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    Case Study Pumps 1

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    Aravazhi Ramasami Thangaraj
    This document provides a case study on a boiler feed pump. It describes the major components of the pump and issues that can cause excessive vibration such as misalignment, clearances, or an unbalanced rotor. It also discusses causes of other problems like seizures, shaft failures, and solutions implemented like modifying the shaft diameter or converting a thrust collar. Precautions are recommended to prevent future issues.

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    © All Rights Reserved
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    Case Study Pumps 1

    Uploaded by

    Aravazhi Ramasami Thangaraj
    543 views36 pages
    This document provides a case study on a boiler feed pump. It describes the major components of the pump and issues that can cause excessive vibration such as misalignment, clearances, or an unbalanced rotor. It also discusses causes of other problems like seizures, shaft failures, and solutions implemented like modifying the shaft diameter or converting a thrust collar. Precautions are recommended to prevent future issues.

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    case study of 21o mw pumps

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    This document provides a case study on a boiler feed pump. It describes the major components of the pump and issues that can cause excessive vibration such as misalignment, clearances, or an unbalanced rotor. It also discusses causes of other problems like seizures, shaft failures, and solutions implemented like modifying the shaft diameter or converting a thrust collar. Precautions are recommended to prevent future issues.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    543 views36 pages

    Case Study Pumps 1

    Uploaded by

    Aravazhi Ramasami Thangaraj
    This document provides a case study on a boiler feed pump. It describes the major components of the pump and issues that can cause excessive vibration such as misalignment, clearances, or an unbalanced rotor. It also discusses causes of other problems like seizures, shaft failures, and solutions implemented like modifying the shaft diameter or converting a thrust collar. Precautions are recommended to prevent future issues.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
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    The document discusses various case studies and failure modes of boiler feed pumps and their components. It provides details on the components, common issues, recommended vibration limits, and maintenance practices.

    The main components of a boiler feed pump include the pump casing, discharge cover, suction guide, ring section assembly, diffusers, journal bearing, thrust bearing, bearing housing, shaft, impeller, abutment ring, mechanical seal, balancing drum, thrust collar, and coupling.

    Excessive vibration in a boiler feed pump can be caused by rotor unbalance, coupling misalignment, bearing misalignment, loose holding down bolts, excessive clearances of internals, or an unbalanced rotating assembly.

    CASE STUDY - PUMPS

    BOILER FEED PUMP-FK6D30


    CASE STUDY - PUMPS
    BOILER FEED PUMP-FK6D30
    • Pump Casing
    • Discharge cover
    • Suction Guide
    • Ring section assembly ( Stage assembly)
    • Diffusers
    • Journal bearing
    • Thrust bearing ( 8No.Thrust pads per side)
    • Bearing housing
    BOILER FEED PUMP-FK6D30
    Rotating assembly
    • Shaft, Impeller, Abutment ring, Keys
    • Rotating part of Mechanical seal
    • Balancing drum & Nut
    • Thrust collar & Nut
    • Pump Half coupling
    BOILER FEED PUMP-FK6D30
    • Hydraulic Balance
    The pump has been designed such that
    the shaft is kept in position by the location
    of a Balance drum at the NDE. Only a
    small residual thrust remains to be
    transferred.
    Balancing arrangement comprises of the
    Balance chamber, Balance drum and
    Balance drum bush.
    BOILER FEED PUMP-FK6D30
    • The different pressure acting on the equal
    areas tends to move the rotating assembly
    towards the DE
    • The thrust force varies with the load.
    BOILER FEED PUMP-FK6D30
    Excessive vibration
    • Misalignment of pump set.
    • Bearing Misalignment
    • Holding down bolts losse.
    • Excessive clearances of pump internals.
    • Rotating assembly out of balance.
    BOILER FEED PUMP-FK6D30
    • Vibration problem
    Vibration measurement shall be done in
    microns ( Peak to peak / RMS valve )
    • BHEL Recommendation
    High – 11 mm/sec RMS
    V.High – 18 mm/sec RMS
    • BHEL does not Recommend tripping of
    pump with high vibration. Trend shall be
    observed
    BOILER FEED PUMP-FK6D30
    • Case of vibration
    Rotor unbalance
    Coupling MIS- Alignment
    Hydraulic unbalance
    • If coupling alignment is frequently getting
    disturbed, pipe support system shall be
    looked.
    BOILER FEED PUMP-FK6D30
    • BFP Seizures
    Ensure cleanliness of the system
    Proper centering of the rotor assembly
    Do not trip the running BFP when
    unit trip / pump not required. Switch over
    to recirculation mode & stop the pump
    after 15 to 30minutes
    BOILER FEED PUMP-FK6D30
    • BFP Shaft failure
    Most vulnerable location is thrust collar
    portion
    Shaft modified from 64mm to 70mm dia
    Thrust collar interference is 0.04 to
    0.08mm
    Thrust collar bore should be uniform
    BOILER FEED PUMP-FK6D30
    • Precautions
    Always check interference after
    maintenance
    Torque tighten the collar nut – 675 N-m
    Ensure proper abutment of collar with
    shaft shoulder
    Always check rotor shifting towards
    discharge side 0.75mm after maintenance
    BOILER FEED PUMP-FK6D30
    • Conversion of thrust collar
    • Thrust collar 64 mm machined at the bore
    to suit 70mm shaft on emergency
    • It served more than a year. It was replaced
    later
    BOILER FEED PUMP-FK6D30
    • Thrust pad failure
    It may be due to the failure of white mettal
    bonding with base metal
    Due to change in lube oil viscosity-water
    mixing
    sediments in lube oil
    CASE STUDY - PUMPS
    CASE STUDY - PUMPS
    CASE STUDY - PUMPS
    CASE STUDY - PUMPS
    CASE STUDY - PUMPS
    CASE STUDY - PUMPS
    BOILER FEED PUMP-FK6D30

    Thrust pad failure


    Shaft broken at thrust collar position
    CEP
    CEP
    • Discharge pressure low – after unit

    synchronized
    1st stage impeller assembled in reverse
    direction
    Shaft failure at 3rd stage
    CEP
    • Thrust bearing seizure
    Water mixed with lube oil
    Boiler feed booster pump
    • Mechanical seal leak- 2C
    On inspection it was observed that
    clearance in un even in the top & bottom
    of seal bore.
    • First bearing housing lifted at one end
    • Casing wearing rings grinded to get even
    clearance
    • Gland plate holes grinded to upset the
    assembly to get even clearance
    Boiler feed booster pump
    • Discharge pressure low
    On inspection noticed heavy deposits in
    the impeller suction eye
    Suction filter choking (Ferrous & copper
    deposits )
    Turbine cooler booster pump
    • Discharge pressure low
    Shaft failure at NDE side
    It was rectified by making thread inside
    the shaft at one end
    At the other end also threaded and shaft
    joined with a stud, then welded.
    The surface machined to the size. It has
    served for 8 years
    Hydraulic coupling
    • Failure of main oil pump
    • After overhaul, the BFP started first time
    Noticed heavy hissing noise from coupling
    • On inspection noticed drive gear assembly
    of main oil pump moved from it position
    • Noticed one of the main oil pump gear
    locating pin damaged

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