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, DUTY & OPERATION
• FREQUENCY VARIATION
• POWER SUPPLY DETAILS
 CHARACTERISTIC CURVE OF A PUMP

1800
52.5 Hz

HEAD (mlc)
50 Hz
1600

1400

1200
47.5 Hz
POWER (kW) 1000

2000

1500

1000

500

90

80

70
EFFICIENCY (%)

60

50 20

NPSHR (mlc)
40 15

30 Η 10
3% ∆
20 5

10 0

0 30 60 90 120 150 180 210 240 270 300 330 360 390 420 450
SUCTION FLOW (cub. m. / hr.)
* Head ~ Capacity Curve :
- Rising characteristic
- Drooping characteristic
- Steep characteristic
- Flat characteristic
- Unstable characteristic

HEAD

FLOW
* Power ~ Capacity Curve :
- Non-over loading Curve ER
OW
- Overloading Curve DI
NG
P

L OA
ER
- OV
N ON

E R
NG POW
AD I
OV ERLO

* 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 Q α D
H α N2 and H α D2
P α N3 P α D3
where N is the Speed of the Pump, rpm
D is the Diameter of the Impeller
COMPARISION BETWEEN NPSHA & NPSHR :

AVAI
LABL
E
NPSH

UI R ED
REQ
• 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 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 PARAMETERS .

FLOW HEAD SPEED

Cub.m/hr mwc rpm

BOILER FEED 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 210 MW 50% 16000 25 490
WATER 500 MW 33% 30000 25 333
BFP TYPICAL PARAMETERS FOR COMBINED CYCLE PLANTS

GT FRAME 3 x 50% 2 x 50%

Q H Q H
(M 3/ HR) (MLC) (M3/HR) (MLC)

105 - - 63 750

205 63 751 - -

106 - - 80 980

206 80 1250 - -

109 125 1250 - -

209 265 1500 - -

 CEP TYPICAL PARAMETERS FOR CCPPs

GT FRAME 50% DUTY 100% DUTY

FLOW HEAD FLOW HEAD
Cub.m/hr Mts. Cub.m/hr 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 keep the Shaft or Rotor in correct alignment with stationary
parts under the action of radial and axial loads.

They are of two types :

Line Bearings

Thrust Bearings
Line Bearings :
- 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, Multi Stage, Multi-Shaft.
Can 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 rubber line bearings with axial flutes.

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

High sustained Efficiency.

Cutless rubber line bearings with axial flutes.

Tilting pad Thrust Bearing for Axial Thrust.

Shaft 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

h 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.
- The selector switch for Test/Normal(LCP)/Trial operation of
CWPs shall be provided in the SwitchGear.
- Lockable type emergency stop push button shall be provided
local to each CWP for tripping in the event of any emergency.
- CWPs status indication(ON/OFF/TRIP) shall be provided in LCP
& UCB.
- Tripping of any CWP shall give audio-visual indication in LCP &
UCB.
- 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.
- 1 no. Pressure Gauge shall be provided at discharge of each CWP
for local reading.
- 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.
 - 1 Pr. Transmitter shall be provided at Common Discharge Header
outside CW Pump house for indicating CWP discharge header
pressure in DAS.
- 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 :
- Sump/Fore bay level ‘Not Low’.
- CWP discharge BFV ‘Not Open’.
- Motor Winding Temp. ‘Not High’.
- Pump Motor Bearing Temp. ‘Not High’(signal from Temp.
Scanner mounted on LCP).
- Motor protection ‘Not Acted’ (signal from Breaker relay).
- Breaker in ‘Service condition’ (signal from the Breaker).
• CWP Motor integral Instruments/Interlocks :
- Motor Winding Temp. ‘High’ (Annunciation in LCP).
- Motor Winding Temp. ‘Very High’ (Annunciation in LCP & Trip).
- Pump Motor set Bearing Temp. ‘High’ (Annunciation in LCP).
- Pump Motor set Bearing Temp. ‘Very High’ (Annunciation in
LCP & Trip).
- Thrust Bearing Oil Temp. ‘High’ (Annunciation in LCP).
- Thrust Bearing Oil Temp. ‘Very High’ (Annunciation in LCP &
Trip).
- Pump Bearing Vibration ‘High’ (Annunciation in LCP).
- Pump Bearing Vibration ‘Very High’ (Annunciation in LCP &
Trip).
- Motor Bearing Vibration ‘High’ (Annunciation in LCP).
- Motor Bearing Vibration ‘Very High’ (Annunciation in LCP &
Trip).
• CWP Discharge Butterfly Valve Controls/Interlocks :
- 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.
- 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.
- If BFV fails to close, an audio-visual alarm shall be given in the
LCP to enable the operator to close it manually.
- 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.
- Status indication for BFV open/Close shall be provided in the LCP
& UCB.
• CW make up line Controls/Interlocks :
- 2 nos. 500 Nb CW make up pipe work installed for supplying CW
make up.
• Common Group Alarm provided in UCB for individual alarms in
LCP :
- Motor Winding Temp., Bearing Temp., Oil Temp., Vibration, etc.
- BFV failure to Open.
- BFV failure to Close.
- 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.
SYMPTOM PROBABLE FAULT REMEDY
No.
01 Wrong direction of rotation Reverse the direction of
rotation
I Pump does not 02 Inadequate priming Re-prime
deliver liquid 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.
SYMPTOM PROBABLE FAULT REMEDY
No.
01 Suction strainer choked Clean strainer
02 Restriction in delivery pipe Clear obstruction
03 Head under-estimated Reduce losses as required
II Pump does not 04 Leak in delivery Repair leakage
deliver rated 05 Blockage in Impeller or Clear obstruction
quantity Casing
06 Excessive wear at neck Restore original clearances
rings
07 Impeller damaged Renew Impeller
08 Pump gaskets leaking Renew defective gaskets
 PUMP FAULTS AND REMEDIES

Sl.
SYMPTOM PROBABLE FAULT REMEDY
No.
01 Wrong direction of rotation Reverse the direction of
rotation
III Pump does not 02 Speed less Increase the speed
generate rated 03 Excessive wear at neck Restore original clearances
head 04 Impeller damaged or Renew Impeller or clear
choked blockage
05 Pump gaskets leaking Renew defective gaskets
 PUMP FAULTS AND REMEDIES

Sl.
SYMPTOM PROBABLE FAULT REMEDY
No.
01 Not fully primed - air or Stop pump and re-prime
vapour lock in suction line
IV Pump loses 02 Inlet of suction pipe Ensure adequate
liquid after insufficiently submerged submergence
starting 03 Air leaks in suction line or Arrest leaks or renew gland
gland packing
 PUMP FAULTS AND REMEDIES
Sl.
SYMPTOM PROBABLE FAULT
No.
01 Pump gaskets leaking
02 Leak in delivery line
03 More flow
04 Speed too high
V Pump overloads 05 Impeller neck rings worn
driving unit 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.
SYMPTOM PROBABLE FAULT REMEDY
No.
01 Air or vapour lock in Stop Pump and re-prime
suction
02 Suction pipe insufficiently Ensure adequate submergence
submerged
03 Mis-alignment Realign Pump and driving
VI Excessive unit
vibration 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.
SYMPTOM PROBABLE FAULT REMEDY
No.
01 Misalignment Correct the alignment
02 Oil level too low or too Replenish/drain to correct
high level
03 Wrong grade of oil Refill correct grade of oil
VII Bearing 04 Dirt in bearings Clean out and refill with
overheating clean oil
05 Moisture in oil Refill oil without moisture
06 Bearings too tight Renew bearings if necessary
07 Too much grease Repack with correct quantity
08 Pipe stress Disconnect pipe work and
realign to Pump
 PUMP FAULTS AND REMEDIES

Sl.
SYMPTOM PROBABLE FAULT REMEDY
No.
01 Mis-alignment Realign Pump and driving unit.
Renew bearings if requried.
02 Shaft bent Renew Shaft. Renew bearings
if required.
03 Dirt in bearings Clean and refill with clean oil
VIII Bearings wear 04 Lack of lubrication Ensure proper lubrication.
Renew bearings if required.
05 Bearing badly installed Follow manufacturer's
instructions. Renew bearings if
needed.
06 Pipe stress Ensure pipe work is correctly
aligned to Pump. Renew
bearings if needed.
07 Excessive vibration Refer to Symptom VI.
 PUMP FAULTS AND REMEDIES

Sl.
SYMPTOM PROBABLE FAULT REMEDY
No.
01 Air or vapour lock in Stop Pump and re-prime
suction line
IX Irregular 02 Fault in driving unit Examine driving unit and
delivery 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.
SYMPTOM PROBABLE FAULT REMEDY
No.
01 Air or vapour lock in Stop Pump and re-prime
suction line
02 Inlet of suction pipe Ensure adequate
X Excessive noise insufficiently submerged submergence
level 03 Air leaks in suction line or Make good any leaks or
gland repack gland
04 Mis-alignment Realign Pump and driving
unit
05 Worn or loose bearings Renew Shaft
06 Shaft bent Renew Shaft
07 Foundation not rigid Strengthen Foundation