DOCUMENT CODE MM-WI-IMS-026 REV. # 01 REV.

DATE 02/08/2018 PAGE 1 of 7

WORK INSTRUCTION UNIT:

DEPARTMENT: MAINTENANCE MAINTENANCE

TITLE: OVERHAULING OF SINGLE STAGE OVERHUNG PUMPS

1.0 CHANGE RECORD:

SR. # REV. DATE PAGE # SECTION # DESCRIPTION OF CHANGE
1 01 02-Aug-18 1 4.0 - General chemicals encountered have been added
1 5.0 - General hazards applicable to all pumps added
2 7.0 - Safety pre-requisites have been added
- Preparation, PTW requirements and manpower revised
- Dismantling, cleaning and assembly sections have been
elaborated to include more details.
- Cautions for specific activities have been enlisted to
3-7 8.4
address safety and quality risks.
- Section 8.4.2.11 added for dimensional records
- Section 8.4.4 added to incorporate need for trial
operation before handover to operations
7 9.0 - Reference documents have been enlisted

2.0 PURPOSE:
2.1 To provide standard guidelines for overhauling of single stage overhung pumps to ensure quality of
maintenance and reliability of these machines.

3.0 SCOPE:
3.1 This procedure is applicable to all single stage overhung pumps maintained by FFL machinery team at all
operating units.

4.0 CHEMICALS INVOLVED:

4.1 Service chemicals handled by specific machine (acidic, basic, flammable, toxic etc)
4.2 Lubricating oils and greases
4.3 Cleaners (WD 40, Kerosene oil, Rustolene, ZOK cleaning fluid etc)
4.4 Other chemicals as per PTW

5.0 HAZARDS AND RISKS INVOLVED:

5.1 Service chemicals:
5.2 Moving machinery parts:
5.3 Hot and cold burns:
5.4 Falling Load:
Exposure to service chemicals being handled by specific machine (acidic,
toxic etc)
Injury from accidental energization of machinery, unauthorized or mis-
operation, reverse rotation due to stored potential energy or passing or open
valves in suction and discharge lines, open bypass of isolation valves etc
Exposure to hot and cold surfaces
Falling parts during rigging of heavy components e.g casing, bearing
assembly, shaft, impeller etc

ROUTE PREPARED BY REVIEWED BY REVIEWED BY APPROVED BY REFERENCE

NAME Mohsin Murtaza Adeel Haider ASIF ALI RAJPUT Iqbal Khan
QMS : 7.5
DATE HSE : 7.5
DESIG./SIGN
DOCUMENT CODE MM-WI-IMS-026 REV. # 01 REV. DATE 02/08/2018 PAGE 2 of 7

5.5 Noise: From surrounding plant equipment or process

5.6 Dust:
5.7 Ergonomics Hazards:
5.8 Environmental hazards:
5.9 Slips, trips and falls:
5.10 Spills, leaks and toxic release:
5.11 Other hazards as per PTW
In solid handling areas and near dust generation processes
Ergonomic injury due to improper access, awkward work position,
constrained space and hard to reach points, pinching by heavy parts.
Confined area with limited ventilation, high temperature in surroundings due
to heat losses from process equipment, high humidity, high ambient
temperature, low lux level, direct exposure to sun etc
General slip, trip and fall hazards in area, trenches, grating, raised floor
level and equipment foundation, piping and supports, floor slope, wet floor,
slippery surface etc
Area specific hazards

6.0 PPE’s REQUIRED:

6.1 Mandatory PPEs (safety shoes, safety glasses, hard hat)
6.2 Working Gloves
6.3 Ear Plugs (in high noise areas)
6.4 Cut resistant gloves for handling sharp objects, heat resistant gloves for high temperature services and hot
surfaces and chemical gloves for chemicals (where applicable)
6.5 Dust mask in dusty areas like bulk storage, rock phosphate, lime and scrapper areas
6.6 Other PPEs as per PTW

7.0 SAFETY PRE-REQUISITES:

7.1 Proper PPE should be worn at all the times.
7.2 Ensure compliance of all general / special purpose PPEs as required in this procedure or PTW.
7.3 Ensure all hand tools, power tools, measurement tools and rigging equipment are tested and certified
7.4 Proper illumination should be done especially during night shift.
7.5 Special tools and jigs should be checked by area supervisor and job technician for certification.
7.6 Hold a safety talk before starting the job.
7.7 Ensure that a valid PTW is available for the job.
7.8 Ensure equipment is protected against mis-operation, unauthorized operation or accidental energization by
completing all applicable physical and electrical isolation and LOTO procedures.
7.9 Ensure minimum of two persons are allocated to perform the task.
7.10 Ensure all safety guards and covers are installed back before handover for operation.
7.11 Ensure formal job safety analysis is conducted and available for high hazard activities.

8.0 EXECUTION / OPERATING STEPS:

8.1 PREPARATION
8.1.1 Respective operation unit shall raise Maintenance Work Request well before start of the job.
8.1.2 Area Engineer shall plan the overhauling activity in consultation with area supervisor under guidance
of concerned unit manager. He shall review manpower resources, spare parts, special tools and
fixtures, lifting equipment and crane requirements etc during job planning.
8.1.3 Area Engineer should preferably prepare a bar chart if job duration is expected to exceed 24 hours.
8.1.4 Area supervisor shall include the job in weekly plan.
8.1.5 Machinery technician assigned on the job should receive work permits from concerned operations
unit on the day of job (unless a higher authority is required to accept PTW as per revised PTW system
guidelines). He shall make sure all team members are aware of safety hazards associated with the
activity. He shall ensure compliance of all applicable safety systems (LOTOTO, Physical isolation,
JSA, tools testing and tagging etc)
8.1.6 Machinery technician should conduct a brief safety and quality talk with his crew before start of job.
DOCUMENT CODE MM-WI-IMS-026 REV. # 01 REV. DATE 02/08/2018 PAGE 3 of 7

8.2 WORK PERMITS REQUIRED

8.2.1 Generally following type of permits will be required during overhauling of single stage overhung
pumps. Exceptions can be expected depending on nature and specific hazards of the area;

Sr. # Type of Permit Color of Permit Card Required

1 Cold Green Yes
2 Hot Red Yes
3 Electrical Purple --
4 Instrument Pink --
5 Radiography Yellow --
6 Confined Space Entry Blue --
7 Vehicle Entry Grey Yes
8 Excavation & Civil Work White --

8.3 MANPOWER
8.3.1 Following manpower resources are required for overhauling of single stage overhung pumps;

Supervisor Technician Millwright Rigger Insulator

01 01 02 (on demand) (on demand)

8.4 WORK EXECUTION PROCEDURE

8.4.1 DISMANTLING
8.4.1.1 Make sure all fluids have been drained from pump casing and bearing housing.
8.4.1.2 Disconnect any auxiliary piping including cooling water lines to bearing housing (inlet and
outlet), seal flush lines, lube oil piping, quench lines etc.
8.4.1.3 Check as found driver to driven machine alignment. Disconnect driver to pump coupling and
remove coupling spacer (if available). Inspect coupling as per checklist (MM-CHK-IMS-084)
and record the observations for reference.

Caution: If pump is fitted with a mechanical seal, lock it before further dis-assembly.

8.4.1.4 While disassembling, use match marks, labels, tags or otherwise positive means to identify
location, position and orientation of all parts. Use separate containers or bags to store small
parts, fasteners, keys etc.
8.4.1.5 For small pumps where removal of complete pump unit including bearing housing and volute
casing is feasible, disconnect inlet and outlet piping flanges and take out complete pump unit.
This will provide opportunity for detailed inspection of all wetted parts.
8.4.1.6 For medium to large size pumps, bearing housing and rotor assembly can be removed from
complete unit while leaving the volute casing in place and without a need to remove inlet and
outlet piping. In such a case, support load with chain block before loosening volute casing (or
bonnet) bolts.
8.4.1.7 Remove support plate/leveling plate installed for supporting bearing housing.
8.4.1.8 To remove pump from casing volute, first loosen all studs and bolts and then use jacking bolts
to break cover from casing gasket joint.

Caution: Follow first break procedure while opening any connection whether it be inlet or
outlet piping or bonnet flange (volute flange) of pump. Trapped, pressurized, hot or
hazardous liquid may spill out during first break of any connection.
DOCUMENT CODE MM-WI-IMS-026 REV. # 01 REV. DATE 02/08/2018 PAGE 4 of 7

8.4.1.9 Carefully slide pump from casing volute, ensuring that no rubbing or hindrance takes place
between fixed components and the parts being removed.
8.4.1.10 Once the pump has been removed with or without volute casing, it is a good practice to shift
it to maintenance work shop for further dismantling and detailed maintenance checks.
8.4.1.11 Place pump assembly safely on suitable horizontal supports and secure properly to prevent
over-turning or fall.
8.4.1.12 Free and remove casing gasket from pump casing flange.

Caution: Inspect and clean the gasket groove properly on both volute casing and bearing
bracket. Any leftover particles in the groove can cause leakage during operation.

8.4.1.13 Remove impeller (and impeller sleeve if used) from the shaft
For keyed impellers, loosen impeller lock washer and remove impeller lock nut by turning it
in pump’s direction of rotation. Remove the impeller and impeller key from the shaft by using
proper pulling arrangement.
For threaded impellers, use proper fixture to unscrew the impeller from shaft or sleeve
against the pump’s direction of rotation. Health of fixture should be ensured before dis-
assembly as improper contact with the vanes can cause the vanes to break.
8.4.1.14 Carefully remove mechanical seal (if used) as per procedure specified in IOM manual.

Caution: Mechanical seal faces are very brittle and highly fragile parts. Take care not to
damage seal faces during removal. Do not attempt to applying excessive force.

8.4.1.15 Remove pump side coupling hub by using a method appropriate for the kind of fit. Clearance
fit hubs can be removed through gentle tapping of hub sleeve or using mechanical pullers.
Interference fit hubs are to be removed by heating with or without a combination of hydraulic
pullers. Proper risk assessment shall be carried out while using heating torch or hydraulic
pullers to remove hubs.

Caution: Do not apply puller on hub flanges as these can be deformed due to excessive
force. Instead apply the puller on sleeve part of coupling hub which has more strength.

8.4.1.16 Dis-assemble bearing bracket as follows:

For fan cooled bearings, remove screws and remove the fan housing from bearing bracket.
Remove the oil ring retainers.
Remove outboard cover cap screws and slide out the bearing cover/bearing isolator assembly
and gaskets.

Caution: File or de-burr shaft around coupling hub keyway before removing outboard
bearing cover plate. It will remove any sharp corners or nicks and avoid damage to O-ring
in the bearing cover and prevent seizure of parts.

Pump shaft can only be removed in one direction. Press pump shaft from impeller end
through the bearing bracket and towards the coupling end.
For cylindrical roller bearings with separable inner race, remove bearing (without inner race)
from the housing.
8.4.1.17 Remove the bearings as follows;
Remove radial bearing (or only the inner race) from shaft using a puller or hydraulic press.
Remove oil rings if applicable.
Remove locknut and lock washer to loosen thrust bearing. Application of heat may be
required for the removal and replacement of thrust bearings. Use puller or press if needed.

Caution: Do not remove thrust bearings if condition is satisfactory and these are to be
reused
DOCUMENT CODE MM-WI-IMS-026 REV. # 01 REV. DATE 02/08/2018 PAGE 5 of 7

8.4.2 CLEANING, INSPECTION AND TESTING

8.4.2.1 Thoroughly clean all parts with kerosene or equivalent and dry all parts with compressed air
or a clean lint free cloth.
8.4.2.2 Inspect all components for corrosion, erosion, pitting and scoring. Damaged parts should be
replaced with OEM parts or approved locally fabricated spares.
8.4.2.3 Carryout shaft inspection as follows;
Check impeller seat for cracks, wear, erosion, threads or keyway damage or any other defects.
Inspect bearing and coupling seat for surface defects.
Check shaft runout on all radial surfaces including impeller seat, coupling seat, seal area etc
preferably on lathe machine or on V-blocks. Shaft run out should not exceed 0.001 inch
(0.0254 mm) T.I.R or as specified in OEM manual.
Measure shaft diameters at impeller, seal, bearing and coupling seats to check mounting fit
(clearance, transition or interference) according to the specification.
Perform crack (Dye penetrant) testing of impeller seats and shaft shoulder
Polish all shoulders and seating areas on shaft to remove any burrs, nicks and deposits etc.
8.4.2.4 Carryout impeller(s) inspection as follows;
Check impellers for surface defects such as wear, erosion, cracks, missing edges etc
Inspect impeller hub and keyway (or threads) for any defects or abnormalities.
8.4.2.5 Check casing and impeller wear rings for any damage or increased clearance.
8.4.2.6 Carryout mechanical seal inspection as follows;
Inspect seal stationary and rotating face. Lap or replace seal faces after consulting area
supervisor or engineer.
Check for ingress of foreign particles in seal housing. Clean properly before reassembly.
Check elastomers for pressing, deformation or attack. Replace all elastomers in consultation
with area supervisor or engineer.
8.4.2.7 Carryout volute casing inspection as follows;
Check for erosion, thickness loss or mechanical damages on inner surface of volute casing
Check casing bonnet gasket (volute casing to bearing bracket or volute casing to rear cover
plate) seating area for any nicks, burrs, material loss etc. Clean this surface properly.

Caution: Never use pointed sharp edge tools to clean bonnet gasket seating area. You may
end up permanently damaging the sealing area and leakage will occur.

8.4.2.8 Inspect bearings for any fault indications including lack of lubrication, overheating, cage
damage, race damage or rolling element damages etc. If bearings are removed from shaft for
any reason these must be replaced unless authorized by concerned area engineer.
8.4.2.9 Check and clean auxiliary piping connections and passages in bearing housing.
8.4.2.10 If impeller, shaft or coupling is replaced, perform balance check and balance rotor to G6.3 or
better tolerance grade.
8.4.2.11 Measure and record following important dimensions / fits for reference;
As found and final alignment record
Wear ring’s diameter and clearance
Coupling hub bore, coupling seat diameter and fit details
Impeller bore size, impeller seats diameter and fit details
Bearing bore size, bearing seat diameter and fit details
Bearing outer diameter, housing bore size and fit details
Mechanical seal sleeve bore size, seal seat diameter and fit details
Shaft radial runout record at all locations
Rotor axial location details (free float, axial float, deflector gap, impeller front/rear gap etc)

8.4.3 ASSEMBLY
8.4.3.1 Refer to OEMs manual and follow the specific assembly sequence. Below are only general
guidelines which are applicable to most of the single stage overhung pumps.
DOCUMENT CODE MM-WI-IMS-026 REV. # 01 REV. DATE 02/08/2018 PAGE 6 of 7

8.4.3.2 Install any components fitted between both bearings (oil slinger of splash ring, flyweights
where applicable etc) on the shaft and lock these parts in place.
8.4.3.3 Install thrust (locating) bearings on shaft as per following sequence;
Lubricate bearing seating areas on the shaft to facilitate mounting and preserve parts
Heat bearing in an induction heater to required temperature (generally 230 °F /110 °C, or as
specified by OEM) and slide them onto the shaft. (Use heat resistant gloves)

Caution: Make sure bearing remains properly seated against shaft shoulder after cooling
down. Wait until the bearing(s) reach room temperature before starting next step.

Install lock-washer so that it is in contact with the thrust bearing on the coupling side.
Install lock nut and tighten using a spanner wrench until its snug. Then tighten with a hammer
and spanner wrench to advance the lock-nut by at least one-eighth (1/8) and up to one quarter
(1/4) turn, to firmly snug the assembly.
Align a tab (tooth) of lock-washer with one of the slots in lock-nut and bent it into the slot to
lock it. Use a screwdriver and a hammer for this task.

Caution: For paired arrangement, make sure that both bearings are firmly seated together
and against the shaft shoulder and these could easily be rotated in opposite direction. If any
one or both bearings cannot rotate freely, there is a problem with the assembly.

8.4.3.4 Insert shaft into the bearing bracket, following the below steps;
Place bearing bracket vertically on a table (having a hole at center) with coupled end upwards.
Drive the rotor assembly slowly by hand into the bearing bracket until the thrust bearing is
seated against the shoulder.
Tap the shaft softly (by hitting a wooden piece placed against the shaft) on coupling side to
ensure that the thrust bearing outer race is firmly seated against shoulder of bearing bracket.
8.4.3.5 Install the free (floating) bearing on the shaft by heating and sliding it onto the shaft (use soft
mallet if required). Lubricate the bearing outer race and the bearing bracket.
8.4.3.6 Rotate the shaft by hand to ensure free rotation.
8.4.3.7 Slide oil deflector onto the shaft. Make sure that deflector is not cocked during installation.
8.4.3.8 Install bearing bracket deflector on coupling side and also install bearing housing end plate.
8.4.3.9 Install shaft end sealing unit;
For pumps with a cartridge type mechanical seal, slide the cartridge assembly onto the shaft,
fasten its screws and lock it firmly.
For pumps with gland packing, install sealing sleeve. Insert gland packing after step 8.4.3.10.
8.4.3.10 Install wetted end cover plate of bearing bracket and tighten its bolts and nuts.
8.4.3.11 Install impeller (and impeller sleeve if used) on to the shaft;
For threaded impellers, apply anti-seize on both shaft and impeller threads and screw the
impeller onto the shaft by rotating it in pumps direction of rotation.
For keyed impellers, insert impeller key in shaft keyway and slide the impeller in place. Insert
impeller lock washer and tighten the lock nut. Bend the washer teeth to lock the nut firmly
8.4.3.12 Perform axial centering of pump (adjust axial float, gap behind impeller and impeller front
clearance) as per procedure specified in OEM manual.
8.4.3.13 Install pump side coupling hub after heating it by oven or induction heater.

Caution: Never hit coupling hub flanges with a hammer directly.

8.4.3.14 If volute casing was left in area, transport assembled unit back to its location.
8.4.3.15 Install casing gasket on the seating area (groove in volute casing).
8.4.3.16 Hang the pump assembly with chain blocks and install the pump into the casing volute. Make
sure that the impeller does not touch the casing volute.
8.4.3.17 Tighten the nuts on volute casing studs following the below steps;
Follow OEM specified sequence and technique for tightening of volute casing nuts.
Follow cross pattern for tightening of bolts as specified for flanges in FM-WI-IMS-001.
DOCUMENT CODE MM-WI-IMS-026 REV. # 01 REV. DATE 02/08/2018 PAGE 7 of 7

If manual striking is required involving two persons, follow the specific checklist.
Use power and hydraulic tools if required after complying all safety requirements.
Complete tightening sequence in three rounds of 50%, 80% and 100% torque respectively.
Make sure that the pump rotates freely during tightening sequence.
8.4.3.18 Install auxiliary piping i.e. seal flush lines and cooling water lines after proper blowing.
8.4.3.19 Fill the bearing housing with proper lubricating oil or grease in required quantity. Follow
guidelines specified in MM-WI-IMS-003 or SAF-WI-IMS-011 whichever is applicable.
8.4.3.20 Check driver rotation and health by conducting a solo run for the driver (if required).
8.4.3.21 Remove locking and transportation bolts of mechanical seal (if provided)
8.4.3.22 Carry out shaft alignment as per guidelines specified in MM-WI-IMS-004.
8.4.3.23 Couple the pump with driver and rotate assembly by hand to ensure free rotation.
8.4.3.24 Install all safety devices and guards properly.

Caution: Make sure that no part of coupling guard is in contact with moving parts.

8.4.4 TEST RUN OPERATION

8.4.4.1 Carryout trial operation of pump for atleast fifteen minutes and note following parameters;
Hydraulic parameters (discharge pressure, flow rate and efficiency etc)
Power absorbed (motor amperes, turbine steam rate and RPM etc)
Mechanical parameters (Bearing temperatures, shaft vibrations and sound etc)
Lubricant quantity and quality variations.
8.4.4.2 Engage inspection for collecting new baseline vibration data.
8.4.4.3 Handover the pump for normal operation.

9.0 ATTACHMENT / RELATED DOCUMENTS:

9.1 FM-WI-IMS-001 FLANGE DE-BOLTING AND TIGHTENING PROCEDURE
9.2 MM-WI-IMS-003 WORK INSTRUCTIONS FOR LUBE OIL REPLACEMENT
9.3 MM-WI-IMS-004 WORK INSTRUCTIONS FOR ALIGNMENT OF PUMPS & SMALL MACHINES
9.4 SAF-WI-IMS-011 BEARING GREASE LUBRICATION INSTRUCTIONS

10.0 DISTRIBUTION LIST:

10.1 Original: IMS Office
10.2 Controlled Copy: it-fileserver (Soft)
10.3 Controlled Copy: IMS files of machinery sections
10.4 Uncontrolled copy: Machinery staff office