Cooling Tower Pump P-11445B

Inspection Action Plan Report

Date: 1/6/2022

Contents:
1- Pump Data
2- Problem Description
3- Our plan for check
4- Inspection Measurement
5- Procedure Plan
6- Tools – Equipment
7- Time Period
8- Manpower Required.
9- Conclusion & Recommended

1-Pump Data
  RPM: 1489
 Head: 60 M
 Flow Rate: 1400 M3 / hr.
 Model: 20 ENL-2
 Bowl Diameter :20 inch
 impeller Type: E (Enclosed)
 Bowl Model Type: N
 Impeller Model Designation: L
 No of Stage: 2

2-Problem:
pump shutoff pressure decreases from 10 bar to 4.5 bar.
3-Our plan to check the following points
 Inner diameter of First stage suction bell wear ring
 Outer diameter of first stage impeller wear ring
 Diameter of housing of Protective collar in first stage
 Outer diameter of protective collar in First Stage
 Shaft axial play
 Fist stage impeller status
 Shaft sleeves condition
And the Result of checking will be as the following:
 4-Inspection Measurement

SN Des Actual Image

measure
1 (319 A) wear 309 mm
Ring – Suction
Bell

2 Impeller Wear 305mm

Ring (008)

3 Protective collar 77.5mm

(64) C84400
Bronze
4 Protective collar 79.315mm
housing in
Suction bell
(55) 79.575mm

5 Shaft Axial Play 0.75mm

6 1St impeller Cracks found

Status ID = in 5 points

Runout The shaft must

Measurement be straight to
within 0.127
at Top shaft-
mm (0.005
119.18” LG
in.) total
@ sleeve
indicator
Position (014)
reading
0.2 mm
@ Middle of
shaft 0.25mm
@ Bearing
Position 0.2 mm
at Pump Shaft
(006)
@1st stage
impeller
position 0.1mm
@ 2nd stage
 impeller
0.14mm

1St impeller
inner Diameter
@1 =62.15 Dis
@3 =62.13 Suc
2nd impeller
inner Diameter
@1 =62.02 Dis
@3 =62.02 Suc

7 Shaft sleeve Found

clearance
between shaft
sleeve (14) and
line shaft
bearing (39) as
following :
61.715- 69.7
55.3 ( dia of
top shaft)
8 (319 B) wear 309mm
Ring – Bowl

9 Impeller Wear 304.2mm

Ring (008) 2nd
stage
10 line shaft 69.715mm
bearing (39)
70.43mm

11 Bowl bearing 1st bowl sleeve

(322) Suction side:
65.53mm
65.6mm

Shaft
diameter :61.8
4 mm
corrosion 62-
61.84=.16mm

1st bowl sleeve

Discharge side
:
65.65mm
65.7mm

Shaft
diameter :61.8
4 mm
corrosion 62-
61.84=.16mm

2nd bowl sleeve

Suction side:
 66.7mm

Shaft
diameter :61.8
5 mm
corrosion 62-
61.85=.15mm
2nd bowl sleeve
Discharge side:
69.4mm
69.31mm

Shaft
diameter :61.8
5 mm
corrosion 62-
61.85=.15mm
12 2nd impeller Cracks found
Status in 5 points

Corrosion No Suction Discharge side

side
1 3.15 9
diffuser 2
3
3.05
4
9.7
9.3
vanes in bowl 4
5
3.2
3.2
8.64
8.5

intermediate 6
7
2.75
3.17
8.95
8.85

(310 B)
(Thickness
survey)
 Corrosion No Suction Discharge side
side
1 7.5 8.9
diffuser 2
3
7.1
6.55
8.3
8.5
vanes in bowl 4
5
7.5
7
8.25
8.8

Top (310 A) 6
7
6.8
6.87
8.69
9.19

At discharge side

5-Procedure Plan for inspection the pump:

1. Issued cold work permit with electrical isolate for pump
2. Removed pump electrical cables
3. Measured coupling spacer distance between pump motor Hub
face and pump hub face head (137mm) , then removed coupling
spacer.
4. Looseness pump motor bolts and discharge pipe bolts
5. Inserted lifting tools, used crane (120 Ton) to remove the
pump motor 3800Kg.
6. Looseness pump foundation skit bolts, Inserted lifting tools
and used crane (120 Ton) to remove the pump 2350Kg
7. Checked pump suction strainer (PN.82121401) it was clean
8. Put pump body in safe location in horizontal direction and
start to disassembly the pump.
9. Disassembly pump half coupling using puller
10. Removed motor stand
11. Disassembly pump thrust bearing (29417+22217)
and bearing housing
12. Removed pump packing gland
13. Removed pump discharge head.
14. Removed shaft middle sleeve then removed column pipe
15. Disassembly threated coupling shaft
16. Removed pump suction strainer

17. Disassembly pump second stage casing then removed second

impeller from the shaft
18. Disassembly pump first stage casing then removed first
impeller from the shaft
19. Removed pump suction bell.
20. Measured in three points pump shaft diameter, first stage
impeller inner diameter, second stage impeller inner diameter,
wear ring outer diameter for both impellers, first and second
stage casing inner diameters to check with clearance.

Status now (Finish till point No:8 , Date : 31-5-2022 )

6-Tools:
Chain Block :2, Puller, slings :4, hand tools, Micrometer.
Equip:
Mobile Crane 120 Ton
7-Time Period:
2 days (48 hr.)
8-Man power Required:
1 Engineer + 2 Rotary Tech + 1 Helper

9- Conclusion & Recommendation

1-found Abnormal clearance between Impeller Wear ring and

bowl wear Ring
as per standard should be not exceed 0.5 mm
For 1st stage actual clearance is( 309-305)=4 mm
For 2nd Stage actual clearance is (309-304.2)=4.8 mm

So, we need new Wear rings for impeller and bowl at both stage

2-Found ununiform corrosion of Protective collar housing

So, we need Repairing for protective collar housing and new
protective collar suitable for it
3-Found Cracks in the 1st impeller
So, we need Inspection for impeller to determine if impeller
accepted or need new one
4-Found corrosion in the shaft sleeve
so, we need new line shaft bearing (39)
5-Run out for the shaft and wearing at sleeves position (Top
Shaft & Pump Shaft), Thread of pump shaft Damaged
so, We need new shafts, Coupling Shaft 070
6-We have wear on Bowl bearing (322) so We need 4 Bowl
bearing C84400 Bronze