UP-211-A (20-04-2012) - Final

Check List - Oil Replacement

Form # : MAC-55

Rev. # : 00

Job Report

MACHINERY MAINTENANCE UNIT Tag # UP-211-ADated: 20-04-12

BEARING INSPECTION DUE TO HIGH TEMPERATURES (DATED: 20-04-2012) HP AMMONIA PUMPUP-211APrepared By: Ahmed Usman KakarReviewed By: Kamran Rashid MirzaSubmitted To: Ghulam Mustafa KhanCONTENTS3EXECUTIVE SUMMARY

4PROBLEM

4OBSERVATION

4WORK DONE

5TECHNICAL DATA

6THRUST PROBES DATA

6PARTS REPLACED

6TEAM

7SPARES CONSUMED

7SNAP SHOTS

EXECUTIVE SUMMARYHP Ammonia pump (UP-211A) was taken in service after TA 2012. Pump was running smooth but in the month of April there were some observations regarding bearing temperatures. Bearing temperatures of high speed shafts (1st and 2nd stages) were reported high (see attached table). The values of bearing temperatures kept on increasing and on 19 04 2012 TI 21141 and TI 21145 were 90 C and 88C respectively. In view of the above mentioned problem, UP 211 A was taken for preventive maintenance.

UP-211A was handed over for overhauling / necessary maintenance on 20 04 2012 at 1000 hrs after purging with Nitrogen. 1st & 2nd stage seals of the pump were removed, bearings were taken apart, main lube oil pump was dismantled & high speed shafts removal was carried out. Problems identified have been detailed under observation. Following actions were taken during maintenance activity:1. Condition and clearances of the bearings were checked for any abnormalities using inside micrometer and micrometer screw gauge.2. 1st and 2nd stages seals were inspected for any damages and face contacts were checked using Prussian blue. All the faces were lapped and no abnormalities were detected.3. Lube oil cooler and lines were inspected for any debris.Maintenance of the pump was completed in 24 hours. Leak test of the pump was carried out on 21 04 2012 with Nitrogen at 8 kg/cm2 for 1 hour and no outflow was observed. After that it was pressurized with Liquid Ammonia at 20 kg/cm2 and no leakages were observed.PROBLEMHigh bearing temperatures of 1st and 2nd stages were documented.

OBSERVATIONHigh temperatures of 1st and 2nd stages bearings were documented and reported to machinery department. Because of the persisting trend of temperatures, it was decided to take the pump for preventive maintenance.Observations after dismantling the pump were as follows: High speed shafts (1st and 2nd stages) were found ok. (Snap attached)

Both 1st and 2nd stages mechanical seals were in good condition. No abnormalities were found except for slight scratches. (Snap attached) Both the impellers of 1st and 2nd stages were in good condition. (Snap attached) Thrust and radial bearings of 1st and 2nd stages were in good condition. (Snap attached)WORK DONE Seal faces were lapped and reused because face contacts were checked using Prussian blue. All the O-Rings of mechanical seals and bearing housings were replaced with new ones.

Thrust bearing, thrust washers, thrust runners and radial bearings were cleaned and assembled back in their respective housings.TECHNICAL DATABEFORE MAINTENANCEDESCRIPTION1ST STAGE2ND STAGE

Axial Float (With Impeller)0.35 mm0.32 mm

Gap b/w Impeller and Discharge plate0.90 mm1.0 mm

Radial Lift 0.18 mm0.20 mm

High Speed Shaft run out0.00 mm0.00 mm

High shaft speed run out in seal area0.01 mm0.01 mm

High speed shaft (1st Stage):Journal bearing ID: 44.47 mm

Shaft journal OD: 44.37 mm

Clearance: 0.10 mm High speed shaft (2nd Stage):

Journal bearing ID: 44.47 mm

Shaft journal OD: 44.37 mm

Clearance: 0.10 mm

AFTER MAINTENANCEDESCRIPTION1ST STAGE2ND STAGE

Axial Float (With Impeller)0.35 mm0.34 mm

Gap b/w Impeller and Discharge plate0.93 mm1.01 mm

Radial Lift 0.18 mm0.20 mm

THRUST PROBES DATA

LOCAL DATA (BY VOLT METER); GAP VOLTAGES

DESCRIPTIONAWAY FROM PROBE (TOWARDS PH&S)TOWARDS PROBE (CCR SIDE)

ZT-211.44 A11.35 V8.78 V

ZT-211.48 A11.25 V8.75 V

RACK ROOM DATA

DESCRIPTIONAWAY FROM PROBE (TOWARDS PH&S)TOWARDS PROBE (CCR SIDE)

ZT-211.44 A- 0.19 mm+ 0.18 mm

ZT-211.48 A- 0.15 mm+ 0.18 mm

PARTS REPLACED

O RingsTEAM MEMBERSDAY:Kamran Rashid Mirza (Section Manager)Muhammad Shafique (Sub Engr. II)Ahmed Usman Kakar (App Engr)

Haji Akbar (Supervisor) Rafique Gulzar (Sr. Technician)

Sheraz Akhtar (Technician)NIGHT:Khalid Bhatti (Asst. Manager)Nawazish (Sub Engr. II)Fahad Saleem (Sr. Technician)SPARES CONSUMEDList of spares consumed is detailed in SAP maintenance orders # & .SNAP SHOTS1ST STAGE

2ND STAGE

Slight scratches on Thrust Bearing

Slight scratches on Thrust Washer

Slight scuffing on Thrust Washer

Prepared By : Ahmed Usman KakarReviewed By: Kamran Rashid Mirza

FAUJI FERTILIZER BIN QASIM LTD

1