Procedure Details for Pump Repairs in and Around Perth
Before making any activities ensure that the machine has been locked-out and installs precautionary warning sign or tag-out device to energy-isolating device of a machine or equipment on which preventive maintenance is being performed. Notify affected employees and machine operators that a lock-out or tag-out system is going to be utilized and the reason therefore.
1. Pulling out the Motor
Note: Before making any attempt, ensure that Lock-Out/Tag-Out system has been applied; isolating circuit breakers and magnetic contactors at panel board.
a. Remove coupling cover, if required.
b. Loosen coupling nut setscrews
c. Remove all fixing bolts on the base plate that holds the motor.
d. Pull-out the motor straightly aligned away from the pump.
2. Pulling out the Pump
Note: Before making any attempt, ensure that Lock-Out/Tag-Out system has been applied; isolating valves and gate valves must be securely shut-off or closed.
a. Remove all the bolts that hold the pump on the base plate.
b. Loosen and remove all the bolts on suction and discharge flanges.
c. Pull out the pump assembly.
3. Disassembling the Pump
a. Loosen and remove all the bolts from volute, then pull out the volute cover.
b. Remove the impeller lock-nut.
c. Pull out the impeller using puller if necessary.
d. Remove flange coupling, use puller if necessary.
e. Remove mechanical seal. Be sure to measure first the correct distance of mechanical seal from the other end of the shaft before pulling it out.
Note: Ensure that lubricants (e.g. grease, oil) are removed before removing casing.
f. Remove the bolts on the casing covers.
g. Pull the shaft with bearings from the housing.
Note: Extra care must be applied during dismantling and fitting of mechanical seal.
4. Pull out the bearing from the Shaft
a. Pull out the bearing using bearing Puller.
5. Inspection and Repair
a. Check the condition of the bearings. Worn-out and damaged bearings must be replaced.
b. Check the physical appearance of the shaft seals and oil seals and proper bearing fitness to the shaft and to the housing.
c. Damaged mechanical seals and oil seal must be replaced.
6. Recondition/Replacement of Parts
a. If there is no defective part, if necessary, System Maintenance Technician shall perform the reconditioning or refurbishing of the parts/components of the pump.
b. Thorough evaluation of the parts or components is needed to conclude whether it can be reconditioned, or be replaced by a new one.
c. System Maintenance Technician shall re-install the refurbished/reconditioned parts/components as it was dismantled.
Note: Refurbishing and reconditioning shall be done with extra care some parts or components are delicate, fragile and sensitive to dirt.
7. Obtain Spare/Parts Procurement
a. If there is a defective part, System Maintenance Technician shall give the defective parts/components to the System Maintenance Supervisor and they will check Spare Parts Stock Room for the availability of the said parts/components.
b. If spare is not available at Stock Room, perform Purchasing of Spare Parts procedure.
c. As soon as the components/parts are available, the System Maintenance Technician shall perform the installation/fitting of components/parts. Installation shall be done carefully, because some components/parts are miniature, delicate, fragile and sensitive to dirt.
d. System Maintenance Technician shall install/fit the new one as it dismantled.
8. Assembling the Pump
a. Install bearings and oil seals on the shaft.
b. Install the shaft on the housing.
c. Put front and back covers and tighten the bolts.
d. Install mechanical seal on correct distance from the other end of the shaft.
e. Install flange coupling on the other end.
f. Install the impeller then put and tighten impeller lock-nut.
g. Install the suction volute housing, then put and tighten the bolts.
9. Installalling the Pump
a. Place and tighten all the bolts that hold the pump on the base plate.
10. Drive Motor Installation and Alignment
a. Position the motor on the base plate with its shaft and flange coupling linearly aligned with the pump’s shaft and flange coupling.
b. Slide the motor forward to the pump to connect their flange couplings and shafts.
c. Align pump and motor. Check radial and linear alignments, by using dial indicator. Adjust the motor position if necessary to attain proper alignment.
d. Put and tighten coupling setscrew
e. Put and tighten all fixing bolts on the base plate that holds the motor.
f. Apply grease and oil lubricants.
11. Test run
a. Energize and proceed to testing