PV POWER SERVICES JSC

Docurment:

Docurment code:

QT-SCL
File:

QT_BNC

METHOD STATEMENT
ISO ITEM:

ISSUE TIME:

Date of validity:

1; ...-...-2009

--2009

Validity apply:

PVP-SERVICE

Page No:

1/ 13

PV-Power Service

DISTRIBUTION:
1.

General Director

01

2.

Deputy General Director

01

3.

Engineering Department

01

4.

Camau Maintenance Enterprise

01

5.

Electrical Department

01

METHOD STATEMENT
And Risk Analysis
Subject:

Method Statement for Overhaul the MV Motors for

Feed water pump & Condensate extraction pump in the PM 3 Power Plant

PREPARED BY

CHECKED BY

APPROVED BY

Signature:

Signature:

Signature:

Full name: Hoang Ngoc Son

Full name: Le Van Tu

Full name: Ma Ngoc Ky

Title:

Title:Vice Manager
Mechanical Department

Title: Deputy General Director

CONTENTS

PVP-SERVICE

METHOD STATEMENT
ISO ITEM:

ISSUE TIME:

DATE OF VALIDITY:

1;...-...-2009

--2009

DOCURMENT CODE:

QT-SCL
PAGE No:

2/ 13

I.

SCOPE OF WORK..............................................................................................03

II.

PROCEDURE.......................................................................................................03

1. Safety / Health..............................................................................................................03
2. Preparation...................................................................................................................04
3. Sequence of works........................................................................................................04
3.1

Obtain work permit...............................................................................................04

3.2

Obtain work permit if necessary..........................................................................04

3.3

Prepare and park the crane at suitable location.................................................04

3.4

Disassembly / Assembly the Motor & Bearings...................................................04

A. Feed Water Pump Motor with rolling bearing..........................................................05

1) Motor disassemly....................................................................................................05
2) Motor assembly.......................................................................................................07
3) Rolling Bearing disassebly.....................................................................................07
4) Rolling Bearing assembly.......................................................................................07
B. Condrnsate Extraction Pump Motor with Sleeve Bearing.......................................07
1) Motor disassemly....................................................................................................07
2) Motor assembly.......................................................................................................09
3) Sleeve Bearing disassebly.......................................................................................09
4) Sleeve Bearing assembly.........................................................................................09
3.5

Place the motor on location....................................................................................09

3.6

Final inspection & alignment check.....................................................................10

3.7

Commissioning the system.....................................................................................10

3.8

To carry out house keeping after completed the job..........................................10

4. Personnel.......................................................................................................................10
5. Risk assessment............................................................................................................10

I.

SCOPE OF WORK

PVP-Service

PVP-SERVICE

METHOD STATEMENT
ISO ITEM:

ISSUE TIME:

DATE OF VALIDITY:

1;...-...-2009

DOCURMENT CODE:

QT-SCL
PAGE No:

--2009

3/ 13

This method statement discribles the work to be performed for Overhaul of the MV Feed
Water Pumps & Condensate Extraction Pumps in the ULA & UMA buildings
1. Familiarization with Equipment data, Latest drawings;
2. Record data from name plate;
3. Disconnecting the power cable and uncoupling;
4. Remove the motor from the foundation;
5. Pick up the motor and transport to workshop or GT building;
6. Motor disassembly must be mark carefully motors parts;
7. Inspection (Static test) and Milliohm check (Winding resistance) insulation
check;
8. Motor dismantling and separate rotor form stator;
9. Replacing and fixing any damage motors parts: Bearings, nuts, screws,....,
10. Cleaning the stator winding and rotor cleaning liquid
11. Cleaning and painting for all mechanical part & motor patrs
12. Varnish clears on stator core & ouside frame
13. Anti corrosion treatment the motor frame Red varnish spray
14. Reassemble the motor completely
15. Re-greasing the bearings / replace lubrication oil
16. Perform static check after reassembling Winding inductance Winding insulation
resistance
17. Reinstall the motor at foundation
18. Connect power cable and tighten terminal connector with torque screw driver or
torque wrench
19. Thermal stickers at HV terminals
20. Rotation test

PVP-Service

PVP-SERVICE

METHOD STATEMENT
ISO ITEM:

ISSUE TIME:

DATE OF VALIDITY:

1;...-...-2009

DOCURMENT CODE:

QT-SCL
PAGE No:

--2009

4/ 13

21. Coupling alignment with the pump / fan

22. Record all problems happened during the work
23. Final inspection
24. Commissoining
25. To carry out house keeping after completed the job.
II.

PROCEDURE

1.

Safety / Health
-

All personnel have fully the personnel safety devices and follow safety rules;

Carry out tool box meeting with personnel involved before doing any job;

To ensure to follow the confined space entry procedure;

To ensure all hand tools and lifting epuipment are in good condition and certified;

To ensure follow the hot work procedure if necessary;

To ensure to be used safety harness when working;

To ensure the load to be lifted does not exceed the lifting capacities of the lifting
device;

To ensure no any personnel standing or stay under suspended load;

To ensure ony certified crane operator operates the crane;

To ensure the working area to be barricaded and signboard work in Progress;

To ensure ony authorized personnel involved in this job can access to the working
area;

2.
1)

Proper lighting to be used;

Preparation
Hand tools, consumable & Equipments.(Hand tools and lifting devices with
certified safe)

2)

Manpower:

PVP-Service

08 persons
4

PVP-SERVICE

METHOD STATEMENT
ISO ITEM:

ISSUE TIME:

DATE OF VALIDITY:

1;...-...-2009

3)

DOCURMENT CODE:

QT-SCL
PAGE No:

--2009

5/ 13

Schedule: 29 day (from 15th August to 12th September, 2009)

(Please see them on attachments)

3.

Sequence of works

3.1.

Obtain work permit

3.2.

Obtain work permit if necessary

3.3.

Prepare and park the crane at suitable location

3.4.

Disassembly / Assembly the Motor & Bearings

A.

FEED WATER PUMP MOTOR WITH ROLLING BEARING

1)
-

Motor disassemly
Switch off the circuit breaker & Disconnect the motor from the mains supply,
auxiliary equipments and grounding connections

Remove mounting bolts & dowel pins between motor frame and mounting base or
from coupled machine.

Remove the half - coupling in order to release the motor & Drive

Lifting the motor by suitble slings and bring it to the large space to allow to
operation the machine

Remove the half coupling following instructions given in paragraph and remove
the key

Remove the screen and air baffle

Unscrew external fan securing screw and draw out external fan

Disconnect fan casing support brackets, unscrew securing screws and remove fan
casing complete

Remove heat exchanger

Unscrew safety screws of labyrith seals and remove the labyrth seals & V-ring seals

Lifting the rotor of Motor on the proper supports by suitble slings

PVP-Service

PVP-SERVICE

METHOD STATEMENT
ISO ITEM:

ISSUE TIME:

DATE OF VALIDITY:

1;...-...-2009
-

DOCURMENT CODE:

QT-SCL
PAGE No:

--2009

6/ 13

Remove the bolts securing shields to frame and the passing through screws
securing inner caps

Remove out end shields from the frame by facing them with levers agains the
raised lugs

Insert a strip of metal sheet in the air gap between the stator and the rotor to protect
surfaces against rubbings during removal

Carefully make the rotor resting on the stator and remove the lifting slings and two
shields

Disassembly two air baffles from the stator, unscrewing their fixing screws and
draw out two interminal fans & their safety screws

Fit an extension steel pipe over the drive end of the rotor shaft after protecting it
properly by means of cloth or paper.

Sling the rotor respectively at the steel pipe end, in the proper seat and opposite
side. Chek that the angle of spread of the slings be not greater then 600

Rise slightly the rotorand slowly slide it out of the stator until the internal fan on
the extension side has completely gone outside the frame

Lay down the rotor core, along its entire lenght on a wooden saddle, suitable avoid
the rotor movements

Remove slings from the steel pipe and locate it close to the drive end internal fan,
avoiding that the sling rests against it.

Lay down again the rotor on the saddle and remove the extension pipe from the
shaft end

Remove the bearings from the shaft proceede as bellow:

Unscrew lockrings securing the bearings to the shaft and remove the lock
whashers and grease retaining disk
Push caps and inwards & draw out bearings

PVP-Service

PVP-SERVICE

METHOD STATEMENT
ISO ITEM:

ISSUE TIME:

DATE OF VALIDITY:

1;...-...-2009
-

DOCURMENT CODE:

QT-SCL
PAGE No:

--2009

7/ 13

If the stator core pack or windings need major repairs, the stator should be removed
from the frame. This should be made by drilling out pins and heating frame in order

2)
-

Motor reassembly
Reassemble the motor we carry out the previously detailed operations in the
reverse sequence

3)

Rolling Bearing disassembly

Bearing s are vitally importance to the proper operation of any electrical machine

Care must be taken to avoid damaging the ball races and journal and bearing
surfaces must be protected while bearings are being moved. After removing the end
sheilds, slide of the bearing with an extractor to motor disassembly

After disassembly , both the bearings are surfaces of the shaft should be protected
against shocks and oxidation

4)
-

Rolling Bearing assembly

Before assembly a bearing, clean it thoroughly with solvent and also check that all
adjacent parts are clean and free from burrs

If grinding is necessary, ensure that not metal dust or particales reach the bearings
or left on the adjacent parts

Apply a thin film of grease to the surface of journals and adjacent parts to protect
them from corrosion. Heat the bearing in an oil bath at 700 - 800 slide it on the
journal and ensure that it is pressed firmly against the shoulders of the shaft until it
cools down to ambient temperature

B.

1)
-

MOTOR WITH SLEEVE BEARING

Motor disassembly
Switch off the circuit breaker & Disconnect the motor from the mains supply,
auxiliary equipments and grounding connections

Shut the forced oil lubrication circuit & drain oil from bearing housings by
unscrewing drain plugs

PVP-Service

PVP-SERVICE

METHOD STATEMENT
ISO ITEM:

ISSUE TIME:

DATE OF VALIDITY:

1;...-...-2009

DOCURMENT CODE:

QT-SCL
PAGE No:

--2009

8/ 13

Remove the thermal couples from the bearing housing , remove the oil level

Remove mounting bolts and dowel pins between motor frame and the mounting
base

Remove the haft couplings in order to release the motor from driven machine

Lifting the motor by suitble slings and bring it to the large space to allow operation
the machine

Remove the half coupling following instructions given in paragraph and remove
the key

Remove the Grille from the casing and this operation includes the air baffle

Remove the fan casing by removing the connecting screw from the heat exchanger
and lower the bracket

Remove heat exchanger

Remove the clamping plate, external fan from the hub and extract the fan hub

Unscrew the securing screw of DE & NDE external protections from the rotor
shaft

Remove te upper havles of supports and top havles of bearings

Support properly the rotor by mean of crane and two slings placed araund the shaft
on both sides

Slightly under tension the slings without forcing, rotate gently up and remove the
two bottom half bearings . Remove oil ring on the shaft

Remove bearing supports

Lay down the rotor core on the stator core

Remove end sheilds and having first removed their screw and using two opposite
threaded holes suitable level against the frame

Remove the air baffle at the on- drive end side

PVP-Service

PVP-SERVICE

METHOD STATEMENT
ISO ITEM:

ISSUE TIME:

DATE OF VALIDITY:

1;...-...-2009
-

--2009

DOCURMENT CODE:

QT-SCL
PAGE No:

9/ 13

Insert an extension steel pipe onto the main shaft end, after protecting it properly by
mean of cloth or paper

Sling the rotor respectively at the steel pipe end, in the properseat and at the
opposite side. Check that the angle of spread of the slings be not greater than 600

Rise slightly the rotorand slowly slide it out of the stator until the internal fan on
the extension side has completely gone outside the frame

Lay down the rotor core, along its entire lenght on a wooden saddle, suitable avoid
the rotor movements

Remove slings from the steel pipe and locate it close to the drive end internal fan,
avoiding that the sling rests against it.

Lay down again the rotor on the saddle and remove the extension pipe from the
shaft end

If the stator core pack or windings need major repairs, the stator should be removed
from the frame. This should be made by drilling out pins and heating frame in order

2)
-

Motor reassembly
Reassemble the motor we carry out the previously detailed operations in the
reverse sequence

3)
-

Sleeve Bearing disassembly

Sleeve bearings are realized in two halves. Their removal does not require the
shields removal

Care must however be taken to avoid damaging the bearings: all the exposed
journal and bearing surfaces must be protected against shocks and oxidation wkile
bearings are being removal

4)
-

Sleeve Bearing assembly

Before assembly a bearing, clean it thoroughly with solvent and also check that all
adjacent parts are clean and free from burrs

PVP-Service

PVP-SERVICE

METHOD STATEMENT
ISO ITEM:

ISSUE TIME:

DATE OF VALIDITY:

1;...-...-2009
-

DOCURMENT CODE:

QT-SCL
PAGE No:

--2009

10/ 13

If grinding is necessary, ensure that not metal dust or particales reach the bearings
or left on the adjacent parts

Apply an oil film to the surface of journals and adjacent parts to protect them from
the corrosion before assembling

3.5.

Place the motor on location

3.6.

Check alignment

3.7.

Final inspection

After finish the work, to carry out final inspection for all the parts of equipments
are right position and according maintain procedure

Inspect all the areas & equipments are clean and make sure that all the hand tools,
equipments,.....are removed

Inspect all the equipments are good condition and on schedule

3.8.

Commissioning the system

3.9.

To carry out house keeping after completed the job.

4.

Personnel

PV Power Service Company have to carry out this job under supervised by
PM 3 Power Plant supervision

5.

Risk assessment

ACTIVITY DESCRIPTION

ASSESSMENT TEAM

Overhaul the MV Motor for Feed Water

Date: 01/04/2009

Pumps & Condensate Extraction Pumps

No

STEP DESCRIPTION

PVP-Service

EQUIPMENT

REFERENCE No

PROCEDURE

10

PEOPLE

DOCUMENTS

SUPERVISOR

DOCURMENT CODE:

METHOD STATEMENT

PVP-SERVICE

ISO ITEM:

ISSUE TIME:

QT-SCL

DATE OF VALIDITY:

1;...-...-2009

PAGE No:

--2009

11/ 13

/TOOLS

01

Disconnect/Connect the

Handtools

power cables

M/Statement

02

M/Statement

05

M/Statement

05

M/Statement

04

M/Statement

02

M/Statement

02

M/Statement

02

M/Statement

04

Handtools,
02

Remove/Install the Motor

lifting
equipment,
crane
Handtools,

03

Disassembly/Assembly
the Motor

lifting
equipment,
crane

04

Replacing/Fixing any

Handtools

damaged motors parts

Handtools,
05

Cleaning the Stator &

lifting

rotor

equipment,
crane

Cleaning & paiting for all

06

mechanical parts &

Handtools,
lifting
equipment,

Motor parts

crane

Varnish clear on stator

core & outside, anti
corrosion treatment the
07

motor frame red

Handtools

varnish spray, Regreasing the bearings /

replace lubrication oil

08

Handtools

Perform static

& other

check/Rotation test

equipments
Handtools

09

Coupling alignment

& other

03

equipments

No

ACTION TAKEN

PVP-Service

HAZARD

RF

ADDITIONAL CONTROLS TO

11

RF

APPROVED

PVP-SERVICE

METHOD STATEMENT
ISO ITEM:

ISSUE TIME:

DATE OF VALIDITY:

1;...-...-2009

01

Connect the

Slip, fall,
drop,
shock

Remove/Install

Slip, fall,

the Motor

drop

Disassembly/As
03

sembly the
Motor

12/ 13

BE USED

power cables

02

QT-SCL
PAGE No:

--2009

IN STEP

Disconnect/

DOCURMENT CODE:

Slip, fall,
drop

To obtain work permit

- To ensure electrical
equipment in condition and
secured
- If necessary, hot work to
be carried out, proper hot
work procedure to be
followed
- Proper hot work safety
gears to be worn, dust
mask, ear plugs, gloves,
goggles. Fire blanket and
extinguisher must be placed
- To ensure the crane is in
good condition
- To ensure load to be lifted
does not exceed lifting
capacities of the lifting
devices
- If necessary, hot work to
be carried out, proper hot
work procedure to be
followed
- Proper hot work safety
gears to be worn, dust
mask, ear plugs, gloves,
face shield, goggles. Fire
blanket and extinguisher
must be placed at site

Replacing/
04

Fixing any

Slip, fall,

damaged

drop

motors parts

05

Cleaning the
Stator & rotor

Slip, fall

Cleaning &
06

paiting for all

Slip, fall,

mechanical parts

paited

- To ensure be used proper

tools
- To ensure to be used
safety harness, gloves
- To ensure electrical
equipment in condition and
secured
- Lifting equipments with
certified safe

& Motor parts

07

Varnish clear on

Slip, fall,

stator core &

drop

outside, anti
corrosion
treatment the
motor frame

PVP-Service

- To ensure be used proper

tools
- To ensure to be used
safety harness, gloves
- To ensure electrical
equipment in condition and
secured
- Lifting equipments with
certified safe

12

PVP-SERVICE

METHOD STATEMENT
ISO ITEM:

ISSUE TIME:

DATE OF VALIDITY:

1;...-...-2009

DOCURMENT CODE:

QT-SCL
PAGE No:

--2009

13/ 13

red varnish
spray, Regreasing the
bearings /
replace
lubrication oil
Perform static
08

check/Rotation
test

09

Slip, fall,
drop

Coupling

Slip, fall,

alignment

drop

PVP-Service

G
- To ensure be used proper
tools
- To ensure to be used
safety harness, gloves
- To ensure electrical
equipment in condition and
secured
- Lifting equipments with
certified safe

13