Work Instruction 1 (10)

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Checked and verified by Maintenance Manager, Approved by Station Manager, Date

Date

Jan Woch _____ / _____ Sauli Lehtinen _____ /

/ 2015 _____ / 2015
Effective date Distribution
13 Jauary 2015 HC: Respective Managers, Respective Area
SC : Docushare
Keywords Replaces
BMS, (please fulfilled)

XXXX-YY-WIxx CHEMICAL UNLOADING, INJECTION & TRANSFER PUMP

DIS-ASSEMBLY AND INSPECTION

1 PURPOSED
This Work Instruction will be as the guideline for Maintenance personnel to perform
Chemical Unloading, Injection & Transfer Pump Disassembly and Inspection.

2 SCOPE
This Work Instruction will be applied for Chemical Unloading, Injection & Transfer
Pump Disassembly and Inspection at Tanjung Jati B Power Plant. The works not
mentioned in this instruction will be performed in accordance with drawings and
appropriate specifications then will be considered to be added in this Work Instrcution
later. This Work Instruction is refer to O&M manual from OEM.

3 RESPONSIBILITY
1. The Maintenance Manager has responsibility for updating this instruction.
2. The Maintenance Engineer has responsibility to control maintenance works made
according to the instruction and co-ordinate with other teams during planning and
report activities to the Maintenance Manager.
3. The Maintenance Engineer and Supervisor have responsibility to plan, supervise and
report of maintenance works which are undertaken in accordance with this procedure.
4. The Maintenance Technician has responsibility to implement the Works Instruction in
 Work Instruction 2 (10)
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safe manner.

4 DETAIL OF WORKS
4.1 Preparation
1. Work should be carried out by two people.
2. Prepare all necessary documents Iwaki Magnetic Drive Pump, Model MFD-L
Instruction Manual, Iwaki Magnetic Pump outline and sectional drawing 2A308600 &
2A308601 and inspection report form (replacement parts record and vibration data
record) prior to start of work.
3. Prepare the necessary parts, tools and equipment before commencing actual work.
4. Co-ordinate with Civil Section to provide access and lifting
5. Confirm that the equipment is isolated and a permit to work is available before
commencing work.
6. Prepare a suitable lay-down area.
7. Remove the auxiliary piping, piping supports and all instruments that may interfere
with the disassemble/reassemble procedures

4.2 Tools and Others

4.2.1 Personal Protective Equipment
1. Chemical Suit
2. Chemical Hand Gloves
3. Full face chemical masker with suitable cartridge filter
4. Ear Plug or Ear Muff

4.2.2 Consumable Material

1. WD 40
2. Cotton Rag
3. Molykote
4. Loctite 596
5. Dow Corning 111
6. Permatex
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7. Abrasives Paper
8. Plastic Blanket
9. Brush
10. LPS G-49 degreaser
11. Oil and Grease
12. Wearing Compound

4.2.3 Spare Part

Detail List of spare parts use for Chemical Unloading, Injection & Transfer Pump
available on attachment 1.

4.2.4 Tools and Special Tools

1. Webbing sling length 2 meter end loop capacity 2 Ton, 2 set.
2. Chain block 3 ton 1 set
3. Lever block 1 ½ Ton 1 set
4. Socket set complete with extension: 19 mm, 27 mm.
5. Combination spanner set: 19 mm, 27 mm.
6. Allen Key 9 mm.
7. Hammer, punch, screw driver set.
8. Inside micrometer
9. Outside micrometer
10. Vernier calliper

4.3 Removal Suction and Discharge Pipe

1. The most important things before start the work are please wear chemical hand
gloves, chemical suit and Full face chemical masker with suitable cartridge filter refer
to chemical liquid.
2. Please provide flushing water continue flowing through the floor under chemical
spillage.
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3. Please open venting cap and drain cap to empty the chemical inside pump and line.

4. Loosen and removal all flanges bolts, both of suction and discharge pipe by socket
and combination spanner 27 mm and 19 mm.
5. Remove suction pipe and discharge pipe from the system.

Suction and discharge pipe

4.4 Remove the front casing from the foot support

1. Disassemble only after thoroughly washing out the liquid inside the pump by use of
flushing piping. Remove the cap to discharge the liquid from the pump. Then, clean
the inside of the pump.
2. Wear protectors (goggles, rubber gloves, etc.). Certain liquids are dangerous. They
may hurt your eyes and skin.
3. Remove the front casing from the foot support by remove the hex socket bolts (or hex
bolts) and take out the front casing from the foot support. Be careful with the spindle
which remains pressed-fit in the front casing.
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Caution:
 Strong impacts may crack the spindle or casing. Do not hit them with a tool.
 The spindle is integrated with the rear casing, not pressed into the front casing
 During disassembly, discharge the liquid from the casing and clean the inside
of the pump

4.5 Pull out the impeller and magnet capsule assembly

1. Be careful not to scratch the surface of each part. Since the magnet capsule is strongly
magnetized, store it in a place free of metal pieces or metal powder. Handle the front
casing, magnet capsule, and impeller with extra care so as not to scratch the sliding
surface.

2. The impeller is fixed to the magnet capsule by screwing. When removing the impeller
from the magnet capsule, hold the magnet capsule by hand and rotate the impeller
counterclockwise (from the impeller side). If thread part is too tight and the impeller
is not disconnected from the magnet capsule, put the magnet capsule with the impeller
on hot water (about 90 ºC) for 5 minutes. And then rotate the impeller
counterclockwise. Beware of scald while this procedure.

Caution:
When disassembling and reassembling MDF-L 422 and 423 magnet capsule and
impeller, pay attention to followings:
 The O ring is inserted between the impeller and thread part of the magnet
capsule. This O ring prevents that the impeller comes loose from thread part of
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the magnet capsule, even if the pump rotates reverse direction. When
replacing the impeller and/or the magnet capsule, confirm the pump rotating
direction is correct before reassembling the impeller and the magnet capsule
without O ring.
 If the impeller and the magnet capsule are reassembled with O ring, there is
possibility that the impeller is not screwed into thread part of the magnet
capsule completely. This may cause pump damage.

4.6 Remove the rear casing

1. Insert a flat-head screwdriver into the perimeter of the rear casing and pull the rear
casing forward while lifting it slightly up.
2. Pay extra attention not to scratch the sealing surface.

4.7 Replacement of spindle

1. The spindle is pressed into the front casing. Pay attention to the following points
when replacing the spindle.
2. Hold the worn spindle in one hand and hit the perimeter of the front casing (cast part)
lightly and evenly with a resin hammer to remove the spindle from the casing. In this
step, never strike the seal surface of the front casing or the spindle.
3. Wipe off the stains on the front casing. Then, insert a new spindle into the casing by
hand and strike it gently with the resin hammer to press it in.
4. Do not disassemble the spindle section unless it is seriously worn and needs to be
replaced.
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5. If the spindle does not come off easily, warm the front casing in hot water (about 90
°C) before pulling it out for replacement.
6. In the case of the MDF-L250, 401, 422, 423 and 425, the casing and the spindle are
integrated. It is not possible to replace only the spindle.

4.8 Assembly
1. The pump should be assembled by carrying out the steps of disassembly in reverse.
Pay attention to the following points.
2. When replacing the O ring or gasket, be sure to install a new one. In addition, see that
the O ring or gasket is not twisted or pressed by another part.
3. The sealing section should be cleaned free of dust or scratches before installation.
4. Fasten the bolts in diagonal order by applying the fastening torque (Type Hex. Socket
head bolt M10x40L, M10x75L fastening torque 24.5 N.m.). Apply an equal torque to
each bolt.
5. Apply fluorocarbon grease inside the bearing and the perimeter of the spindle.
Otherwise, it will wear out in a short time.
6. Attach the impeller to the magnet capsule. Rotate the impeller clockwise, and screw
the impeller on the magnet capsule.
Caution
 When replacing the impeller and /or the magnet capsule, confirm the pump
rotating direction is correct before reassembling the impeller and the magnet
capsule without O ring.
 If the impeller and the magnet capsule are reassembled with O ring, there is
possibilitiy that the impeller is not screwed into thread part of the magnet capsule
completely. This may cause pump damage.
7. Insert the impeller and the magnet capsule unit to the rear casing. Then, the rear
casing, the impeller and the magnet capsule set is installed onto the foot support.
Caution
 Since the magnet used in the pump is very powerful, be careful not to get your
fingers caught between elements by inserting wood pieces or plastic pieces
between the rear casing and the foot support.
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8. Confirm there is no dust or scratches on the seal surface of the front casing. Then,
attach the O ring onto the front casing.
9. Attach the front casing onto the foot support.
10. Fasten the hex. socket head bolts in diagonal order, applying an equal torque to each

4.9 TESTING AND RECORDING COMPLETION OF WORK

1. After inform, get permition (from PTW officer) and coordinate with operator, please
do running test, record bearing vibration parameter and temperature, record discharge
pressure and flow.
2. While in progress running test, please do nice housekeeping to clean our work place
from exused spare parts, remaining consumable, cotton rag and other rubbish. Also
please check and clean our tools (keep our personal tools is complete) to do next other
works.
3. After pump performance is acceptable, please do not forget to closed the PTW and
handed over the pump to operator to operate and follow normal operation.
4. All data should be recorded in the inspection report form (replacement parts record
and vibration data record).
5. Supervisor will keep those inspection reports and upload to Work Order attachment in
Maximo during finishing (including fulfilling actual date started & finished,
Competence Person and engineering comment).

5 REFERENCE
1. Iwaki Magnetic Drive Pump, Model MFD-L Instruction Manual
2. Iwaki Magnetic Pump outline and sectional drawing 2A308600 & 2A308601
 Work Instruction 9 (10)
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6 ATTACHEMENT
1 List of spare parts use for Chemical Unloading, Injection & Transfer Pump.
2 Iwaki Magnetic Drive Pump, Model MFD-L Instruction Manual.
3 Iwaki Magnetic Pump outline and sectional drawing 2A308600 & 2A308601.
4 Inspection report form.
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1. List of spare parts use for Chemical Unloading, Injection & Transfer Pump
Item Description Quantity
BEARING - SLEEVE, MFG: IWAKI MAGNET, PARTNO: MFL0580, SIZE: F40 X 5
58-12-90-055 0, MATL: ALUMINA CERAMIC 1 PCS

SEAL - O-RING, MFG: IWAKI MAGNET, DRAWNO: F91-4181-101, PARTNO: J

85-53-98-058 1 PCS
IS-B2401G165, MATL: EPDM
GASKET. - FLAT. ROUND, F13 X T2. MFG: IWAKI MAGNET. DRAWNO: F91-
85-41-67-026 1 PCS
4181-101. THICK: 2 MM. O/D: 13 MM. MATL: EPDM
PUMP - CENTRIFUGAL, HORIZONTAL, MDL: MDF-L423CFEW-D, MFG: TOSH
30-82-25-022 IBA, DRAWNO: 2A308601, SIZE: SUCT 2 IN X DISCH 1-1/2 IN, POWER: 2.2 K 1 PCS
W, CAP: 20 L/MIN, SPEED: 2860 RPM
BOLT. - MACHINE. HEX HEAD, FULL THREADED, CW 1 NUT, 1 SPRING WAS
MG02-000197 HER, 1 PLATE WASHER. SIZE: M14 X 60 MM. MATL: SS316 8 PCS

BOLT. - HEX SOCKET HEAD. C/W NUT & LOCK WASHER. SIZE: W 5/8 IN X 2-
81-81-82-002 8 PCS
1/2 IN, 11 UNC - 2A. MATL: CS. GRADE: GR 8.8
BOLT - STUD, FULL THREADED, C/W 2 NUT, SIZE: 5/8 IN UNC X 80 MM, MA
81-38-61-006 TL: A193GRB7/2H 8 PCS

BOLT - HEX HEAD, C/W: FLAT AND SPRING WASHER, SIZE: M14 X 60 MM,
81-03-45-119 GRADE: 8.8 8 PCS

RING. - LINER. ITEM 18, MDL: MDF-L423CFVW-D, FOR IWAKI MAGNETIC D

30-66-68-001 RIVE PUMP. MFG: IWAKI MAGNET. DRAWNO: 2A308605. MATL: ALUMINA 1 PCS
CERAMICS 99.5%
SPINDLE. - SPECIAL. ITEM 20, FOR IWAKI MAGNETIC DRIVE PUMP. MFG: I
30-66-25-016 WAKI MAGNET. DRAWNO: 2A308602. MATL: ALUMINA CERAMICS 99.5% 1 PCS

CAPSULE. - MAGNET. ITEM 15, MODEL: MDF-L423CFVW-D, C/W BEARING

30-66-25-014 PN: 21. MFG: IWAKI MAGNET. DRAWNO: 2A308607. MATL: BARE EARTH 1 PCS
MAGNET, CFRETFE
IMPELLER. - ASSY. ITEM 3, MODEL: MDF-L423CFVW-D, C/W: IMPELLER TH
30-66-25-009 RUST PN: 19, MOUTH RING PN: 22. MFG: IWAKI MAGNET. DRAWNO: 2A30 1 PCS
8601. MATL: CFRETFE