DISMANTLING PROCEDURE

1) DISMANTLING :( Discharge Side) a. Dismantling the bearing and add-on devices : Hood is unscrewed which contains bush for indicator. Indicator is unscrewed. Bearing end cover which is mounted on bearing cooling cover is
removed.

Angular contact ball bearing unscrewed from shaft. Spacer sleeve is removed from the space between the bearings. 8 nos. of spring removed from the fasteners. Bearing cooling cover of thrust bearing is removed from adapter. Adapter is removed from end bearing housing cover. The plain bearing housing is removed by unscrewing 4 hex bolts. Labyrinth seals from bearing cover are removed. Plain bearing cover is removed by unscrewing Allen screws. Plain bearing is removed from the shaft.

b. Dismantling Casing, Impeller, Diffuser and Balance disc : Splash ring removed from the shaft. Gland follower unscrewed and removed carefully. Cooling water cover dismantled from body by unscrewing allen screws. Removed Circlip attached next to the sleeve. Removed sleeve (after removal of worn out packing)-Discharge end. Removed retaining ring Removed split ring from the shaft. Removed spacer ring from shaft. Removed balance disk by pulling. Removed counter-balancing disk along with the discharge casing attached to it. Removed the seventh stage sleeve which is located before the seventh stage as viewed from discharge end. Removed seventh stage impeller (with key) from shaft. Removed sixth stage diffuser casing. Removed sixth stage diffuser sleeve. Removed sixth stage impeller (with key) from shaft. Removed fifth stage diffuser along with its casing. Removed fifth stage diffuser sleeve.

Removed fifth stage impeller (with key) from shaft. Removed fourth stage diffuser along with its casing. Removed fourth stage diffuser sleeve. Removed fourth stage impeller (with key) from shaft. Removed third stage diffuser along with its casing. Removed third stage diffuser sleeve. Removed third stage impeller (with key) from shaft. Removed second stage diffuser along with its casing. Removed second stage diffuser sleeve. Removed second stage impeller (with key) from shaft. Removed first stage diffuser along with its casing. Removed first stage diffuser sleeve. Removed first stage impeller (with key) from shaft. Shaft removed from suction casing and sent to workshop for bending test.

2) DISMANTLING :-( Suction Side) c. Dismantling the Connecting Coupling : The connection coupling is marked properly and the connection coupling is dismantled. Grub screws are loosened. The coupling hubs are removed. The key is marked prior to removing from the shaft groove. The coupling is removed with a proper extracting device. Bearing housing dismantled. Labyrinth Seals dismantled. Plain bearings dismantled carefully. Sleeve along with stuffing box dismantled. Discharge casing dismantled.

d. Dismantling Suction side Bearing :-

OBSERVATIONS
Rotor run out recorded = 0.08 mm (coupling end side) Clearance between Impeller wearing ring and casing wearing ring = 0.3 mm 0.6 mm. Clearance between counter balancing drum and balance disc = 1.2 mm Clearance between plain bearing and shaft = 0.04 mm. 1st stage impeller from suction side is inserted in 1st stage diffuser casing. Suction side casing is mounted on first stage impeller. The discharge side casing is provided with a diffuser which gets inserted in the seventh stage impeller. There is no wearing ring on the discharge side casing as it is mounted on the plain side of the seventh stage impeller. Counter balancing drum is attached to the discharge side casing with the help of Allen bolts. Total axial play recorded = 5.7 mm. Total radial clearances recorded = 0.5 mm. The counter balancing drum doesnt contain any O ring inside. It has a O ring groove on the Outer diameter. The balance disc contains one O ring, one groove and one keyway hole. Total number of labyrinth seals Suction Side 2 nos Discharge side 1 no. Residual axial thrust is balanced by angular contact ball bearings. While mounting the bearing cooling cover of suction side, the thrust bearing is mounted with the help of 8 nos. fasteners. 8 nos. springs are mounted on the 8 fasteners. The spacer sleeve is inserted in-between the springs.

REPLACEMENT/MACHINING
Impeller rings of impeller 1, impeller 2 and impeller 7 damaged. Replaced with new ones and their OD machined from 150mm to 149.7mm. 2 nos. of spacer sleeve replaced as both of them were damaged Suction sleeves, Discharge casing sleeve and centering sleeve ID reduced to 58.10 mm. Discharge side sleeve( 70 dia x 30 length) ID machined, Suction side sleeve ( 73.5 dia x 52 length) ID machined. First stage diffuser replaced by a new one. 1 no. impeller replaced. All O rings replaced with new ones.

SIZE OF REPLACED PARTS :

Sl.no 1 2 3 4 5 6 7

Name of part Wearing ring (Impeller) Wearing ring (diffuser) Spacer Sleeve Circlip Stage Sleeve Impeller Thrust bearing

Sl.no Name of Part 1 Balance disc 2 Counterbalancing Drum Sleeve 3 Spacer sleeves 4 Counterbalancing Drum 5 Diffuser and casing 6 Cooling cover 7 Between 7th stage casing and discharge casing

Size 150 ID/164.5OD x 12 197 ID/210 OD x 30 70 dia x 125 mm 58dia x 2mm 73.5dia x 25 mm 267mm 3310 C3 O Rings Size 60 dia x 3 mm thick(1 no.) 60 dia x 3 mm thick(1 no.) 53 dia x 3 mm thick( 2 nos) 80 dia x 3 mm thick 347 dia x4 mm thick 105 dia x 3 mm thick 210 dia x 4 mm thick

ASSEMBLING PROCEDURE
ASSEMBLY:
1st impeller mounted on shaft with key. 1st stage diffuser sleeve mounted with key. Mounted 1st stage diffuser. Mounted 2nd stage impeller on shaft. 2nd stage diffuser sleeve mounted with key. Mounted 2nd stage diffuser. Mounted 3rd stage impeller on shaft. 3rd stage diffuser sleeve mounted with key. Mounted 3rd stage diffuser. Mounted 4th stage impeller on shaft. 4th stage diffuser sleeve mounted with key. Mounted 5th stage diffuser. Mounted 5th stage impeller on shaft. 5th stage diffuser sleeve mounted with key. Mounted 5th stage diffuser. Mounted 6th stage impeller on shaft. 6th stage diffuser sleeve mounted with key. Mounted 6th stage diffuser with casing. Mounted 7th stage impeller Discharge casing mounted on shaft Suction casing mounted on shaft. Tie rods clamped on both the casings. Counterbalance drum fitted in place. Balance drum mounted and keyed on shaft. Spacer ring mounted , split ring and retaining ring mounted carefully Circlip mounted in place. Discharge side seal assembly sleeve mounted. Discharge side cooling water cover mounted on shaft. Gland follower inserted, kept loosened. Splash ring mounted on shaft. Discharge side end bearing cover housing mounted with gasket in-between

 Suction side bearing and housing cover mounted after installing circulating water cover box with gasket in-between. Suction side sleeve is mounted, cooling water cover box along with stuffing box attached to it fitted. Labyrinth seals inserted into the guide ways provided on the bearing housing. Adapter mounted on end bearing housing with 8 nos. allen bolts along with a gasket. Bearing cooling cover mounted on adaptor. Spacer plate inserted in the space between the springs. Angular contact ball bearing mounted on the shaft and keyed in place. Bearing end cover is mounted on bearing cooling cover. Labyrinth seal inserted in the guide ways. Indicator is screwed tightly on shaft end, Bush for indicator is screwed on bearing cover. Hood is screwed on bush for indicator.

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