SMP For Ba Overflow Pump

Power from knowledge
KSK Mahanadi Power Company Ltd.

KMPCL/MAINT/BAOP/01
6 X 600 MW Power Plant
SMP FOR BA OVERFLOW PUMP
Issue No: 1 Issue Date: Revision: 1 Revision Date: 29.07.13 File no: Page 1 of 14
STANDARD MAINTANENCE PROCEDURE
FOR
BA OVERFLOW PUMP
Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Name: Name:
Designation: Designation: Designation:
KMPCL/MAINT/BAOP/01
OBJECTIVE

Name: Name: Name:
KMPCL/MAINT/BAOP/01
The purpose of this work instruction is to explain the procedure for carrying out Overhaul of
BA OVERFLOW PUMP.
1. BA OVERFLOW PUMP
The details of the BA OVERFLOW PUMP are as follows :
Make: Weir Minerals Ltd.; TYPE 8/6 E-AH, Q=305m3/h, H=0.29MPa, 415V, 37 KW, PART
NO.-EAM005M.
DETAILED INSTRUCTION
Sr. Activity Respons
ibility
No.
I Overhaul to be done as per Checklist
1 Before commencing dismantling operations, ensure that the

following tools and tackles are available:
 A crane / chain pulley block suitable for handling the weight of pumping
unit.
 A selection of ring and open-ended spanners in Metric sizes.
 Eyebolts in Metric sizes.
 Hardwood and metal packing blocks.
 Miscellaneous tools including a set of Allen keys, drills, pin drivers, files
etc.
 Extractor / puller for bearing and coupling.
.
After a long service, wear will occur in parts of the pump necessitating the
renewal of the parts. Those most likely to be affected are impeller, Wear
Rings, Bearings, and Sleeves.

Name: Name: Name:
KMPCL/MAINT/BAOP/01
2 Dismantling
1. Before dismantling, make sure the motor is disconnected.

2. The suction and discharge shutoff valves must be closed.
3. The pump casing must have cooled down to ambient temperature.
4. The pump casing must be empty and not under pressure.
5. Detach all auxiliary supply pipe lines.
6. Remove coupling guard.
7. Remove coupling half from the pump shaft. Refer fig. no. 1
8. Pull out bearing bracket with discharge cover and complete rotor
(assembled unit).
9. If the pump has been in operation for a long time some parts may be
difficult to remove.
In this case use a penetrating oil or suitable pull-off device.
10.Loosen & remove impeller Lock nut.
11.Remove impeller from pump shaft. Refer fig. no. 2
Fig. no. 1: Dismantling the pump set

Fig. no. 2: Removal of Impeller

Name: Name: Name:
KMPCL/MAINT/BAOP/01
Construction Drawing For BA OVERFLOW PUMP

1 Bearing Assy.
4 Shaft Sleeve
5 Shaft Sleeve O-Ring
6 Frame Plate Liner Stud
7 Seal Ring
8 Frame Plate Liner Insert
9 Impeller
10 Discharge Joint
11 Cover Plate
12 Throat bush
13 Cotter
14 Intake Joint
20 Volute Liner Seal
21 Volute Liner
22 Frame Plate
23 Keeper Plate
29 Packing
30 Shaft Spacer
31 Gland(2 Piece)
32 Gland Bolt-1Nut-1Washer
33 Lantern Restrictor
34 Stuffing Box
35 Impeller O-Ring
36 Gland Clam Bolt
47 Grease Cup
48 Grease Cup Adaptor
50 Neck Ring
53 Expeller Ring
54 Lantern Ring
55 Expeller
56 Shaft O-Ring

Name: Name: Name:
KMPCL/MAINT/BAOP/01
1 SHAFT
3 2 SHAFT KEY
3 LABYRINTH LOCKNUT
4 GREASE NIPPLE
5 GREASE CAP
6 NAMEPLATE IVET
7 NAME PLATE
8 GREASE RETAINER
9 BEARING HOUSING
10 PLUG
11 END COVER
12 BEARING SEAL
13 SHIM SET
14 BEARING
15 END COVER SET SCREW
16 PISTON RING
17 LABYRINTH
Fig. No. 3 : Bearing Assembly.
Dismantling the Bearing Unit
1. Remove bearing covers and gaskets by unscrewing of hex. Bolt. Refer fig.
no. 3
2. Fasten the bearing unit firmly to the bench vice refer fig. no. 4 Strike the
pump shaft end with a soft hammer. Refer fig. no. 4
3. Fasten the shaft (with bearings) to the bench vice and detach bearings
from shaft with a bearing puller. Refer fig. no. 5

Name: Name: Name:
KMPCL/MAINT/BAOP/01
Note: Always replace the bearings once they have been removed from the
shaft with new ones.
Unnecessary removal of the bearings should be avoided because removal of
the bearing can damage it and cause deterioration of the interference fit.
Except where removal is necessary to give access to the other parts, bearing
should be removed only if they need close inspection. Symptoms, which will
indicate the state of bearing, are the condition of the lubricant, the bearing
running temperature, noise level and vibration during operation.

Name: Name: Name:
KMPCL/MAINT/BAOP/01
4 Examination of Internal Components :
Wearing Rings
The wearing rings have to be replaced when the clearances between the
wearing ring & the impeller & the Discharge cover exceeds three times the
max. Value as shown in the below table or when the reduction of efficiency
of the pump is noticed.
Note: - In MEGA GC wearing ring is not provided.
Original Clearance on the Diameter

Pump Size Casing Side Impeller Side
Maximum Minimum Maximum Minimum
80-200 0.445 0.33 0.445 0.33
New wearing ring clearances are:-
MEGA GC - 0.5 mm on diameter

MEGA - 0.3 mm on diameter
Shaft Sleeves
Replace shaft sleeve if it is grooved or generally worn.
Impeller
a. Inspect the impeller as follows:
i. Examine the impeller for damage.

ii. For corrosive /erosion pitting.
iii. Cavitations pitting.
iv. Bent or cracked vanes, inlet and outlet vane end wear.

Name: Name: Name:
KMPCL/MAINT/BAOP/01
Any of the above may be repaired, or if damage is extensive, impeller may

need replacement.
b. Around the eye, wearing rings protects the impeller. Examine around
the eye at neck portion for grooving in alignment with spindle axis;
slight grooving is acceptable but deep or profuse grooving must be
remedied by machining the impeller by taking a polish cut on wearing
ring. Spare wear rings are supplied with excess outside diameter to
facilitate machining after fitting. The wear rings are shrink fitted on
impeller neck and are screwed.
c. To check wear, around the impeller neck, use precision instruments
such as outside micrometer to accurately measure the outside
diameter. Measurements should be taken at intervals around the
circumference to check the uneven wear. Differences between the
neck OD and the neck ring ID measured will give us the clearance
between the two. Clearance thus obtained should not be more than
150% of maximum designed clearance.
Shaft & keys
Shaft should be checked for the trueness, or any other mechanical

damage and corrosion. If the shaft is not true within 0.1 mm TIR, it
should be replaced / repaired. Examine the shaft keys and key ways.
Remove damaged or worn out keys
Bearings
a. Clean all the components using clean white spirit. Do not use
chlorinated solvents such as trichloroethylene and carbon
tetrachloride because they introduce a corrosion risk when used on
ferrous materials.
b. Visually inspect the bearing. The balls, the inner and outer tracks
must all be free from chipping cracks, abrasions or discoloration.

Name: Name: Name:
KMPCL/MAINT/BAOP/01
c.
1. Check
Vacuumthat
andthe parts
blow outofallthe cage are
cavities firmly fixed
of bearing together.
housing.
d. Visually inspect the bore for any sign of damage. Burrs or any
scratches caused during bearing withdrawal should be carefully
removed by hand application of a fine oilstone, the treatment being
confined to the minimum possible area.
e. Visually inspect Bearing Housing

the outside diameter for signs of fretting, any stains
may be carefully polished off, but abrasion must be kept to the
2. absolute
Set bearing housingthat
minimum vertical on flange.
is required, followed by cleaning.
3. Press in shaft assembly as shown.
4.f. Check
Fasten that
outerbearing
bearingrotates
cover assembly.
freely and smoothly. If there is any doubt
5. regarding
Secure inner bearing cover assembly.
the serviceability of the bearing it should be replaced.
g. If after inspection, the bearing is reusable, completely coat all parts

with rust preventive oil, working it well into the internal parts of the
bearing. Wrap in clean greaseproof paper and store until required for
replacement or refit on to the spindle if needed. In case of immediate
use, coating of rust preventive oil is not necessary.
6. Fit box
Stuffing deflectors
bush at pump side
7. Fit coupling key.
Check
8. Add bore
PVC tapeof to
stuffing box bush and compare with sleeve diameter. If
secure.
9. Place back cover on bench.
"clearance is excessive, the bush should be renewed.
10. Insert the packing / logging ring set into this stuffing box.
Note: While assembling stainless steel component, molybdenum-disulphide
paste
a. should
Before be applied tothoroughly
repacking, prevent galling
clean /stuffing
seizure and
box also to facilitate
gland, packing
easy removal in future.
compartment and shaft protection sleeve.
b. Cut the packing ring to correct length and ends at 45º. Ensure
that the packing rings ends come into contact with one another
on fitment.

Name: Name: Name:
KMPCL/MAINT/BAOP/01
5 Reassembly
11. Coat the fits and screw connections with molykote or

similar before reassembly.
12. Check oil seal & o-rings for its damage; replace if
necessary.
13. All gaskets must be renewed; make sure the new ones
have the same thickness as the old ones.
14. Check the shaft with its spacer sleeve / or shaft protection
sleeve (as applicable) for eccentricity, between centers.
Maximum allowable eccentricity is 0.05mm.
15. Fasten the shaft to the bench vice using soft polish sheets
between the vice clamp jaws to avoid damage. Refer fig. no. A.
16. Heat the bearings in the induction heater about 80-90Deg.C
max. and push it on to the shaft. Fig. no. A Allow the bearings to
cool down. Then tap it lightly against the shoulder using suitable
pipe punch.
17. Fit shaft circlip
Shaft assembly Inner Bearing Cover assembly

Name: Name: Name:
KMPCL/MAINT/BAOP/01
18. Place back cover on bench.
19.Fasten back cover assembly to bearing housing assembly.
20.Rotate shaft & check for rubbing.
21.Fit impeller key tightly and apply.“Locktite” anti seize compound

to shaft.
22.Tap impeller lightly into place.
23.Tighten impeller nut, holding the shaft steady at coupling end.
24.Check operating gap 0.5-1.5 mm.
25. Lightly grease” O” ring & fit.
6. Possible Faults and Removal

Name: Name: Name:
KMPCL/MAINT/BAOP/01
REVIEW DATE:-
Faults Cause Removal
Pump fails to Air leaking into suction or gland; Seal the leakage;
discharge any Incorrect direction of pump rotation & impeller worn; Check direction of rotation and replacing impeller;
liquid Suction pipe blocked Removal blockage.
Gland excessively tightened against packing rings; Loosen gland bolts;
Rotating component rubbing on a stationary part; Remove the rubbed parts;
Shaft power Bearing is worn; Replace the bearing;

consumption is Drive belt tension too tight; Adjusting belt;
excessive Flow rate is too large; Modify the pump duty and speed;
Pump speed & ratio too high; Adjusting drive and pump shaft.
Misalignment or unparallel of drive shaft and pump shaft. Adjusting drive and pump shaft.
Lubricants too much or less; Lubricating as requirements;
Bearing is over
Containing impurities in the lubricant; Replace new lubricant;
heating
Bearing worn. Replace new bearing.
Misalignment or unparallel of drive and pump shaft; Adjusting drive and pump shaft;
Shaft is bent; Replacing shaft;
Bearing has Impeller unbalanced due to wear; Remove rubbing and new Impeller;
short life Foreign object entered into the bearing or insufficient Clean the bearing;
lubrication;
Incorrect procedure followed in fitting bearings. Replacing or refitting the bearing.
Packing rings are excessive worn; Replace new packing rings;
Excessive
leakage from Shaft sleeve is worn; Replace shaft sleeve;
stuffing box
Dirty sealing water. Change clean sealing water.
Bearings worn; Replaced by new bearings;
Pump vibrates Impeller unbalanced; Replaced by new impeller;

or is noisy Air entered into suction pipe or blocked; Discharge air and remove block;
Flow rate non-uniform and pump not primed Improve on the pump feeding.
SMP WILL BE REVIEWED IN EVERY SIX MONTH FROM THE DATE OF ISSUE BASED ON
ACTUAL PROBLEM FACED AND SHALL BE UPDATED ACCORDINGLY.
MECHANICAL MAINTANENCE TEAM WILL VISIT THE EQUIPMENT TWICE IN A WEEK & IF
ANY ABNORMALITY NAMELY (VIBRATION, ABNORMAL SOUND, TEMPERATURE RISE, BELT
TIGHTNESS ETC) OF EQUIPMENT IS OBSERVED AND THEN THE SAME WILL BE RECTIFIED
WITHIN PRESCRIBED TIME PERIOD.
DO’s & DONT’s :

Name: Name: Name:
KMPCL/MAINT/BAOP/01
DO’s :
1. Ensure relevant equipment/system PTW is available before starting the work.
2. Ensure relevant equipment/system is electrically isolated before starting the work, if applicable.
3. Ensure relevant air/water valves are fully closed for the equipment/system before starting the work.
4. Provide Danger Boards before starting the work involving dismantling of any equipment/system.
5. Ensure proper follow-up of all statutory requirements & hazard norms.
6. Ensure proper follow-up of all plant practices, existing regulations, prescribed procedures & general
safety prior to carry out any work.
7. While replacing any spares/oil, ensure that the same must be as per OEM recommendation.
8. After overhauling of any equipment, ensure proper preservation of spares/oil.
9. Always use the special tools as recommended by OEM for certain equipments like HCSD Pump.
DONT’s :
1. Don’t start the work without presence of Safety Personnel in case fire / other hazards are involved.
2. Don’t use hammer / heating for removing bearings / gears.
3. Don’t use tools & tackles which are not calibrated / certified by relevant authority.
4. Don’t start the work in Pressure Vessels/Pressure Line/Water Line, unless it is completely de-
pressurised.
5. Don’t start the work, especially at height, without proper PPE’s.
6. Don’t start the work, without presence of skilled personnel/expert.

Name: Name: Name:

SMP For Ba Overflow Pump

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

SMP For Ba Overflow Pump

Caricato da

Copyright:

Formati disponibili

Power from knowledge

KSK Mahanadi Power Company Ltd.

STANDARD MAINTANENCE PROCEDURE

Prepared by: Reviewed by: Approved by:

Prepared by: Reviewed by: Approved by:

The details of the BA OVERFLOW PUMP are as follows :

1 Before commencing dismantling operations, ensure that the

Prepared by: Reviewed by: Approved by:

1. Before dismantling, make sure the motor is disconnected.

Fig. no. 1: Dismantling the pump set

Prepared by: Reviewed by: Approved by:

Construction Drawing For BA OVERFLOW PUMP

Prepared by: Reviewed by: Approved by:

Fig. No. 3 : Bearing Assembly.

Dismantling the Bearing Unit

Prepared by: Reviewed by: Approved by:

Prepared by: Reviewed by: Approved by:

4 Examination of Internal Components :

Note: - In MEGA GC wearing ring is not provided.

Original Clearance on the Diameter

New wearing ring clearances are:-

MEGA GC - 0.5 mm on diameter

Replace shaft sleeve if it is grooved or generally worn.

a. Inspect the impeller as follows:

i. Examine the impeller for damage.

Prepared by: Reviewed by: Approved by:

Any of the above may be repaired, or if damage is extensive, impeller may

Shaft & keys

Shaft should be checked for the trueness, or any other mechanical

Prepared by: Reviewed by: Approved by:

e. Visually inspect Bearing Housing

g. If after inspection, the bearing is reusable, completely coat all parts

Prepared by: Reviewed by: Approved by:

11. Coat the fits and screw connections with molykote or

Shaft assembly Inner Bearing Cover assembly

Prepared by: Reviewed by: Approved by:

18. Place back cover on bench.

19.Fasten back cover assembly to bearing housing assembly.

20.Rotate shaft & check for rubbing.

21.Fit impeller key tightly and apply.“Locktite” anti seize compound

23.Tighten impeller nut, holding the shaft steady at coupling end.

24.Check operating gap 0.5-1.5 mm.

25. Lightly grease” O” ring & fit.

6. Possible Faults and Removal

Prepared by: Reviewed by: Approved by:

Faults Cause Removal

Shaft power Bearing is worn; Replace the bearing;

Pump vibrates Impeller unbalanced; Replaced by new impeller;

DO’s & DONT’s :

Prepared by: Reviewed by: Approved by:

1. Ensure relevant equipment/system PTW is available before starting the work.

5. Ensure proper follow-up of all statutory requirements & hazard norms.

8. After overhauling of any equipment, ensure proper preservation of spares/oil.

2. Don’t use hammer / heating for removing bearings / gears.

5. Don’t start the work, especially at height, without proper PPE’s.

6. Don’t start the work, without presence of skilled personnel/expert.

Prepared by: Reviewed by: Approved by:

Potrebbero piacerti anche