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Scope:

This section deals with standard overhauling and inspection procedures used for
centrifugal, single stage, single suction, centrelins supported pump [back pull – out type]
of Kirloskar Ebara make.

This list of pump covered through these procedures are as follows:

43-P-001A/B/C, 43-P-002A/B/C, 42-P-001A/B

Introduction:

Before proceeding towards disassembly, ensure all safety precautions and follows all
instruction as mentioned in the ‘permit to work’.

Disassembly procedure :

1. R em ove all t he auxi li ary l i nes aft er t he pum p has been drai ned and com pl et el y isol at ed.
2. R em ove coupli ng spacer.
3. R em ove nut and bol t s hol di ng casi ng [001] and Gl and Cover [018- 2].
4. R em ove B eari ng Housi ng [051], Gl and C over[018- 1, 018- 2] and rot at i ng com ponent s from t he
casi ng. Use j ackscr ew on t he Gl and C over and the Eye- bol t [122]on t he B eari ng Housi ng[051] t o
faci l i t at e di sassem bl y.
N OT E
 The procedure det ai l ed bel l ow i s for St andard pum p i .e. wi t hout Inducer, wi t h st andard
beari ng arrang em ent i .e. B ack to B ack posit i on of angul ar cont act beari ngs and wi t h
F li nger t ype l ubri cat i on.
5. R em ove the set screw securi ng t he Im pel l er Nut [048- 1] and t he Im pel l er [021].
6. Hol d t he S haft [031] and turn the Im pel l er Nut [048-1] in t he sam e di rect i on as pum p rot at i on to
rem ove i t .
7. R em ove the Im pel l er [021] from the Shaft [031].
8. R em ove Nuts and bolt s hol di ng Gl and C over [018-1], S eal End Pl at e [016-1], B eari ng Housi ng
[051], and sl i de t owards t he beari ng si de by about 5m .m . Then, care ful l y pul l Gl and Cover [018-
1] from t he shaft .
9. R em ove Mechani cal S eal [111] t oget her wit h S haft S l eeve [042] from t he S haft . Then, R em opve
t he Mechani c al S eal from the Sl eeve.
10. C areful l y rem ove t he S eal End P l at e[016- 1] from the Shaft [031].

CAUTION
 Som et i m es t he Mechani c al S eal Insert / Mat i ng R i ng fi tt ed in S eal End Pl at e is C arbon
whi ch i s fragi l e and hence be careful not hi t it agai nst ot her com ponent ]

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11. R em ove coupli ng from shaft [031] wi t h a coupl i ng pul l er.

12. R em ove B eari ng C overs [053- 1, 053-2].
13. R em ove Shaft [031] t oget her wi t h B all B eari ngs [056-1, 056- 2] from the beari ng housi ng
t owards t he dri ver si de.
14. R em ove B eari ng Nut [129] on t he dri ver si de from t he S haft [031] by t urni ng i n t he sam e di rect i on as
norm al rot at i on of pum p.
15. R m ove B al l B eari ng [056- 1, 056-2 from the Shaft .

[ CAUTION :
 Do not rem ove beari ngs i f t hey are not due to repl ac em ent ]
[ NOTE:
 The procedure det ai l ed bel ow is for St andard pum p i .e. wi t hout Inducer, wi t h a st andard
beari ng arrang em ent i .e. B ack to B ack posit i on of angul ar cont act beari ng and wi t h Oi l Ri ng
t ype l ubri cat i on. ]
16. P rocedure sam e as under #5 t o #11.
17. R em ove B eari ng C over [053-1, 053- 2], and Housi ng C over [053-4].
18. Li ft Oi l Ri ngs[067] from t he Oil R i ng R et ai ner [271] and hang t hem up on t he S haft [031].
19. P ull out S haft [031] t owards dri ver si de by such a di st ance t hat t he Thrust B eari ng [056-1] com es out
of B eari ng Housi ng [051].
20. Move Oil R i ngs [067] t o t he posi ti on at whi ch t he B al l B eari ngs [056- 1] were inst al l ed.
21. R em ove Shaft [031] t oget her wi t h B all B eari ngs [056-1, 056- 2] and Oil R i ngs [067] from beari ng
housi ng by pull i ng t owards dri ver si de.
22. R em ove B eari ng Nut [129] on t he dri ver si de from t he S haft [031] by t urni ng i n t he sam e di rect i on as
norm al rot at i on.
23. R em ove B al l B eari ngs [056-1, 056- 2] from t he Shaft .

[ NOTE:
 The procedure det ai l ed bel ow is for pum ps wit h i nducer, wi t h a st andard beari ng arrang em ent
i .e. B ack t o B ack posi ti on of angul ar cont act and wi t h Fl i nger t ype Lubri cat i on ]
24. R em ove set screw securi ng Inducer Nut [048- 2] and Inducer [024].
25. Hol d t he S haft [031] and turn the Inducer Nut [048- 2] i n t he sam e di rect i on as pum p rot at i on t o
rem ove i t .
26. R em ove the Inducer [024] from t he S haft [031].
27. R em ove set screw securi ng Im pel l er Nut [048-1] and S haft [031].
28. Hol d t he S haft [031] and turn Im pel l er Nut [048- 1] i n t he sam e di rect i on as pum p rot at i on t o rem ove
it.
29. P rocedure sam e as under #7 t o #15.
[ NOTE:

The procedure det ai l ed bel ow is for pum p Inducer, wi t h a st andard beari ng arrang em ent i .e.
B ack t o B ack posit i on of angul ar cont act beari ng and wit h Oi l R ing Type l ubri cat i on. ]
30. P rocedure sam e as under #24 t o #28.
31. P rocedure sam e as under #17 t o #23.
[ NOTE:
 The procedure det ai l ed bel ow is for pum ps havi ng speci al rei nfor ced beari ng arrang em ent wi t h

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Tandem C om bi nat i on of Thrust B eari ng. ]

32. P rocedure sam e as under #3 t o #15 or #17 t o #29 consi deri ng t he pum p or wi t hout the Inducer.
[ CAUTION:
 R em ove di st ance pi ece [045- 5] al ong wi t h B eari ng Cover [053- 2] and preserve i t careful l y t o
reuse i t agai n.
 C heck t he resi l i ence of t he spri ng by pressi ng S pri ng Hol der [045- 6]. Do not t ake out gui de
B olt s [120- 15] provi ded i n B eari ng C over [053-1] , unl ess Spri ngs [102] need repl acem ent ]

Replacement of Wear Parts.

A. Rep l acemen t of Imp el l er Wear Ri n g .

1. To rem ove Im pel l er Wear Ri ngs [025- 1, 025-2] fi rst rem ove set screws. Ri ng can be m achi ned
off or gri nd t wo sl ot s di am et ri cal l y opposi t e across t he wi dt h of t he ri ng so i t can be spl it apart .
Do not dam age t he i m pel l er hubs
2. Make sure that the ri ng whi ch are t o fi t on t he i m pel l er are free of nocks and burrs. Heat the
new ri ngs t o = 107 0 C and i nst al l on im pel l er. Dri l l , t ap and i nst al l new set screws on the Wear
R i ngs. New im pel l er Wear R i ngs m ay be requi red t o be m achi ned t o est abl i sh t he runni ng
cl ear ances as per t he checkl i st .

[ CAUT IO N: t he head of the set screw shoul d al ways be bel ow t he face of the Wear R i ng by about
1 m .m . and ensure l ocki ng i n posit i on by pri cki ng punchi ng. ]
B. Rep l acemen t of Casin g Wi re Rin g.

1. Remove lock screw from C asi ng and C asi ng Wear R i ngs and press out t he Wear R i ngs. If
need be spl i t apart the Wear R i ngs to rem ove.
2. New ri ng t o be i nst al l ed shoul d be shrunk by freezi ng when i nst al l i ng i n casi ng or casi ng cover.
When i nst all i ng new ri ngs, m ake sure t he count er bore i n the ri ng li nes up wi t h the count erbore
i n t he casi ng or casi ng cover. R epl acem ent Wear R i ngs si ze are general l y st andard and m ay not
requi re m achi ni ng.

[ CAUT IO N: The head of t he set screw shoul d al ways be bel ow t he face of t he Wear Ri ng by about
0.3m m t o 0.8m m and ensure locki ng i n posi ti on by pri ck punchi ng. ]

C. Rep l acemen t of Th roat Bu sh

1. R em ove the set screw and ease out t he Throat B ush [082] car eful l y .
2. To i nst al l , the reverse of t he above procedure i s adopt ed. Ensure Throat Bush cl earan ces as per
checkl i st .

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{ Speci al poi nt s to be consi dered whi l e repl aci ng wear part s:

 Som et i m es set screws are di ffi cul t to t ake out due t o corrosi on / erosi on of t he screw head. In
such a case, it i s advi ce t o m achi ne out t he wear part on t he l at he.
 Aft er repl acem ent of wear part s, ensure t hat new posi t i ons for fi t ti ng of set screws are ot her
t han ol d one. }

Inspection:

1. Check for wear and gal li ng by m easuri ng cl earan ce bet ween C asi ng Wear R i ng and Im pel l er Wear
Ri ng. R efer Overhaul i ng C heckl i st for the speci fi ed cl earanc es.
2. If cl ear anc e at Wear Ri ng i s m ore t han speci fi ed, check for bent Shaft .
3. R epl ace B all B eari ng i f t hey are worn or dam aged.
4. Check Im pel l er and Inducer for corrosi on, wear and cracks.
5. If dam age or wear i s found on shaft sl eeve, m echani cal seal , packi ng, t hroat bush-repl ac e t hem . If
scori ng m akes are observed on seal ri ng or i nsert / m ati ng fac es – rel ap t hem .
6. Check S haft for run- out as speci fi ed i n Overhaul i ng C heckl i st .
7. P roceed as per t he Overhaul i ng C heckl i st ensuri ng t hat al l requi rem ent are ful fi l l ed.

Assembly Procedure:

1. P um p assem bl y – Assem bl y i n reverse order of disassem bl y payi ng speci al at t ent i on t o t he

fol l owi ng :
 Heat ant i -fri ct i on beari ng to = 80 t o 1000C i n an oi l bat h or by i nduct i on heat er pri or t o
m ount i ng on shaft .
 Mount t he beari ng at dri vi ng end i n B ack to B ack posit i on unl ess ot herwi se speci fi ed t o be
m ount ed i n Tandem arrangem ent .
 Lock washer [136] shal l be properl y l ocked t o B eari ng Nut [129] once t he B eari ng Nut i s
ful l y t i ght ened.
 Thi ckness of B eari ng Gasket [117- 3, 117- - 4] shal l be 0.2 m m unl ess ot herwi se speci fi ed.
 Defl ect ors [093] shal l be fi xed t o t he shaft [031] wi t h set screw and pri ck punch t he set
screw to avoi d looseni ng duri ng operat i on.
 C heck shaft run – out aft er the shaft i s i nst al l ed in t he beari ng housi ng.
 S et screw for t he Im pel l er Nut [048- 1] and t he Inducer Nut [048- 2] shoul d be l ocat ed on
t he hub of t he Im pel l er [021] or Inducer [024] consi deri ng t he full t i ght ened posi t i on of
t he Im pel l er Nut or Inducer Nut .
[ NOTE:
S pare Im pel l er Nut [ 048-1] or Inducer Nut [048-2] are suppl i ed wit hout hol e for set
screw. Ti ght en the nut and m ark t he locat i on for set screw wi t h referen ce to t apped hol e for
set screw on Im pel l er Hub or Inducer Hub and dri l l t he hol e by t aki ng out t he nut . ]
 Ti ght en t he Gl and C over [018- 2] evenl y t o the Pum p C asi ng [001]. Alt ernat el y and
gradual l y ti ght en t wo bol t s posit i oned sym m et ri cal l y wit h respect to t he axi s, and t hen
t i ght en t wo bolt s posi t i oned at ri ght angl es t o t he axi s. C ont i nue i n t he sam e fashi on ti l l
t he bol t are al l t i ght ened evenl y.
 The Mechani cal seal shoul d be i nst al l ed as per inst ruct i ons i n #2 gi ven bel ow.

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 Mount t he coupl i ng hal f in col d or warm condit i on as requi red.

 Aft er com pl et i on of assem bl y, m anual l y rot at e t he shaft t o confi rm t hat t here i s no
physi cal bet ween rot at i ng and st at i onary com ponent s.
2. Mechanical Seal [ Standard overhauling procedure ]

 Di sm ant l e t he seal part by part and carry out a t horough i nspect i on t o det erm i ne part s t o be
repl ac ed. {Not e: It i s recom m ended t hat al l el ast om ers be repl ac ed duri ng every seal
overhaul i ng. }
 C l ean the shaft , sl eeve, st uffi ng box at funct i onal areas t horoughl y and rem ove al l dent s,
ni cks, burrs, and scrat ch es. Ensure that shaft , st uffi ng box bores / spi got s are wi t h proper
cham fers for easy dam age- free assem bl y.
 Assem bl y t he seal cart ri dge as per drawi ng wi t h adequat e care and ensure t hat al l
precaut i ons are t aken.
 B ri ng t he cart ri dge assem bl y for i nst al l at i on. Ensure socket set screw cl am pi ng dri ve
col l ar t o shaft , does not proj ect at ID of sl eeve.
 Gent l y sl i de t he cart ri dge on t he shaft and push it t o near beari ng end.
 Assem bl e st uffi ng box t o the beari ng housi ng and cl am p t he sam e.
 S li de back the cart ri dge t il l t he gl and face m at es wi t h t he st uffi ng box face and t i ght en al l
bol t s. Ensure “F l ushi ng”, “Quenchi ng”, “Drai n”, are correct l y ori ent ed as per drawi ng.
 Ti ght en t he socket set screws cl am pi ng t he sl eeve and t he dri ve coll ar t o t he shaft .
 P ush t he sli di ng washers out ward and ti ght en. {Not e: S li di ng washers shoul d not t ouch
rot at i ng part s.}

3. In case of Gland Packing arrangement, the following should be noted: -

 The unm oul ded gl and packi ng are usuall y i n t he form of a rope. Wi nd t hi s rope on a
ground rod [pi pe or wooden rod ] havi ng t he sam e di am et er as t he shaft the shaft sl eeve
di am et er and cut the wound packi ng wit h a sharp kni fe / t ool i n a st rai ght l i ne so t hat cut
ri ngs can be obt ai ned. Use t hese cut ri ngs as t he gl and packi ng whi l e refi l l i ng the st uffi ng
box. R epl ace al l packi ng at one t i m e.
 R em oval of gl and packi ng from t he st uffi ng box shoul d be done careful l y. Use of packi ng
t ool / Cork – S crew T B ar i s recom m ended.
 Appl y l ubri cant to t he gl and packi ng before i nst al l i ng and open cut sect i ons wi t hout
di st ort i on.
 S hi ft each cut sect i on of packi ng by about 90 0 on t he shaft sl eeve.
 Ini t i al l y do not ti ght en gl and packi ng excessi vel y. Adj ust the l eak quant i t y by gradual
gl and t i ght eni ng when the pum p i s put i nt o operat i on. Do not t i ght en gl and when pum p i s
st opped. S li ght dri ppi ng i s advi sabl e t o prevent t he gl and from heat i ng up i n operat i on.
AFT E R CO MPL E T IO N OF AL L MAINT E NANCE JOB S :-

A. Ensure t hat al l checkl i st s are dul y fi l l ed up aft er pum p assem bl y

B. C arry out an al i gnm ent check and box-up coupl i ng spacer.
C. B ox up al l auxi l i ary l i nes and cl ean up area.
D. R et urn, “P erm i t t o Work” t o i ssui ng aut hori t y.

MECHANICAL OVERHAULING CHECKLIST

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PLANT: I O P DATE:
Tag No: Kirlosker Ebara UCWM [ Back-Pull Out Type ] Pumps.

SL Specified Limit
NO Item Description Minimum Maximum Actual
Values Remarks

Shaft run –out at seal area

1 without sleeve [TIR] 0.05mm

Shaft run-out at Impeller area

2 [TIR] 0.05mm

Axial end play of shaft 0.05mm

3
4 Radial play of bearing 0.05mm

5 Wear ring diametrical As per attached Wear Ring

clearance [DE side] Data-sheet

Wear ring diametrical As per attached Wear Ring

6 clearance [NDE side] Data-sheet

7. Throat Bush Diametrical 06~1.00mm

clearance
Permitted miss-alignment on [+ Or -]
8. Rim {Radial}-[TIR] 0.05mm

9. Permitted miss-alignment on [+ Or -]
Face {Axial}-[TIR] 0.05mm
11 DBHE

Inspected by: Certified by:

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MECHANICAL COMPLETION & EQUIPMENT HANDOVER CHECKLIST

Plant: IOP Date:
Tag No:
NOT
OK OK REMARKS

1 Unit assembly

2 Cleaning of suction strainer

3 Lube Oil replacement

4 Hook – up of all disturbed piping

5 Oil leveler level

6 Seal pot top – up [ pressurise if applicable ]

7 All casing drains closed

8 Motor DOR check [if re-commended]

9 DBSE check

10 Alignment check

11 Coupling box-up with proper torquing

12 Seal sliding washers removed

13 Installation of coupling guard

14 Working area cleaned of debris

15 “Permit to Work’ returned to operation

16 All checklist dully filled up & complete

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