SMP For Supply Water Pump

Power from knowledge
KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL/MAINT/SWP/01

SMP FOR SUPPLY WATER PUMP
Issue No: 1 Issue Date: Revision: 1 Revision Date: 29.07.13 File no: Page 1 of 13
STANDARD MAINTANENCE PROCEDURE
FOR
SUPPLY WATER PUMP
Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Name: Name:
Designation: Designation: Designation:

OBJECTIVE

Name: Name: Name:

The purpose of this work instruction is to explain the procedure for carrying out Overhaul of
SUPPLY WATER PUMP.
1. SUPPLY WATER PUMP
The details of the SUPPLY WATER PUMP are as follows :
Make: BOSHAN; TYPE-IS-100-65-200, Q=90m3/h, H=0.51MPa MOTOR TYPE Y180M-2,

22KW, 415V, RPM-2900.
DETAILED INSTRUCTION
Sr. Activity Responsibility
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:

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:

Construction Drawing For SUPPLY WATER PUMP

Name: Name: Name:

Fig. No. 3 : Dismantling the Bearing Unit
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
Fig. no. 4 : Dismantling the pump shaft from bearing bracket
Fig. no. 5: Dismantling the bearings from the pump shaft.

Name: Name: Name:

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:

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:

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:

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
2. the
Set absolute
bearing housing
minimum vertical
that ison flange. followed by cleaning.
required,
3. Press in shaft assembly as shown.
4.f. Check
Fasten that
outerbearing
bearingrotates
cover assembly.
freely and smoothly. If there is any
5. doubt
Secure regarding
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
6. necessary.
Fit deflectors at pump side
7. Fit coupling key.
8. Addbox
Stuffing PVCbush
tape to secure.
9. Place back cover on bench.
Check the
10. Insert borepacking
of stuffing box bush
/ logging ring and compare
set into with sleeve
this stuffing box.
diameter. If "clearance is excessive, the bush should be renewed.
a. Before repacking, thoroughly clean stuffing box gland, packing
Note: compartment
While assembling
and stainless steel component,
shaft protection sleeve. molybdenum-
disulphide
b. Cut paste should ring
the packing be applied to prevent
to correct length galling
and ends/ seizure and
at 45º. also
Ensure
to facilitate easy removal in future.
that the packing rings ends come into contact with one another
on fitment.

Name: Name: Name:

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:

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:

Faults Cause Removal

Air leaking into suction or gland; Seal the leakage;
Pump fails to Incorrect direction of pump rotation & impeller Check direction of rotation and replacing
discharge worn; impeller;
any liquid
Suction pipe blocked Removal blockage.
Gland excessively tightened against packing Loosen gland bolts;
rings;
Shaft power Rotating component rubbing on a stationary Remove the rubbed parts;
consumption part;
is excessive Bearing is worn; Replace the bearing;
Flow rate is too large; Modify the pump duty and speed;
Misalignment Adjusting drive and pump shaft.
Lubricants too much or less; Lubricating as requirements;
Bearing is
Containing impurities in the lubricant; Replace new lubricant;
over heating
Bearing worn. Replace new bearing.
Misalignment or unparalleled of drive and pump Adjusting drive and pump shaft;
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 Clean the bearing;
insufficient lubrication;
Incorrect procedure followed in fitting bearings. Replacing or refitting the bearing.
Excessive Packing rings are excessive worn; Replace new packing rings;
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 Impeller unbalanced; Replaced by new impeller;
vibrates or is Air entered into suction pipe or blocked; Discharge air and remove block;
noisy Flow rate non-uniform and pump not primed Improve on the pump feeding.
REVIEW DATE:-
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.

Name: Name: Name:

SMP For Supply Water Pump

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SMP For Supply Water Pump

Uploaded by

Copyright:

Available Formats

Power from knowledge

KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL/MAINT/SWP/01

STANDARD MAINTANENCE PROCEDURE

SUPPLY WATER PUMP

Prepared by: Reviewed by: Approved by:

6 X 600 MW Power Plant KMPCL/MAINT/SWP/01

Prepared by: Reviewed by: Approved by:

6 X 600 MW Power Plant KMPCL/MAINT/SWP/01

1. SUPPLY WATER PUMP

The details of the SUPPLY WATER PUMP are as follows :

Make: BOSHAN; TYPE-IS-100-65-200, Q=90m3/h, H=0.51MPa MOTOR TYPE Y180M-2,

1 Before commencing dismantling operations, ensure that the

 A crane / chain pulley block suitable for handling the weight of

Prepared by: Reviewed by: Approved by:

6 X 600 MW Power Plant KMPCL/MAINT/SWP/01

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

Fig. no. 1: Dismantling the pump

Prepared by: Reviewed by: Approved by:

6 X 600 MW Power Plant KMPCL/MAINT/SWP/01

Construction Drawing For SUPPLY WATER PUMP

Prepared by: Reviewed by: Approved by:

6 X 600 MW Power Plant KMPCL/MAINT/SWP/01

Fig. No. 3 : Dismantling the Bearing Unit

Dismantling the Bearing Unit

1. Remove bearing covers and gaskets by unscrewing of hex. Bolt.

Fig. no. 4 : Dismantling the pump shaft from bearing bracket

Fig. no. 5: Dismantling the bearings from the pump shaft.

Prepared by: Reviewed by: Approved by:

6 X 600 MW Power Plant KMPCL/MAINT/SWP/01

Prepared by: Reviewed by: Approved by:

6 X 600 MW Power Plant KMPCL/MAINT/SWP/01

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:

6 X 600 MW Power Plant KMPCL/MAINT/SWP/01

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

b. Around the eye, wearing rings protects the impeller. Examine

Shaft & keys

Shaft should be checked for the trueness, or any other

Prepared by: Reviewed by: Approved by:

6 X 600 MW Power Plant KMPCL/MAINT/SWP/01

e. Visually inspect Bearing Housing

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

Prepared by: Reviewed by: Approved by:

6 X 600 MW Power Plant KMPCL/MAINT/SWP/01

11. Coat the fits and screw connections with molykote or

Shaft assembly Inner Bearing Cover assembly

Prepared by: Reviewed by: Approved by:

6 X 600 MW Power Plant KMPCL/MAINT/SWP/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

22.Tap impeller lightly into place.

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