Summit Meghnaghat Power Company Limited

Mechanical Maintenance Department

Maintenance / Inspection Report

Condensate Extraction Pump # A

Maintenance Report

(1st December – 8th December ‘2020)

Sr. Field Supervisor Engineer / Sr. Engineer GM PM

Signature

Kazi Md. Shamim Ashik Ahmed Hyeongkug Chae

Hossain

Prepared by Reviewed by Approved by Noted

 Summit Meghnaghat Power Company Limited
Condenser Extraction Pump # A Maintenance Report
1st Dec. to 8th Dec. 2020 Page 1 of 16

Table of Contents

TABLE OF CONTENTS ........................................................................................................................................................1

BACKGROUND ......................................................................................................................................................................2
SCOPE OF WORK .................................................................................................................................................................2
TECHNICAL SPECIFICATION ..........................................................................................................................................2
CRAFT PERSON & DURATION .........................................................................................................................................3
PREPARATION OF WORK .................................................................................................................................................3
RESOURCE UTILIZATION .................................................................................................................................................3
HAND & POWER TOOL ..........................................................................................................................................................4
CONSUMABLE ITEM ...............................................................................................................................................................4
DRAFT & DOCUMENT ............................................................................................................................................................4
MAINTENANCE ACTIVITIES ............................................................................................................................................5
PUMP DISASSEMBLING ..........................................................................................................................................................5
DYE PENETRANT TEST (DPT)................................................................................................................................................6
MEASUREMENT & CLEARANCE DATA ...................................................................................................................................7
SHAFT RUN-OUT ....................................................................................................................................................................8
PARTS CLEANING & DECONTAMINATING ..............................................................................................................................8
PARTS INSPECTION & REPLACEMENT ....................................................................................................................................9
PUMP ASSEMBLING .............................................................................................................................................................10
PICTORIAL ..........................................................................................................................................................................11
ALIGNMENT & SOLO TEST.............................................................................................................................................14
FUNCTIONAL TEST & VIBRATION COMPARISON ..................................................................................................15
OBSERVATION & RECOMMENDATION ......................................................................................................................16
CONCLUSION ......................................................................................................................................................................16

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 Summit Meghnaghat Power Company Limited
Condenser Extraction Pump # A Maintenance Report
1st Dec. to 8th Dec. 2020 Page 2 of 16

Background
On 26th November, CEP#A encountered motor high vibration (DE > 4 mm/s) as well as the sibilating
sound raised from pump bearing housing. In addition, during pump lift check it’s been observed that
the shaft is not lifted enough. Inducer got stuck with suction bell inner periphery.
Total running hours recorded 12738 where it is common that overhaul interval period is subject to
16000 working hours. It must take into account the physical state (vibration, noise, stress), pump
switching frequency, equipment failure, demand availability and so on. Abnormal working condition
requirements the immediate pump corrective maintenance to prevent mechanical withstand of
undesirable vibration, noise and stress.

Scope of Work
It has been decided that MMD will overhaul the pump and scope of the work to be followed-
Disintegrate the pump sequentially Find out actual problem & resolution
Check the accuracy of the dismantled parts Do correct leveling & alignment (if needed)
Check wearing parts & data recording Minimize pump vibration & noise as well
Spare to be used if any rejection occurred Carry out test run & Consequence Analysis

Technical Specification

Pump Mechanical Seal

Condensate
(Shanghai Apollo Machinery Co.) (Eagle Burgmann)

Suction
Type 16NLT-215 - 0.60 Bar Product Index 427-H75N/100-E2
Press.

Delivery API 682 /

Capacity 670 m3/h 23 Bar Design
Press. ISO 21049

Carbon Graphite
Speed 1480 rpm pH Level 8.8 - 9.3 Face Material Antimony Impregnated

NPSHr & Head 3.5 m & 176 m Conductivity < 10 μS/cm Seat Material Silicon Carbide

Coupling Bearing
Power 412 KW
(Shanghai Apollo) (SKF)

Flexible /
Weight 6000 KG C#1, Type Identity 7326 BCBM
Rubber Bush

API 610 (VS)

Design Vertically Suspended
C#2, Type Rigid / Split Arrangement Back to Back

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 Summit Meghnaghat Power Company Limited
Condenser Extraction Pump # A Maintenance Report
1st Dec. to 8th Dec. 2020 Page 3 of 16

Craft Person & Duration

S/N Name Designation S/N Name Designation

1 Ashik Ahmed DGM 5 Md. Zahirul Islam Sr. Field Supervisor
2 Md. Sakhawatul Bari Manager 6 Sujon Kumar Debnath Sr. Field Supervisor
3 Md. Jabaidur Rahman Asst. Manager 7 K M Shamim Hossain Sr. Field Supervisor
4 Mahbubur Rahman Asst. Manager 8 Md. Mizanur Rahman Field Supervisor
Duration 80 Working Hours

Preparation of Work
It’s a massive task, so prepared pump overhaul plan to conduct one by one in accordance. Hence some
following preparation needed to be executed.

Work Permit :
Issued work permit no. PTW20201201001 and date of initiation 1st December, 2020.
Warehouse Stock :
Checked warehouse availability for consumable items and pump spares if there any possibility of
replacing. PR generated against deficiency of required items.
Lifting Gear :
Functional load test of lifting hoist has been carried out earlier. All lifting gears i.e. slings, shackles,
chain blocks are inspected by the certified company. Necessary items shifted to the workplace.
Material & Tool Management :
Arranged all kinds of essential hand tools, power tools and measuring tools along with an organizer.
Several ply boards and wood padding blocks have been set in the workplace to keep small, loose &
bulky items as well as disintegrated parts.

Resource Utilization
A maintenance requires a lot to be performed. In this regard, various hand tools, power tools, precision
tools, marking tools, consumable items, non-consumable items, borrowed items, documents, manuals
and so on have been used and it is not logical to include all names & history. Some important items are
categorized shortly as following tables -

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 Summit Meghnaghat Power Company Limited
Condenser Extraction Pump # A Maintenance Report
1st Dec. to 8th Dec. 2020 Page 4 of 16

Hand & Power Tool

S/N Name of the Item Specification / Purpose Unit Qty.

1 Combination Spanner 9-36 mm Set 1

2 Slogging Spanner (ring+open) 24mm, 30mm, 32mm, 36mm Pc 1 Each
3 Box Wrench ¾, ½ drive Set 1 Each
4 Allen Key 1.5-12mm Set 1
5 Hammer Ball Pein, Copper, Sledge Pc 1 Each
6 Screwdriver & Pry Bar Diff. Size Pcs 4
7 Chain Block 1T, 2T, 5T, Pcs 3 Each
8 Synthetic Belt & Wire Sling Diff. Size Pcs 8&6
9 Eye Bolt & Shackle Diff. Size Pcs 4 Each
10 Hydraulic Jack 10T, 20T Pcs 1 Each
11 Induction Heater Capable to Heat Bearing Pc 1
12 Grinding / Cutting Machine 4’’ Pcs 1
13 Wooden Padding Block 250x300x510 mm Pc 4
14 Transparent Hose Parts Cleaning Purpose Meter 15
15 Inside & Outside Micrometer Diff. Size Pc 1 Each
16 Precision Tools Dial / Feeler Gauge Pc 1 Each

Consumable Item

S/N Name of the Item Specification Unit Qty.

1 Silicon Grease & Sealant Anabond 662, Threebond 1212 Tube 1 Each
2 Rag Cotton, White Color KG 10
3 Rust Remover & Molykote WD40 & 1000 Paste Can 5&1
4 Emery Paper (Grit) Diff. Size Pcs 16
5 Cup Brush, Cutting / Grinding Disc 4 Inch Pcs 2 Each
6 Masking Tape & Caution Tape 2 Inch & 3 Inch Reel 1 Each
7 Lube Oil L-TSA 46 / ISO VG 46 Liters 10
8 LP Gas 12.5 Kg Cylinder 1

Draft & Document

Planning, drafting and vendor recommendations has followed to the document titled Condensate
Pump, document no. SP311-OM-ST-04-0015 and Sectional Drawing refer 16NLT-215-000 (Apollo).

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 Summit Meghnaghat Power Company Limited
Condenser Extraction Pump # A Maintenance Report
1st Dec. to 8th Dec. 2020 Page 5 of 16

Maintenance Activities

Pump Disassembling

Decoupling & Auxiliaries Removal :

All electrical power connections have been disconnected and instruments have been taken out by I&C.
Before decoupling all data have been recorded. Removed all auxiliaries such as motor cooling water
line, seal & bearing cooling water line, flushing water line, suction & delivery flange as well.

Motor (3.5T) & Support Removal :

Dismantled connecting bolts between motor and pump. Affixed 4 wire slings within two 5T chain
blocks by calculating motor overall load, then lifted up the motor by ST crane auxiliary hook and
dispatched to the workshop for facilitating EMD to replace the motor bearings. Unscrewed the support
bolts and taken out motor support firmly.

Coupling Hub, Bearing Housing :

Removed coupling hub without heating. Unplugged of bearing lower cover under thrust bearing,
evacuate lubricating oil through the temporary connecting pipe. Loosened the bolt of thrust bearing
base plate, removed bearing upper cover and adjusting nut, then integrally lift out thrust bearing device
together with oil case, cooling coil, bearing lower cover, bearing and disintegrate this part in the
workshop table. Before that, checked out shaft lifting whether its free or not.
From housing bearings have been removed by using the special tool (ref. photo#7). Then Unscrewed
the lock nut clockwise. Finally separated it from the sleeve.

Mechanical Seal & Stuffing box :

Top ring of mechanical seal unscrewed and 4 locking plates inserted into the groove of the rotating
part. Then loosened bolts of stuffing box for safe lifting together.
In the workshop disintegrated the mechanical seal by using jack bolts (ref. photo#12). Checked
carefully static and rotating parts of the sealing point.

Lifting of Pump Unit from Sole Plate :

Used Four wire slings, one master ring with two legs, two 5T chain blocks and four bow shackles
during lift of the pump assembly. It had been kept in the ST operating floor. All dismantled activity
performed there.

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 Summit Meghnaghat Power Company Limited
Condenser Extraction Pump # A Maintenance Report
1st Dec. to 8th Dec. 2020 Page 6 of 16

Delivery Head, Outer Column & Retainer:

Unbolted labyrinth seal part and kept safely for avoiding its teeth damage. Then removed the pump
delivery head, outer column and retainer (ref. photo#15) sequentially. After that, decoupled the shaft. It
was split coupling. Firstly, unscrewed all fastening bolts; then opened its top half as well as bottom half
and removed clasp from both shaft ends. (ref. photo#17).

Inducer & Suction Bell :

A special tool (ref. photo 8) has been fabricated for safe removal of the stuck inducer. Once it removed,
slacked all nuts (M20) and taken out suction bell. Arranged some plywood to keep all these
disintegrated parts steadily.

Impeller & Guide Vane :

Loosened impeller nut M22x1.5, dismantled first stage impeller and first stage impeller locating shaft
sleeve in sequence. According to the sequence of guide vane shell, secondary impeller, inter-stage shaft
sleeve, guide vane shell to step by step. Dismantled the second stage to the fifth stage in sequence and
lifted all the parts by using ST crane. Parts kept according to serial no to prevent interchanging (ref.
photo#16). In the process of dismantling, added wood padding block under the rotor and the stationary
part and kept relatively parallel to avoid components abrading of pump shaft (ref. photo#18).

Dye Penetrant Test (DPT)

Actually pump inducer and two shafts were targeted to do DPT as they encountered & raised some
abnormalities while lifting. DPT has been done and maintained with basic procedure which has given
below –

Pre-cleaned the parts to be tested by cleaner or rust remover.

Applied penetrant aerosol (red color), kept it around 5 to 10 mins.
Remove penetrant properly
Applied developer aerosol (white color), kept it around 10 to 15 mins.
Then evaluated indications
Performed post clean.

Finally There were no severe mark or finding during penetration test. (ref. photo#10 & #11).

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 Summit Meghnaghat Power Company Limited
Condenser Extraction Pump # A Maintenance Report
1st Dec. to 8th Dec. 2020 Page 7 of 16

Measurement & Clearance Data

Recommended clearance between shaft sleeve & sliding bearing is considered not more than 0.3 mm
and unilateral gap of impeller & pump casing ring is 0.5 mm. Physical measurements are following –

Bearing, Shaft & Sleeve Clearance Data

Position In Location Bearing / Shaft ID Sleeve OD Clearance

Guide Vane Shell # 1 Bottom Shaft 93.76 mm (B) 93.44 mm 0.32 mm
Guide Vane Shell # 2 Bottom Shaft 93.83 mm (B) 93.46 mm 0.37 mm
Guide Vane Shell # 3 Bottom Shaft 93.73 mm (B) 93.44 mm 0.29 mm
Guide Vane Shell # 4 Bottom Shaft 93.78 mm (B) 93.44 mm 0.34 mm
Guide Vane Shell # 5 Bottom Shaft 93.76 mm (B) 93.45 mm 0.31 mm
Spider / Retainer # 1 Bottom Shaft 102.23 mm (B) 101.77 mm 0.46 mm
Spider / Retainer # 2 Top Shaft 102.03 mm (B) 101.78 mm 0.25 mm
Labyrinth Seal Top Shaft - 109.55 mm -
Rolling Bearing House Top Shaft 85.92 mm (S) 86.07 mm 0.15 mm

Impeller Wear Rings Clearance at Suction Side

Suction Side Wear Ring ID Impeller Suction Side Impeller Eye OD Clearance
Guide Vane Shell # 1 251.05 mm Impeller # 1st Stage 250.67 mm 0.38 mm
Guide Vane Shell # 2 251.03 mm Impeller # 2nd Stage 250.65 mm 0.38 mm
Guide Vane Shell # 3 251.02 mm Impeller # 3rd Stage 250.65 mm 0.37 mm
Guide Vane Shell # 4 251.01 mm Impeller # 4th Stage 250.67 mm 0.34 mm
Guide Vane Shell # 5 251.02 mm Impeller # 5th Stage 250.66 mm 0.36 mm

Impeller Wear Rings Clearance at Delivery Side

Delivery Side Wear Ring ID Impeller Delivery Side Impeller Eye OD Clearance
Guide Vane Shell # 1 251.01 mm Impeller # 1st Stage 250.68 mm 0.33 mm
Guide Vane Shell # 2 251.01 mm Impeller # 2nd Stage 250.66 mm 0.35 mm
Guide Vane Shell # 3 251.08 mm Impeller # 3rd Stage 250.66 mm 0.42 mm
Guide Vane Shell # 4 251.00 mm Impeller # 4th Stage 250.66 mm 0.34 mm
Guide Vane Shell # 5 251.04 mm Impeller # 5th Stage 250.69 mm 0.35 mm

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 Summit Meghnaghat Power Company Limited
Condenser Extraction Pump # A Maintenance Report
1st Dec. to 8th Dec. 2020 Page 8 of 16

Shaft Run-out

Radial run-out involves distance inaccuracy from one point to another which will cause vibration. It
has been checked by dial indicator into some points by putting the shaft onto fabricated blocks.

Shaft Radial Run-out Reading

Point A B C D
Top Shaft 0.04 0.01 0.01 0.02
Rotation Anti-clockwise Bottom Shaft 0.02 0.03 0.01 0.01

Parts Cleaning & Decontaminating

All dismantled parts have been cleaned properly. Rusty mating surface, ‘O’ ring groove cleaned by
power brush. Plain surfaces with light dirt cleaned by emery papers (320 grit), WD40 and rags. Bolts &
nuts were cleaned by using wire brushes.
Bearing housing and cooling chamber cleaned by pollen free rags. Finally service air blown away into
all the parts to prevent adhesion and decontamination in any precise parts.

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 Summit Meghnaghat Power Company Limited
Condenser Extraction Pump # A Maintenance Report
1st Dec. to 8th Dec. 2020 Page 9 of 16

Parts Inspection & Replacement

Pump parts are checked thoroughly. The following table summarizes the state of each part –

Parts Inspection Parts Inspection

Part Name Condition Remark Part Name Condition Remark
Rolling Bearing Set Noisy, Scrached Sleeve Replaced Mechanical Seal Malfunctioning Replaced
Guide Bearing # 01 Clearance Within Limit Reused Shaft Sleeve # 01 Clearance Within Limit Reused
Guide Bearing # 02 Clearance Within Limit Reused Shaft Sleeve # 02 Clearance Within Limit Reused
Guide Bearing # 03 Clearance Within Limit Reused Shaft Sleeve # 03 Clearance Within Limit Reused
Guide Bearing # 04 Clearance Within Limit Reused Shaft Sleeve # 04 Clearance Within Limit Reused
Guide Bearing # 05 Clearance Within Limit Reused Shaft Sleeve # 05 Clearance Within Limit Reused
Guide Bearing # 06 Clearance Within Limit Reused Shaft Sleeve # 06 Clearance Within Limit Reused
Guide Bearing # 07 Clearance Within Limit Reused Shaft Sleeve # 07 Clearance Within Limit Reused
Labyrinth Teeth/Groove Ok Reused Shaft Sleeve # 08 Clearance Within Limit Reused
Impeller # 01 Clearance Within Limit Reused Guide Vane # 01 Clearance Within Limit Reused
Impeller # 02 Clearance Within Limit Reused Guide Vane # 02 Clearance Within Limit Reused
Impeller # 03 Clearance Within Limit Reused Guide Vane # 03 Clearance Within Limit Reused
Impeller # 04 Clearance Within Limit Reused Guide Vane # 04 Clearance Within Limit Reused
Impeller # 05 Clearance Within Limit Reused Guide Vane # 05 Clearance Within Limit Reused
Split Coupling No Issue Reused Clasp Set Having Rise Spot Reused
Retainer/Spider # 01 No Issue Reused Inducer Jammed, Scratched Reused
Retainer/Spider # 02 No Issue Reused Internal Column Dirty Surface Cleaned
Top Shaft Scratched, Peeled Off Machined Column 'O' Ring Not Damaged Reused
Bottom Shaft No Issue Reused Rubber Bush One Damaged Replaced

According to the top table, some parts needed to be replaced. The following table represents details –

Details of Replaced Spare Parts

Part Name Part No. / Specification Unit Qty.
Angular Contact Ball Bearing 7326 BCBM Pieces 2
Bearing Sleeve SL.1.10.3 Piece 1
Mechanical Seal SL.1.10.1 / 427-H75N/100-E2 Piece 1
Rubber Bush Piece 1

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 Summit Meghnaghat Power Company Limited
Condenser Extraction Pump # A Maintenance Report
1st Dec. to 8th Dec. 2020 Page 10 of 16

Pump Assembling

Guide Vane, Impeller & Inducer Installation :

Pump assembling process basically opposite to dismantling process. According to the marking from
last guide vane shell to first guide vane shell installed by sequence. With same fashion last stage
impeller to first stage impeller (5th Guide vane then 5th stage impeller, then 4th guide vane, then 4th
impeller accordingly). Some silicon grease has been used in O’ ring. Finally installed suction bell and
inducer. And tightened all nuts perfectly (ref. photo#19). After finishing rotor movement checked by
hammering softly. It played total 7 mm.
Internal Column, Coupling & Retainer Installation :
Installed internal column and bolted them. Before installing retainers, sleeves should be inserted
properly. During coupling bottom half installed first with clasp. Then top half. Before that, have to
make sure both key centerline. Otherwise, it will not set properly into its position.
Pump Lifting and Entering Into Well :
Installed labyrinth and inserted sleeve. Then tightened lock nut clockwise.After that, installed delivery
head/column into the rotor. The pump made vertical from horizontal position. Finally, pump lifted
following by the same lifting procedure of removal and entered into the well without any touching or
damaging.
Mechanical Seal & Bearing Housing Installation :
New mechanical Seal has been installed with much care. Locking plates are well grooved. Kept looses
stuffing box nuts.
After honing operation (ref. photo#9) bearing sleeve got enough clearance and after polishing shaft also
easy to insert sleeve. Bearing installed back to back arrangement to the sleeve by pre heating. Heating
temp was recorded as 90 deg C. Made sure bearing touches end of the sleeve coller. Additional 0.10
mm shim is being discarded (ref photo#6) which was installed last maintenance. Before bearing
installed in the housing, it's been heated up to 85 deg C. After that total housing installed in the shaft.
Rotor Lift Check & Mechanical Seal Normalize :
Carried out rotor lifting. Set properly the dial gauge and total 7 mm lifted. Repeatedly up and down
three times to confirm its smooth lifting. Then lock nut tightened anti-clockwise when the rotor has
been lifted in 3.8 mm. After tightening plate it come until 3.4 mm. So the final lift got 3.4 mm.
Tightened all stuffing box bolts. Mechanical seal upper ring screwed and four locking plates made free
from the groove.
Motor and Accessory Pipeline Fixing :
Motor hauled from workshop then fixed all sling following by the same lifting procedure of removal.
Then fixed it to its base properly. Tightened all base bolts.
Fixed all auxiliaries such as motor cooling water line, seal & bearing cooling water line, flushing water
line, suction & delivery flange as well. New gasket has been used in suction pipe flange.

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 Summit Meghnaghat Power Company Limited
Condenser Extraction Pump # A Maintenance Report
1st Dec. to 8th Dec. 2020 Page 11 of 16

Pictorial

Photo#1: Shaft Scratches Photo#2: Sleeve Scratches Photo#3: Clearance Mark

Photo#4: Stuck Inducer Photo#5: Damaged Rubber Bush Photo#6: Discarded Bearing Shim

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 Summit Meghnaghat Power Company Limited
Condenser Extraction Pump # A Maintenance Report
1st Dec. to 8th Dec. 2020 Page 12 of 16

Photo#7: Bearing Removal Tool Photo#8: Inducer Removal Tool Photo#9: Honing Operation

Photo#10: Inducer DPT Photo#11: Shaft DPT

Photo#12: M.Seal Parting Photo#13: Inside Bearing Housing Photo#14: Safe Work Practice

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 Summit Meghnaghat Power Company Limited
Condenser Extraction Pump # A Maintenance Report
1st Dec. to 8th Dec. 2020 Page 13 of 16

Photo#15: Retainer / Spider Photo#16: Impeller & Guide Vane Photo#17: Coupling & Clasp

Photo#18: Wood Blocking Photo#19: Assembled Impeller Photo#20: Safe Lifting

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 Summit Meghnaghat Power Company Limited
Condenser Extraction Pump # A Maintenance Report
1st Dec. to 8th Dec. 2020 Page 14 of 16

Alignment & Solo Test

0.0 N 0.0 N

E E

- 0.04 Face + 0.02 + 0.06 Rim - 0.01

W W

S + 0.03 S + 0.05

Alignment carried out by following rim & face method. Above figure representing final alignment data
and during alignment no shim is inserted. Measured the distance between the pump and the motor
coupling hub is 8.03 mm.

Before testing motor heater was kept on for dehumidifying. In 08.12.2020, Under SFT motor solo test
has been performed. It was running around 30 minutes and vibrations were recorded as below -

Motor Vibration Data (ACOEM Analyser)

NDE DE
Before
Maintenance
Axial Horizontal Vertical Axial Horizontal Vertical

Velocity (mm/s) 2.12 2.66 1.39 1.17 0.981 1.21

Acceleration (g) 0.637 0.840 0.873 0.511 0.250 0.246

NDE DE
After
Maintenance
Axial Horizontal Vertical Axial Horizontal Vertical

Velocity (mm/s) 0.253 0.949 0.599 0.345 0.452 0.326

Acceleration (g) 0.091 0.077 0.073 0.243 0.174 0.222

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 Summit Meghnaghat Power Company Limited
Condenser Extraction Pump # A Maintenance Report
1st Dec. to 8th Dec. 2020 Page 15 of 16

Functional Test & Vibration Comparison

During pump rolling, bearing & mechanical seal cooling water and flushing water was adjusted
according to the vendor recommendations. All operational & electrical parameters were within limits.
The pump noise level & vibration found normal and much less than before. Performance kept
monitoring while running, data has recorded by ACOEM OneProd Analyser. Overall vibration data &
velocity comparison chart is following –

Overall Vibration Record

Motor NDE Motor DE Pump DE

Before
Maintenance
Axial Horizontal Vertical Axial Horizontal Vertical Axial Horizontal Vertical

Velocity (mm/s) 4.24 2.92 1.62 4.42 1.19 1.35 2.08 1.42 1.33

Acceleration (g) 1.54 1.28 1.27 2.75 0.868 0.799 1.58 1.51 1.44

Motor NDE Motor DE Pump DE

After
Maintenance
Axial Horizontal Vertical Axial Horizontal Vertical Axial Horizontal Vertical

Velocity (mm/s) 1.08 1.5 1.17 0.91 0.712 0.41 0.434 0.837 0.386

Acceleration (g) 0.2 0.144 0.128 0.703 0.259 0.289 0.153 0.11 0.115

Overall Velocity Comparison

4.5
4
3.5
3
2.5
2
1.5
1
0.5
0
Axial

Axial

Axial
Vertical

Vertical

Vertical
Horizontal

Horizontal

Horizontal

Motor NDE Motor DE Pump DE

Before Maintenance After Maintenance

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 Summit Meghnaghat Power Company Limited
Condenser Extraction Pump # A Maintenance Report
1st Dec. to 8th Dec. 2020 Page 16 of 16

Observation & Recommendation

While maintenance, its been observed some difficulties to perform the work such as heating, jacking,
shaft leveling/straightening and so on. Some recommendations are given below-

Arrangement of enough light in the pump surroundings.

Heating process should be safer, smarter, cost-effective and eco-friendly for assembling &
disassembling of all sorts of transmission components. Induction heater can be played an important
role because it eliminates the inconsistencies, quality and time issues associated with open flame,
torch heating and other conventional methods.
Following product has been recommended with the flexible long (20m) inductors.
BETEX MF Quick Heater 2.5
Appropriate shaft padding block (semi-circle shaped) with jacking devices for shaft leveling while
coupling and other assembly work.
Some ready made jacking bolt required for removing parts by jacking. So M10 to M24 jacking
bolts need to be fabricated to facilitate maintenance.

Conclusion

Overhauling activities done successfully with no harms, no human injuries and no interruptions.
Involved persons have given their best efforts, sincerities and having good leadership. As a result
earlier vibration, noise and some operational issues are resolved technically.
The above report has briefly discussed on the various aspects of maintenance activities. The downtime
cost for such equipment overhauling or maintenance is expected to be very high. To meet these
challenges, it had to use plant available resources and maintenance skills in all spheres of activities to
perform its effective role in the profitability of the company.
The entire reel of work brought to pass successfully. However, the situation faced some difficulties
which need to be resolved. As a part of this it is desired that above mentioned items really needed in
the next overhauling. Therefore, annual planning & budgeting section should include the right
information about the advised special item. If it can be done, hopefully it will save a lot of time and
cost as well in any major maintenance in particular rotating equipments.

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