SMP For Slurry Pump

Power from knowledge
KSK Mahanadi Power Company Ltd.

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

Signature: Signature: Signature:
Name: Name: Name:
Designation: Designation: Designation:
KMPCL/MAINT/SP/01
SMP FOR SLURRY PUMP
OBJECTIVE
The purpose of this work instruction is to explain the procedure for carrying out Overhaul of
Slurry Pump.
1. Slurry Pump
The details of the Slurry Pump are as follows
Make: Shijiazhuang Kingda Pump Industries Ltd.; Model:200ZGB; Capacity: 160 cum/hr;
Max Working Pressure: 6kg/sqcm; Head: 60 Meter; Motor Speed: 2950RPM
DETAILED INSTRUCTION
Sr. Activity Responsibility
No.
I Overhaul to be done as per Checklist
Before commencing dismantling operations, ensure that the

1 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/SP/01
SMP FOR SLURRY PUMP
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/SP/01
SMP FOR SLURRY PUMP
Construction Drawing For Type ZGB Slurry Pump
1. Cover volute plate 2. Impeller 3.volute 4. Frame body 5. Shaft 6. Set nut B 7.
Set nut A 8. Access hole cover 9. Expeller gland 10. Expeller 11. Casing volute
plate 12. Casing 13. Cover

Name: Name: Name:
KMPCL/MAINT/SP/01
SMP FOR SLURRY PUMP
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:
KMPCL/MAINT/SP/01
SMP FOR SLURRY PUMP
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/SP/01
SMP FOR SLURRY PUMP
Examination of Internal Components :

4 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/SP/01
SMP FOR SLURRY PUMP
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/SP/01
SMP FOR SLURRY PUMP
c. Check that the parts of the cage are firmly fixed together.
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 the outside diameter for signs of fretting, any

stains may be carefully polished off, but abrasion must be kept
to the absolute minimum that is required, followed by cleaning.
f. Check that bearing rotates freely and smoothly. If there is any

doubt regarding 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.
Stuffing box bush
Check bore of stuffing box bush and compare with sleeve

diameter. If "clearance is excessive, the bush should be
renewed.
Note: While assembling stainless steel component, molybdenum-

disulphide paste should be applied to prevent galling / seizure and also
to facilitate easy removal in future.

Name: Name: Name:
KMPCL/MAINT/SP/01
SMP FOR SLURRY PUMP
1. Vacuum and blow out all cavities of bearing housing.
Bearing Housing
2. Set bearing housing vertical on flange.

3. Press in shaft assembly as shown.
4. Fasten outer bearing cover assembly.
5. Secure inner bearing cover assembly.
6. Fit deflectors at pump side

7. Fit coupling key.
8. Add PVC tape to secure.
9. Place back cover on bench.
10. Insert the packing / logging ring set into this stuffing box.
a. Before repacking, thoroughly clean stuffing box gland, packing

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/SP/01
SMP FOR SLURRY PUMP
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/SP/01
SMP FOR SLURRY PUMP
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/SP/01
SMP FOR SLURRY PUMP
Faults Cause Removal

Air leaking into suction or gland; Seal the leakage;
Pump fails to
discharge any Incorrect direction of pump rotation & impeller worn; Check direction of rotation and
liquid replacing impeller;
Suction pipe blocked Removal blockage.
Gland excessively tightened against packing rings; Loosen gland bolts;
Shaft power Rotating component rubbing on a stationary part; Remove the rubbed parts;
consumption is Bearing is worn; Replace the bearing;
excessive 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 over
Containing impurities in the lubricant; Replace new lubricant;
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.
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;
Impeller unbalanced; Replaced by new impeller;
Pump vibrates
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.
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.
DO’s & DONT’s :

Name: Name: Name:
KMPCL/MAINT/SP/01
SMP FOR SLURRY PUMP
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 Slurry Pump

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Power from knowledge

KSK Mahanadi Power Company Ltd.

STANDARD MAINTANENCE PROCEDURE

Prepared by: Reviewed by: Approved by:

Before commencing dismantling operations, ensure that the

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

Prepared by: Reviewed by: Approved by:

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

Fig. no. 1: Dismantling the pump

Prepared by: Reviewed by: Approved by:

Construction Drawing For Type ZGB Slurry Pump

Prepared by: Reviewed by: Approved by:

Fig. No. 3 : Dismantling the Bearing Unit

Dismantling the Bearing Unit

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:

Prepared by: Reviewed by: Approved by:

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

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

Shaft & keys

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

Prepared by: Reviewed by: Approved by:

e. Visually inspect the outside diameter for signs of fretting, any

f. Check that bearing rotates freely and smoothly. If there is any

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

Stuffing box bush

Check bore of stuffing box bush and compare with sleeve

Note: While assembling stainless steel component, molybdenum-

Prepared by: Reviewed by: Approved by:

1. Vacuum and blow out all cavities of bearing housing.

2. Set bearing housing vertical on flange.

6. Fit deflectors at pump side

a. Before repacking, thoroughly clean stuffing box gland, packing

Prepared by: Reviewed by: Approved by:

11. Coat the fits and screw connections with molykote or

17. Fit shaft circlip

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

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

Prepared by: Reviewed by: Approved by:

Faults Cause Removal

DO’s & DONT’s :

Prepared by: Reviewed by: Approved by:

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