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OISD - STD - 119

Revision-1
FOR RESTRICTED
CIRCULATION ONLY
INSPECTION OF PUMPS
OISD-standard-119
Revision - I
First Edition, February 1996
Oil Industry Safety Directorate
o!ern"ent of India
Ministry of Petroleu" # Natural as
OISD - STD - 119
Revision-1
February, 1996
FOR RESTRICTED
CIRCULATION ONLY
INSPECTION OF PUMPS
Prepared by :
Co""ittee on $Ins%ection of Pu"%s&
Oil Industry Safety Directorate
'
nd
Floor( $)ailas*&
'+( )astur,a and*i Mar-
Ne. Del*i / 001 110
NOTE
OISD publiations are prepared !or use in t"e oil and #as
industry under $inistry o! Petroleu% & '"e%ials( T"ese are
t"e property o! $inistry o! Petroleu% & '"e%ials, Deptt( o!
Petroleu% and )atural *as and s"all not be reprodued or
opied and loaned or e+"ibited to ot"ers ,it"out ,ritten onsent
!ro% OISD(
T"ou#" every e!!ort "as been %ade to assure t"e
auray and reliability o! t"e data ontained in t"ese
dou%ents, OISD "ereby e+pressly dislai%s any liability or
responsibility !or loss or da%a#e resultin# !ro% t"eir use(
T"ese dou%ents are intended only to supple%ent and not
to replae t"e prevailin# statutory re-uire%ents(
FORE2ORD
T"e Oil Industry in India is over 1.. years old( /eause o!
ollaboration a#ree%ents, a variety o! international odes, standards and
praties "ave been in vo#ue( Standardisation in desi#n p"ilosop"ies and
operatin# and %aintenane praties at a national level ,as "ardly in
e+istene( T"is oupled ,it" !eedba0 !ro% so%e serious aidents t"at
ourred in t"e reent past in India and abroad, e%p"asised t"e need !or t"e
industry to revie, t"e e+istin# state o! art in desi#nin#, operatin# and
%aintainin# oil and #as installations(
1it" t"is in vie,, t"e $inistry o! Petroleu% and )atural *as in 1926
onstituted a Sa!ety 'ounil assisted by t"e Oil Industry Sa!ety Diretorate
3OISD4 sta!!ed !ro% ,it"in t"e industry in !or%ulatin# and i%ple%entin# a
series o! sel!-re#ulatory %easures ai%ed at re%ovin# obsolesene,
standardisin# and up#radin# t"e e+istin# standards to ensure sa!e operation(
5ordin#ly, OISD onstituted a nu%ber o! !untional o%%ittees o! e+perts
no%inated !ro% t"e industry to dra, up standards and #uidelines on various
sub6ets(
T*e %resent docu"ent on 3Ins%ection of Pu"%s4 *as
,een %re%ared ,y t*e Functional Co""ittee on 3Ins%ection of Rotary
E5ui%"ent64 T*is docu"ent is ,ased on t*e accu"ulated 7no.led-e
and e8%erience of industry "e",ers and t*e !arious national and
international codes and %ractices6 T*is docu"ent is "eant to ,e used
as su%%le"ent and not as a re%lace"ent for e8istin- codes and
%ractices6 It s*all ,e ,orne in "ind t*at no standard can ,e a
su,stitute for t*e 9ud-e"ent of a res%onsi,le 5ualified En-ineer6
Su--estions are in!ited fro" t*e users after it is %ut into %ractice to
i"%ro!e t*e docu"ent furt*er6 T*is docu"ent .ill ,e re!ie.ed
%eriodically for i"%ro!e"ents ,ased on t*e ne. e8%eriences and
,etter understandin-6 Su--estions for a"end"ents to t*is docu"ent
s*ould ,e addressed to t*e Coordinator( Co""ittee on $Ins%ection of
Rotary E5ui%"ent&( Oil Industry Safety Directorate( '
nd
Floor(
$)ailas*&( '+( )astur,a and*i Mar-( Ne. Del*i / 001 1106
T"is standard in no ,ay superedes t"e statutory re-uire%ents o!
bodies li0e I/R, ''E, Fatory Inspetorate or any ot"er *overn%ent /ody
,"i" %ust be !ollo,ed as appliable(
COMMITTEE ON
$Ins%ection of %u"%s&
Re!ision / I
////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////
Na"e Or-anisation
////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////
Leader
S"ri 7( *opala0ris"nan 'o"in Re!ineries 8i%ited
$e%bers
S"ri '( 8al Oil & )atural *as 'orpn( 8td(
3SR/'-$adras4
S"ri R( Ra#ot"a%an 9industan Petroleu% 'orpn( 8td(
3$ar0etin#-/RP8 Operation4
S"ri S( P( 5s"o00u%ar 'o"in Re!ineries 8td(
S"ri R( P( S"ri,as Indian Oil 'orporation 8td(
3R&P Division-Pipelines4
S"ri $( '"a0ravarty *as 5ut"ority o! India 8td(
S"ri D( :a#annad"a Rao $adras Re!ineries 8td(
S"ri R( Re"%an 9industan Petroleu% 'orpn( 8td(
3$ar0etin# - 8P*4
$e%ber oordinator
S"ri S( /( S"a" Oil Industry Sa!ety Diretorate
////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////
In addition to t"e above, several ot"er e+perts !ro% industry ontributed in t"e preparation, revie,
and !inalisation o! t"e dou%ent(
INSPECTION
OF
PUMPS
CONTENTS
//////////////////////////////////////////////////////////////////////////////////////////////////////////////////////
SECTION DESCRIPTION
//////////////////////////////////////////////////////////////////////////////////////////////////////////////////////
061 INTRODUCTION
'61 SCOPE
:61 PREDICTI;E MAINTENANCE SC<EDULE
FOR CENTRIFUAL PUMPS
=61 PRE;ENTI;E MAINTENANCE INSPECTION
SC<EDULE FOR CENTRIFUAL PUMPS
;(1 9ori<ontal 'entri!u#al Pu%ps
3/ot" ends supported4
;(= 9ori<ontal 'entri!u#al Pu%ps 3Over"an#in# Type4
;(> Sub%ersible Pu%ps 31et $otor Type and
Dry $otor Type4
;(; ?ertial 'entri!u#al Pu%ps
;(@ Part,ise Inspetion durin# o%plete Over"aul o!
'entri!u#al Pu%ps
;(6 'o%%issionin# and Testin# Proedures !or
'entri!u#al Pu%ps
>61 PRE;ENTI;E MAINTENANCE INSPECTION SC<EDULE
FOR POSITI;E DISPLACEMENT PUMPS
@(1 Reiproatin#APlun#erADiap"ra#% Pu%ps
@(= *ear Pu%psASre, Pu%ps
@(> Part,ise Inspetion durin# o%plete over"aul
o! Reiproatin# Pu%ps
@(; 'o%%issionin# and testin# Proedures !or
Reiproatin# Pu%ps
+61 DIFFERIN SC<EDULES
?61 DOCUMENTATION
@61 REFERENCES
INSPECTION OF PUMPS
061 INTRODUCTION
T"e rotary e-uip%ent play a vital role in
"ydroarbon proessin# industry( Ti%ely
inspetion and %aintenane o! rotary
e-uip%ent ,ill #o a lon# ,ay in ensurin# sa!er
operations o! t"e installations in Oil Industry(
'61 SCOPE
T"is standard overs t"e %ini%u%
re-uire%ents !or inspetion, %aintenane,
o%%issionin# and testin# proedures !or t"e
!ollo,in# Rotary E-uip%ent used in t"e Oil
Industry:
i4 'entri!u#al Pu%ps 39ori<ontalA?ertial,
/ot" ends supportedAover"an#in# type,
Sin#leA$ulti sta#e and Sub%ersible type4
ii4 Positive Displae%ent Pu%ps
3reiproatin# Pu%ps, *ear Pu%ps,
Sre, Pu%ps and Dosin# Pu%ps4(
:61 PREDICTI;E MAINTENANCE
SC<EDULE FOR CENTRIFUAL
PUMPS
T"e ondition o! entri!u#al pu%p an be
assessed by %easure%ent o! vibration and
s"o0 pulse levels o! anti!rition bearin#s( T"e
!re-ueny o! %easure%ent s"all depend on
t"e ritiality o! t"e e-uip%ent( OISD RP 1=;
3Preditive $aintenane Praties4 s"all be
re!erred !or preditive %aintenane o!
entri!u#al pu%ps(
=61 PRE;ENTI;E MAINTENANCE
INSPECTION SC<EDULE FOR
CENTRIFUAL PUMPS
'entri!u#al Pu%ps are lassi!ied in t"e
!ollo,in# #roups !or preparation o! preventive
%aintenane inspetion s"edule :
i4 9ori<ontal 'entri!u#al Pu%ps 3bot" ends
supported4
ii4 9ori<ontal 'entri!u#al Pu%ps
3over"an#in# type4
iii4 ?ertial 'entri!u#al Pu%ps
iv4 Sub%ersible Pu%ps
'"e0 list on Inspetion ite%s !or ea" type o!
pu%ps s"all be as per t"e s"edule #iven
belo,(
=60 <ORIAONTAL CENTRIFUAL
PUMPS BCOT< ENDS SUPPORTED4
5ll t"e !ollo,in# ite%s s"all be
"e0edAreorded a!ter t"e spei!ied period :
=6060 After 0111 runnin- *ours or :
"ont*s .*ic*e!er earlier
i4 /earin# lubriant 3!or ,ater
onta%ination and sedi%ents4
ii4 Oil rin# !or per!or%ane
iii4 De!letor !or looseness
iv4 'onstant level oiler !or lea0a#e
v4 $e"anial seal !or lea0a#e
vi4 Seal !lus"in#A-uen"in# syste% 3o!
$e"anial Seal4 !or lo##in# and
"o0in#(
vii4 *land !or lea0a#e 3ad6ust as
neessary4
viii4 'oolin# ,ater !lo, in bot" t"e bearin#
"ousin#s
i+4 'ondition o! bearin# by sound and
te%perature 3in runnin# ondition4
+4 Per!or%ane o! all %easurin#
instru%ents 3PressureATe%perature
#au#es and Flo, $eters4
+i4 'ouplin# *uard
+ii4 Eletri $otor load urrent
+iii4 5+ial position indiator 3in ase o!
%ultista#e pu%p4
+iv4 Do,el pins 3in position or notB
,"erever provided4
=606' After =111 runnin- *ours or 0 year
.*ic*e!er earlier
i4 Repeat all "e0s per ;(1(1(
ii4 Flus"in# o! bearin# ,it" lube oil and
re!illin# o! oil to re-uired level, ,"et"er
arried out or not
iii4 Flus"in# o! oolin# ,ater lines and
strainers, ,"et"er arried out or not 3to
ensure proper !lo, o! oolin# ,ater(
iv4 Foundation, !oundation bolts and
supports
v4 Replae%ent o! old pa0in# ,it" ne,
ones and ondition o! #land !ollo,er,
lantern rin# and sleeves 3in ase o! #land
pa0in#4
vi4 'ondition o! ouplin#, ouplin# bolts,
nuts, sprin# ,as"ers and t"eir on!ir%ity
to uni!or% si<e( '"an#e #rease in "al!
ouplin# in ase o! #ear type(
=606: After @111 *ours or ' years
.*ic*e!er earlier
i4 Repeat all "e0s per ;(1(=(
ii4 'ondition o! outboard bearin#, lo0 nut
and lo0 ,as"er 3in ase lo0 ,as"er
!ound da%a#ed and lo0 nut loose, s"a!t
a+ial play s"all be "e0ed4
iii4 Follo,in# ite%s o! :ournal bearin#s :
a4 'learane o! IA/ and OA/ bearin#s
b4 9i#" spot 39i#" Spots s"all be
srapped4
4 'ondition o! t"rust bearin#, lo0 nut
and lo0 ,as"er 3in ase lo0 ,as"er
!ound da%a#ed and lo0 nut loose,
s"a!t a+ial play s"all be "e0ed4(
iv4 OISD RP 1=> s"all be re!erred !or
inspetion o! bearin#s( 3Replae t"e
bearin#s i! neessary4
v4 Pu%p !loat 3ad6ust i! neessary4
vi4 Oil !ilter !or leanliness i! 6ournal bearin#s
are "ydrodyna%i
vii4 'ondition o! %e"anial seals 3OISD RP
1=@, CInspetion and $aintenane o!
$e"anial sealsD s"all be re!erred4
viii4 5li#n%ent 3$isali#n%ent s"all not be
%ore t"an .(.@ %%4
i+4 Paintin# o! e-uip%ent, ,"et"er arried
out or not
)otes:
i4 5!ter o%pletin# t"e "e0s listed
above t"e pu%p s"all be started and
t"e !ollo,in# s"all be "e0ed durin#
t"e trial run 3t"e trial run duration s"all
be "al! to one "our !or eletri driven
and > to ; "ours !or diesel driven4 :
a4 Dis"ar#e pressure
b4 Sution pressure
4 8i-uid !lo, 3i! possible4
d4 'ondition o! $e"anial
SealA*land Pa0in#
e4 Eletri $otor load urrent at
dis"ar#e valve s"uto!! and open
ondition
!4 'ondition o! bearin# by sound and
te%perature
#4 5ny lea0a#e
"4 ?ibration and s"o0 pulse readin#
as per OISD 1=;
ii4 Pu%ps in "ot servie s"all not be rotated
unless it is #radually "eated up to a
te%perature lose to t"at o! t"e ,or0in#
!luid(
=606= After 0+111 *ours or = years
.*ic*e!er earlier
'o%plete over"aulin# o! t"e pu%p s"all
be arried out(
T"is s"all inlude part-,ise inspetion as
per ite% ;(@ and all "e0s spei!ied !or 2...
"ours(
=6' <ORIAONTAL CENTRIFUAL
PUMPS BO;ER<ANIN TYPED
5ll t"e !ollo,in# ite%s s"all be
"e0edAreorded a!ter t"e spei!ied
period :
=6'60 After 0111 *ours or : "ont*s
.*ic*e!er earlier
i4 Oil in bearin# "ousin# !or ,ater
onta%ination and sedi%ent 3Replae
oil i! neessary4
ii4 Oil rin# !or proper ,or0in#
iii4 'onstant level oiler !or proper ,or0in#
iv4 *land pa0in# 3!or lea0a#e4
v4 'ondition o! $e"anial Seal 3OISD
RP 1=@, CInspetion and $aintenane
o! $e"anial SealsD s"all be re!erred
!or replae%ent4
vi4 'oolin# ,ater !lo,
vii4 'ondition o! ouplin# #uard
viii4 'ondition o! bearin# by sound and
te%perature
i+4 Eletri $otor load urrent 3at
dis"ar#e valve s"uto!! and open
ondition4
+4 Per!or%ane o! all %easurin#
instru%ents 3PressureATe%perature
#au#es and !lo, %eters4
=6'6' After =111 *ours or 0 year .*ic*e!er
earlier
i4 Repeat all "e0s per ;(=(1(
ii4 Flus"in# o! oolin# ,ater lines and
leanin# o! Strainers, ,"et"er arried
out or not 3to ensure proper !lo, o!
oolin# ,ater4
iii4 'ondition o! ouplin# 3in deoupled
ondition4
iv4 'ouplin# end support !or any
abnor%ality
v4 Foundation, !oundation bolts and
supports(
vi4 5li#n%ent 3Reali#n, i! neessary4
vii4 Per!or%ane o! all %easurin#
instru%ents and reordin# o! readin#s
viii4 Sution line strainer !or leanliness
=6'6: After @111 *ours or ' years
.*ic*e!er earlier
'o%plete over"aulin# o! t"e pu%p
s"all be arried out( T"is s"all inlude part-
,ise inspetion as per ite% ;(@ and all "e0s
per ite% ;(=(=(
)otes:
i4 5!ter o%pletin# t"e "e0s listed above
t"e pu%p s"all be started and t"e
!ollo,in# s"all be "e0ed durin# t"e trial
run 3t"e trial run duration s"all be "al! to
one "our !or eletri driven and > to ;
"ours !or diesel driven4:
a4 Dis"ar#e pressure
b4 Sution pressure
4 8i-uid !lo, 3i! possible4
d4 'ondition o! $e"anial SealA*land
Pa0in#
e4 Eletri $otor load urrent at
dis"ar#e valve s"uto!! and open
ondition
!4 'ondition o! bearin# by sound and
te%perature
#4 5ny 8ea0a#e
"4 ?ibration and s"o0 pulse readin# as
per OISD 1=;
ii4 Pu%ps in "ot servie s"all not be rotated
unless it is #radually "eated up to a
te%perature lose to t"at o! t"e ,or0in#
!luid(
=6: SUCMERSICLE PUMPS B2ET
MOTOR TYPE AND DRY MOTOR
TYPED
T"e !ollo,in# ite%s s"all be "e0edA
reorded:
=6:60 After e!ery '>1 *ours or fortni-*tly
.*ic*e!er earlier
i4 Ensure opti%u% li-uid level to avoid
dry run ,"erever auto ut inAut out not
provided
ii4 $otor load urrent
iii4 Pu%p dis"ar#e pressure
iv4 5ny abnor%al sound and vibration o!
onneted pipin#
=6:6' After e!ery @111 *rs6 or ' years
.*ic*e!er earlier BFor saline
ser!ice( t*is inter!al "ay ,e
reduced as re5uiredD
'o%plete over"aulin# o! t"e pu%p
s"all be arried out( T"is s"all inlude part-
,ise inspetion as per ite% ;(@(
=6= ;ERTICAL CENTRIFUAL PUMPS
5ll t"e !ollo,in# ite%s s"all be
"e0edAreorded a!ter t"e spei!ied period:
=6=60 After 0111 *ours or : "ont*s
.*ic*e!er earlier
i4 Oil in bearin# "ousin# !or ,ater
onta%ination and sedi%ent 3Replae
oil i! neessary4
ii4 'onstant level oiler !or proper ,or0in#
iii4 *land pa0in# 3!or lea0a#e4
iv4 'ondition o! $e"anial Seal 3OISD
RP 1=@, CInspetion and $aintenane
o! $e"anial sealsD s"all be re!erred
!or replae%ent4
v4 'oolin# ,ater !lo,
vi4 'ondition o! ouplin# #uard
vii4 'ondition o! bearin# by sound and
te%perature
viii4 Eletri $otor load urrent 3at
dis"ar#e valve s"uto!! and open
ondition4
i+4 Per!or%ane o! all %easurin#
instru%ents 3PressureATe%perature
#au#es and !lo, %eters4
=6=6' After =111 *ours or 0 year .*ic*e!er
earlier:
i4 Repeat all "e0s per ;(=(1(
ii4 Flus"in# o! oolin# ,ater lines and
leanin# o! Strainers, ,"et"er arried
out or not 3to proper !lo, o! oolin#
,ater4
iii4 'ondition o! ouplin# 3in deoupled
ondition4
iv4 Foundation, !oundation bolts and
supports
v4 5li#n%ent 3Reali#n, i! neessary4
vi4 Per!or%ane o! all %easurin#
instru%ents and reordin# o! readin#s
vii4 Sution line strainer !or leanliness
=6=6: After e!ery '=111 *ours or = years
.*ic*e!er earlier E
'o%plete over"aulin# s"all be arried out(
Durin# over"aulin#, part-,ise, inspetion
as per ite% ;(@ and "e0s spei!ied !or ;...
"ours s"all be arried out(
=6> PART2ISE INSPECTION DURIN
COMPLETE O;ER<AUL OF
CENTRIFUAL PUMPS
Part-,ise inspetion s"all be arried
out durin# o%plete over"aul(
For t"e purpose o! part-,ise
inspetion t"e parts o! entri!u#al pu%p are
lassi!ied into !ollo,in# t,o ate#ories:
i4 Stationary parts
ii4 Rotatin# parts
=6>60 STATIONARY PARTS
iD Casin-( ;olute and Stuffin- Co8

a4 asin# and volute s"all be
inspeted !or avitation, erosion
or orrosion(
b4 Stu!!in# bo+ ,alls s"all be
"e0ed !or orrosion, ovality and
ot"er da%a#es inludin#
desalin# in ,ater,ays(
4 *as0etin# sur!ae o! $e"anial
Seal !lan#e s"all be inspeted !or
pittin# and unevenness(
d4 'asin# ,ear rin# seat s"all be
inspeted( It s"ould be o%plete
round, s%oot" and !ree !ro%
orrosionAirre#ularities(
e4 ?olute, di!!user blades s"all be
inspeted !or ,earAda%a#e(
iiD land follo.erFMec*anical Seal
flan-e

a4 Flan#e !ae s"all be inspeted !or
,ear due to orrosion and erosion
b4 T"e !ollo,in# learanes s"all be
%easured
- Stu!!in# bo+ inside dia and
!ollo,er outside dia(
- S"a!tAsleeve outside dia and
!ollo,er inside dia
iiiD Cearin- <ousin-

a4 /earin# seats s"all be inspeted
!or trueness ,it"in presribed
li%it(
b4 Oil li!ter rin#s s"all be inspeted
!or ,ear and ovality
4 1ater 6a0et s"all be
desaledAleaned and
"ydrotested(
d4 Oil seal seat and de!letor rin#
#roove s"all be inspeted
e4 Fittin#s o! %a0e up oil bottle s"all
be "e0ed(
!4 'onstant level oiler s"all be
"e0ed !or per!or%ane(
#4 5+ial t"rust bearin# seat s"all be
inspeted !or ovality
"4 $a#neti drain plu# s"all be
inspeted( Ordinary drain plu#
s"all be replaed ,it" %a#neti
drain plu#(
i!D Casin- .ear rin-FCase se%aratin-
rin-sFI"%eller se%aratin- rin-s

a4 Rin#s s"all be inspeted !or ,ear
and da%a#e and di%ension s"all
be veri!ied(
b4 8o0in# arran#e%ent s"all be
"e0ed(
!D T*roat ,us*( Calancin- ,us* and
Calancin- slee!e
a4 /us" sleeve s"all be inspeted !or
,ear and da%a#e(
b4 OD and ID s"all be %easured
4 8o0in# arran#e%ent s"all be
"e0ed
!iD Lantern Rin-

a4 OD and ID s"all be %easured
b4 *rooveA"ole !or oolin# %edia
s"all be "e0ed
4 8antern rin# s"all be inspeted !or
,ear, da%a#e, orrosion and
sur!ae s%oot"ness(
!iiD Coolin- syste"FStea" snuffin-
syste"Fland sealin- line
a4 *eneral ondition o! s%all bore
lines and balanin# lines 3a!ter
sealin# lines4 s"all be "e0ed(
b4 'ondition o! all pipe !ittin#s s"all
be "e0ed(
4 Pipin# s"all be "e0ed !or proper
!lo,(
!iiiD ColtFNutF2as*er
5ll boltsAnutsA,as"ers s"all be
inspeted !or ,ear, pittin# and
da%a#e(
i8D Cou%lin- uard

a4 'ouplin# #uard s"all be inspeted
!or da%a#eAorrosion
b4 'ouplin# #uard-lo0in# syste%
s"all be "e0ed(
8D Flo. ,y%ass syste"
Flo, bypass arran#e%ent syste%
s"all be "e0ed(
8iD Protection de!ices
Protetion devies !or "i#" asin#
te%perature, "i#" vibration, "i#"
bearin# te%perature et( s"all be
"e0ed( For overload relays,
standard 1>E CInspetion o! Eletrial
E-uip%entD s"all be !ollo,ed(
=6>6' Rotatin- Parts
iD I"%eller
a4 I%peller vanes s"all be "e0ed !or
lo##in#(
b4 I%peller s"all be "e0ed !or ra0s in
vanes, outer plates and "ub
4 I%peller s"all be inspeted !or pittin#,
orrosion, erosion and si#n o!
avitation
d4 Overall dia%eter s"all be %easured(
e4 /ore dia%eter and 0ey #roove s"all
be "e0ed(
!4 I%peller ,earin# seat s"all be
inspeted and t"e dia%eter s"all be
%easured(
#4 /alanin# "oles s"all be "e0ed(
"4 I%peller s"all be balaned be!ore
asse%bly(
i4 In ase o! ne, I%peller, diretion o!
vanes and %aterial o! onstrution
s"all be "e0ed(
iiD S*aft
a4 S"a!t s"all be "e0ed !or burr, rid#e
and ra0
b4 Di%ension at t"e !ollo,in# positions o!
t"e s"a!t s"all be %easured
F at bearin# seat
F at i%peller seat
F at sleeve seat
F at ouplin# seat
4 *roove tolerane and t"reads s"all be
"e0ed
d4 S"a!t trueness s"all be "e0ed( T"e
s"a!t run out s"all not be %ore t"an
.(.@ %%(
iiiD I"%eller 2ear Rin-
'"e0s o! ;(@(1 iv4 s"all be done(
i!D I"%eller Loc7 Nut
a4 T"reads s"all be "e0ed !or da%a#e(
b4 8o0in# sur!ae s"all be "e0ed !or
s%oot"ness(
4 9e+a#onal setion o! t"e nut s"all be
"e0ed !or any burrAde!or%ation(
!D )ey
a4 $aterial o! onstrution s"all be
"e0ed !or ne,
b4 Di%ensions s"all be "e0ed ,it"
respet to 0ey,ay #roove di%ensions
!iD S*aft Slee!e and S%acer Slee!e
a4 $aterial o! onstrution s"all be
veri!ied in ase o! ne,Areplae%ent
b4 IDAOD s"all be %easured and
"e0ed ,it" %atin# parts(
4 *as0etin# seats s"all be "e0ed
d4 GOH rin# #roove 3i! provided4 s"all be
"e0ed(
e4 Ensure ti#"tness o! sleeves
viii4 Calancin- Dru"
a4 $aterial o! onstrution s"all be
veri!ied in ase o! ne,Areplae%ent
b4 ODAID s"all be %easured(
4 *as0etin# seats s"all be inspeted(
i+4 Deflector
a4 De!letor s"all be "e0ed !or ra0,
erosion and orrosion(
b4 /ore dia and step dia 3,"i" !its in
bearin# "ousin#4 s"all be %easured(
4 8o0in# sre,At"reads in t"e de!letor
plate s"all be "e0ed(
i8D Oil Rin- and ot*er syste" of oil
liftin-6
T"e oil rin# and ot"er syste% o! oil
li!tin# s"all be "e0ed !or ,earAra0,
ovality and s-uareness(
8D Rotor asse",ly
Dyna%i balanin# o! t"e rotor
asse%bly s"all be "e0ed provided
in ase(
pu%p ,as runnin# ,it" "i#"
vibration prior to over"aulin#(
o%ponents o! t"e rotor "ave
been replaed(
,ear observed on o%ponents o!
t"e rotor(
I! i%balane is observed in rotor
asse%bly, t"en dyna%i balanin# o!
individual o%ponent s"all be
"e0ed(
8iD Cearin- and Cou%lin-
OISD RP 1=> CInspetion and
/earin#, 'ouplin#s and /eltsD s"all be
re!erred(
8iiD Mec*anical Seal
OISD RP 1=@ CInspetion and
$aintenane o! $e"anial SealsD
s"all be re!erred(
=6+ COMMISSIONIN AND TESTIN
PROCEDURES FOR CENTRIFUAL
PUMPS
T"e !ollo,in# proedures s"all be
!ollo,ed !or o%%issionin# and
testin# o! over"auled and ne,ly
installed pu%ps:
=6+60 O!er*auled Pu"%s
iD Pre Startin- %rocedures
a4 Pu%p and Pri%e %over ali#n%ent
s"all be "e0ed in unoupled
ondition
b4 SutionAdis"ar#e pipin#s s"all be
"e0ed to ensure no strain o%in#
on t"e pu%p
4 Diretion o! rotation o! pri%e %over
s"all be "e0ed
d4 5ll pipin# onnetions s"all be
"e0ed
e4 Ensure all instru%ents are alibrated
!4 Foundation bolts s"all be ti#"tened
and ali#n%ent re"e0ed(
#4 Pu%p s"all be oupled to t"e pri%e
%over
"4 Ensure replae%ent o! lubriantsA
lubriatin# oil 3a!ter !lus"in# as
neessary4(
i4 'ouplin# #uard s"all be !i+ed(
64 Sution strainer s"all be "e0ed !or
orret si<e(
04 Pu%p s"all be pri%ed by #radually
openin# t"e sution valve 3In ase o!
"ot pu%p-oolin# ,ater, seal oil and
stea% -uen"in# s"all be 0ept open
,"ile "eatin# t"e pu%p4(
l4 8ea0s !ro% 6ointsA!ittin#s 3a!ter t"e
pu%p attainin# sution pressure4 s"all
be attended(
%4 5!ter o%pletin# all t"e above "e0s
and t"e pu%p "ousin# attainin#
te%perature lose to t"at o! t"e !luid,
t"e %otor s"all be rotated to ensure
!ree rotation(
n4 5li#n%ent s"all be re"e0ed a!ter t"e
pu%p "as been "eated up by t"e
sution !luid(
o4 Ensure t"at t"e dis"ar#e valve is
!ully losed and sution is !ully
opened(
iiD Start u% Procedures
5!ter o%pletin# t"e pre-startin#
proedure t"e pu%p is ready !or start up( T"e
start up proedures #iven belo, s"all be
!ollo,ed(
a4 'learane !or ener#isin# t"e $otor 3in
ase o! eletrial drive4 s"all be
obtained(
b4 T"e pu%p s"all be started & t"e
dis"ar#e valve opened #radually(
iiiD Post Start C*ec7s
T"e !ollo,in# s"all be "e0edAobserved:
a4 5ll instru%ents s"all be "e0ed and
readin#s observed at re#ular intervals,
and t"e per!or%ane o! e-uip%ent
o%pared ,it" %anu!aturerHs data(
b4 ?ibration readin#s s"all be "e0ed
!or abnor%ality 3i! any4 and orretive
ation s"all be ta0en as neessary(
Si#nature !or ritial Pu%ps s"all be
"e0ed(
4 Te%perature rise, and abnor%al
sound 3i! any4 !or bearin#s s"all be
"e0ed(
=6+6' Ne.ly Installed Pu"%s
iD Pre Startin- Procedures
aD E5ui%"ent
Pu%p s"all be t"orou#"ly
leaned(
,D Pi%in-
5sse%bly o! all pipin# s"all be
"e0ed to ensure t"at t"ey are
as per t"e desi#n dra,in#( Pipin#
s"all be t"orou#"ly !lus"ed to
re%ove rust preventiveA!orei#n
%aterial(
cD Su%%ort
Relevant pipe supports s"all be
"e0ed to ensure t"at t"ey are
as per desi#n dra,in#(
dD Ali-n"ent
5li#n%ent o! pu%p and pri%e
%over s"all be arried out( OISD
RP 1=6, CSpei!i $aintenane
PratiesD s"all be re!erred(
eD Cearin-
/earin#s s"all be lubriated ,it"
orret lubriant ,"erever
appliable(
fD Pri"e Mo!er
T"e pri%e %over s"all be
prepared !or operation as
%anu!aturerHs instrution( In
ase o! Eletri Drive orret
diretion o! rotation s"all be
ensured in deoupled ondition(
Insulation value o! %otor and
able s"all be "e0ed and
reorded(
-D Pac7in-FMec*anical Seal
For #land pa0in# and
%e"anial seal, oolin# and
!lus"in# s"all be ensured(
$e"anial Seals 3i! appliable4
s"all be installed as per
%anu!aturerHs
reo%%endations(
*D <eatin- u% ,efore Startu%
Pu%ps on "i#" te%perature
servie s"all be "eated up
#radually to an even te%perature
be!ore puttin# on servie(
iD Calancin- dru" lea7a-e
For pu%ps e-uipped ,it"
balanin# dru%s, any valve in
t"e line s"all be lo0ed open !or
ensurin# lea0a#e return to pu%p
sution or to t"e vessel(
9D <i-* te"%erature %u"%
o%eration
T"e !ollo,in# preautions s"all
be ensured:
T"e re-uired sution "ead(
Su!!iient !lo, to prevent
!las"in# o! li-uid passin#
t"rou#" t"e pu%p(
Sudden "an#e o!
te%perature s"all be avoided
to prevent t"er%al s"o0s to
t"e pu%p(
T"e lubriation o! bearin#s
and stu!!in# bo+ to prevent
da%a#e(
7D After t*e a,o!e c*ec7s(
%rocedures %er =6+60 s*all
,e follo.ed6
iiD Start u% Procedures
T"e proedures as #iven belo, s"all
be !ollo,ed !or start up(
a4 T"e !ree rotation o! t"e pu%p s"all be
"e0ed(
b4 Ensure all instru%ents are installed as
per P&I dia#ra%(
4 Ensure t"at strainer is provided in t"e
sution line(
d4 Dis"ar#e valve s"all be losed 3i! not
already losed4(
e4 On pu%ps "avin# e+ternally sealed
stu!!in# bo+es, t"e in6etion line
valves s"all be opened and sealin#
!luid allo,ed to !lo, to t"e seal a#es(
!4 Pu%p s"all be properly pri%ed(
#4 Pri%e %over s"all be started as per
presribed reo%%endation(
iiiD Post Start C*ec7s
a4 5ll instru%ent readin#s s"all be
"e0ed and reorded periodially(
b4 ?ibration readin#s s"all be "e0ed
and si#nature s"all be ta0en as
neessary(
4 Stu!!in# bo+ pa0in# s"all be "e0ed
!or over"eatin#(
d4 Te%perature rise, vibration and any
abnor%al sound !ro% bearin#s s"all
be "e0ed(
e4 'oolin# ,ater !lo, s"all be "e0ed
!re-uently(
!4 Sution and dis"ar#e pressure s"all
be %onitored to ensure proper
operatin# ondition(
#4 5li#n%ent s"all be re"e0ed ,it"in
1.. "ours o! operation(
>61 PRE;ENTI;E MAINTENANCE
INSPECTION SC<EDULE FOR
POSITI;E DISPLACEMENT PUMPS
Positive displae%ent pu%ps are
lassi!ied in t"e !ollo,in# #roups !or
preparation o! preventive %aintenane
inspetion s"edule:
i4 Reiproatin# Pu%psAplun#er pu%p
ii4 *ear Pu%psASre, Pu%ps
'"e0list on inspetion ite%s !or ea"
type o! pu%ps s"all be as per t"e !ollo,in#
s"edules:
>60 RECIPROCATIN F PLUNER F
DIAP<RAM PUMPS
5ll t"e !ollo,in# ite%s s"all be
"e0edAreorded a!ter t"e spei!ied period(
>6060 After 0111 <ours
i4 'ran0 ase oil ondition !or
onta%ination
ii4 *ear /o+ oil ondition !or
onta%ination
iii4 *land !or lea0a#e 3s"all be ad6usted i!
neessary4
iv4 'ouplin# #uard ondition 3s"all be
reti!ied i! neessary4
v4 $otor and *ear bo+ bearin#s by sound
and te%perature 3in runnin# ondition4
vi4 Relie! valves !or passin#
vii4 8ubriatin# oil pu%p and non return
valve 3!or stea% driven pu%p only4
>606' After =111 <ours
i4 'ran0 ase oil replae%ent 3ran0ase
s"all be !lus"ed be!ore oil
replae%ent4
ii4 *ear bo+ oil replae%ent 3#ear bo+
s"all be !lus"ed be!ore oil
replae%ent4(
iii4 'ondition o! pistonAplun#er and liner
!or ,ear
iv4 8ubriatin# oil strainer and pipin#s
v4 /earin# and *ear o! *ear bo+ !or any
da%a#e
vi4 'ouplin# #uard ondition
vii4 1or0in# o! sa!ety relie! valve
viii4 Ensure replae%ent o! #land
pa0in#
i+4 5li#n%ent
+4 Sution and dis"ar#e valve, valve
seat et(
+i4 Stro0e ad6ustin# %e"anis% 3s"all be
servied i! neessary4
+ii4 8ubriation !or t"e stea% driven side
3in ase o! strea% driven pu%p4
+iii4 Foundation, !oundation bolts and
supports
)ote : T"e pu%p s"all be started
a!ter o%pletin# t"e "e0s listed i to
+ii above and t"e !ollo,in# s"all be
"e0ed :
a4 ?ibration and te%perature o!
bearin# o! *earbo+ and $otor
b4 *land !or lea0a#e 3s"all be
ad6usted i! neessary4
4 Pu%p per!or%ane
>606: After @111 <ours
'o%plete over"aulin# o! t"e pu%p
s"all be arried out( T"is s"all inlude part-
,ise inspetion as per ite% @(> and all "e0s
spei!ied !or ;... 9ours(
>6' EAR PUMPSFSCRE2 PUMPS
For *ear Pu%psASre, Pu%psA
Dosin# Pu%ps, t"e inspetion s"edule s"all
be !i+ed dependin# on t"e spei!i nature o!
appliation and %anu!aturerHs
reo%%endation(
>6'60 Ins%ection ite"s of ear Pu"%s
T"e !ollo,in# s"all be "e0edA
reorded:
iD ear Casin-

a4 'learane bet,een #ear and
asin#(
b4 End learane bet,een #ears and
end overs
4 /a0las"
iiD Cus*FCearin-
a4 'learane bet,een #ear s"a!t and
bus"(
b4 /earin# as per OISD 1=>
iiiD Seal
a4 'ondition o! Seal
b4 Replae%ent o! elasto%er
>6'6' Ins%ection Ite"s of Scre. Pu"%s
T"e !ollo,in# s"all be "e0edA
reorded:
iD Scre.FCasin-
a4 'learane bet,een sre, and
asin#
b4 5+ial learane bet,een sre,
and end over(
iiD Cearin-
OISD RP 1=>, Inspetion and
$aintenane o! Rotatin# E-uip%ent
G'o%ponentsH s"all be re!erred(
iii4 Seal
a4 'ondition o! seal
b4 Replae%ent o! elasto%er
>6: PART2ISE INSPECTION
DURIN COMPLETE
O;ER<AUL OF
RECIPROCATIN PUMPS
Part-,ise inspetion s"all be arried out
durin# o%plete over"aul(
For t"e purpose o! part-,ise inspetion,
reiproatin# pu%p parts are divided into t"e
!ollo,in# t,o #roups :
i4 8i-uid end parts
ii4 Po,er end parts
T"e li-uid end per!or%s t"e sution and
dis"ar#e !untions o! t"e pu%p !or t"e li-uid
"andled ,"ereas t"e po,er end provides t"e
po,er !or t"e pu%p(
>6:60 Li5uid end %arts
iD Cylinder Liner
T"e ylinder liner s"all be "e0ed !or
,ear, ovality and srat"es( T"e baseAovality
s"all be %easured, reorded and
%aintained ,it"in presribed li%its(
In ase o! replaeable liners, t"e liner
,ear plate and #as0et s"all be re%oved,
"e0ed and replaed i! neessary( T"e
#as0et s"all be replaed every ti%e ,"en it is
re%oved(
iiD PistonFPlun-er
Piston or plun#er s"all be "e0ed !or
,ear, ovality and sorin# %ar0s( In
t"e ase o! piston ,it" piston
rin#s t"e ,ear on piston rin# #rooves
s"all be "e0ed( T"e piston and
piston rin# #rooves s"all be brou#"t
ba0 to aeptable toleranes(
iiiD Plun-er Pac7in- Set
T"e pa0in# s"all be replaed( T"e
lantern rin# and spaer rin# s"all be
"e0ed !or ,ear and orrosion(
i!D land Pac7in-
*land pa0in# s"ould be replaed(
!D Suction and Disc*ar-e ;al!e
T"e sution and dis"ar#e valve s"all
be inspeted !or :
a4 1earA'orrosion
b4 'learane o! valve #uide
4 'ondition o! seatin# !ae
d4 Sprin# or dead ,ei#"t !or
,ear, ra0 and orrosion(
!iD Piston Rod
Piston rod s"all be "e0ed !or
strai#"tness and ,ear(
!iiD T*rottle Cus*
T"e learane bet,een t"rottle bus"
and t"e s"a!t s"all be %easured and
t"e bus" s"all be replaed i! t"e
learane is !ound %ore t"an
presribed(
>6:6' Po.er End Parts Bstea" dri!enD
iD Cylinder
T"e ylinder s"all be "e0ed !or
,ear, ovality and sorin#( T"e bore &
ovality s"all be %easured, reorded
and %aintained ,it"in presribed
li%its(
iiD Piston
T"e piston s"all be "e0ed !or ,ear,
ovality and sorin#( Piston rin#
#rooves s"all be "e0ed !or
,ear(
iiiD Piston Rin-
Piston rin# s"all be "e0ed !or ,ear,
tension and #ap( Piston rin# ,idt"
s"all be "e0ed(
i!D Piston Rod
Piston rod s"all be "e0ed !or
strai#"tness and ,earAsorin#(
!D T*roat Cus*
T"e learane bet,een t"rottle bus"
and t"e s"a!t s"all be %easured(
!iD Slide ;al!es
T"ese s"all be "e0ed !or ,ear(
>6:6: Po.er end %arts B"otorFen-ine
dri!enDFear,o8
T"e !ollo,in# s"all be "e0ed :
a4 1ar% s"a!t !or trueness(
b4 /a0las"A#ear learanes
4 /lue %at"in# o! #ear teet" !or
uni!or% ontat(
d4 'ondition o! ran0s"a!t ,it"
bearin#s(
e4 'ondition o! onnetin# rod ,it"
bearin#s(
!4 'ross "ead and ross "ead pin
learane(
#4 Pinion s"a!t or spro0et s"a!t and
bearin# learane
"4 'ondition o! driveAdriven spro0et
and "ain
i4 'ondition o! pu%p s"eave or
ouplin#(
>6:6= Dia%*ra-"
a4 s"all be "e0ed !or ondition and
elon#ation
b4 s"all be replaed i! di%ensions
donHt %at" ,it" ori#inal values(
4 lube oil su%p s"all be !lus"ed and
oil replaed(
>6= COMMISSIONIN AND TESTIN
PROCEDURES FOR
RECIPROCATIN PUMPS6
T"e !ollo,in# ativities s"all be
per!or%ed ,"en a ne, reiproatin# pu%p or
,"en a pu%p ,"i" is idle !or a lon# period o!
ti%e or a pu%p a!ter over"aulin# is started(
iD Pre Startin- Procedures
a4 Pu%p and strainer s"all be
leaned
b4 Pu%p alon# ,it" sution
dis"ar#e line s"all be !lus"ed(
4 Ensure ross "ead, plun#er are
!ree o! rust and lean(
d4 Ensure !reeness and diretion o!
rotation o! pu%p(
e4 Ensure proper lubriant in ran0
ase( In ase o! %ultiple+ pu%p
ea" ran0 ase s"all be "e0ed(
!4 Ensure installation o! Relie! ?alve
and Pressure *au#e in dis"ar#e
line(
#4 Ensure replae%ent o! "ardened
any dry synt"eti rubber pa0in#(
"4 For pu%p ,it" stu!!in# bo+
lubriation, t"e volu%e o! oil in
lubriatin# tan0 s"all be "e0ed(
8ubriatin# pressure s"ould not be
raised "i#"er t"an neessary(
iiD Startin- Procedures
a4 Sution valve s"all be opened
and t"e li-uid is allo,ed to !lo,
and no pressure is put on t"e
dis"ar#e side( In ase o! li-uid
end ,it" 6a0et, li-uid s"all be
allo,ed to pass a!ter t"e li-uid
end "as rea"ed a set
te%perature(
b4 b4 1"en startin# !or !irst ti%e or
a!ter a lon# s"utdo,n, stro0e s"all
be set at GOH be!ore s,it"in# on
t"e eletri po,er soure( Pu%p
s"all be run unloaded ,it" stro0e
at GOH !or a !e, %inutes(
4 Stro0e len#t" s"all be raised
#radually and pu%p is allo,ed to
run !or a ,"ile until 1..I stro0e
len#t" is attained( Durin# t"is
interval, "e0 t"at no abnor%al
soundAabnor%al vibrations "ave
developed and t"e stro0e
ad6ustin# "andle is ,or0in#
s%oot"ly(
d4 Pressure s"all be raised #radually
until o%plete load is attained( In
ase t"e pressure annot be
applied on t"e proess side, t"e
ba0 pressure valve an be used
to load( T"e pressure s"ould be
raised by ,at"in# t"e pressure
#au#e but at !irst t"e set pressure
o! t"e ba0 pressure valve s"ould
be at .(
e4 5%%eter s"all be "e0ed to
ensure t"at t"ere is no overload(
!4 *land s"all be "e0ed !or
lea0a#e and over"eatin# 3s"all be
ad6usted as neessary4
#4 On ensurin# %e"anial
soundness, volu%e "e0 s"ould
be %ade under atual operatin#
onditions(
+61 DIFFERIN SC<EDULES
T"e s"edules #iven in t"is standard
are very broad based on present e+periene
and praties and %ay be %odi!ied !ro% ti%e
to ti%e( T"e s"edules indiate t"e %a+i%u%
interval o! ti%e bet,een t,o inspetions(
Or#anisations "avin# "istorial reords and
analysis o! !ailures %ay alter t"e inspetion
interval aordin#ly( Reords s"all be
%aintained as per sa%ple !or%at o! "istory
ards and spei!iation s"eets provided in
OISD STD 1=E, ,it" respet to proble%s on
e-uip%ent in di!!erent servies( /ased on t"e
!eedba0 obtained, t"e 'o%%ittee s"all
up#rade inspetion s"edules and proedures(
?61 DOCUMENTATION
Dou%entation and reord 0eepin#
!or% an inte#ral part o! total Inspetion
$ana#e%ent Syste%( T"e various inspetion
reords on all areas s"all be %aintained in
standard !or%ats desi#ned spei!ially !or t"e
individual re-uire%ents(
@61 REFERENCES
a) API 610Centrifugal Pumps for
General Refinery Services
b) API 67Positive !isplacement Pump"
Reciprocating
c) #IS! RP1$% Inspection of
&earings' Couplings an( &elts
() #IS! RP 1$ Pre(ictive
)aintenance Practices
e) #IS! RP 1$* Inspection an(
)aintenance of )ec+anical Seals
f) #IS! RP 1$6 Specific )aintenance
Practices ,Rotating -.uipment)
g) #IS! 1$7 /istory Recor(ing
,Rotating -.uipment)
Notes