FEEDBACK No.

8
PROBLEM : TRIPPING COOLING WATER PUMPS ON OVER LOAD DURING OPERATION AT THE FREQUENCY OF 50 HZ. NORTH CHENNAI TPS

PROJECT : HISTORY :

The cooling water pumps were operating near full load right from the commissioning time while the frequency was in the range of 40 - 49 Hz. In the recent past, the condition further got deteriorated and the pumps were experiencing more nuisance trippings. The problem was analysed and the observations are a. System resistance seems to have increased which is getting indicated by high differential pressure across the debris filter and deterioration of condenser cleanliness. The filter back wash gear drive is not operational in Unit-1 and 2 due to defects in gear box. Understand from TNEB that spares ore being ordered and will be made good in the near future. For improving the cleanliness of the condenser tubes, TNEB was requested to regularly operate ball cleaning system.

b.

To prime the system , the operation staff ere requested to vent the condenser on regular basis and maintain the vacuum of 300 mm of Hg at condenser outlet water box. The cooling water fore bay level is going low due to shortage of back water from sea. The quality of water is also found to have deteriorated affecting the density of water. The configuration of the cooling water, particularly in the vicinity of the pump inlet by way of Head and density affects the pump performance and cavitation effect was noticed. The extensive pitting marks noticed in the bell mouth and impeller surfaces confirms the above phenomenon of cavitation. The pumps are also experiencing failure of spider ribs and deflector plate assembly near top flange joint. The above two failures were suspected to be due to fatigue caused by the disturbance on cavitations.

c.

The customer has agreed to carry out certain modifications in cooling water intake canals to improve pump inlet head conditions in the near future (in six months) to prevent the above problems.

BHEL/Hyd. also agreed to increase the capacity of the motor with respect to pump in future to take care of operating conditions to improve the reliability of cooling water pumps.

DAMAGES OBSERVED ON COOLING WATER PUMPS AT NORTH CHENNAI TPS

Cooling water pumps were operating at rated load since commissioning of the units. The cooling water pump system is experiencing the following failures recently Extensive Pitting damage on Bell mouth and Impellors Cracks in bottom most support spider ribs Flange cracks in stainless steel sleeve The first two damages are because of cavitations due to low suction pressure . The support spider houses the rubber guide bearings which are wafer lubricated. The failure of support brackets are because of fatigue resulting from excessive vibrations due to pump cavitation. The cooling water fore bay level is not being maintained due to shortage of back water from sea. The quality of water is also getting deteriorated due to sea water contamination. Certain system modifications are being implemented by TNEB and the water intake level would improve in six months time. Failures are observed at weld joints near the deflector plate top flange. The customer has been advised to provide additional sleeve to strengthen the weld area. However the failures have been referred to pumps engineering , Hyderabad for further advice. (PI. refer the sketch in the next page)

Plane of flange Failure

Deflector Pump Shaft

Spider support

Bottom most Spider rib cracked

Pump Impeller

Extensive Pitting damage

Failure Locations on Cooling water Pumps at North Chennai TPS