You are on page 1of 39

CASE STUDY

Equipment & Location: Steam Condensate Pump-A

Dates of Checking’s: January to July 2006

Instruments used: Vibration Data Collector/Analyser, Model Easy-Viber

Abstract of Case: This pump had been experiencing high vibration levels after few months’ operation
since commissioning. The maintenance personnel had seen the wear of pump parts
and centralizer bearings. The clearances of the bearings were increased by the
personnel in anticipation rubbing of shaft due to less clearance. On the contrary
vibration levels continued to show the same pattern of characteristics and did not yield
any fruitful results. Thus the pump was required to be checked every after 3~4 months
operation and the wear pattern appeared to be of similar nature. However, the other
similar pump “B” had not shown this kind of problem.

While studying further on this recurring problem, it was observed that normally both the
pumps were put in operation due to generation on more quantity of steam condensate
than the designed/rated estimates. In such situation, the suction of this pump was near
the baffle plate in the shell and tube type steam condenser, was found leading to the
starvation, cavitations, inadequate dynamic suction head resulting in erratic behavior of
the vibration levels.

Ultimately, recirculation of steam condensate was recommended to keep the minimum


level in the condenser, so that the dynamic suction head on this pump remains more or
less constant and to remove the effect of transient vibrations caused by the hydraulic
effects. Thus the frequent repair/overhaul, replacement of spares, production loss due
to non-availability of this pump was resolved permanently, saving maintenance efforts,
time and money.
Equipment Specifications: Motor - ABB Type M2BK280SMA2. Coupling: Metastream Type TSKS 0033.
Pump: Vertical Centrifugal Pit Type, Two Stages, Rated Power 22.2 KW, Flow Rate
79.7 M3/Hour, Suction Pressure 0.107 bar, Discharge Pressure 6.7 bar, Speed
2,940 rpm. Mechanical Seal Make Burgmann, Seal Type H75K/70.
Vibration Data: Observed Trend of Vibration Levels during the Operations is given below.
Point No. & Velocity BC Displ.
Actual Dates Accln. G pk
Direction mm/sec Value Microns
4th Feb 2006 1-Axial 0.5708 0.00 ------ ------
th
7 Feb 2006 1-Axial 0.6663 0.01 ------ ------
th
12 Feb 2006 1-Axial 0.8107 0.01 1.7950 ------
th
14 Apr 2006 1-Axial 0.3714 0.22 ------ 0.264720
nd
22 Apr 2006 1-Axial 1.0457 0.01 ------ ------
th
4 Feb 2006 1-Horizontal 0.7583 0.01 ------ ------
th
12 Feb 2006 1-Horizontal ------ 0.11 2.620 ------
th
14 Apr 2006 1-Horizontal 0.8902 0.25 ------ 0.461650
nd
22 Apr 2006 1-Horizontal 1.9442 0.03 ------ ------
th
8 Jul 2006 1-Horizontal 2.051 0.54 ------ ------
th
4 Feb 2006 1-Vertical 0.6623 0.02 ------ ------
th
12 Feb 2006 1-Vertical ------ 0.05 2.8967 ------
th
14 Apr 2006 1-Vertical 1.2063 0.30 ------ 0.4682
nd
22 Apr 2006 1-Vertical 1.3090 0.13 ------ ------
th
4 Feb 2006 2-Axial 0.688064 ------ ------ ------
th
7 Feb 2006 2-Axial 1.036309 ------ ------ ------
th
12 Feb 2006 2-Axial 1.041969 0.39 1.0245 ------
th
14 Apr 2006 2-Axial 0.578019 0.55 ------ 0.6782887
nd
22 Apr 2006 2-Axial 1.051927 ------ ------
th
4 Feb 2006 2-Horizontal 0.5735 0.10 ------ ------
th
12 Feb 2006 2-Horizontal ------ 0.22 3.945 ------
th
14 Apr 2006 2-Horizontal 0.5506 0.35 ------ 0.283137
nd
22 Apr 2006 2-Horizontal 1.4896 0.40 ------ ------
th
8 Jul 2006 2-Horizontal 2.020 0.78 ------ ------
th
4 Feb 2006 2-Vertical 0.5594 0.23 ------ ------
7th Feb 2006 2-Vertical 0.7942 0.28 ------ ------
th
12 Feb 2006 2-Vertical 0.7081 0.19 1.8579 ------
th
14 Apr 2006 2-Vertical 0.6169 0.33 ------ 0.429229
nd
22 Apr 2006 2-Vertical 0.6766 0.40 ------ ------
th
4 Feb 2006 3-Axial 0.5970 0.00 ------ ------
th
7 Feb 2006 3-Axial 0.551141 0.43 0.4221 ------
th
12 Feb 2006 3-Axial 0.690728 0.01 0.8334 ------
th
14 Apr 2006 3-Axial 0.7793 0.49 ------ 0.887076
nd
22 Apr 2006 3-Axial 1.0868 1.73 ------ ------
th
4 Feb 2006 3-Horizontal 0.8319 0.28 ------ ------
th
12 Feb 2006 3-Horizontal ------ 0.50 1.5192 ------
th
14 Apr 2006 3-Horizontal 0.6274 0.51 ------ 0.7123
nd
22 Apr 2006 3-Horizontal 1.0521 0.63 ------ ------
th
4 Feb 2006 3-Vertical 0.5818 0.54 ------ ------
th
7 Feb 2006 3-Vertical 0.5621 0.17 ------ ------
th
12 Feb 2006 3-Vertical 6903 0.31 0.8565 ------
th
14 Apr 2006 3-Vertical 0.448009 0.51 ------ 0.325388
nd
22 Apr 2006 3-Vertical 0.8062 0.55 ------ ------
Background History: The pump had undergone repairs/overhaul works during first week of February 2006.
The parts of pump like shaft, bearings, guide bushes, wear rings etc. were replaced by
during the repairs/overhaul works. The vibration level had decreased considerably after
carrying out the repairs/overhaul works, which were all well within the acceptable limit.

Operational Variations: According to the original operational philosophy considered during design stage was to
operate only single pump and other pump shall be in standby duty. But, in fact, the
operator had to operate both the pumps in parallel operation for handling the excess
generation of steam condensate than the anticipated during the design stage. This
resulted in to operational requirement of both the pumps in normal operation, causing
depletion of standby one. This was a serious problem in operating the entire plant in a
reliable manner. However the OEM and Designing Agency had been informed time to
time on this typical problem, who had never come forward with any viable solutions in
studying the root cause or for suggesting the necessary changes in operations.
Vibration Analysis: This pump had been experiencing high vibration levels after few months’ operation
since commissioning. The maintenance personnel had seen the wear of pump parts
and centralizer bearings. The clearances of the bearings were increased by the
personnel in anticipation rubbing of shaft due to less clearance. On the contrary
vibration levels continued to show the same pattern of characteristics and did not yield
any fruitful results. Thus the pump was required to be checked every after 3~4 months
operation and the wear pattern appeared to be of similar nature. However, the other
operating pump “B” had not shown this kind of problem. While studying further on this
recurring problem, it was observed that normally both the pumps were put in operation
due to generation on more quantity of steam condensate than the designed/rated
estimates. In such situation, the suction of this pump was near the baffle plate in shell
and tube type steam condenser, was found starving, leading to cavitations, inadequate
dynamic suction head resulting in the erratic behavior of vibrations.
Ultimately, recirculation of flow of the steam condensate was recommended to keep
the minimum level in the condenser, so that the Dynamic Suction Head is maintained
constant for reducing transient vibrations caused by hydraulic effects. Thus frequent
repair/ overhaul, replacement of spares, production loss due to non-availability of this
pump could be resolved permanently, saving maintenance efforts, time and money.
Otherwise, Operational Staff had been insisting to install one more additional pump
installed as a ready standby unit as the generation of steam condensate had been
showing increasing trend and they had no confidence in operation of these pumps.

Conclusion: The Design and Installation of Machinery can have some differences in comparison to
similar models machines, exhibiting a quite different characteristics and operational
problems due to the variations existing in the associated/auxiliary components. Some
times past experience of similar kind of machinery may not be of much help or useful
due to the inherent design or operational variations. Also, some times, designer or
original equipment manufacturer may not be of any help due to lacking of their own
experience on the operations of their products in a typical operational situation. Hence,
the end user must carry out a comprehensive/detailed study looking in to integration of
all available operating parameters and experiences, which can give a better idea and
viable solution to such engineering problems.
TREND REPORT (22nd Apr 2006)
Steam Condensate Pump-A, Point # 1-Horizontal

TREND REPORT (22nd Apr 2006)


Steam Condensate Pump-A, Point # 1-Vertical
TREND REPORT (22nd Apr 2006)
Steam Condensate Pump-A, Point # 1-Axial

TREND REPORT (22nd Apr 2006)


Steam Condensate Pump-A, Point # 2-Horizontal
TREND REPORT (22nd Apr 2006)
Steam Condensate Pump-A, Point # 2-Vertical

TREND REPORT (22nd Apr 2006)


Steam Condensate Pump-A, Point # 2-Axial
TREND REPORT (22nd Apr 2006)
Steam Condensate Pump-A, Point # 3-Horizontal

TREND REPORT (22nd Apr 2006)


Steam Condensate Pump-A, Point # 3-Vertical
TREND REPORT (22nd Apr 2006)
Steam Condensate Pump-A, Point # 3-Axial

SPECTRA REPORT (4th February 2006)


Steam Condensate Pump-A, Point # 1-Horizontal
SPECTRA REPORT (4th February 2006)
Steam Condensate Pump-A, Point # 1-Vertical

SPECTRA REPORT (4th February 2006)


Steam Condensate Pump-A, Point # 1-Axial
SPECTRA REPORT (4th February 2006)
Steam Condensate Pump-A, Point # 2-Horizontal

SPECTRA REPORT (4th February 2006)


Steam Condensate Pump-A, Point # 2-Vertical
SPECTRA REPORT (4th February 2006)
Steam Condensate Pump-A, Point # 2-Axial

SPECTRA REPORT (4th February 2006)


Steam Condensate Pump-A, Point # 3-Horizontal
SPECTRA REPORT (4th February 2006)
Steam Condensate Pump-A, Point # 3-Vertical

SPECTRA REPORT (4th February 2006)


Steam Condensate Pump-A, Point # 3-Axial
SPECTRA REPORT (7th Feb 2006)
Steam Condensate Pump-A, Point # 1-Axial

SPECTRA REPORT (12th Feb 2006)


Steam Condensate Pump-A, Point # 1-Axial
SPECTRA REPORT (7th Feb 2006)
Steam Condensate Pump-A, Point # 2-Vertical

SPECTRA REPORT (12th Feb 2006)


Steam Condensate Pump-A, Point # 2-Vertical
SPECTRA REPORT (7th Feb 2006)
Steam Condensate Pump-A, Point # 2-Axial

SPECTRA REPORT (12th Feb 2006)


Steam Condensate Pump-A, Point # 2-Axial
SPECTRA REPORT (7th Feb 2006)
Steam Condensate Pump-A, Point # 3-Vertical

SPECTRA REPORT (12th Feb 2006)


Steam Condensate Pump-A, Point # 3-Vertical
SPECTRA REPORT (7th Feb 2006)
Steam Condensate Pump-A, Point # 3-Axial

SPECTRA REPORT (12th Feb 2006)


Steam Condensate Pump-A, Point # 3-Axial
SPECTRA REPORT (7th Feb 2006)
Steam Condensate Pump-A, Point # 3-Axial

SPECTRA REPORT (12th Feb 2006)


Steam Condensate Pump-A, Point # 3-Axial
SPECTRA REPORT (12th Feb 2006)
Steam Condensate Pump-A, Point # 1-Horizontal

SPECTRA REPORT (12th Feb 2006)


Steam Condensate Pump-A, Point # 1-Vertical
SPECTRA REPORT (12th Feb 2006)
Steam Condensate Pump-A, Point # 1-Axial

SPECTRA REPORT (12th Feb 2006)


Steam Condensate Pump-A, Point # 2-Horizontal
SPECTRA REPORT (12th Feb 2006)
Steam Condensate Pump-A, Point # 2-Vertical

SPECTRA REPORT (12th Feb 2006)


Steam Condensate Pump-A, Point # 2-Axial
SPECTRA REPORT (12th Feb 2006)
Steam Condensate Pump-A, Point # 3-Horizontal

SPECTRA REPORT (12th Feb 2006)


Steam Condensate Pump-A, Point # 3-Vertical
SPECTRA REPORT (12th Feb 2006)
Steam Condensate Pump-A, Point # 3-Axial

SPECTRA REPORT (14th Apr 2006)


Steam Condensate Pump-A, Point # 1-Horizontal
SPECTRA REPORT (14th Apr 2006)
Steam Condensate Pump-A, Point # 1-Vertical

SPECTRA REPORT (14th Apr 2006)


Steam Condensate Pump-A, Point # 1-Axial
SPECTRA REPORT (14th Apr 2006)
Steam Condensate Pump-A, Point # 2-Horizontal

SPECTRA REPORT (14th Apr 2006)


Steam Condensate Pump-A, Point # 2-Vertical
SPECTRA REPORT (14th Apr 2006)
Steam Condensate Pump-A, Point # 2-Axial

SPECTRA REPORT (14th Apr 2006)


Steam Condensate Pump-A, Point # 3-Horizontal
SPECTRA REPORT (14th Apr 2006)
Steam Condensate Pump-A, Point # 3-Vertical

SPECTRA REPORT (14th Apr 2006)


Steam Condensate Pump-A, Point # 3-Axial
SPECTRA REPORT (14th Apr 2006)
Steam Condensate Pump-A, Point # 1-Horizontal

SPECTRA REPORT (14th Apr 2006)


Steam Condensate Pump-A, Point # 1-Vertical
SPECTRA REPORT (14th Apr 2006)
Steam Condensate Pump-A, Point # 1-Axial

SPECTRA REPORT (14th Apr 2006)


Steam Condensate Pump-A, Point # 2-Horizontal
SPECTRA REPORT (14th Apr 2006)
Steam Condensate Pump-A, Point # 2-Vertical

SPECTRA REPORT (14th Apr 2006)


Steam Condensate Pump-A, Point # 2-Axial
SPECTRA REPORT (14th Apr 2006)
Steam Condensate Pump-A, Point # 3-Horizontal

SPECTRA REPORT (14th Apr 2006)


Steam Condensate Pump-A, Point # 3-Vertical
SPECTRA REPORT (14th Apr 2006)
Steam Condensate Pump-A, Point # 3-Axial

SPECTRA REPORT (22nd Apr 2006)


Steam Condensate Pump-A, Point # 1-Horizontal
SPECTRA REPORT (22nd Apr 2006)
Steam Condensate Pump-A, Point # 1-Vertical

SPECTRA REPORT (22nd Apr 2006)


Steam Condensate Pump-A, Point # 1-Axial
SPECTRA REPORT (22nd Apr 2006)
Steam Condensate Pump-A, Point # 2-Horizontal

SPECTRA REPORT (22nd Apr 2006)


Steam Condensate Pump-A, Point # 2-Vertical
SPECTRA REPORT (22nd Apr 2006)
Steam Condensate Pump-A, Point # 2-Axial

SPECTRA REPORT (22nd Apr 2006)


Steam Condensate Pump-A, Point # 3-Horizontal
SPECTRA REPORT (22nd Apr 2006)
Steam Condensate Pump-A, Point # 3-Vertical

SPECTRA REPORT (22nd Apr 2006)


Steam Condensate Pump-A, Point # 3-Axial
TREND REPORT (08-JUL-2006)
(After raising the level of Condensate in the Hot Pot/Well)
Condensate Pump-A, Point # 1-Horizontal

SPECTRA REPORT (08-JUL-2006)


(After raising the level of Condensate in the Hot Pot/Well)
Condensate Pump-A, Point # 1-Horizontal
TREND REPORT (08-JUL-2006)
(After raising the level of Condensate in the Hot Pot/Well)
Condensate Pump-A, Point # 2-Horizontal

SPECTRA REPORT (08-JUL-2006)


(After raising the level of Condensate in the Hot Pot/Well)
Condensate Pump-A, Point # 1-Horizontal