ACW PUMP-C11-04-2012During ACW pump-C start up we observed some smoke from pump bearing housing area immediately stopped the pump. Pump bearing housing was opened for inspection purpose and found gun metal bush & bearing are not in proper condition. So that both the sleeve & Bearing replacement work attended and completed.12-04-2012ACW Pump-C trail run taken and found motor NDE side horizontal vibrations having high (18 mm/sec) and same vibration rectification purpose pump coupling hub run out checked and observed 1.2 mm shaft run out. Pump coupled with motor and kept in emergency stand-by.13-04-2012ACW pump-C dismantling work has been completed for pump overhauling purpose. And the following abnormalities were found. 1. Head shaft having 1.2mm run out observed2. Brass bush worn out.NIGHT SHIFT ACTIVITIES ACW pump-C all line shafts run out checked and shaft no.3 run out decreased from 0.35 mm to 0.15 and shaft no.4 run out decreased to 0.3 mm to 0.1 mm. Pump all parts buffing & cleaning work has been completed. ACW pump-C gaskets preparing work has been completed. ACW pump-C all necessary measurements were taken for reference and the pump is kept ready for assembling work.PUMP OLD PARTS CLEARANCESSL.NOLOCATIONPHYSICAL READINGCLEARANCE

1Impeller OD to Impeller housing ID307.16-307.970.81

2Impeller ID to Impeller shaft OD61.96-61.800.16

3Impeller shaft OD (Position-3) to Rubber bearing ID (Position-3)61.79-62.110.32

4Impeller shaft OD (Position-2) to Rubber bearing ID (Position-2)61.48-61.900.42

5Impeller shaft OD (Position-1) to Rubber bearing ID (Position-1)61.79-62.140.35

6No.4 shaft OD to No.3 Bearing ID55.55-55.830.28

7No.3 Shaft OD to No.2 Bearing ID55.65-56.270.62

8No.2 Shaft OD to No.1 Bearing ID55.55-55.840.29

14-04-2012ACW pump-C shafts sent to vemagiri work shop i.e. head shaft & line shafts total 05 Nos to check the shafts run out. But they could not rectify, new WPIL pump spares were arrived at site at 19:30 Hrs. After arriving the spares clearances again checked and measured.SL.NOLOCATIONPHYSICAL READINGCLEARANCE

1Impeller shaft OD to Impeller ID61.91-62.300.39 mm

2Impeller shaft OD (Position-3) to Rubber bearing ID (Position-3)61.91-61.770.14 mm

3Impeller shaft OD (Position-2) to Rubber bearing ID (Position-2)61.91-62.030.12 mm

4Impeller shaft OD (Position-1) to Rubber bearing ID (Position-1)61.91-62.130.22 mm

5No.4 shaft OD to No.3 Bearing ID55.58-55.920.34 mm

6No.3 Shaft OD to No.2 Bearing ID55.53-56.130.60 mm

7No.2 Shaft OD to No.1 Bearing ID55.55-55.820.27 mm

Pump assembling was started and..............................................15-04-2012Pump head shaft lock nut area shaft threaded portion found damaged while removing the gland sleeve. Shaft sent to ravulapalem work shop for threads damage rectification purpose. And it was rectified and brought to site at 11.15 hrs. Pump assembling was started at 11.15 hrs and all the clearances measured, found satisfactory. Pump assembling work has been completed at 16.30 hrs and clearance given to EMD to connect the terminals. Motor no load trial run taken and vibrations found NDE side horizontal 3.8 mm/sec. Pump coupled with motor and load trial run taken at 18.15 hrs. Vibrations measured and found motor NDE side horizontal 2.9 mm/sec. pump side vibrations found max 0.6 mm/sec. same pump was kept in service for observation.SL.NOLOCATIONCLEARANCE

1Gun metal bush to bearing 0.15 mm

2Bearing ID to Base bush0.65 mm

3Free float18 mm

4Final float (each side)9 mm