Method Statement For Pumps FF

CONTRACTOR
COMPANY
GUJARAT STATE FERTILIZERS & CHEMICALS LIMITED
REVAMPING OF UREA-II PLANT
VADODARA, GUJARAT, INDIA
DOCUMENT NO:
Method statement for revamping Urea plant Ammonia (NH3) AND Re-
Document Tittle
cycled Carbamate (R.C) Pumps
ISSUED FOR APPROVAL CODE
 CODE A– NO COMMENTS. PROCEED WITH MANUFACTURE /

FABRICATION / CONSTRUCTION AS PER THE DOCUMENT.
 INFORMATION
 CODE B – PROCEED WITH MANUFACTURE / FABRICATION /
CONSTRUCTION AS PER COMMENTED DOCUMENT. REVISED
 REVIEW/APPROVAL
DOCUMENT REQUIRED FOR REVIEW.
 CODE C – DOCUMENT DOES NOT CONFORM TO BASIC
 CONSTRUCTION
REQUIREMENTS AS MARKED. RESUBMIT FOR REVIEW
 CODE D – DOCUMENT IS RETAINED FOR RECORDS. PROCEED
 AS BUILT
WITH MANUFACTURE /FABRICATION
Sens
itivit  CODE E – DOCUMENT IS RETAINED FOR INFORMATION WITH
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This COMMENTS.
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Rev No. Description Prepared by Reviewed by Approved by Approved Date
Index
1. Introduction................................................................................................................................3
2. Safety...........................................................................................................................................4
3. NH3 & R.C Pump Specification.................................................................................................5
4. Pump Parts.................................................................................................................................9
5. Why revamp of Pumps?..........................................................................................................19
6. OEM recommendation.............................................................................................................20
7. Pump Wise Scope –.................................................................................................................23
8. Execution Methodology...........................................................................................................27
9. Reports:.....................................................................................................................................45
10. Annexures.................................................................................................................................45
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1. Introduction
M/s. GUJARAT STATE FERTILIZERS & CHEMICALS LIMITED (GSFC) hereinafter

referred to as the “OWNER” has awarded the project “Revamping of Urea-II Plant” to M/s.
Larsen & Toubro Limited on EPC basis for Revamping of Urea Plant-II at its existing
Fertilizer Nagar complex, Vadodara, Gujarat.
M/s. GSFC is having two Urea plants at Vadodara unit producing fertilizer grade pilled Urea
having capacity of 323 and 800 MTPD each. Urea I & II plants were established way back in
year 1967 & 1969 respectively. GSFC is operating these plants for more than 50 years with
regular repair & Maintenance.
To improve the reliability and safety of very old plants along with reducing specific energy
consumption to meet the targeted energy norms stipulated by Government of India, GSFC
intends to revamp Urea-II plant with increased capacity of 1175 MTPD from existing Plant
capacity of 800 MTPD by using some of the equipment / machinery of Urea – I Plant like
use of One CO2 Compressor, Prilling Tower etc.
XU-P101C & XU-P101B:
Total 6 nos. of Pumps are being used for UREA-2 plant placed in the compressor house. 2
nos. of working for high pressure liquid ammonia feed pumps supplied by Peroni Italy
currently in working condition requiring valve modification to accommodate to licensor
requirements. [ Tag no. XU-P101C & XU-P101B].
Sens
itivit XU-P101A:
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This Replacement of ammonia pump XU-P101A is required. New pump and motor will be
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new pump to insure its adequacy. Pulsation analysis to be performed post installation.
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XU-P102C to be replaced as well. Spare pump and its attachments to be collected from
GSFC warehouse. Testing of foundation is required before installation of new pump to
insure its adequacy. If fails new foundation must be made as a replacement at the same
location. Pulsation analysis to be performed post installation.
XU-102B:
Pump XU-102B to be retained as it is for standby i.e., no modification or revamp activity is
required.
XU-P102A:
Modification in pump XU-102A as per the requirement suggested by the OEM. Change of
nozzle ring are required.
XU-P107:
Installation of new motor, new coupling, and non-sparking perforated coupling guard to the
pump. Replacement of gaskets O-rings and new foundation bolts
2. Safety
A. General Safety Precautions
1. All JSA’s and Task risk assessments should be in approved form & all Work
Permits to be checked and ensured in place before the start of any work.
2. Conduct Toolbox talk before starting of any activity/shift with execution team to
ensure flawless and safe execution.
Sens
itivit 3. All required tools shall be prepared and brought into place when site conditions
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This allow.
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nt is
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5. When crane lifting/ Hydra (at new canteen location) is required to execute the
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B. Permit Issuing Methodology
“No Permit No Work”
1. All Job safety analysis (JSA) and risk assessment will be in approved state
before starting of any activities.
2. Prior to start of work all mandatory safety protocols shall be followed.
3. All hot work/ cold /height work permits, and permissions will be obtained in
advance from relevant authorities of client in accordance with client HSE
system and format.
4. Appropriate methodology statements shall be submitted on obtaining, handling
& closure of all permits by L&T HSE.
5. Single point responsibility shall be established for co-ordination of receipt of
permits from Client.
3. NH3 & R.C Pump Specification
 Load Specification for IHI Pumps [XU-P101A; XU-P102B/C]

Table: R.C. Pump Loads [XU-P101A; XU-P102B/C]
Weight (Static Load)

Pump 1600kg
Base 1200kg
Turbine 1100kg
Sens R. Gear 600kg
itivit
y: Common Base 1000kg
This Location Of Dynamic Load
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Turbine 550kg
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 Specification For [NH3] Peroni Triplex Pump [XU-P101B/C]
Table: Discharge Pulsation Damper XU-P101B/C
XU-101B/C Shell Tube

Design Pressure 237 -
Test Pressure 378.1 -
Min. Design Temp. -33 -
MAX. Design Pressure 75 -
Corros. Allow 3 -
X-Ray FULL -
Stress Reliving YES -
Capacity 190 -
Surface - -
Table: Suction Pulsation Damper XU-P101B/C
XU-P101B/C Shell Tube

Design Pressure 46 2.5
Test Pressure 59.8 3.3
Min. Design Temp. -33 -33
MAX. Design Pressure 60 140
Corros. Allow 3 0
X-Ray FULL -
Stress Reliving None -
Capacity 1570 4
Surface - -
Table: Specification of Pump XU-P101B/C
Horizontal Triplex Plunger

Type of Pump Pump
Sens Capacity 45 m^3/hr
itivit Suction Pressure 18 kg/cm^2
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This Suction Temperature 38 Deg C
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Discharge Pressure 215~230 kg/cm^2
nt is Discharge Temperature 42 Deg C
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Fluid Liquid Ammonia
d as Sp. Gravity 0.59
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Gen Motor Power & Speed 500kW&1472 RPM
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Gear Box Ratio 14:01
Table: Specification of XU-P102 B/C
Ishikawajima Harima Heavy Industries,

Make Japan
Type Vertical, septuplex, plunger type
Driven by 1 stage gear reducer coupled to motor
Fluid Recycled Carbamate Solution
Capacity 30 m^3/hour
Suction Temperature 100 C
Suction Pressure 16kg/cm^2 g
Delivery Pressure 235kg/cm^2g
Diameter of plunger 60 mm
Stroke 150 mm
Number of revolutions 190 RPM
 Specification For [NH3] IHI Pump XU-P101A
Table: Specifications of XU-P101A
Ishikawajima Harima Heavy Industries,

Make Japan
Type Vertical, septuplex, plunger type
Driven by 1 stage gear reducer coupled to motor
Fluid Liquid Ammonia (NH3)
Capacity 41 m^3/hour or 24 MT/hr
Suction Temperature 35 C
Suction Pressure 16kg/cm^2 g
Delivery Pressure 220 kg/cm^2g
Diameter of plunger 60 mm
Sens
itivit Stroke 150 mm
y: Number of revolutions 260 RPM
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 Specification For Turbine Driven Pump [XU-P102A]
Table: Specification of XU-P102A
Pump Type 100x60 SSP VIIGT

Liquid Pumped Carbamate solution
Inlet Temp 100 C
Specific Gravity 1.15
Capacity 60 m^3/H
Discharge Pressure 242 kg/cm^2g
Suction Pressure 22 kg/cm^2 g
Pump Speed 7650 RPM
Pump Shaft 655 SKW
Suction Flange 4" ANSI 300LB RF
Discharge Flange 2 .1/2" Special 300K DMF
No. of Stages 8
Req. NPSH 17.5m at 60m^3H
Minimum Flow 35m^3/H
Casing Design Pressure 302 kg/cm^2g
Casing Hydraulic test Pres-
sure 462kg/cm^2g
Clockwise Viewed from driven
Rotating Direction end
Stuffing Box Mechanical seal (external)
Bearing
Radial Sleeve
Thrust Kingbury No. 5
Lubrication Forced (supplied from LOU)
Coupling Gear Type (with spacer)
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This 4. Pump Parts
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d) Water Seat nut

e) Gland packing
f) Gland packing Bush
g) Stuffing Box
h) Cylinder
i) Head Valve
j) Distance Piece
k) Crosshead
l) Crank Shaft
m) Shaft Bearings
n) Nozzle Ring [Turbine Pump]
o) Suction and Discharge valves/piping.
2. Gear Box –
a) Reduction Gear Box [ Reduces motor rpm of 14000app. to 4000app.]
3. Electric Motor –
a) Three phase induction motor
b) Squirrel cage rotor (Cu)
c) Horizontal Foot Mounting
d) Direct Coupling
e) Rated Output – 410 kW.
f) Rated Voltage – 3300 V
1. Crank case / Frame
The first thing you’ll notice in a compressor is its heavy and rugged frame which encloses all
the rotating components such as the crankshaft and crosshead assembly.
The frame is also called a crankcase and it has a square or rectangle shape. Its role is to
offer support to the crankshaft & cross head assembly.
2. Cylinder
The cylinder is a pressure vessel that contains the gas in the compression cycle. they are
one of the most important components of a reciprocating compressor. Double-acting
cylinders compress gas in both directions of piston travel. Most reciprocating compressors
use double-acting cylinders. Choice of cylinder material is determined by operating
Sens pressure.
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3. Distance piece
Doc
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nt is
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sifie arrangement. the single design uses a structure where the distance between the diaphragm
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T cylinder stuffing box.
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4. Crank shaft
The crankshaft rotates around the frame axis and drives the connecting rod, piston rod, and
piston. Crankshafts as reciprocating compressor parts are either connected to the electric
motor directly or indirectly with the use of a belt and pulley system. As the motor shaft
rotates, the crankshaft also performs a rotary motion which gives the piston the ability to
carry out its reciprocating motion inside the cylinder. But first, a rod must be connected to
the crankshaft and rod to enable the piston to perform an upward and downward movement.
5. Connecting rod
This component connects the crosshead and crankshaft, converting a rotary motion into a
motion that is reciprocating. Manufactured out of forged steel, the connecting rod also has a
drilled hole to allow for the passage of oil.
6. Cross head
A crosshead enables the piston to be inserted in the cylinder bore. The use of a crosshead
enables a compressor to use a narrow piston and it enables longer strokes and higher
efficiency.
7. Piston rod
Threaded through the piston, the piston rod is responsible for transmitting the reciprocating
crosshead into the piston. This component is traditionally manufactured out of alloy steel.
Where it is passed through the cylinder packing, the surface must be polished and
hardened.
8. Piston rod packing
Like the piston rod, rod packing is essential to preventing gas leakage as it is passed
through the cylinder and crank closure. Where a cooling pack is needed, stuffing boxes may
be jacketed for liquid coolant. Packing rings sit at the heard of the rod packing assembly.
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The piston is often referred to as the heart of the reciprocating compressor. The piston
sifie moves up and down in the cylinder. This movement knows as a reciprocating movement.
d as The piston sucks and compresses the air during its motion. The piston is located at the end
"LN
T of the piston rod and acts as the movable barrier in the compressor cylinder. Selection of
Gen material is based on strength, weight, and compatibility with the gas being compressed. The
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piston is usually made of a lightweight material such as aluminium or from cast iron or steel
with a hollow centre for weight reduction.
10. Piston ring
During the piston movement within the cylinder, the coolant must not leak through the space
between the piston and the cylinder wall. So, this air compressor component covers with the
piston ring. The piston rings are wounded on the piston and as the piston moves up and
down the cylinder, the piston rings come in contact with the walls of the cylinder. Due to the
amount of friction created during this reciprocating motion, rings must be replaced
frequently to maintain the seamless operation of the compressor. In some cases, a wear
band or rider ring is used as an additional piston ring.
11. Bearing
Bearings located throughout the compressor frame assure proper radial and axial position-
ing of compressor components. Main bearings are fitted in the frame to properly position the
crankshaft. Crank pin bearings are located between the crankshaft and each connecting
rod. Wrist pin bearings are located between each connecting rod and crosshead pin.
Crosshead bearings are located at the top and bottom of each crosshead. Most of the bear-
ings in reciprocating compressors are hydrodynamic lubricated bearings. Pressurized oil is
supplied to each bearing through oil supply grooves on the bearing surface. The grooves
are sized to ensure adequate oil flow to prevent overheating.
12. Suction & Discharge valve
The essential function of compressor valves is to permit gas flow in the desired direction
and to block all flow in the opposite (undesired) direction. Each operating end of a
compressor cylinder must have two sets of valves. The set of inlets (suction) valves admits
gas into the cylinder. The set of discharge valves is used to evacuate compressed gas from
the cylinder.
13. Nozzle Ring (Turbine Pump)

Sens
itivit The nozzle ring is a crucial component that directs steam flow onto the turbine blades. It’s
y:
This
typically located at the entrance of the turbine casing. The nozzle ring controls the velocity
Doc and angle of the steam flow, optimizing turbine performance and efficiency. Adjusting the
ume nozzle ring can modulate the amount of steam entering the turbine, allowing for precise
nt is
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Pump
Crank Shaft Pump

Electric Casing Header
RGB to
Motor Crankshaft
3300V Coupling Oil Cooler
RGB
Fig:R.C Pump Major Components
Motor-RGB
Coupling
Motor Forced
Terminal Lubrication Cooling
Box System Water
Gear Box Oil Outlet
Lubrication
System
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Connecting
Rod
Tie Rod
Water seal
nut
Stuffing box
bolts
Cooling line
outlet
Note: Cooling inlet Stuffing

on the opp. side Box
Cylinder
Header
Note: Header Valve

are present inside
the header b/w
suction and
Fig: R.C Motor-Crankshaft Pumps compression
chamber
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Distance
Piece for
header.
Suction
Crankshaft Line
Casing
Opening
Lubrication
Oil Drain
Cooling
Water Line
Discharge
Line
Fig: R.C. Pump Connections
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B. Part Details and working of XU-P102A:
Discharge
Line
Turbine to
Balance RGB
Line RGB
Coupling
Suction
Line
Note: Nozzle Ring is

Centrifugal present inside the
Pump steam turbine casing
Flush Steam
Water Line Turbine
Pneumatic
RGB-Pump Controller
Coupling
Fig: Turbine Driven Centrifugal Pump XU-P102A

Sens
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Note: Steam inlet and
Steam
y: condensation line on outlet line
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Balance
Line Suction
Line
Discharge
Line
Centrifugal
Pump
Flush
Water Line
Fig: Centrifugal Pump XU-P102A
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C. Part Details and working of XU-P101B/C:
Slow Suction
Electric Coupling Pulsation
Gear with guard
Motor Main Pump Damper
Reducer
Fig: Peroni Pump (Pp) Main Components
Pump
Lube Oil Discharge Manifold
Discharge Suction Line
Pump Motor Line
Pulsation
Damper
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D. Part Details and working of XU-P107:
Coupling Guard Electric Driver

Effluent Effluent Air Vent for Motor
Inlet outlet bearing casing
Fig: XUP-107 SULZER Centrifugal Pump Main Components
Gland and Motor Bearing Constant Motor- Foundation

Base Plate Packing type Casing Level Oiler Pump Bolt
sealing Coupling
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5. Why revamp of Pumps?
A. Energy Efficiency Enhancement
 The power output and input of the pumps are required to change to be inline with
the values provided by the LICENSOR for the changes made in the UREA-II plant.
 The Energy requirement will reduce from 730kW to 408kW.
B. Vibration issue
 Problem of high vibration has been observed mainly urea-2 pumps. GSFC wants to
reduce the vibration issue.
 Use of Pulsation analysis is required to be done pre and post
installation/modification.
C. Replacement of Pumps
 The older models of pumps are not energy efficient as compared to the newer
models hence requiring proper dismantling, inspection, and replacement.
D. Modification in existing Pumps
 Modifications related to changes in valve are required to change the pressure and
change in flow rate to make the process more energy efficient and match the new
plant requirements.
 Inlet Pressure Changes form 33kg to 35 kg
E. Foundation Suitability
 Suitability / adequacy of existing pump foundation with respect to new pump and
motor with all accessory’s installation shall be checked as the foundation are nearly
50+ years old. If not adequate, new foundation shall be considered for installation of
available spare warehouse centrifugal pump along with required new accessories at
same location i.e. existing pump foundation.
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6. OEM recommendation
1. Comparison b/w current and required operating condition –
2. EBARA Pump TAG: XU-P102A
 PUMP- Pump Maintenance and parts replacement might be required after

dismantling inspection.
 Gear - Gear maintenance and parts replacement might be required after
dismantling inspection.
 Turbine – Decrease speed and power to accommodate to new plant requirements.
Changing Parts to be replaced provided by seller – (1no.s) Nozzle ring; (1no.s)
Turbine Nameplate.
 Turbine and gear base needs modification.
 Pump base to be moved to turbine side.
 Pump base to move to upper side to be inline the shaft, 250mm.
 Piping for pump suction and discharge shall be modified.
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Fig: Modifications Recommended in XU-P102A
3. Peroni Triplex Plunger Pumps TAG: XU- P101B/C
 Pump column Valve Needs upgradation.

 Rectification of existing dampeners, i.e., discharge pulsation damper and suction
pulsation damper.
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Fig: Discharge & Suction Pulsation Damper
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4. TAG: XU-P102C
 Pump Maintenance and parts replacement might be required after dismantling

inspection.
 New gear, motor (supply 3300V), coupling, base plate, LOU, interconnecting line
between LOU & pump base plate.
 New Lube Oil Unit (LOU) to be installed.
 New SWU including supply plunger, strainer, and auxiliary piping.
 Modification in Sealing water unit
5. SULZER Single Stage Centrifugal Pump TAG: XU-P107
 Requirement for a new electric motor of 7.5 kW power rating.

 Installation of new coupling and perforated coupling guard.
 Installation of new wearing ring in the pump main casing.
 Installation of new Internal/grounding lug and Earthing skid with all the attached
accessories.
 Installation of new foundation bolts and base plate for new motor mounting.
7. Pump Wise Scope –

1. XU-P101A:
 Existing pump along with all the accessories to be dismantled.

 Existing XU-P101A (IHI Machine) to be replaced by New reciprocating pump
with new motor and accessories on existing foundation.
 Installation Elastic multi disc type coupling with SS spacer and guard which is
metallic and non-sparking type.
 Pulsation Analysis of new pump in parallel operation with the existing pump
(XU-P101B/C) and carry out modification as per the recommendation.
 Pulsation Analysis of suction and discharge piping system as API 674 3rd
edition with residual pulsation within +/- 2%
 Noise data shall be provided by supplier of the complete package and shall be
Sens within 85 dB.
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 Hydro and pneumatic test as applicable and Helium leak test wherever
This applicable.
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 Alignment of the pump coupling to be done with no. of installed shims limited
nt is to 3.
clas  Insulation and heat tracing in applicable.
sifie
d as  On-Site hydrotest of the pump package. M/s Peroni shall provide the hydrotest
"LN procedure.
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Gen  Mechanical & Performance Run test of pump for at least 4 hours at site under
eral Vendor supervision as per API 674 3rd edition.
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 Complete unit test including MRT, performance test and NPSH test with Job
motor and Job VFD. During complete unit test, shop dampeners shall be used.
 Cleaning and overhauling of the Pump Unit Parts if deemed necessary.
 Replacement of any other parts or components as pre their perceived
condition and reusability.

2. XU-P101B:
 Replacement and Installation of new valve components (suction and

discharge) according to the revised operating conditions.
 Replacement and Installation of Discharge and Suction dampers as existing
dampers are no more functional. Only engineering details to be provided by
M/s Peroni.
 Flushing to be done at the stuffing box with condensate as per the existing
pumps.
 Pulsation study Analysis to be done in parallel operation with the new installed
pump and carry out modifications as recommended.
within 85 dB.
 On-Site hydrotest of the pump package. M/s Peroni shall provide the hydrotest
procedure.
 Mechanical & Performance Run test of pump for at least 4 hours at site under
Vendor supervision as per API 674 3rd edition.
 Alignment and soft foot check According to API 686.
 Insulation and heat tracing in applicable.
condition and reusability
3. XU-P101C:
Sens  Replacement and Installation of new valve components (suction and

itivit
y:
discharge) according to the revised operating conditions.
This  Replacement and Installation of Discharge and Suction dampers as existing
Doc
ume
dampers are no more functional. Only engineering details to be provided by
nt is M/s Peroni.
clas  Flushing to be done at the stuffing box with condensate as per the existing
sifie
d as pumps.
"LN  Pulsation study Analysis to be done in parallel operation with the new installed
T
Gen pump and carry out modifications as recommended.
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within 85 dB.
 On-Site hydrotest of the pump package. M/s Peroni shall provide the hydrotest
procedure.
Vendor supervision as per API 674 3rd edition.
 Alignment and soft foot check According to API 686.
 Insulation and heat tracing in applicable.
4. XU-P102A:
 Replacement of following components –

I. One (1) NEW Nozzle Ring
II. One (1) NEW Governor Valve and Stem Assembly
III. One (1) NEW Governor Valve Seat
IV. One (1) NEW PG Worm Gear for 5.1667/1 ratio
V. One (1) NEW PG Worm Wheel for 5.1667/1 ratio
VI. One (1) NEW Set of Bearing Liners
VII. One (1) NEW Trip Pin Assembly
 No changes in currents gear ratio (1.506)
 No changes in coupling i.e. Pump to Gearbox and Gear Box to Turbine.
 Use of existing LOU without any modifications.
 EBARA to provide with lubrication detailing.
 NDT for applicable steam turbine parts.
Vendor supervision.
Sens  Lateral Analysis of the new modified pump.
itivit
y:
This  Replacement of any other parts or components as pre their perceived
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nt is 
clas 5. XU-P102B:
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"LN  Pump to remain in stand by hence, no modification or revamp activity required
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Gen on the pump.
eral  Cleaning and overhauling of the Pump Unit Parts if deemed necessary.
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
6. XU-P102C:
 Installation of New drive motor (3.3KV, 500KW, 4 Pole, AMA 400L4A BAI
type, ABB make)
 Installation of New gear box suitable for revised pump operating parameters.
 Installation of New couplings (between pump, gear box and motor) including
related Coupling guards (rotating parts fully enclosed)
 Installation of New common base plate for pump, gear box, and motor to
accommodate for space limitations.
 Installation of New LOU (Lube Oil Unit) for Pump and gear box.
 Installation of New SWU (Seal water Unit) suitable for revised pump operating
conditions.
 No modification at existing bearing design.
 Shims, Levelling Pads, Lifting Pads, Anchor Bolts, Earthing/Grounding Bolts to
be provided by EBARA.
 Heat Tracing not required. Installation of Insulation on the Pumps.
 NDT of Gearbox, LOU, Mechanical Seal, auxiliary piping shall be as per
manufacture’s standard.
 Hydrostatic test of pressure parts to be provided by EBARA.
Vendor supervision.
 EBARA to provide with lubrication detailing.
 Lateral Analysis of new pump.
 TPI for motor, LOU, SWU and gearbox shall be Lloyds and TPI costs be
considered by L&T.

7. XU-P107:
Sens  Installation of New Motor (7.5 kW) supplied by SULZER.

itivit
y:  Installation of New coupling to be supplied by SULZER.
This  Installation of New non-sparking perforated coupling guard (not of brass).
Doc
ume  Impeller wear ring not applicable. Installation of New Casing wear ring.
nt is  Installation of new baseplate on existing foundation/foundation bolt pockets.
clas
sifie  Installation of New of Internal Earthing/Grounding Lugs and Earthing within
d as skid (includes earthing of all components inside skid)
"LN
T  Replacement of gaskets, O-rings, other consumables (as applicable) for the
Gen parts which are required to be opened to carry out the revamp activity.
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 Installation of new foundation bolts.

 Installation of SS shims for alignment as required.
 Installation of New nameplate.
 Hydrostatic test of pressure parts to be provided by Vendor.
Vendor supervision.
8. Execution Methodology
Key Points Before Starting Execution –

 Insure to take up permit form proper authorities before starting the execution work.
 Insure to wear proper PPE with as Ammonia is corrosive gas and may cause loss of
consciousness.
Sens
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 In Compressor house a 15MT EOT crane is present. Proper permission is required to

before using it for lifting.
 Pumps XU-P101B/C requires Special tool for removal and installation of the
manifolds. Specialised tool for such jobs to be provide by GSFC during the time of
modification.
Fig: 15MT EOT Present in the Compressor House
 Disassembled pieces must be removed from the compressor house as soon as

possible using the help of EOT crane and a trailer. Sufficient space is present in
south side of the compressor house to allow entry of a trailer.
 Poclain crawler will be used for foundation demolition and digging.
 Poclain Crawler entry space will also be given from the south side of the compressor
house.
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Fig: Space at south side of the compressor for entry
Fig: Location of entry space on plot plan

 Requirement of crane and appropriate capacity trailer for movement of Spare pump
from GSFC warehouse.
 Some of the bolts used in the Pump requiring disassembly (i.e. in headers 55mm,
stuffing box 30mm flat head) are using Hex Nut requiring Allen/Hex Key for opening
please refer to the chart given below to get the key sizes details.
Sens
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A. IHI Pump Disassembly [XU-P102B/C & XU-P101A]:
 Remove the power supply form the electric motor and other wiring connections from
the pump.
 Remove top canopy from the motor, couplings and RGB.
 Remove the 4 base bolts from motor, remove 4 bolts from coupling and slide the
motor backwords i.e., away from the RGB to detach the coupling.
 Lift and remove the motor.
 Decouple the RGB and crankshaft of the pump.
 Drain the lubrication oil from the RGB from drain valve.
Motor-RGB
RGB Coupling
RGB Oil
Drain Valve
Motor
Fig: Motor-RGB Coupling
Sens
itivit
y:
This
Doc  Remove all the oil lines and other attached lines from the RGB.
ume
nt is  Remove 4 base bolts from the base of the RGB,
clas  Remove the coupling bolts and slide it away from the Pump to remove coupling from
sifie
d as crank shaft the remove the RGB as Love Joy Coupling as used.
"LN
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Removal Dir.
Fig: Disassembly of R.C. Pumps
 Disconnect the suction, discharge, cooling water, oil lubrication and any other
connected lines from the pump. And make sure that the ammonia is clear from the
lines and is safe to proceed.
 Close valves and add blinds to the valves for safety.
 Remove connection cooling water inlet and outlet lines form the piston plunger
[ nos.7] and remove the connecting line.
 Drain the oil from the oil drain valve [ as shown in fig].
 Remove the top bolts from the head then remove head and tie rod.
Sens
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Hex Key
Water line
Fig: Bolts and Piping for Removal
Sens
itivit  Remove the plunger after unscrewing the water seal nut and gland nut from the
y: pump. [ Be cautious as high-pressure gas may release]
This
Doc
 Remove the 4 bolts holding the stuffing box (using Allen/Hex Keys) and remove it
ume carefully using the EOT.
nt is  Remove the header bolts hence, removing the header and distance piece.
clas
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Hex/Allen Key Req.
Fig: Position Of Hex Bolts Holding the Headers and Distance Piece
 Open the side window panels and case opening at front from the crankshaft casing.
 Remove the piston, connecting rods and other connected part from the crank shaft.
 Hold the crank shaft using the EOT still inside the casing and slide out the bearings
from the front opening of the casing.
 Remove the crank shaft from the casing.
 Dismantle the top part of the pump casing by removing the side bolts. Remove the
base bolts and completely remove the pump casing.
 Make sure if any other compliance is remaining or not in presence of GSFC and Civil
department.
Sens  Hand over to the project to Civil for foundation work.
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B. Modification on Peroni Triplex Pumps [XU-P101B/C]-
Changing safety Valve.
Fig: Location of Safety Valve at North Side of the Peroni Pump
 Shut the connecting pipeline to the Safety valve.

 Remove the safety valve by removing the bolts.
 Replace old safety valve with the new one.
 Make sure that it is secured in place and no leaks and present.
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Changing Suction and Discharge Valves in Peroni Triplex Pumps.
 Shutdown the pump before progressing. Remove any electrical supply to the motor.
 Disengage the motor to crankshaft power transfer connection.
 Disconnect or close any attached pipeline to the pump, i.e., suction line, LOU line,
discharge line, cooling water supply line, etc.
Discharge
Pulsation
Damper
Suction
Pulsation
Damper
By-pass
Discharge
Line
Line
Pump
Manifold
End Cover
Suction
Line
Fig; Peroni Triplex Plunger Pump
 Make sure that the manifold is clear of all the working fluid (Ammonia) before
proceeding any further.
 Loosen up the end-cover bolts (6nos.) of the manifold. {Be careful Ammonia Might
leak}
Sens  To completely remove the end-cover a special L-shaped attachment will be
itivit
y: provided by GSCF under their supervision to insure proper and safe removal of the
This end-cover.
Doc
ume
 After removal of end cover unscrew and remove the Allen Plug (4nos.) visible inside
nt is the manifold’s bore along with other attachments (i.e., O-ring, support rings, backup
clas rings, etc.)
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Fig: Allen Plug
 Make sure to note the order in which the attachments O-ring, support rings, backup
rings, etc. are removed for re-installation purposes (also you can check GAD for
Peroni pump).
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Fig: Cross-section of Manifold of Peroni Triplex Pump
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 Remove the discharge valve spring plate assembly and discharge valve spring.
 The suction-discharge mono block is stuffed inside the manifold tightly and can be
removed by using a puller by applying significant amount force.
 Once the mono block is out disassembling the mono block by removing the tying
bolts (4 nos.) form the Monoblock.
Suction
End
Groove For Discharge

NH3 Inlet End
(Suction)
Fig: Valve Block

 Remove the suction valve spring plate assembly and suction valve spring.
 Make sure to clean each part of the mono block for and dirt and leftover oils.
 Make sure to measure the ID for the manifold bore & guide cylinder and the OD of
the new valve block, suction valve & discharge block so that they all fit together
perfectly without any unnecessary distortions or movements.
Sens
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 Clean and lubricate inside of the manifold bore.

 Clean and lubricate the Monoblock before re-installing ensuring any foreign particles
are not present.
 Change the suction and discharge valve spring (if recommended by the OEM)
 Install the O-ring and support rings in the order they were removed. Make sure to
check for any defects.
 Re-Install the suction valve spring plate assembly and suction valve spring.
 Re-Install the mono-block back in its place.
 Re-Install discharge valve spring plate assembly and discharge valve spring and all
the adjoining attachments.
 Screw the Allen Plugs back on the assembly.
 Attach the end covers along with its bolts back on the manifold.
The end covers must by bolted onto the manifold by torquing-
Top Bolt
End
Cover
Bottom
Bolt
Sens Fig: Front View of Pump Manifold

itivit
y:
This
Doc  First torque the bottom bolt by applying a torque of 1300 Nm [i.e. 52x25Nm]
ume
nt is
 The do the same for the upper bolt.
clas  For second and final round apply torque of 4009 Nm [i.e. 160x25 Nm]
sifie
d as
 Then do the same for upper bolt of the end cover.
"LN  Repeat till all the end cover are re-installed.
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C. Modification on Turbine Centrifugal Pump [XU-P102A]

Changing Turbine nozzle ring.
Fig: Nozzle Ring
 Shut down the turbine by shutting off the steam supply to the turbine.
 Remove any other electrical connection from the turbine.
 Ensure that the turbine is depressurised and cooled before accessing the turbine.
 Remove the turbine casing to gain access to the old turbine nozzle.
 Remove the old turbine nozzle ring carefully.
 Ensure the surface the internals of the turbine are clean before installation of new ring.
 Place the turbine nozzle ring on the casing carefully the with proper alignment and
torque specifications.
 Make sure all the surfaces and components are clean before closing the turbine casing.
 After closing the casing make sure that all the bolts are tightened properly without any
loose parts or any leak.
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Fig: Cross section of a steam turbine nozzle block

Changing the Gear –
 Ensure the gearbox and associated machinery such as forced lubrication system are
shut down and safe to work on.
 Drain the gear box from the
 Gain access to the gearbox, which may involve removing covers or panels.
 Locate the gear you want to change. Gears are typically labelled or identified by their
position within the gearbox.
RGB-Pump
Coupling
RGB-
Turbine
Coupling
RGB
Sens
itivit Lubrication
y: Oil Unit
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Fig: Gear Box of Turbine Centrifugal Pump
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 If the gearbox is under load, ensure it's released to prevent sudden movements when
changing gears.
 Disconnect power or disengage any coupling mechanisms that connect the gearbox
to other components i.e., from the turbine side as well as from the pump side.
 Remove bolts or clips, holding the gear in place.
 Carefully lift or slide the gear out of its position within the gearbox. This may require
some force depending on the design of the gearbox.
 Make sure that everything is checked during this time for any defects or other prob-
lems.
 Ensure that every surface is cleaned and lubricated before installation.
 Insert the new gear into the appropriate position within the gearbox. Ensure its prop-
erly aligned and seated.
 Reinstall any retaining mechanisms to secure the new gear in place. Tighten bolts or
clips according to manufacturer specifications. If disconnected, reconnect power or
reengage coupling mechanisms.
D. Modification on the SULZER Pump [ XU-P107] –

Removal of base plate and foundation bolts -
 Shutdown the motor before progressing.

 Remove all the electrical connections from the motor and pump.
 Close all the valves connecting to the motor and disconnect the adjoining piping
connections from the motor and blind the piping.
 Remove the coupling guard by removing bolts (4 nos.) from the base plate.
 Decouple the motor with the bearings and remove the old coupling before
progressing.
 Remove the motor form the base plate.
 Detach the Bearing Casing from base plate by removing the bolts form the base
plate and removing the bolts form centrifugal pump.
 Remove the shaft connection between motor-bearing and remove the bearing
casing.
 Remove pump from the base plate.
 Once all the parts have been removed start removing the base plate by removing
the foundation bolts and breaking away the grouting which is holding base plate in
place.
Sens
itivit  Once the base plate has been removed hand it over to the civil department for
y: further work related to the foundation and foundation bolts.
This
Doc
ume Replacement of Casing wear ring –
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 Remove pump casing find the wear ring attached to the pump bore.
 Remove the ring from bore and clean the surface and casing of any kind of
surface gunk and contaminations.
 Install the new ring by tapping it lightly with a mallet all around the circumference
till it fights tightly.
 Clean the surfaces before re-assembling the pump casing.
 Make sure that all the O-rings are replaced and not leaking before installation of
the pump.
Installation of base plate and foundation bolts
Sens
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 After inspecting and taking over of foundation along with newly erected foundation
"LN bolts with desired measurements, base plate must be installed.
T  Once the base plate is secured to the foundation we can begin erection of the
Gen
eral motor.
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 Install the motor, bearing casing and the centrifugal pump of the base plate using
proper bolts.
 Aling the motor to pump coupling within the given tolerances and tighten the
coupling bolts.
 Connect the pipes to the pump securely and recheck the alignment of the
coupling.
 Add the New coupling guard and secure it to the base plate.
 Add grouting to the base plate after final inspection of the motor.
E. Good House Keeping:
 After Completion of work the site should be cleaned properly before handing over.
 Work site area should be clean with no hazardous objects laying in the workplace.
 Objects such as bolts, nuts, tool, etc. should be kept in their designated places to
clear the workplace.
 Oil spills are a hazard to the workplace and should be attended to immediately.
Cleaning the area with dry cotton cloth.
 Before ending the shift, the workplace must be completely cleaned.
 The GSCF Engineer in charge shall inspect the site to provide clearance
certificate.
F. Mechanical cleaning & preassembly work:
XU-P101B/C (Peroni Pumps):
 Box-up of stage cooling water jacket, cover and cooling and cooling water inlet/outlet
line, lube oil line using new gasket, “O”-Ring, etc.
 Overhauling & assembly of all suction and discharge valves with internals
 Measurement od ID of bore in Peroni Pumps before inserting the suction-discharge
valve Monoblock assembly inside.
 Measurement of OD of Suction valve, discharge valve bock and of complete
preassembled Monoblock before installation
 O-ring cross-section, backup ring cross-section should be checked such that O-rings
thickness should not exceed that of support rings.
 Installation of suction and discharge valves.
Sens  Proper fastening and assembly of all the components of Monoblock before
itivit installation.
y:
This  Cleaning and oiling of manifold before installation.
Doc  Oiling and cleaning of Monoblock before installation.
ume
nt is
 The valve seating area on the valve block and manifold shall the lean.
clas  The grooves for all the O-ring installation shall be cleaned to avoid any leaks post
sifie installation.
d as
"LN  The O-ring shall be checked for and damages on it.
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XU-P102 A (Turbine driven centrifugal Pump):
 When the turbine casing is opened make sure the all the dirt is removed and
cleaned.
 Clean all the moving parts inside the turbine.
 The nozzle ring place holder shall be cleaned thoroughly for any contaminations or
grease before installation of the nozzle ring.
 The gears in the gear box shall be cleaned before closing it up.
 The new gear shall be visually inspected for any deformities before installation.
 The section where new gear is to be installed should cleaned.
 The new gear should be lubricated before installation to avoid and wear in it.
 New lubricating oil should be added to the LOU before commissioning of the pump.
 The gear should be aligned properly to fit inside the gear box.
XU-P107 (SULZER Centrifugal Pump):
 Before installation of the base plate of pump and motor the level of the foundation
must be checked.
 The elevation level, distance between alternate and diagonal distances of the
foundation bolts must be check before installation of base plate.
 Levelling of base plate must be done and inspected properly before installation of the
pump and motor upon it.
 Box up of the pump casing along with the proper fitting of the gland & packing in the
casing.
 The base plate must be levelled and bolted tightly before installation of the motor and
pump.
 Wear ring must be removed skilfully as it has a tight fitting with the casing.
 Overhauling & Assembly of all the inlet and outlet valves and piping.
 Cleaning and oiling of the bearings before reinstallation.
 All the O-rings, gaskets and attached consumables must be replaced as per
requirements.
G. Measurement of various clearance & Dimensions:
 Measurement OD & ID of bore in Peroni Pumps before inserting the suction-

Sens
itivit discharge valve Monoblock assembly inside.
y:  Measurement of OD of Suction valve, discharge valve bock and of complete
This
Doc preassembled Monoblock before installation.
ume  O-ring cross-section, backup ring cross-section should be checked such that O-rings
nt is
clas
thickness should not exceed that of support rings.
sifie  Thickness of supports rings shall be checked before installation as it is a very critical
d as part.
"LN
T  Before installation of the base foundation must be checked for proper levelling.
Gen  The elevation level, distance between alternate and diagonal distances of foundation
eral
Busi
bolts must be check before installation of base plate.
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 Base plate must be tightened securely and inspected before installation of the pump
and motor upon it.
 Vibration the pumps shall be checked using vibrometer in most sensitive places of
the pump where the vibrations and amplitudes of forces are high.
 The alignment of the rotating, vibrating or any moving part shall be checked before &
after installation of the piping and other accessories.
 The OD and ID of the wear ring of SULZER pump must be checked before
installation.
 The alignment of the motor should be checked and must be given clearance by
GSFC before grouting and handing over to the electrical department for supply
connections.
 The O-ring shall be checked for cuts and damages on it.
 OD of new gear for Turbine pump.
 The length of the Gear should be measured to check for correct dimensions and
proper fitment.
Please refer attached inspection format for details.
H. Pre-start trails & recommissioning of the compressor:
 Dry run/no load test run of the pumps before use of the actual working fluid.
 Increasing the working load in steps, if possible, to test for and issues with the pumps
before using the pump at full load.
 The input and the output pressure shall the checked using the pressure gauges
installed in the respected lines to check for and inconsistency or variation from the
actual desired pressure.
 Testing of all the joints, valves connections, bolts torquing pressure shall be checked
on priority basis.
 Pump and its attachments shall be checked for any leaks of any kind before
commissioning.
 Contractor shall carry out all the re-commissioning activities with the working fluid,
running it an unload condition for a few hours (i.e., 4-5 hours), on full load run &
taking it into operation.
 Electrical connections and reading of all the attached instrumentation shall be
Sens
itivit
checked to check for any inconsistencies or any kind of variations.
y:  Vibration the pumps shall be checked using vibrometer in most sensitive places of
This the pump where the vibrations and amplitudes of forces are high.
Doc
ume  Pulsation Analysis shall be carried to check for any adjoining piping to check for any
nt is mechanical in them.
clas
sifie  The output RPM of the power shaft of the Turbine pump shall be checked before
d as connecting it to the pump.
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9. Reports:
 Preparation and submission of overhauling report indicating all the important

activities, observations, clearances, alignment readings, etc. to be prepared.
 Individual report for each pump shall be prepared including all the inspections and
the test results as per the requirement of the GSFC.
10. Annexures
A. Inspection formats
B. IHI Operation & maintenance manual
C. OEM proposal for revamp
D. GSFC RFP document
E. CASALE datasheet
F. EBARA datasheet
G. PERONI POMPE datasheet
H. Revamp scope & 2 years spare list
I. Revamp parts list
J. Agreed deviation list.
Sens
itivit
y:
This
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ume
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"LN
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46 | P a g e

Method Statement For Pumps FF

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Method Statement For Pumps FF

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CONTRACTOR

ISSUED FOR APPROVAL CODE

 CODE A– NO COMMENTS. PROCEED WITH MANUFACTURE /

Rev No. Description Prepared by Reviewed by Approved by Approved Date

M/s. GUJARAT STATE FERTILIZERS & CHEMICALS LIMITED (GSFC) hereinafter

A. General Safety Precautions

B. Permit Issuing Methodology

“No Permit No Work”

3. NH3 & R.C Pump Specification

 Load Specification for IHI Pumps [XU-P101A; XU-P102B/C]

Weight (Static Load)

 Specification For [NH3] Peroni Triplex Pump [XU-P101B/C]

Table: Discharge Pulsation Damper XU-P101B/C

XU-101B/C Shell Tube

Table: Suction Pulsation Damper XU-P101B/C

XU-P101B/C Shell Tube

Table: Specification of Pump XU-P101B/C

Horizontal Triplex Plunger

Gear Box Ratio 14:01

Table: Specification of XU-P102 B/C

Ishikawajima Harima Heavy Industries,

 Specification For [NH3] IHI Pump XU-P101A

Table: Specifications of XU-P101A

Ishikawajima Harima Heavy Industries,

 Specification For Turbine Driven Pump [XU-P102A]

Table: Specification of XU-P102A

Pump Type 100x60 SSP VIIGT

d) Water Seat nut

1. Crank case / Frame

8. Piston rod packing

10. Piston ring

12. Suction & Discharge valve

13. Nozzle Ring (Turbine Pump)

Crank Shaft Pump

Fig:R.C Pump Major Components

Note: Cooling inlet Stuffing

Note: Header Valve

Fig: R.C. Pump Connections

B. Part Details and working of XU-P102A:

Note: Nozzle Ring is

Fig: Turbine Driven Centrifugal Pump XU-P102A

Fig: Centrifugal Pump XU-P102A

C. Part Details and working of XU-P101B/C:

Fig: Peroni Pump (Pp) Main Components

D. Part Details and working of XU-P107:

Coupling Guard Electric Driver

Fig: XUP-107 SULZER Centrifugal Pump Main Components

Gland and Motor Bearing Constant Motor- Foundation

5. Why revamp of Pumps?

A. Energy Efficiency Enhancement

D. Modification in existing Pumps

1. Comparison b/w current and required operating condition –

2. EBARA Pump TAG: XU-P102A

 PUMP- Pump Maintenance and parts replacement might be required after

Fig: Modifications Recommended in XU-P102A

3. Peroni Triplex Plunger Pumps TAG: XU- P101B/C

 Pump column Valve Needs upgradation.

Fig: Discharge & Suction Pulsation Damper

 Pump Maintenance and parts replacement might be required after dismantling