SMP For Sealing Water Pump Multi Stage.

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KSK Mahanadi Power Company Ltd.
6 X 600 MW Power Plant KMPCL/MAINT/SEWPMS/01

SMP FOR SEALING WATER PUMP
Issue No: 1 Issue Date: Revision: 1 Revision Date: 29.07.13 File no: Page 1 of 13
STANDARD MAINTANENCE PROCEDURE
FOR
SEALING WATER PUMP

(MULTI STAGE)
Prepared by: Reviewed by: Approved by:

Signature: Signature: Signature:
Name: Name: Name:
Designation: Designation: Designation:

OBJECTIVE
The purpose of this work instruction is to explain the procedure for carrying
out Overhaul of SEALING WATER PUMP.
1. SEALING WATER PUMP
The details of the SEALING WATER PUMP are as follows :
Make: BOSHAN; TYPE-IS50-200C, Q=15m3/h, H=0.34MPa MOTOR TYPE Y112M-2 , 4KW ,

415V, RPM-2000 / TYPE-DC6-25X6, Q=8m3/h, H=1.25MPa MOTOR TYPE Y160M1-2,
11kW, 415V, RPM-2950 / TYPE-IS0-65-160B, Q=35m3/h, H=0.25MPa, MOTOR TYPE
Y200L-4, 5.5kW, 415V, RPM-2900 / TYPE-DC12-50X3,H-1.55MPA., Q-12.5M³/H, RPM-2930.
MOTOR-18.5 KW, SHAFT POWER-12.5 KW.
DETAILED INSTRUCTION
Sr. Activity Responsibility
No
.
I Overhaul to be done as per Checklist

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1 Before commencing dismantling operations, ensure that the

following tools and tackles are available:
 A crane / chain pulley block suitable for handling the weight of

pumping unit.
 A selection of ring and open-ended spanners in Metric sizes.
 Eyebolts in Metric sizes.
 Hardwood and metal packing blocks.
 Miscellaneous tools including a set of Allen keys, drills, pin drivers,
files etc.
 Extractor / puller for bearing and coupling.
.
After a long service, wear will occur in parts of the pump necessitating
the renewal of the parts. Those most likely to be affected are impeller,
Wear Rings, Bearings, and Sleeves.

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2 Dismantling
1. Before dismantling, make sure the motor is disconnected.

2. The suction and discharge shutoff valves must be closed.
3. The pump casing must have cooled down to ambient
temperature.
4. The pump casing must be empty and not under pressure.
5. Detach all auxiliary supply pipe lines.
6. Remove coupling guard.
7. Remove coupling half from the pump shaft.
8. Pull out bearing bracket with discharge cover and complete rotor
(assembled unit).
9. If the pump has been in operation for a long time some parts
may be difficult to remove.
In this case use a penetrating oil or suitable pull-off device.
10.Loosen & remove impeller Lock nut.
11. Remove impeller from pump shaft. Refer fig. no. 1
Fig. no. 1: Removal of

Impeller

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Construction Drawing For SEALING WATER PUMP

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Fig. No. 3 : Dismantling the Bearing Unit
Dismantling the Bearing Unit
1. Remove bearing covers and gaskets by unscrewing of hex. Bolt.

Refer fig. no. 3
2. Fasten the bearing unit firmly to the bench vice refer fig. no. 4 Strike
the pump shaft end with a soft hammer. Refer fig. no. 4
3. Fasten the shaft (with bearings) to the bench vice and detach
bearings from shaft with a bearing puller. Refer fig. no. 5
Fig. no. 4 : Dismantling the pump shaft from bearing bracket
Fig. no. 5: Dismantling the bearings from the pump shaft.

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Note: Always replace the bearings once they have been removed from
the shaft with new ones.
Unnecessary removal of the bearings should be avoided because
removal of the bearing can damage it and cause deterioration of the
interference fit. Except where removal is necessary to give access to the
other parts, bearing should be removed only if they need close
inspection. Symptoms, which will indicate the state of bearing, are the
condition of the lubricant, the bearing running temperature, noise level
and vibration during operation.

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4 Examination of Internal Components :
Wearing Rings
The wearing rings have to be replaced when the clearances between the
wearing ring & the impeller & the Discharge cover exceeds three times
the max. Value as shown in the below table or when the reduction of
efficiency of the pump is noticed.
Note: - In MEGA GC wearing ring is not provided.
Original Clearance on the Diameter

Pump Size Casing Side Impeller Side
Maximum Minimum Maximum Minimum
80-200 0.445 0.33 0.445 0.33
New wearing ring clearances are:-
MEGA GC - 0.5 mm on diameter

MEGA - 0.3 mm on diameter
Shaft Sleeves
Replace shaft sleeve if it is grooved or generally worn.
Impeller
a. Inspect the impeller as follows:
i. Examine the impeller for damage.

ii. For corrosive /erosion pitting.
iii. Cavitations pitting.
iv. Bent or cracked vanes, inlet and outlet vane end wear.

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Any of the above may be repaired, or if damage is extensive, impeller

may need replacement.
b. Around the eye, wearing rings protects the impeller. Examine

around the eye at neck portion for grooving in alignment with
spindle axis; slight grooving is acceptable but deep or profuse
grooving must be remedied by machining the impeller by taking a
polish cut on wearing ring. Spare wear rings are supplied with
excess outside diameter to facilitate machining after fitting. The
wear rings are shrink fitted on impeller neck and are screwed.
c. To check wear, around the impeller neck, use precision
instruments such as outside micrometer to accurately measure
the outside diameter. Measurements should be taken at intervals
around the circumference to check the uneven wear. Differences
between the neck OD and the neck ring ID measured will give us
the clearance between the two. Clearance thus obtained should
not be more than 150% of maximum designed clearance.
Shaft & keys
Shaft should be checked for the trueness, or any other mechanical

damage and corrosion. If the shaft is not true within 0.1 mm TIR,
it should be replaced / repaired. Examine the shaft keys and key
ways. Remove damaged or worn out keys
Bearings
a. Clean all the components using clean white spirit. Do not use
chlorinated solvents such as trichloroethylene and carbon
tetrachloride because they introduce a corrosion risk when used
on ferrous materials.
b. Visually inspect the bearing. The balls, the inner and outer tracks
must all be free from chipping cracks, abrasions or discoloration.

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c.
1. Check that
Vacuum theblow
and parts of all
out thecavities
cage are firmly fixed
of bearing together.
housing.
d. Visually inspect the bore for any sign of damage. Burrs or any
scratches caused during bearing withdrawal should be carefully
removed by hand application of a fine oilstone, the treatment
being confined to the minimum possible area.
e. Visually inspect Bearing Housing

the outside diameter for signs of fretting, any
stains may be carefully polished off, but abrasion must be kept to
2. the
Setabsolute
bearing housing
minimum vertical
that ison flange. followed by cleaning.
required,
3. Press in shaft assembly as shown.
4. Fastenthat
f. Check outer bearingrotates
bearing cover assembly.
freely and smoothly. If there is any
5. doubt
Secureregarding
inner bearing cover assembly.
the serviceability of the bearing it should be
replaced.
g. If after inspection, the bearing is reusable, completely coat all

parts with rust preventive oil, working it well into the internal
parts of the bearing. Wrap in clean greaseproof paper and store
until required for replacement or refit on to the spindle if needed.
In case of immediate use, coating of rust preventive oil is not
6. necessary.
Fit deflectors at pump side
7. Fit coupling key.
8. Add
Stuffing PVC
box tape to secure.
bush
9. Place back cover on bench.
10.Check
Insertbore of stuffing
the packing box bush
/ logging ringand
setcompare
into this with sleeve
stuffing box.
diameter. If "clearance is excessive, the bush should be renewed.
a. Before repacking, thoroughly clean stuffing box gland, packing
Note: While assembling
compartment andstainless steel component,
shaft protection sleeve. molybdenum-
disulphide
b. Cut paste should be
the packing ringapplied to prevent
to correct lengthgalling / seizure
and ends andEnsure
at 45º. also
to facilitate easy removal in future.
that the packing rings ends come into contact with one another
on fitment.

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5 Reassembly
11. Coat the fits and screw connections with molykote or

similar before reassembly.
12. Check oil seal & o-rings for its damage; replace if
necessary.
13. All gaskets must be renewed; make sure the new ones
have the same thickness as the old ones.
14. Check the shaft with its spacer sleeve / or shaft protection
sleeve (as applicable) for eccentricity, between centers.
Maximum allowable eccentricity is 0.05mm.
15. Fasten the shaft to the bench vice using soft polish sheets
between the vice clamp jaws to avoid damage. Refer fig. no. A.
16. Heat the bearings in the induction heater about 80-90Deg.C
max. and push it on to the shaft. Fig. no. A Allow the bearings to
cool down. Then tap it lightly against the shoulder using suitable
pipe punch.
17. Fit shaft circlip
Shaft assembly Inner Bearing Cover assembly

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18. Place back cover on bench.
19.Fasten back cover assembly to bearing housing assembly.
20.Rotate shaft & check for rubbing.
21.Fit impeller key tightly and apply.“Locktite” anti seize compound

to shaft.
22.Tap impeller lightly into place.
23.Tighten impeller nut, holding the shaft steady at coupling end.
24.Check operating gap 0.5-1.5 mm.
25. Lightly grease” O” ring & fit.
REVIEW DATE:-
SMP WILL BE REVIEWED IN EVERY SIX MONTH FROM THE DATE OF ISSUE BASED ON
ACTUAL PROBLEM FACED AND SHALL BE UPDATED ACCORDINGLY.
MECHANICAL MAINTANENCE TEAM WILL VISIT THE EQUIPMENT TWICE IN A WEEK & IF
ANY ABNORMALITY NAMELY (VIBRATION, ABNORMAL SOUND, TEMPERATURE RISE,
BELT TIGHTNESS ETC) OF EQUIPMENT IS OBSERVED AND THEN THE SAME WILL BE
RECTIFIED WITHIN PRESCRIBED TIME PERIOD.
DO’s & DONT’s :

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DO’s :
1. Ensure relevant equipment/system PTW is available before starting the work.
2. Ensure relevant equipment/system is electrically isolated before starting the work, if applicable.
3. Ensure relevant air/water valves are fully closed for the equipment/system before starting the work.
4. Provide Danger Boards before starting the work involving dismantling of any equipment/system.
5. Ensure proper follow-up of all statutory requirements & hazard norms.
6. Ensure proper follow-up of all plant practices, existing regulations, prescribed procedures & general
safety prior to carry out any work.
7. While replacing any spares/oil, ensure that the same must be as per OEM recommendation.
8. After overhauling of any equipment, ensure proper preservation of spares/oil.
9. Always use the special tools as recommended by OEM for certain equipments like HCSD Pump.
DONT’s :
1. Don’t start the work without presence of Safety Personnel in case fire / other hazards are involved.
2. Don’t use hammer / heating for removing bearings / gears.
3. Don’t use tools & tackles which are not calibrated / certified by relevant authority.
4. Don’t start the work in Pressure Vessels/Pressure Line/Water Line, unless it is completely de-
pressurised.
5. Don’t start the work, especially at height, without proper PPE’s.
6. Don’t start the work, without presence of skilled personnel/expert.

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SMP For Sealing Water Pump Multi Stage.

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Power from knowledge

KSK Mahanadi Power Company Ltd.

6 X 600 MW Power Plant KMPCL/MAINT/SEWPMS/01

STANDARD MAINTANENCE PROCEDURE

SEALING WATER PUMP

Prepared by: Reviewed by: Approved by:

6 X 600 MW Power Plant KMPCL/MAINT/SEWPMS/01

1. SEALING WATER PUMP

The details of the SEALING WATER PUMP are as follows :

Make: BOSHAN; TYPE-IS50-200C, Q=15m3/h, H=0.34MPa MOTOR TYPE Y112M-2 , 4KW ,

Prepared by: Reviewed by: Approved by:

6 X 600 MW Power Plant KMPCL/MAINT/SEWPMS/01

1 Before commencing dismantling operations, ensure that the

 A crane / chain pulley block suitable for handling the weight of

Prepared by: Reviewed by: Approved by:

6 X 600 MW Power Plant KMPCL/MAINT/SEWPMS/01

1. Before dismantling, make sure the motor is disconnected.

Fig. no. 1: Removal of

Prepared by: Reviewed by: Approved by:

6 X 600 MW Power Plant KMPCL/MAINT/SEWPMS/01

Construction Drawing For SEALING WATER PUMP

Prepared by: Reviewed by: Approved by:

6 X 600 MW Power Plant KMPCL/MAINT/SEWPMS/01

Fig. No. 3 : Dismantling the Bearing Unit

Dismantling the Bearing Unit

1. Remove bearing covers and gaskets by unscrewing of hex. Bolt.

Fig. no. 4 : Dismantling the pump shaft from bearing bracket

Fig. no. 5: Dismantling the bearings from the pump shaft.

Prepared by: Reviewed by: Approved by:

6 X 600 MW Power Plant KMPCL/MAINT/SEWPMS/01

Prepared by: Reviewed by: Approved by:

6 X 600 MW Power Plant KMPCL/MAINT/SEWPMS/01

4 Examination of Internal Components :

Note: - In MEGA GC wearing ring is not provided.

Original Clearance on the Diameter

New wearing ring clearances are:-

MEGA GC - 0.5 mm on diameter

Replace shaft sleeve if it is grooved or generally worn.

a. Inspect the impeller as follows:

i. Examine the impeller for damage.

Prepared by: Reviewed by: Approved by:

6 X 600 MW Power Plant KMPCL/MAINT/SEWPMS/01

Any of the above may be repaired, or if damage is extensive, impeller

b. Around the eye, wearing rings protects the impeller. Examine

Shaft & keys

Shaft should be checked for the trueness, or any other mechanical

Prepared by: Reviewed by: Approved by:

6 X 600 MW Power Plant KMPCL/MAINT/SEWPMS/01

e. Visually inspect Bearing Housing

g. If after inspection, the bearing is reusable, completely coat all

Prepared by: Reviewed by: Approved by:

6 X 600 MW Power Plant KMPCL/MAINT/SEWPMS/01

11. Coat the fits and screw connections with molykote or

Shaft assembly Inner Bearing Cover assembly

Prepared by: Reviewed by: Approved by:

6 X 600 MW Power Plant KMPCL/MAINT/SEWPMS/01

18. Place back cover on bench.

19.Fasten back cover assembly to bearing housing assembly.

20.Rotate shaft & check for rubbing.

21.Fit impeller key tightly and apply.“Locktite” anti seize compound

22.Tap impeller lightly into place.

23.Tighten impeller nut, holding the shaft steady at coupling end.

24.Check operating gap 0.5-1.5 mm.