Form # : MAC-55

Rev. # : 00
Tag # WP-111

Job Report
MACHINERY MAINTENANCE UNIT

Dated: 15 - 02- 15

OVERHAULING OF WASTE WATER PUMP

(WP-111)

PREPARED BY :

M.SAQIB RAZA RABBANI

MANAGEMENT ASSOCIATE

REVIEWED BY:

SHAFIQ UR REHMAN
DEPUTY MANAGER

SUBMITTED TO:

MUHAMMED IRFAN ANWAR

UM (MACHINERY)

WP-111
JOB DESCRIPTION:

Prepared By : SRR

Reviewed By: SHR

FAUJI FERTILIZER BIN QASIM LTD

Page 1of 6

Form # : MAC-55
Rev. # : 00

Job Report
MACHINERY MAINTENANCE UNIT

Tag # WP-111
Dated: 15 - 02- 15

Waste Water Pump (WP-111) operated in reverse (clockwise) direction, impeller

strike with casing at bottom and pump shaft lifted in upward position and ultimately
thrust bearing housing lifted up breaking housing bolts.
EXECUTIVE SUMMARY:

Electrical department changed the JB and cables of Waste water pump (WP-111).
Operation engineer verified the direction of rotation, motor rotated in the reverse
direction (Clockwise) due to operational mistake and abnormal sound produced at
startup of pump, therefore pump immediately turned off and it was decided to
overhaul the complete pump to check for the damage. After the removal of motor
the complete pump assembly removed and shifted to machinery workshop.
Pump disassembled; during disassembly it was observed that the run out of
Impeller shaft was high. Carbon Graphite Bush in the retainer bearing, bush on
impeller shaft had ovality and worn out. The bearings suspected to be damaged
due to lifting of pump shaft in upward direction, thrust bearing replaced. New
impeller shafts issued from warehouse, run out checked and shaft installed. Three
new Carbon Graphite bushes were made from the machine shop and installed.
Pump reassembled and shifted to the area.
Gap between bearing housing and hub adjusted (12 mm) to ensure the free
movement of shaft. Pump installed in area and shaft rotated by hand to check easy
rotation. Motor coupled and pump started. At startup gland and packing box
leakage observed and minimized by tightening the packing box.
DISASSEMBLY / OBSERVATION DURING DISASSEMBLY:

1. Motor removed.
2. Coupling hub removed.
3. Set screws were removed that fasten packing box to the pump shaft so that
pump shaft can slide.
4. Discharge head was disconnected from the column.
5. Packing box was removed and bearing housing was loosened.
6. Strainer and suction bell removed.
Prepared By : SRR

Reviewed By: SHR

FAUJI FERTILIZER BIN QASIM LTD

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Form # : MAC-55
Rev. # : 00

Job Report
MACHINERY MAINTENANCE UNIT

7.
I

Tag # WP-111
Dated: 15 - 02- 15

ntermediate 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. 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.

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. Run out checked and
found 0.22 mm that was acceptable. Head shaft run out found 0.06 mm that
was acceptable.
14. Now the impeller was removed after the removing the locking ring that was
holding impeller on the pump shaft in the following sequence.

Locking screws were removed.

Locking ring was removed.

Impeller removed from the pump shaft.

15. Run out of impeller shaft was checked and found 2 mm (Rec: Max Upto 0.1 mm ).So
it was replaced.
ASSEMBLY:

1. New impeller shaft issued from warehouse, shafts Matl: SS-316.

2. Run out check of impeller shaft was done and and it was in the range 0.03 mm
~0.05 mm so that was acceptable.
3. New bushes were made and installed in the machine shop, Matl: Carbon
Graphite.

Prepared By : SRR

Reviewed By: SHR

FAUJI FERTILIZER BIN QASIM LTD

Page 3of 6

Form # : MAC-55
Rev. # : 00

Job Report
MACHINERY MAINTENANCE UNIT

4.
I

Tag # WP-111
Dated: 15 - 02- 15

mpeller was being mounted on the new pump shaft and locking ring fixed by
locking screw.
5. Bearings were changed in the bearing housing and were mounted on the thrust
stand shaft.
6. Intermediate bowl and top bowl were connected together and assembled.
7. Impeller shaft was inserted and assembled in its position and connected to line
shaft with coupling.
8. Line shaft was coupled to the impeller shaft.
9. Enclosing tube suction side half mounted on top bowl from one side and to
threaded retainer bearing on discharge side.
10. Line shaft coupled to the head shaft and discharge side part of enclosing tube
mounted on the threaded retainer bearing holding the tube halves.
11. Column installed in its position and column fixed to the discharge head with
bolts.
12.

Threaded plate behind packing gland installed and packing gland installed.

13. Head shaft coupled to thrust stand shaft and bearing housing was fixed and
coupling hub installed.
14.

Suction strainer was installed and bolted.

15.

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

16.

Coupling hub attached to the shaft.

17. Pump body 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 and gap from hub to bearing housing adjusted to 12
mm. Motor was mounted and operated to check the vibration and heat level.
Data:

New Bush ID = 30.45 mm

Prepared By : SRR

Reviewed By: SHR

FAUJI FERTILIZER BIN QASIM LTD

Page 4of 6

Form # : MAC-55
Rev. # : 00

Job Report
MACHINERY MAINTENANCE UNIT

Tag # WP-111
Dated: 15 - 02- 15

Clearance = 0.3 mm
Head shaft Run out = 0.06 mm
Old impeller shaft run out = 2 mm
Line shaft run out = 0.22 mm
New impeller shaft OD = 62.00 mm
New impeller shaft Run out = 0.05 mm
Startup:

On startup water leakage observed from the gland packing box and plate below the
gland. Packing box tightened and leakage reduced.

Prepared By : SRR

Reviewed By: SHR

FAUJI FERTILIZER BIN QASIM LTD

Page 5of 6

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

Job Report
MACHINERY MAINTENANCE UNIT

Dated: 15 - 02- 15

TEAM
ENGINEER
-

Khalid Mehmood Khan

Shafiq UR rehman

M.Saqib Raza Rabbani

Section Manager
Deputy Manager
Management Associate

STAFF
-

Jameel

Sup

Shahid Pervez

Senior Technician

Qaiser Abbas

Jr. Sup

COS
-

Amin Khan

MWB

Prepared By : SRR

Reviewed By: SHR

FAUJI FERTILIZER BIN QASIM LTD

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