Form # : MAC-55

Rev. # : 00
Tag # WP-111

Job Report
MACHINERY MAINTENANCE UNIT

Dated: 27 - 11- 14

OVERHAULING OF WASTE WATER PUMP

(WP-111)

PREPARED BY :

M.SAQIB RAZA RABBANI

MANAGEMENT ASSOCIATE

REVIEWED BY:

SHAFIQ UR REHMAN
DEPUTY MANAGER (MACH)

SUBMITTED TO:

IRFAN ANWAR
UM (MACHINERY)

WP-111
EXECUTIVE SUMMARY:

Prepared By : SRR

Reviewed By: SHR

FAUJI FERTILIZER BIN QASIM LTD

Page 1of 8

Form # : MAC-55
Rev. # : 00

Job Report
MACHINERY MAINTENANCE UNIT

Tag # WP-111
Dated: 27 - 11- 14

High vibration was reported from pump so it was decided to overhaul the complete
pump. After the removal of motor the complete pump assembly was removed\lifted
and shifted to machinery workshop.
Pump disassembled, during disassembly it was observed that the due to excessive
wear all three shafts i.e Impeller shaft, Line shaft and Head shaft were damaged.
Shaft sleeve under the gland packing, suction bush, bush in the retainer bearing,
bush on impeller shaft damaged. The bearings in the bearing housing were also in a
bad condition. The gland packing was also worn out.
New shafts were issued from warehouse, adjustment in diameter at some points
and length of the new line shaft were carried out as per the old shafts. New bushes
and sleeves were made from the machining shop. While removing the bush from
suction bell by machining, a small part of bush was ignored because it was not
detectable by naked eye at that time. So when the new bush was pressed in the
suction bell, it pushed the old bush portion at the end of the bell. So new bush was
then taken out and the remains of old bush was removed by machining and new
bush and supporting sleeve were installed and welded together.
Run out check of the new shafts was carried out and a run out of 0.01 mm ~ 0.04
mm was found which was acceptable. Impeller was removed from the impeller shaft
and new shaft was installed. A new throttle bush was installed in the casing to
support impeller shaft. New bush was installed in retainer bearing. A new sleeve
was mounted to the head shaft under the packing box and packing rings were
replaced. All shafts were made of SS 316.New Bearings were in installed on the
head shaft in back to back arrangement. Then pump was reassembled and taken to
the area.
Pump installed in area and shaft was rotated by hand to check easy rotation but
after few rotations there was hindrance in the movement of shaft so shaft was
raised up and axial float adjusted to ensure the free movement of shaft. So motor
was coupled and pump was started. Pump running normal at max. Vibration of
1.4mm/sec.

Prepared By : SRR

Reviewed By: SHR

FAUJI FERTILIZER BIN QASIM LTD

Page 2of 8

Form # : MAC-55
Rev. # : 00

Job Report
MACHINERY MAINTENANCE UNIT

Tag # WP-111
Dated: 27 - 11- 14

JOB DESCRIPTION:

High vibration rectifications of WP pump WP-111.

DISASSEMBLY / OBSERVATION DURING DISASSEMBLY:
1. Motor removed.

2. Coupling hub removed.

3. Set screws were removed that fasten packing seal box to the pump shaft so that

pump shaft can slide.

4. Discharge head was disconnected from the column.
5. Then packing box was removed and bearing housing was loosened.
6. Strainer and suction bell removed.
7. Intermediate bowl and top bowl were disconnected after match marking.
8. Impeller shaft was rotated and removed from the coupling. So intermediate bowl
was removed.
9. Then Top bowl was also removed along with the tube that had been enclosing

the line shaft.

10. Tube was removed from the top bowl coupling by rotating it clockwise as it
was having left handed threads.
11.

Then line shaft removed from the top bowl coupling.

12. Tube was dismantled in two halves and by rotating it clockwise as it was also
having left handed screws.
13.

Line shaft was taken out and all the bushes removed.

14. Now the impeller was removed after the removing the locking ring that was
holding impeller on the pump shaft in the following sequence.

Prepared By : SRR

Reviewed By: SHR

FAUJI FERTILIZER BIN QASIM LTD

Page 3of 8

Form # : MAC-55
Rev. # : 00

Job Report
MACHINERY MAINTENANCE UNIT

Locking screws were removed.

Locking ring was removed .

Impeller removed from the pump shaft.

Tag # WP-111
Dated: 27 - 11- 14

ASSEMBLY:

1. New shafts issued from warehouse and modified as per the old shafts, shafts
Matl: SS-316.
2. New packing sleeve was issued from the warehouse and mounted on the new
head shaft by machine shop, Sleeve Matl: SS-416.
3. Ovality was observed on all the shafts and it was in the range 0.01 mm ~0.04
mm so that was acceptable.
4. New bushes were made and installed in the machine shop.
5. Impeller was being mounted on the new pump shaft and locking ring fixed by
locking screw.
6. Bearings were changed in the bearing housing and were mounted on the thrust
stand shaft.
7. Intermediate bowl and top bowl were connected together and assembled.
8. Impeller shaft was inserted and assembled in its position and connected to line
shaft with coupling.
9. Line shaft was then being coupled to the impeller shaft.
10. Enclosing tube halves then coupled together and mounted on top bowl and it
enclosed the shaft.
11. Column was then installed in its position and line shaft and head shaft were
coupled and column was then being fixed to the discharge head with bolts.
12. Packing gland was then mounted and new packing ring installed, Packing Ring
Matl: PTFE.

Prepared By : SRR

Reviewed By: SHR

FAUJI FERTILIZER BIN QASIM LTD

Page 4of 8

Form # : MAC-55
Rev. # : 00

Job Report
MACHINERY MAINTENANCE UNIT

13.
H

Tag # WP-111
Dated: 27 - 11- 14

ead shaft then coupled to thrust stand shaft and bearing housing was then fixed
and coupling hub installed.
14.

Then suction sleeve was installed and bolted.

15.

Axial float had been checked and was within the acceptable range <0.05 mm.

16.

Coupling hub then attached to the shaft.

17. Pump body then lifted by the crane and taken to the installation site where it
was installed and float adjusted. Pump installed in area and shaft was rotated by
hand to check easy rotation but after few rotations there was hindrance in the
movement of shaft so shaft was raised up 1.5 mm and axial float adjusted to
ensure the free movement of shaft.
18.

Motor was mounted and operated to check the vibration and heat level.

19.

Heat level was normal and vibration was acceptable i.e 1.4 mm/s.

MOTOR OVERHAUL:
Motor was removed and sent to the electrical shop and then after rectification it was
installed back on the pump and operated and a max. vibration of 1.4 mm/s was observed.

Prepared By : SRR

Reviewed By: SHR

FAUJI FERTILIZER BIN QASIM LTD

Page 5of 8

Form # : MAC-55
Rev. # : 00

Job Report
MACHINERY MAINTENANCE UNIT

Tag # WP-111
Dated: 27 - 11- 14

Old Packing

Wear due
to bush

New Packing
Ring
Impeller Lock
Ring

Complete
Pump
Wear due to
bush(Line

Prepared By : SRR

Damaged
Bush

Reviewed By: SHR

FAUJI FERTILIZER BIN QASIM LTD

Page 6of 8

Form # : MAC-55
Rev. # : 00

Job Report
MACHINERY MAINTENANCE UNIT

Tag # WP-111
Dated: 27 - 11- 14

Bush Removal by
Machining(Suction
bell)

New bush and

supporting sleeve
(Suction bell)

Prepared By : SRR

Reviewed By: SHR

FAUJI FERTILIZER BIN QASIM LTD

Page 7of 8

Form # : MAC-55
Rev. # : 00
Tag # WP-111

Job Report
MACHINERY MAINTENANCE UNIT

Dated: 27 - 11- 14

TEAM
ENGINEER
-

Khalid Mehmood Khan

Shafiq UR rehman

Section Manager
Deputy Manager

M.Shafique

Sub- Engineer

M.Saqib Raza Rabbani

Management Associate

STAFF
-

Bahar Shah

Sup

Shahid Pervez

Senior Technician

Muhammad Ali

Jr. Sup

COS
-

Amin Khan

MWB

Prepared By : SRR

Reviewed By: SHR

FAUJI FERTILIZER BIN QASIM LTD

Page 8of 8