.
9. Remove upper half with the help of jacking bolts carefully.
10. Remove all oil spray nozzles and tubing's.
11. Remove the inboard outboard bearing upper half with marking carefully.
12. Remove the high speed gear shaft (use nylon rope).
13. Remove the low speed gear shaft.
14. Remove the inboard / outboard bearings lower half and labyrinth seal lower half.
5.3.2 Inspection & Checks
1. Inspection / cleaning all wholes / oil paths and surfaces no burs on it.
2. DPT of various parts like Gears / shafts / Bearings and Seals etc if required.
3. Check all dimensions such as High-speed shaft / Intermediate gear shaft / Low speed shaft /
bearings / seals and shaft run outs compare with recommended values.

5.3.3 Assembly
1. Install the new inboard/outboard bearings lower half and labyrinth seal lower half
2. Install the new high speed and low speed gear shaft
3. Install the oil spray nozzles and tubing's
4. Install the bearings upper half and inserting the labyrinth seal upper half in the gear box
upper casing cover
5. Install the upper casing of the gear box carefully and inserting the all dowels and casing
bolts and tighten with proper sequence
6. Check easy rotation of gear box and checking the axial clearance of high speed / low
speed shaft & backlash
7. Install the new oil pump and tighten
8. Install the inboard/outboard coupling hub.
9. Install the coupling spool piece with matching mark and tighten
10. Install the inlet/outlet pipe of lube oil pump
11. Install the all instrument electrical probs.
12. And align with motor.

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 30 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

13. Alignment method apply rota align / rim & face.


14. If motor disconnected or removed its direction to be checked.

5.4 Machinery Surveillance/ Preventive Maintenance Plan


O / B Vib. Bearing
I / B Vib. (in/Sec) Lube Oil Packing Mech
(in/sec) Temp. (0F) Sound
Leakage Looseness
H V A H V A I/B O/B Level Condition Leakage

* * * * * * * *      

 OK
Legend
X NOT OK

* Actual to be recorded on the additional format (Attach # P-202G / 1).


** For Alarm, Action and Trip limits refer CMMS condition monitoring module.

5.5 Activity Bar Chart


1. See attachment # P-202G / 2.

5.6 Quality Assurance Plan


1. Inspection Briefs / test plans (Hold Points).
 Gear Box Clearance.
 Clearances and Runouts

5.6.1 Allowable Tolerances


During maintenance, carefully check the following items to insure proper operation. It is recommended
records on the following be kept.

1. Run-out of shaft, impeller ring and sleeve.


 Allowable limits are indicated in table 1 ,2.
 If values are exceeded, items must be repaired or replaced.
 Recommended recording sheet No. IR-01.
2. Clearance between impeller ring and case wear ring.
 Recommended limits of clearance are indicated in table 1 ,2.
 Recommended recording sheet No. IR-01.
3. Alignment
 Allowable values are indicated in Paragraph 2 ,7.

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 31 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

 Recommended recording sheet No. IR-02.


4. Operation Record
 It is necessary to measure vibration and bearing temperatures during test operation.
 Recommended recording sheet No. IR-03

5.6.2 Runout & Axial Float

Runout Axial Float Axial Bump

On Shaft On Wear Ring Parts

    0.0098” 6 mm

Max 0.0011” Max 0.00196”

5.6.3 Clearance List

Outer or Inner Clearance on Dia. (mm)


Part #
Dia.
Design Max. Allow.
Liner Ring (107-1,2) 140 140.025
A 0.01377” – 0.01543” 0.04822”
Impeller (021-1  6) 139.39  139.41
Center Stage Piece (074 -1) 100 100.022
B 0.01377” – 0.01543” 0.021929”
Center Sleeve (087 99.63  99.65
Inter Stage Bushing (081) 96  96.022
C 0.01377” – 0.01543” 0.021929”
Inter Stage Sleeve (043 -1,2) 95.63  95.65
Balance Stage Piece (074 – 2) 100  100.022
D 0.01377” – 0.01543” 0.021929”
Balance sleeve (078) 99.63  99.65
Bearing Metal (052) 76.343  76355
E .005” - .0057” 0.00807”
Shaft (031) 76.210  76.215

Neck Bushing both I/B and


F .0236” - .0284” 0.0284”
O/B (082-1,2)

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 32 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

5.6.4 Gear Box Clearances

Bearing Clearances (Cold Diameteral)


General Bearing High Speed 0.005" - 0.009"
General Bearing Low Speed 0.0065" - 0.0125"
Thrust Bearing Low Speed (Axial)
0.0105" - 0.035"

Labyrinth Seal Clearances (Cold Diameteral)


High Speed 0.0135" - 0.0185"
Low Speed 0.0145" - 0.018"
Backlash
0.005" - 0.0125"

5.7 Technical Details / Special Conditions


1. Pump drawing Dwg # S8/9731263
2. Mechanical seal drawing Dwg # T3-24978
3. Coupling drawing Gear box to pump Dwg # S8-9703720
4. Coupling drawing Motor to gear box Dwg # RU1051201-G06
5. Pump data sheet Dwg # 125 x 100SSP6GM
6. Gear box drawing Dwg # RU1051201-G03
7. Lube oil pump drawing Dwg # A9932

6 FINISHING THE JOB


1. Housekeeping.
2. Remove Lock out / Tag out.
3. Hand over permit to Operation.
4. Return Tools, equipment, PPEs etc.
5. Failure Reporting on CMMS – SAP
6. Others etc.

7 RECORDS
1. Retention Time: Till life of the equipment.

8 ATTACHMENTS
1. Hold point document (Last Overhaul) Attach # P – 202 G/1
2. Activity Bar Chart of P – 202 G overhaul. Attach # P – 202 G/2
3. Pump Data Sheet. Attach # P – 202 G/3
4. Pump Drawing Attach # P – 202 G/4
5. Mechanical Seal Drawing Attach # P – 202 G/5
PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G
DOC. NO. JP-UR2-P-202G
` P – 202G EFFECTIVE DATE
REVISION DATE
FEB 2018
FEB 2021
(Carbamate Recycle Pump) PAGE NO. 33 OF 33
Job Plan Manual (Safety Critical)
ORIG. PREPARED BY GKS
REV. NO. 03
Field Maintenance Urea - II ISSUE NO. 01
EFL MANUFACTURING DIVISION UNIT / SECTION : UREA - II AREAS : ALL

6. Gear box Drawing Attach # P – 202 G/6


7. Gear box Data Sheet Attach # P – 202 G/7
8. Lube Oil Pump Drawing Attach # P – 202 G/8
9. Rotor Clearance and Runout Sheet (Blank) Attach # P – 202 G/9
10. Coupling Drawing (Gear box to Motor) Attach # P – 202 G/10
11. Coupling Drawing (Pump to Gear box) Attach # P – 202 G/11

9 REFERENCES
1. PSRM / SP / 01 “Process Safety Information”, Level 2 Procedure.
2. PSRM / SP / 03 “Operating & Maintenance Procedures”, Level 2 Procedure.
3. PSRM / SP / 04 “Safe Work Practice” Level 2 Procedure.
4. PSRM / SP / 06 “Quality Assurance”, Level 2 Procedure.
5. PSRM / SP / 08 “Mechanical Integrity”, Level 2 Procedure.
6. Job plan guidelines, Mechanical Procedure manual.
7. Vendor Manual Ebara Corporation Japan.

PATH
P:\MFG-SOPS\Mech\UR2FM\JP\Machinery\P–202G

Potrebbero piacerti anche