BFP, BP, CEP & CW Pumps.pdf

SELECTION OF PUMP

USER TO SPECIFY Essential information User to specify while purchasing : • FLOW RATE, TOTAL HEAD, TYPE OF FLUID •

TEMPERATURE

•

SUCTION HEAD AVAILABLE

•

APPLICATION : - SYSTEM, DU DUTY & OP OPERATION

•

FREQUENCY VARIATION

•

POWER SUPPLY DETAILS

CHARACTERISTIC CURVE OF A PUMP 1800

   )   c    l 1600   m    (    D1400    A    E1200    H

52.5 Hz

50 Hz

47.5 Hz

1000

   )    W2000    k    ( 1500    R    E1000    W    O 500    P 90 80

   ) 70    %    ( 60    Y    C 50    N    E    I 40    C    I    F 30    F    E 20

   )   c    l 15   m    ( 10   R    H    S 5    P    N 0 20

 Η  3 % ∆

10 0 0

30

60

90 12 120 0 150 150 18 180 0 210 210 24 240 0 270 270 30 300 0 330 330 36 360 0 390 390 42 420 0 450 450

SUCTION FLOW (cub. m. / hr.)

* Head ~ Capacity Curve :

- Rising characteristic - Drooping characteristic - Steep characteristic - Flat characteristic - Unstable characteristic

     D      A      E      H

FLOW

* Power ~ Capacity Curve : - Non-over loading Curve - Overloading Curve

  R   W  E   O   P   N  G   I   D   O A   L   E  R   O  V    N   N  O

 E R  P O W  G   N  I  A D  R L O  O V E

* Efficiency ~ Capacity Curve : - It is a constant curve for a particular Pump.

•

AFFINITY LAWS :

-

All Centrifugal Pumps follow the Affinity Laws which are given  below : Q

α

 N

H

α

 N2

P

α

 N3

and

Q

α

D

H

α

D2

P

α

D3

where N is the Speed of the Pump, rpm D is the Diameter of the Impeller 

COMPARISION BETWEEN NPSHA & NPSHR :

 AV  A

     H       S      P      N

I L AB  L

E 

 E D   R  I  U  R E Q

•

SYSTEM HEAD :

-

It is the total head of a system against which a pump must operate.

-

For a given capacity, it is expressed as System Head = Total Static Head from supplying level to discharge level + Discharge Pressure - Suction Pressure Friction losses - entrance and exit losses

             

 



           

             

•

OPERATING CONDITIONS :

                         

       

           

                      

•

PARALLEL OPERATION :

PUMP A COMBINED PUMP B

SYSTEM HEAD

SPEED ~ TORQUE CURVE OF PUMP 100 90 80 70 60 50 40 30 20 10 0 0

10

20

30

40

50

60

70

80

90 100

USER TO VERIFY When purchasing Pump, User should also check the following : • DUTY POINT IS NEARER TO B.E.P. •

EFFICIENCY IS REALISTIC.

•

MATERIALS ARE COMPATIBLE.

•

CHARACTERISTIC IS STABLE.

•

RUN-OUT FLOW NPSHR IS LESS THAN NPSHA.

TYPICAL PARAMETERS OF PUMPS APPLICATION TG RATING DUTY FLOW Cub.m/hr

BOILER FEED

PARAMETERS . HEAD SPEED mwc

rpm

210 MW

50%

450

2100

5000

500 MW

50%

1000

2100

5600

CONDENSATE

210 MW

100%

700

250

1480

EXTRACTION

500 MW

50%

1000

300

1480

COOLING WATER 

210 MW 500 MW

50% 33%

16000 30000

25 25

490 333

BFP TYPICAL PARAMETERS FOR COMBINED CYCLE PLANTS

GT FRAM E

3 x 50% Q (M 3/ HR)

2 x 50% H (MLC) -

Q (M3/HR)

(MLC)

105

-

205

63

106

-

-

80

206

80

1250

-

-

109

125

1250

-

-

209

265

1500

-

-

751

63

H

-

750 980

CEP TYPICAL PARAMETERS FOR CCPPs

GT FRAME

50% DUTY

100% DUTY

FLOW

HEAD

FLOW

Cub.m/hr

Mts.

Cub.m/hr

HEAD Mts.

Frame-5

40

90

85

90

Frame-6

150

100

265

90

Frame-9

220

115

385

185

SESSION-2

3 DEC 2007

CONSTRUCTIONAL FEATURES OF BOILER FEED PUMP

DESIGN FEATURES OF BFP 

       

Horizontal, Multi Stage, Barrel Casing, Single Suction, Radial Flow. High Efficiency. Fully Cartridgised construction. Stiff Shaft design. Thermal shock capability. Hence no warm up. Balance Brum and tilting pad Thrust Bearing for Axial thrust. First Stage Impeller erosion life : 40,000 hrs (minimum) Shaft sealing by Mechanical Seals. Compatible materials for rotating and stationary parts.

MATERIALS OF CONSTRUCTION BOILER FEED PUMP (FK 6D 30) 

Pump Casing

-

Carbon Steel Forging (0.25 C, Mn Steel)



Pump Shaft

-

13% Cr Stainless Steel Forging with 1% Ni



Impeller

-

13% Cr 4% Ni Stainless Steel Casting



Diffuser

-

13% Cr 4% Ni Stainless Steel Casting



Ring Section

-

13% Cr 4% Ni Stainless Steel Casting



Wearing Ring

-

Cr Ni Cu Mo Corrosion Resistant Stainless Steel



Suction Guide

-

13% Cr 4% Ni Stainless Steel Casting



Discharge Cover

-

C 0.25 Mn Steel Forging



Suction Branch

-

Carbon Steel Casting with 0.25 C, 0.60 Si, 0.90 Mn



Discharge Branch

-

Carbon Steel Forging (0.25 C, Mn Steel)



Water Jacket

-

13% Cr 4% Ni Stainless Steel Casting



Bearing Housing

-

Carbon Steel Casting with 0.25 C, 0.60 Si, 0.90 Mn



Seal Housing

-

13% Cr 4% Ni Stainless Steel Casting

MATERIALS OF CONSTRUCTION BOILER FEED PUMP (FK 6D 30) 

Balance Drum

-

Stainless Steel Forging (17% Cr Ni Steel)



Journal Bearing

-

Mild Steel / White Metal



Thrust Bearing

-

Steel



Mechanical Seal

-

Steel



Spring Disc

-

Cr Ni Cu Mo Corrosion Resistant Stainless Steel



Thrust Collar

-

Alloy Steel

BOILER FEED PUMP CARTRIDGE FEATURES : BFP CARTRIDGE ASSEMBLY COMPRISES OF THE FOLLOWING SALIENT PARTS : •

SHAFT

•

IMPELLERS

•

DIFFUSERS

•

RING SECTIONS

•

SUCTION GUIDE

•

DISCHARGE COVER 

•

BEARING HOUSINGS

•

BEARING BRACKETS

•

JOURNAL BEARINGS

•

THRUST BEARING

•

MECHANICAL SEALS

IN OTHER WORDS BFP CARTRIDGE IS A COMPLETE PUMP EXCEPTING BARREL (PUMP CASING). BFP CARTRIDGE IS TESTED FOR HYDRAULIC AND MECHANICAL PERFORMANCE AT BHEL WORKS LIKE THE ORIGINAL PUMP.

ADVANTAGES :

SPARE BFP CARTRIDGE OFFERS THE FOLLOWING ADVANTAGES : -

IN CASE OF A BREAK DOWN OF RUNNING PUMP, SPARE CARTRIDGE CAN REPLACE IT TOTALLY.

-

DOWN TIME FOR CHANGE OVER WILL BE MINIMUM (ONE OR TWO SHIFTS)

-

SPARE CARTRIDGE RESTORES THE ORIGINAL EFFICIENCY OF THE PUMP

-

SEMI SKILLED TECHNICIANS CAN CARRY OUT THE REPLACEMENT.

RECOMMENDATION :

IT IS RECOMMENDED THAT EACH UNIT COMPRISING 3 NOS. OF BOILER FEED PUMPS SHALL HAVE A MINIMUM OF ONE NO. SPARE BFP CARTRIDGE .

BFP CARTRIDGE

BFP BARREL & CARTRIDGE

MAJOR COMPONENTS OF BFP

•

PUMP CASING :

-

It houses the hydraulic components of Pumps.

-

It prevents the leakage and guides the liquid in a proper direction.

-

It is closed by Suction Guide at it’s suction side and Discharge Cover at it’s discharge side.

•

SUCTION GUIDE :

-

It guides the fluid from suction pipe to the eye of the Impeller.

-

It closes the drive end of Pump Casing and forms the suction annulus.

-

It is not secured to Pump Casing but held against an internal shoulder in the casing by Ring Section Assembly, Discharge Cover and Spring Disc.

-

It is closed by DE Water Jacket and Mechanical Seal Housing.

• IMPELLER : -

It rotates the mass of fluid with the peripheral speed of its vane tips, thereby determining the head developed or the Pump working  pressure.

• DIFFUSER : -

It converts Kinetic energy of the fluid into Pressure Energy.

INTER-STAGE DIFFUSER

END-DIFFUSER  

•

RING-SECTION ASSEMBLY :

-

It consists of Ring Sections located one to another.

-

Each Ring Section houses one Impeller and one Diffuser.

-

Ring Sections along with Diffusers form the passage of liquid from the Impeller outlet of one stage to the Impeller inlet of the next stage.

•

WEARING RING : It is provided in the clearance between rotating & stationary components of the Pump in order to avoid the leakage. It increases the life of the parent components by avoiding direct contact between them. The clearance is in the order of 0.2 to 0.4 mm. It can be put either on Impeller or Diffuser/Ring Section or both. If Wearing Rings are provided on both rotating & stationary components, they should be of dissimilar hardness. It is made of special quality material with high anti-galling  properties. When the wearing ring clearance becomes double, the Wearing Rings have to be renewed.

TYPES OF WEARING RINGS

•

ROTATING ASSEMBLY :

-

It consists of Shaft, Impellers, Balance Drum, Thrust Collar, rotating  parts of Mechanical Seals and the Pump Half Coupling.

-

It is dynamically balanced.



SHAFT :



BALANCE DRUM :

•

DISCHARGE COVER :

-

It closes the NDE of Pump Casing and forms the balance chamber.

-

It is closed by NDE Water Jacket and Mechanical Seal Housing.

-

A Spring Disc is located between the last stage Diffuser and the Discharge Cover Balance Drum Bush.

-

Spring Disc provides the force required to hold the Ring Section Assembly in place against DE of Casing.

•

MECHANICAL SEAL :

-

It consists of two highly polished surfaces, one surface connected to the Shaft and the other to the stationary part of the Pump.

-

Both the surfaces are of dissimilar materials held in continuous contact by a spring.

-

These wearing surfaces are perpendicular to the axis of Shaft.

-

A thin film of working fluid between these faces provides cooling & lubrication.

•

SEAL HOUSING :

-

It houses the Mechanical Seal.

•

BEARINGS :

-

They support the Pump Rotor.

-

They kee eep p th the Sh Shaf aftt or or Rot Roto or in in co corr rreect al alig ignm nmen entt wit with h sta stati tio ona nary ry  parts under the action action of radial and axial loads.

They are of two types : 

Line Bearings



Thrust Bearings



Line Li ne Be Bear arin ings gs :

-

They give radial positioning to the rotor.

They are of two types : * Antifriction Bearings * Sleeve Bearings



Thrust Bearings :

-

They locate the rotor axially & take residual axial thrust.

-

They are fitted in the NDE Bearing Housing.

-

They have 8 white metal lined tilting pads held in a split Carrier Ring positioned on each side of the Thrust Collar.

-

Carrier Rings are prevented from rotating with the Shaft by dowel  pins in each ring which engage in slots in the Bearing Housing top half.

•

BEARING HOUSINGS :

-

They house Journal Bearing at the DE side and both Journal & Thrust Bearings at the NDE side.

-

These are in the form of cylindrical castings split on the horizontal Shaft axis, located one each at DE & NDE sides of the Pump.

-

These are secured to the Bearing Housing Brackets by studs and nuts.

-

Top & bottom halves of the Bearing Housings are secured together   by studs and nuts and located by dowel pins.

TOP HALF

BOTTOM HALF

BEARING HOUSING ASSEMBLY

A DETAIL VIEW OF BEARING HOUSING ASSEMBLY

•

BASE PLATE :

-

It furnishes the mounting surfaces for the Pump feet that are capable of being rigidly attached to the foundation.

-

It may be Individual Frame for each equipment.

-

It may be Common Frame on which all the equipments are mounted.

BFP ASSEMBLY WITH BASE FRAME

BOILER FEED PUMP TUBING

BFP SEAL COOLER PIPING

CONNECTING COUPLINGS

•

COUPLINGS :



Centrifugal Pumps are connected to their drives through either rigid or flexible couplings.

Rigid Coupling :

-

It does not permit either axial or radial relative motion between the driving and the driven shafts.

-

Used in Vertical Pumps.



Flexible Coupling :

-

It transmits the torque from the Driving Shaft to the Driven Shaft.

-

It allows minor misalignment (both angular & parallel).

It is of the following types : 

Pin and Bush Coupling



Lovejoy Coupling



Gear type lubricated Coupling



Diaphragm/Spacer type Coupling





Pin and Bush Coupling :

Lovejoy Coupling :



Gear type lubricated Coupling :



Diaphragm/Spacer type Coupling :

COUPLING ASSEMBLY

BFP TRAIN WITH COMMON FOUNDATION FRAME :

SESSION-3

3 DEC 2007

CONSTRUCTIONAL FEATURES OF BOILER FEED BOOSTER PUMP

DESIGN FEATURES OF BP ♦

Horizontal, Single Stage, Double Suction, Axial Split Casing, Radial Flow.

♦

Double Suction Impeller for minimum NPSHR.

♦

Shaft sealing by Mechanical Seals.

♦

Compatible materials for stationary and rotating parts.

MATERIALS OF CONSTRUCTION BOILER FEED BOOSTER PUMP (FA 1B 56) 

Pump Casing

-

Carbon Steel Casting with 0.25 C, 0.60 Si, 0.90 Mn



Pump Shaft

-

13% Cr Steel Bar with 1% Ni



Impeller

-

13% Cr 4% Ni Stainless Steel Casting



Wearing Ring

-

Cr Ni Cu Mo Corrosion Resistant Stainless Steel



Bearing Housing

-

Carbon Steel Casting with 0.25 C, 0.60 Si, 0.90 Mn



Journal Bearing

-

Mild Steel / White Metal



Thrust Bearing

-

Steel



Mechanical Seal

-

Steel



Thrust Collar

-

Carbon Steel with Chromium plating

•

THRUST COLLAR :

BP ASSEMBLY WITH BASE FRAME

BOOSTER PUMP TUBING

CONSTRUCTIONAL FEATURES OF CONDENSATE EXTRACTION PUMP

DESIGN FEATURES OF CEP  Vertical,  Can

Multi Stage, Multi-Shaft.

type construction with suction nozzle integral with

Canister.  Double

Suction first stage Impeller for minimum NPSHR.

 Balancing

holes and tilting pad Thrust Bearing for Axial

Thrust.  Cutless  Shaft

rubber line bearings with axial flutes.

sealing by PTFE rope packing / Mechanical Seals.

 Compatible

materials for stationary and rotating parts.

•

FIRST STAGE PUMP ASSEMBLY :

-

•

It consists of Pump Casing, a Double Suction Impeller and a Suction Bell Mouth.

SECOND TO LAST STAGE PUMP ASSEMBLIES :

-

It consists of Pump Casings and Single Suction Impellers.

• HEAD PIECE : -

It incorporates the discharge and suction branches and supports Thrust Bearing Housing & Driving Motor.

-

It is sealed where the Shaft passes through Stuffing Box which incorporates soft packing and a Lantern Ring.

-

Apertures are provided on Headpiece for accessing Coupling, Thrust Bearing and Stuffing Box.

-

An air vent pipe is incorporated in the Headpiece for connection to the condenser tank.

•

•

FOUNDATION RING :

-

It consists of a circular flanges with sufficient number of foundation bolt holes drilled on the lower flange.

-

The top flange is provided with holes for fixing the Headgear and Canister.

-

Foundation bolts passing through the lower flange are grouted to the floor, thus fixing the Foundation Ring into the foundation.

CANISTER :

-

It is a fabricated tubular chamber which is closed at the bottom.

-

A flange is provided at the top of the Canister.

-

The flange is secured to the Foundation Ring, thus provides the support for the Headpiece.

•

•

•

STUFFING BOX ASSEMBLY : A water thrower provides protection for the Thrust Bearing and  prevents the gland leakage from entering into the underside of Thrust Bearing. THRUST & JOURNAL BEARING ASSEMBLY : It is mounted in the Headpiece. It absorbs the Pump hydraulic thrust and the weight of the Pump Rotating Assembly. The thrust is absorbed by the tilting white metal faced Thrust pads. White metal lined Journal pads locate the shaft radially. CONNECTING COUPLING : It transmits the drive from the Motor to the Pump. It is of spacer type flexible Coupling. It accommodates a certain amount of Off-set & angular misalignment and also free end float or vertical movement of the Shafts.

MATERIALS OF CONSTRUCTION CONDENSATE EXTRACTION PUMP (EN 7H 32) 

Pump Casing

-

Cast Iron



Pump Shaft

-

13% Cr Steel Bar with 1% Ni



Impeller 1st stage

-

13% Cr 4% Ni Stainless Steel Casting



Impeller other stages

-

Aluminium-Bronze



Wearing Ring

-

17% Cr Ni Stainless Steel



Canister

-

Structural Steel IS:2062



Suction Bellmouth

-

Carbon Steel Casting with 0.25 C, 0.60 Si, 0.90 Ni



Thrust Bearing

-

Steel



Mechanical Seal

-

Steel

SESSION-4

3 DEC 2007

CONSTRUCTIONAL FEATURES OF COOLING WATER PUMP

DESIGN FEATURES OF CWP  Vertical,  High

Single Stage, Multi-Shaft, Mixed or Axial Flow.

sustained Efficiency.

 Cutless  Tilting  Shaft

rubber line bearings with axial flutes.

pad Thrust Bearing for Axial Thrust. sealing by PTFE rope packing.

 Specially

designed Bellmouth.

 Compatible

materials for long life.

DESIGN FEATURES OF CWP  Options

for : Pullout / Non-Pullout design Single / double foundation Non reversible ratchet Shaft enclosing tube Thrust block at discharge bend



System study for Sump Model & Pressure Surge

•

IMPELLER :

-

It is a semi-open type, mixed flow & dynamically balanced.

-

It does not have hydraulic thrust balance holes.

-

It is made up of Stainless Steel.

•

PUMP CASING :

-

It is also known as Diffuser.

-

It converts the Kinetic energy of the fluid into Pressure energy.

-

It houses the Bearing body, into which the Cutless Rubber Bearing is fitted in.

-

It is a grey iron casting.

•

BELLMOUTH :

-

It guides the flow of water into the Impeller.

-

It houses anti-swirl radial ribs to break the swirls before water entering into the Impeller.

-

The suction bell inlet diameter is so chosen that water velocity is within 1.5 m/sec.

-

It is made up of grey iron.

•

COLUMN PIPE :

-

It connects the Pump Casing and the Discharge Elbow.

-

Water is lifted from the Pump Casing through this pipe.

-

It houses the Guide Bearing for the Shafts.

-

The entire length of the Column Pipe is split into 3 parts for the sake of easy handling : Element-I , Element-II & Element-III

•

These elements are made up of Mild Steel.

DISCHARGE ELBOW :

-

It deflects water from the vertical Column Pipe to the horizontal Discharge piping.

-

It houses Stuffing Box where the Shaft Sealing is achieved through Gland Packing.

-

It is made up of Mild Steel plates.

•

•

SUSPENSION :

-

It offers a base for the Motor Stool & the Pump Thrust Bearing.

-

This rests on the Foundation Frame & is connected to the Discharge Elbow at its lower end.

SHAFTS :

-

The entire shaft is divided into 4 parts : Pump Shaft , Intermediate Shaft , Head Shaft & Drive Shaft.

-

These 4 Shafts are joined together by means of 3 Muff Couplings.

-

The Drive Shaft is connected to the Motor Shaft at its top end through a Flexible Coupling.

-

All the 4 Shafts are made up of high tensile Stainless Steel.

•

•

MAIN COUPLING :

-

It connects the Drive Shaft and the Motor Shaft.

-

It is a Flexible membrane type coupling having high degree of flexibility for mis-alignment.

FOUNDATION PLATE :

-

It is grouted in the operating floor.

-

It transmits the forces from the Pump and Motor to the foundation.

•

TILTING PAD THRUST BEARING :

-

It takes the hydraulic axial thrust of the Impeller & also the weight of the Pump rotating parts.

-

It is lubricated by oil.

•

•

MOTOR STOOL :

-

It supports the Motor & mounted on the Suspension.

-

Windows are provided on it for attending the problems on Thrust Bearing & Connecting Coupling.

-

It is made up of Mild Steel.

CUTLESS RUBBER BEARINGS :

-

It supports the Pump Shaft & the Intermediate Shafts.

-

The Rubber is of synthetic nitrile grade with inherent ability to resist the abrasion.

-

These bearings are capable of ‘DRY RUN’ for maximum time of 10 seconds.

CIRCULATING WATER PUMP

DRY WELL

WET WELL

SESSION-1

4 DEC 2007

CONTROL OF BFP SET

Start permissive, Interlock and Annunciation are provided for safe operation of BFP set. •

Lubrication System of BFP set :

-

It consists of one Main Oil Pump (MOP) and one Auxiliary Oil Pump (AOP).

-

MOP caters to the lubrication of bearings during running of BFP.

-

AOP caters to the lubrication of bearings during starting and coasting down when adequate pressure is not developed by MOP.

-

AOP shall cut in and cut out automatically depending on the lube oil pressure in the header.

•

Working Oil System of BFP set :

-

It consists of filling pump, primary wheel, secondary wheel, scoop tube and working oil cooler.

-

Scoop tube is positioned by the actuator which shall receive the signal as per the load requirement.

-

While torque transmission takes place between primary and secondary wheels, working oil temperature rises.

-

Temperature of working oil at inlet to cooler is monitored with Temp. Switches which are interlocked to trip the main motor at high-high temperature.

•

Conditions to be ensured for manual or auto start of Pump:

-

Booster Pump suction valve shall be opened fully.

-

BFP discharge valve shall be closed fully.

-

BFP recirculation valve shall be opened fully.

-

AOP shall be kept running.

-

Cooling water shall be ensured for lube oil coolers, BFP Mechanical Seal Cooler, BFP & BP stuffing box.

-

Hydraulic Coupling scoop tube shall be in minimum position.

•

Conditions to be ensured for tripping of BFP Motor through C&I interlocks :

-

Deaerator level low-low through Level Switch on Deaerator.

-

Lube oil header pressure low-low at 0.8 kg/cm2 through Pr. Switch.

-

Working oil temperature at inlet to working oil coolers high-high at 130 °C through Temp. Switch.

PID OF FEED WATER SYSTEM OF BFP SET

PID OF SEALING & COOLING WATER SYSTEM OF BFP SET

PID OF LUBE OIL SYSTEM OF BFP SET

SESSION-2

4 DEC 2007

CONTROL OF CEP SET

Start permissive, Interlock and Annunciation are provided for safe operation of CEP set. •

Start-up conditions when CEPs are at rest :

-

The circuit breakers of CEP Motor shall be in ‘OFF’ position.

-

Suction Valve, R.C.Valve shall be kept open for all Pumps.

-

Discharge Valve shall be closed.

•

Putting CEPs into operation :

-

Power supply shall be available to the Motor.

-

Oil level in Thrust Bearing gauge glass shall be above the normal level.

-

Cooling water shall be available to the Thrust Bearing.

-

Sealing water shall be available to the Mechanical Seal. (Initially the sealing water is to be taken from emergency source and subsequently from the Pump discharge header when the Pump comes into the operation)

-

The valve in Canister vent line to the Condenser shall be opened.

-

The Solenoid Valve on discharge vent line to the L.P.flash tank shall be opened.

•

Tripping of CEP when any of the following conditions occur :

-

Hot-well level falls to ‘Low-Low’ level.

-

If the discharge pressure before NRV is less than the pre-set value of 13 kg/cm2 , sensed by a Pr. Switch provided at the pump discharge with a time lag of 10 seconds after CEP Motor starting.

•

Conditions to be ensured for starting of CEP when kept as

‘Stand-by’ : Running Pump trips. Discharge header pressure less than a pre-set value of 14 kg/cm2 for more than 10 seconds.  Note: Whenever the running Pump trips due to ‘Low-Low’ level in Condenser hot-well, it should not be possible to start the stand-by Pump.

INSTRUMENTATION SCHEME OF CEP

SEALING & COOLING WATER SCHEME OF CEP

CONTROL OF CWP

Start permissive, Interlock and Annunciation are provided for safe operation of CWP. •

Operational Controls/Interlocks provided for CWP :

-

When any of the 2 working CWPs trips for any reasons, the standby CWP will come into operation automatically, if selected in auto-mode.

-

The start/stop push buttons for CWPs shall be provided in the Local Control Panel (LCP). The selector switch for auto/manual selection of the CWPs shall be provided in the LCP. The selector switch shall be separate for each CWP.

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The selector switch for Test/Normal(LCP)/Trial operation of CWPs shall be provided in the SwitchGear.

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Lockable type emergency stop push button shall be provided local to each CWP for tripping in the event of any emergency.

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CWPs status indication(ON/OFF/TRIP) shall be provided in LCP & UCB.

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Tripping of any CWP shall give audio-visual indication in LCP & UCB.

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3 nos. Level Switches(on 2 out of 3 basis) shall be used for tripping of all CWPs, in the event of CW Sump water level falling below the permissible limit.An audio-visual indication shall be given in LCP & UCB for above.

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1 no. Pressure Gauge shall be provided at discharge of each CWP for local reading.

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3 nos. Pressure Switches shall be provided(on 2 out of 3 basis) on Common Discharge Header of the CWPs for full opening of the CWP discharge BF Valve from 100 to 900. The command shall  be hooked thru “Pumps-ON” condition for opening of the intended BF Valve of the respective CWP only.

•

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1 Pr. Transmitter shall be provided at Common Discharge Header outside CW Pump house for indicating CWP discharge header  pressure in DAS.

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1 Pr. Switch shall be provided on Common Discharge Header for auto start of the stand-by CWP(thru’ timer) at low header Pressure.It shall also give an audio-visual alarm in LCP & UCB for manual tripping of CWP developing low Pressure.

CWP Start Permissive Interlocks :

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Sump/Fore bay level ‘Not Low’.

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CWP discharge BFV ‘Not Open’.

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Motor Winding Temp. ‘Not High’.

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Pump Motor Bearing Temp. ‘Not High’(signal from Temp. Scanner mounted on LCP).

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Motor protection ‘Not Acted’ (signal from Breaker relay).

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Breaker in ‘Service condition’ (signal from the Breaker).

•

CWP Motor integral Instruments/Interlocks :

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Motor Winding Temp. ‘High’ (Annunciation in LCP).

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Motor Winding Temp. ‘Very High’ (Annunciation in LCP & Trip).

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Pump Motor set Bearing Temp. ‘High’ (Annunciation in LCP).

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Pump Motor set Bearing Temp. ‘Very High’ (Annunciation in LCP & Trip).

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Thrust Bearing Oil Temp. ‘High’ (Annunciation in LCP).

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Thrust Bearing Oil Temp. ‘Very High’ (Annunciation in LCP & Trip).

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Pump Bearing Vibration ‘High’ (Annunciation in LCP).

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Pump Bearing Vibration ‘Very High’ (Annunciation in LCP & Trip).

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Motor Bearing Vibration ‘High’ (Annunciation in LCP).

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Motor Bearing Vibration ‘Very High’ (Annunciation in LCP & Trip).

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CWP Discharge Butterfly Valve Controls/Interlocks :

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BFV shall open 100 on receipt of start command of CWP Motor.If the BFV fails to open after prefixed time(say 2 min), the CWP shall automatically trip and an audio-visual alarm shall be given in the LCP & UCB.

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When the CWP Discharge Header Pressure reaches the normal value, the Pr. Switches at the Common Discharge Header will give signal for full opening of the BFV.

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If BFV fails to close, an audio-visual alarm shall be given in the LCP to enable the operator to close it manually.

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BFV shall have Open/Close/Stop P.B. facility from the LCP as well as from local to the actuators.The stop P.B. local to actuators shall  be lockable type.

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Status indication for BFV open/Close shall be provided in the LCP & UCB.

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CW make up line Controls/Interlocks :

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2 nos. 500 Nb CW make up pipe work installed for supplying CW make up.

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Common Group Alarm provided in UCB for individual alarms in LCP :

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Motor Winding Temp., Bearing Temp., Oil Temp., Vibration, etc.

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BFV failure to Open.

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BFV failure to Close.

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Cooling Tower Fans High Vibration & Temp. and low Gear Box Oil Level.



SESSION-3

4 DEC 2007



PUMP MANUFACTURING FACILITIES

PUMP MANUFACTURING FACILITIES (MAJOR)          

CNC Vertical Lathe, SKS 12. CNC Horizontal Boring Machine, WHN 13.8C. CNC Horizontal Machining Centre, HMC 800. CNC Drilling Machine, BR6. Cylindrical Grinding Machine, RUS6000. Balancing Machines - Schenk, ABRO H-4K. Vertical Lathes - BV25/1000, HOMMA 25/1600. CNC Lathe, L45. Horizontal Boring Machine, WD130. Plasma Transfer Arc Automatic Welding Machine.

SESSION-4

4 DEC 2007



PUMP TESTING FACILITIES

SESSIONS - 1 & 2

5 DEC 2007



OPERATION, MAINTENANCE AND TROUBLE SHOOTING OF PUMPS

PUMP FAULTS AND REMEDIES

Sl. No.

I

SYMPTOM

Pump does not deliver liquid

PROBABLE FAULT

REMEDY

01 Wrong direction of rotation Reverse the direction of  rotation 02 Inadequate priming Re-prime 03 Suction pipe insufficiently Ensure adequate submerged submergence 04 Air leaks in suction line or  Arrest leaks or repack  gland gland 05 Speed less Increase speed

PUMP FAULTS AND REMEDIES

Sl. No.

II

SYMPTOM

Pump does not deliver rated quantity

PROBABLE FAULT

01 02 03 04 05

Suction strainer choked Restriction in delivery pipe Head under-estimated Leak in delivery Blockage in Impeller or  Casing 06 Excessive wear at neck  rings 07 Impeller damaged 08 Pump gaskets leaking

REMEDY

Clean strainer   Clear obstruction Reduce losses as required Repair leakage Clear obstruction Restore original clearances Renew Impeller   Renew defective gaskets

PUMP FAULTS AND REMEDIES

Sl. No.

SYMPTOM

III Pump does not generate rated head

PROBABLE FAULT

REMEDY

01 Wrong direction of rotation Reverse the direction of  rotation 02 Speed less Increase the speed 03 Excessive wear at neck Restore original clearances 04 Impeller damaged or  Renew Impeller or clear  choked  blockage 05 Pump gaskets leaking Renew defective gaskets

PUMP FAULTS AND REMEDIES

Sl. No.

SYMPTOM

IV Pump loses liquid after  starting

PROBABLE FAULT

01 Not fully primed - air or  vapour lock in suction line 02 Inlet of suction pipe insufficiently submerged 03 Air leaks in suction line or  gland

REMEDY

Stop pump and re-prime Ensure adequate submergence Arrest leaks or renew gland  packing

PUMP FAULTS AND REMEDIES Sl. No.

V

SYMPTOM

Pump overloads driving unit

PROBABLE FAULT

01 02 03 04 05

Pump gaskets leaking Leak in delivery line More flow Speed too high Impeller neck rings worn excessively 06 Gland packing too tight 07 Impeller damaged 08 Mechanical tightness 09 Pipe stress

REMEDY

Renew defective gaskets Repair leak   Reduce excess quantity Reduce speed Restore original clearances Slacken & re-tighten to finger tightness Renew impeller   Adjust clearances as required Disconnect pipe work and realign to pump

PUMP FAULTS AND REMEDIES Sl. No.

SYMPTOM

PROBABLE FAULT

01

Air or vapour lock in suction 02 Suction pipe insufficiently submerged 03 Mis-alignment VI Excessive vibration

REMEDY

Stop Pump and re-prime Ensure adequate submergence

Realign Pump and driving unit 04 Worn or loose bearings Renew bearings 05 Impeller choked or damaged Clear or renew Impeller  06 Shaft bent Straighten or renew Shaft 07 Foundation not rigid Strengthen the foundation and reinstall Pump 08 Coupling damaged Renew Coupling 09 Pipe stress Disconnect pipe work and realign to Pump

PUMP FAULTS AND REMEDIES

Sl. No.

SYMPTOM

VII Bearing overheating

PROBABLE FAULT

01 Misalignment 02 Oil level too low or too high 03 Wrong grade of oil 04 Dirt in bearings 05 06 07 08

Moisture in oil Bearings too tight Too much grease Pipe stress

REMEDY

Correct the alignment Replenish/drain to correct level Refill correct grade of oil Clean out and refill with clean oil Refill oil without moisture Renew bearings if necessary Repack with correct quantity Disconnect pipe work and realign to Pump

PUMP FAULTS AND REMEDIES

Sl. No.

SYMPTOM

VIII Bearings wear 

PROBABLE FAULT

01

Mis-alignment

02

Shaft bent

03 04

Dirt in bearings Lack of lubrication

05

Bearing badly installed

06

Pipe stress

07

Excessive vibration

REMEDY

Realign Pump and driving unit. Renew bearings if requried. Renew Shaft. Renew bearings if required. Clean and refill with clean oil Ensure proper lubrication. Renew bearings if required. Follow manufacturer's instructions. Renew bearings if  needed. Ensure pipe work is correctly aligned to Pump. Renew  bearings if needed. Refer to Symptom VI.

PUMP FAULTS AND REMEDIES

Sl. No.

SYMPTOM

IX Irregular  delivery

PROBABLE FAULT

01 Air or vapour lock in suction line 02 Fault in driving unit

REMEDY

Stop Pump and re-prime

Examine driving unit and make good any defects 03 Air leaks in suction line or  Arrest leaks or repack gland gland 04 Inlet of suction pipe Ensure adequate insufficiently submerged submergence

PUMP FAULTS AND REMEDIES

Sl. No.

X

SYMPTOM

PROBABLE FAULT

Excessive noise level

01 Air or vapour lock in suction line 02 Inlet of suction pipe insufficiently submerged 03 Air leaks in suction line or  gland 04 Mis-alignment 05 Worn or loose bearings 06 Shaft bent 07 Foundation not rigid

REMEDY

Stop Pump and re-prime Ensure adequate submergence Make good any leaks or  repack gland Realign Pump and driving unit Renew Shaft Renew Shaft Strengthen Foundation