INDIAN PETROCHEMICALS CORPORATION LTD.

BARODA COMPLEX
PLANT: PVC NO: PVC/SMP/M-04 ISSUE NO: 01
STANDARD Page 1 of 3 REV NO: 0
MAINTENANCE DATE OF ISSUE:15/04/06
PRACTICES

1.2 STANDARD OVERHAULING PROCEDURE OF SINGLE STAGE

HORIZONTAL CENTRIFUGAL PUMP
1.2.1 INTRODUCTION

The steps for overhauling Single Stage Horizontal Centrifugal Pump is described
in this procedure. This procedure describes the methods for attending seal
leakage and bearing/shaft replacement. The List of Pumps for which this
procedure is applicable is given in the Annexure-1

1.2.2 SAFETY REQUIREMENTS

Personal Protective Equipment mentioned in the Permit To Work should be used.

1.2.3 PROCEDURE

1. Collect Permit To Work for attending the pump from Superintendent.

2. Contact the area operator to ensure that the preparation is complete, before
starting any work on the pump.

3. Check whether the motor is de-energised or not by switching on the motor in

presence of the operator. Locally lock the switch after checking.

4. Check the discharge pressure guage. It should be reading zero. Also check
whether the casing drain or suction spool drain is open and anything is coming
out from it. If the pressure guage is not showing zero or if something is coming
out from the drain, contact area operator, otherwise proceed with maintenance
work.

5. Remove the coupling guard and decouple the pump.

6. If the pump is with Plan 53 isolate and depressurise the seal pot and remove the
seal inlet and outlet lines. Drain oil from the seal pot if it is to be replaced. If the
seal flush plan is not Plan 53 Isolate the seal lines and remove the inlet line and
the outlet line if available in that plan.

7. Drain the bearing oil and remove the constant level.

8. Attach slings to the pump rotor and take up the slack by means of a jib crane.

9. Open the casing bolts and remove the rotor from the casing. Load it on a trolley.
Measure the casing wear ring I.D. Shift the rotor to the Work Shop.

EVOLVED BY REVIEWED BY REVIEWED BY AUTHORISED BY

(PLANT) (ESD)
SIGNATURE
NAME PIYUSH PANDEY R.D .SOLANKI R.R.JOSHI A.B.DAVE
 INDIAN PETROCHEMICALS CORPORATION LTD.
BARODA COMPLEX
PLANT: PVC NO: PVC/SMP/M-04 ISSUE NO: 01
STANDARD Page 2 of 3 REV NO: 0
MAINTENANCE DATE OF ISSUE:15/04/06
PRACTICES

10. Remove the impeller and find out the front and back wear ring (if back wear ring
is available in the pump) O.D. Measure the back-plate wear ring I.D (if back
wear ring is present). Calculate the front and back wear ring clearances from
these values. These clearances should be within the recommended limits given in
the Overhauling Check List relavent to that pump. For Overhauling Checklist No
Refer to Annexure-1. If wear ring clearance is not with in limits prescribed in
Overhauling Checklist replace the defective pair.

11. Remove the back-plate-mechanical seal assembly from the bearing block.

12. If the mechanical seal had failed, dismantle it and inspect the faces, O-rings,
compression unit and the sleeve for any abnormality. Carry out corrective
actions as per the instructions of the Superintendent to prevent seal failure in
future.

13. Check the axial play and radial play of the shaft by mounting a dial indicator on
the shaft. The acceptable limits for the axial play and radial play are given in the
Overhauling Check List as per Annexure-1. If any of the radial or axial plays is
not within these limits, replace the bearings.

14. Also find out the runout of the shaft in the mechanical seal area with and without
the seal sleeve mounted on the shaft by means of a dial indicator. Refer the
Overhauling Check List as per Annexure-1 for the acceptable limits. If the actual
runout values are not within these limits, dismantle the shaft.

15. While assembling replace the O-rings with new ones. Replace the faces with new
or lapped ones. Repair or replace other defective parts and check seal setting.
Re-assemble and set the seal as per seal assembly drawing.

16. If the seal is Back to back duble seal or seal plan is Plan-53 or Plan-54 pressure
test the seal with oil ( Servo System 32) at seal test pressure mentioned in the
Overhauling Check List as per Annexure-1. Hold the pressure for about 15
minutes to ascertain that there is no leakage.

17. For dismantling the shaft or bearings, remove the coupling hub, bearing cooling
fan or cooling jacket cover if provided, deflectors and bearing covers and pull
out the shaft from the bearing housing.

18. Remove the ball bearings from the shaft by means of a bearing puller and the
roller bearing inner race by heating. Remove the roller bearing from bearing
housing simply by pulling it with hand. Remove the oil ring.

19. Check the shaft runout by mounting it on V-blocks. It should be within the limits
given in the Overhauling Check List as per Annexure-1. Get new shaft and/or

EVOLVED BY REVIEWED BY REVIEWED BY AUTHORISED BY

(PLANT) (ESD)
SIGNATURE
NAME PIYUSH PANDEY R.D .SOLANKI R.R.JOSHI A.B.DAVE
 INDIAN PETROCHEMICALS CORPORATION LTD.
BARODA COMPLEX
PLANT: PVC NO: PVC/SMP/M-04 ISSUE NO: 01
STANDARD Page 3 of 3 REV NO: 0
MAINTENANCE DATE OF ISSUE:15/04/06
PRACTICES

bearings as required. If new shaft is to be installed, check its runout on V-block,

which should again be equal to Overhauling Check List as per Annexure-1.

20. Insert the oil ring on the shaft and assemble the bearings by heating them in oil
bath and installing them on the shaft or by pressing them onto the shaft directly.

21. Repair or replace any defective part and assemble the components of the bearing
block following the dismantling procedure in reverse order. Refer to the pump
assembly drawing.

22. Once again check the shaft runout, radial play and axial play. Record the values
in Overhauling checklist.

23. Install the back-plate-mechanical seal assembly on the bearing block and mount
the impeller on the shaft and tighten the impeller locknut wiht new gasket.

24. Carry the rotor to the site and install it into the casing with new casing gasket.

25. Install constant level oiler and fill oil (Servo system 46) in the bearing block.

26. In the pumps with Plan-53 if the seal pot oil been drained, purge the seal pot
with nitrogen and flush it with new oil. Then charge new oil (Servo System 32)
in the seal pot upto about 75% level

27. Connect the seal inlet and outlet lines and charge the seal by opening the seal
inlet valve. Next, open seal outlet valve if present in that particular plan. In case
of Plan-53 pressurise the seal pot with nitrogen to the pressure mentioned in the
Overhauling Check List as per Annexure-1 and check the seal leakage if any.

28. Align the motor to the pump. The permitted misalignment values are given in
the Overhauling Check List as per Annexure-1.

29. Couple the motor to the pump and install the coupling guard.

30. Clean the area and hand over the permit, duly signed by the area operator to the
Superintendent.

EVOLVED BY REVIEWED BY REVIEWED BY AUTHORISED BY

(PLANT) (ESD)
SIGNATURE
NAME PIYUSH PANDEY R.D .SOLANKI R.R.JOSHI A.B.DAVE