Work Instruction 1 (13)

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Checked and verified by Maintenance Manager, Date Approved by Station Manager, Date

Jan Woch Sauli lehtinen

_____ / _____ / 2012 _____ / _____ / 2012

Effective date Distribution

HC : Respective Managers, Respective Area

SC : Docushare

Keywords

BMS, (please fulfilled)

XXXX-YY-WIxx Sea Water Intake Diassembly for inspection

1. DETAIL OF WORK AND PREPARATION

1.1 Preparation before overhaul
 Prepare PTW to work activities in general.
 Prepare tools and special tools
 Prepare drawing or work instruction
 Prepare suitable lay down area ( cleaning with service water on the underground area )
 Coordinate with electrical department to remove cable power such as vibration monitor
and thermocouples before starting disassemble work.
 Ensure that equipment is isolated and permit to work is available before early work
 Ensure working area is clean
1.2 Tools and others
 Ensure lifting tools (over head crane) can be used
 Work Instruction 2 (13)

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 Prepare special tools refers to manual if any , and support base for motor.
 Lifting tools
 Chain block 5 ton : 1 ea ( check floating,etc )
 Sling wire 1” x 4 m :4 pcs ( remove motor )
 Sling wire 1” x 2 m : 2 pcs
 Sling webbing 4 ton : 2 pcs
 Jacking device( 20 ton x 2 pcs )
 Socket set , air impact
 L key set
 Slogging wrench ( 36,46,55,65,41,80,90 )
 Combination spanner set
 Consumable material ( cotton rag, silicon, molycote, paint remover,etc )
 Prepare material to be replaced when overhaul
 O’ring 7,5 mm x 17 m per unit
 Seal rubber
 Lock plate coupling
2. DISASSEMBLY
2.1. Remove Sea Water intake Motor
(1) Disconnect power cable by electrical team
 Ensure power supply is isolated by electrical team
(2) Disconnect vibration censor by vibration team
(4) Remove auxiliary pipe ( wrench 14,24, wrench pipe )
(5) Remove hand rail and ladder on motor (sling webbing,shackles )
(6) Remove lock plate on Bolt Coupling ( battle and hammer )
(7) Slaken & Remove bolt coupling motor to pump ( spanner 55 and 65,hammer,WD )
 Work Instruction 3 (13)

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(8) Measurement gap between motor coupling and spacer coupling before lift the motor for
reference . Record all data.
 Design Gap : 10 mm ( filler gauge , outside micrometer )- Refer Fig. 1

Motor Coupling

Adjusting plate/spacer

Pump Coupling Bolt Coupling

Fig. 1 Lifting allowance for rotating element

(9) Check Alignment before motor lift up for reference.

 Prepare dial indicator
 Prepare alignment jig
 Prepare stick bolt during alignment
 Record alignment data
(10) Loosen & remove bolt motor ( spanner 65 ,hammer )
 Work Instruction 4 (13)

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(11) Prepare and install sling wire 1” x 4 m ( 4 pcs ) for lifting the motor.
 Ensure over head crane is good condition and operated by Certified operator
 Coordinate with electrical team to monitor during lift up the motor
(12) Lift up the motor and put motor on the support base
(13) Check the Levelling of frame 4 position use Theodolite tool, for reference during
reinstallation.
2.2. Dismantle Circulating Water Pump
(1) Remove coupling long spacer / connecting shaft. Fig 2
 Loosen & remove bolt coupling PN R324 ( spanner 65,hammer )
 Prepare sling webbing 2 ton 4 m 1 ea and remove the spacer coupling using OH Crane.

Connecting Shaft / /Long spacer PN R225

Bolt Coupling PN R324

Adjusting plate R 323
Pump Coupling

Fig.2. Remove connecting shaft

(2) Check floating impeller shaft (Design : max 14 mm) and record all data.
 Prepare bolt M 48 1 ea
 Prepare Chain block 5 ton
 Prepare sling wire 1” 4 m 1 ea
 Prepare sling wire 1” 2 m 1 ea
 Prepare dial indicator 1 set 0-50 mm
 Work Instruction 5 (13)

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(3) Remove Adjsuting plate R 323. Fig.2

 Prepare 1 bolt M 20 2 ea
 Sling webbing 1 ton 1 m 2 ea
 Shackle 1 ton 2 ea
 Prepare stick bolt M30 500 mm 2 ea
(4) Remove pump coupling
 Prepare sling webbing 1 ton 4 m 2 pcs
 Special tool 1 bolt combination
 Prepare burner
 Prepare jacking 20 ton 1 ea
 Prepare long thread M 30 1 m 2 pcs
(5) Remove key way ( stud bolt M 12 )
(6) Remove gland follower ( spanner 24,41 )
(7) Remove stuffing box ( combination tool 32 )
 Prepare sling webbing 1 ton 2 m 1 ea for lifting
(8) Remove grating upper the pump for acces to lifting the pump ( screw drive minus )
(9) Remove conduit pipe electrical by electrical team
(10) Remove frame H-beam base plate motor
 Prepare spanner 55,hammer
 Prepare sling wire 8 ton 4 m 4 pcs
 Prepare 1 bolt M42 4 pcs
 Prepare special tool shackle 4 pcs
(11) Loosen and remove bolt and nut flange discharge elbow and lifting use OH crane
 Prepare spanner 55,90,hammer and lifting tools
 Prepare wire brush
 Work Instruction 6 (13)

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 Prepare air impact

(12) Remove discharge Bowl together with impeller shaft and suction bell and located at
suitable area in vertical position.
 Prepare sling wire 1” 4m 2 ea
 Prepare sling wire 1” 2m 1 ea
 Prepare chain block 5 ton
 Prepare special tool shackle 3 ea
(13) Remove Discharge Bowl included submerged bearing ( integrated ) and located at suitable
area.
 Loosen belt ( spanner 50 ,hammer )
 Prepare sling wire 1” 4 m 4 ea
 Prepare special tool shackle 4 pcs
 Prepare 1 bolt M 42 4 pcs
(14) Remove impeller shaft from suction bell and tailing to horisontal position and located at
suitable area.
 Install scaffolding for acces to install eye bolt and wire sling at cuopling shaft.
 Prepare sling wire 1” 4 m 1 ea
 Prepare special tool ( shackle 3 pcs )
 Prepare 1 bolt M 48 1 ea
 Prepare sling webbing 1” 2 m 2 pcs
 Prepare chain block 5 ton
 Prepare special 1 bolt combination
 Prepare slogging wrench 80
2.3. Internal inspection
 Clean all bolt from paint and give molicote
 Work Instruction 7 (13)

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 Check all bolt thread from flaw to repair or machining

 Ensure rubber gasket is good condition, if worn out replace with the new one
 Inspect o’ring , replace all consumable parts
 Inspect all coating in discharge elbow,Discharge bowl, suction bell, repair if found
defect.
 Inspect condition submerged bearing
 Measure and record part before replace
Inspection Item :
a. Impeller (R 111)
• Inspect the degree of wear and corrosion.
• Verify that there is no damage at the end face of the outer periphery of
the impeller.
• Inspect for cracks using the Dye Penetrant Test,
b. Main shaft (R221)
Inspect situation of corrosion
c . Case of packing sleeve (R237)
• If the amount of wear on the outer diameter exceeds the following
values, it is time for replacement.
Less than 100 mm : 1 mm
100 mm to less than 300 mm :2 mm
More than 300 mm : 3 mm

d. Bearing sleeve (R233)

• Presence or absence of uneven wear
• If the clearance (*9)between the submerged bearing has extended to more
than 2.5 times what it originally was, it is time for replacement. Also,
if there are no recessed or projected portions due to wear on the
 Work Instruction 8 (13)

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sleeve, priority should be given to the replacement of the submerged

bearing.
e. Submerged bearing(B163)
• Presence or absence of uneven wear
• When the clearance (*9)between the bearing sleeve has extended to more
than 2.5 times what it originally was, it is time for replacement.
f. Liner ring (C712)
• When the clearance ( * 9) has extended to more than 2.5 times what it
originally was, it is time for replacement.

Fig.3 Data clearance for rotating parts

Note ! After diassembly and inspection ,organize the records and replenish the spare parts

3. Reassemble CWP
For Assembly the pump should be assembly in the reverse of diassembly procedure.
See , Fig.4 Assembly procedure
 Work Instruction 9 (13)

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 Work Instruction 10 (13)

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Fig.4 Assembly procedure

 Work Instruction 11 (13)

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4. Centering
After confirmation of the pump assembly, mount a driver and perform the centering work.

(1) Centering tool installation.

Place a centering tool as shown in Fig.5, and make the gap uniform between the main
shaft and the inner diameter of the gland packing inserting portion of the stuffing box.

Fig. 5. Centering tools

(2) Centering

a . When the shaft of the driver cannot be turned by hand :

As shown in Fig. 6. attach a dial gauge to the adjusting plate (R323) with pump side
coupling fit to it, measure the outer diameter (deviated center) of the shaft coupling
(R321) on the pump side, and move and adjust the driver so as to drop the value within
the allowable range shown in Table 2-1.
 Work Instruction 12 (13)

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Fig. 6. Allowable values for centering

b . Measure the face-to-face dimension of the shaft coupling using a clearance gauge and
confirm that its face-to-face dimension (parallelism) is within the allowable value show
in Table 2-1. If the face-to-face dimension deviates from the allowable value, then slightly
lift up the rotating element (lifting allowance of the rotating element is less than S (*4)),
then slowly lower it and repeat the steps again from (1).
 Work Instruction 13 (13)

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5. Run test
After confirmation centering pump and motor was done , install the electrical and C&I
connection for solo run test the motor ( 15-30 minute ) prior to see the direction rotation
of the motor was correct.
After solo run test the motor , connect the coupling and pump ready for running test.

6. REPORTING AND COMPLETION OF WORK

 All data should be record and add to check list.
 All defect found during this inspection should be report to Line Supervisor directly or
create defect report by MAXIMO (MMS).
 Clear the working area after completion of inspection and put back all the previous
position.
 Inform control room operator that work has been completed.
 Close safety document and work order.

7. REFERENCE
O&M Manual; Volume 2 Steam Turbine and Auxiliary; Section 1 General Description; Sub
section 1.7 Other Equipment; Sub section 1.7.4 Circulating water Pump.