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Introductory Power Plant Operation

Training Course

Boiler Feed Water Pump

Main Feed Water Pump


Purpose: to pump the water from the feed water system ( from the
DA) and provide this water to the boiler system at
requisite pressure , to generate steam which is responsible for
rolling the Turbine, Therefore Generate Electricity.

Each pump set consists of a booster


pump, directly driven from one end
of shaft of an electric motor, and a
boiler feed pump driven from the
opposite end of the motor shaft
through a variable speed turbo
coupling.

Technical Data
Booster pump
Type : FA1D56A
Suction Temp. : 186 OC
Suction Press. : 1,280 MPa
Flow : 530,7 t/h
Head : 104,09 m
Pump Efficiency : 80,84 %
NPSHr : 3,59 m
Speed : 1490 rpm
Discharge Press. : 2,18 MPa
Shaft Power : 186,02 kW
Bearing housing Vibration : 0,05 mm
Weight : 3050 kg

Feed Water Pump


Type : FK6D32M
Suction Temp. : 186 OC
Suction Press. : 2,18 MPa
Suction Flow: 530,7 t/h
Discharge Flow : 510,7 t/h
Head : 2078,46 m
Pump Efficiency : 82,35 %
NPSHr : 30,69 m
Speed : 5103 rpm
Discharge Press. : 20,11 MPa
Shaft Power : 3554,03 kW
Bearing housing Vibration : 0,038 mm
Weight : 6960 kg

Turbo Coupling (VOITH)


Type
: YOT51A
Input Speed
: 1490 rpm
Output Speed
: 5432 rpm
Output Power
: 4418,63 kW
Variable speed range : 25 100 %
Slip
: 3 %
Weight
: 4000 kg

Motor
Type
: YKS800-4
Rated Power
: 5400 kW
Rated Voltage
: 6 kV
Rated Speed
: 1490 rpm

Boiler Feed Pump

Balancing Device
A small portion of the feed water in the order of about
10% which is not calculated to the guaranteed delivery
capacity is taken of from the space behind the last
impeller for the operation of the automatic balancing
device to balance the hydraulic axial thrust of the
pump rotor. The purpose of the balancing device is to
take up thrust pressure in a similar way as the thrust
bearing.

Balancing Device

PERIODIC AND PREVENTIVE


MAINTENANCE
The following are the primary criteria
for examination and renewal of
wearing parts and it is recommended
that these aspects are checked every
shift.
Reduction in pump performance,
i.e. reduction in head or flow.
Excessive vibration.
Excessive leakage from the
mechanical seals.

Daily
Check the suction and discharge pressures.
Check the pump bearing lubricating oil pressure and
temperature.
Check for excessive leakage from the mechanical seals.
Check all joints and glands for leakage.
Check for any undue noise and/or vibration.
Check the temperature of the motor's air cooler;
Check the cooling water for positive circulation in the
operation oil cooler, lubricating oil cooler, motor; air cooler
and mechanical seal.
Check the lubricating oil flow at the sight flow indicators

Monthly
Check the security of all accessible holding-down bolts and fastenings and
tighten as necessary.
Check the condition of the lubricating oil.
6-Monthly
Check the security of all accessible holding-down bolts and fastenings and
tighten as necessary.
Examine the flexible coupling bolts for wear or fretting and check the
torque loading of the bolts. Visually examine the element laminations for
signs of fatigue cracks local to the anchoring points.
Examine the pump journal and thrust bearings.
Examine the mechanical seals.
Check the condition of the lubricating oil. Purify or completely change the
oil.
Check all alignment of couplings.

Yearly
It is recommended that the lubricating oil be
changed, but this may be amended depending on
running experience and oil sampling results.
Examine the pump journal and thrust bearings.
Examine the flexible coupling bolts for wear or
fretting and check the torque loading of the bolts.
Visually examine the element laminations for signs
of fatigue cracks local to the anchoring points.
Examine the mechanical seals.
Inspect the lube oil coolers for fouling.

Preparation for Maintenance


Isolate the electrical supply to the motor.
Isolate the electrical power supplies to all instruments.
Close the pump set suction and discharge isolating valves and
the minimum flow valve. Refer to the manufacturers
instructions.
Isolate the lubricating oil supply to the pump bearings.
Isolate the cooling water supply.
Close the pump tap stage isolating valve.
Open the casing drain valve and drain the pump.
Warning:
BEFORE PROCEEDING WITH ANY MAINTENANCE ON THE PUMP,
ENSURE THAT THERE IS NO PRESSURE WITHIN THE PUMP

Examination the journal Bearings


Examination the Mechanical Seal
Checking the Axial Running Position
& Thrust Bearing Clearance
(are described at Maintenance
manual)

Overhaul
Including withdrawing, dismantling,
inspection and re-assembly the pump
cartridge.
(Detail instruction are described on
maintenance manual)

Inspection
Impellers & Wear ring
Examine the impellers for any signs of erosion
measure the diametrical clearances between
Impellers & Wear ring

Shaft
Examine the shaft for any signs of damage or
bowing, and check for concentricity: it should
be within 0.02 mm full indicator movement.
Check that all threads are in good condition
and that all keyways are free from burrs.

Mechanical Seal
Examine the seals for signs of damage or wear. Renew as
necessary. Refer to the seal manufacturers instructions.

Journal and Thrust Bearings


Thoroughly clean the journal bearings and examine them
for signs of wear or damage. Measure the bearing
clearances and compare with the standart.
Thoroughly clean the thrust pads and examine them for
signs of wear or damage.
Examine the thrust collar for signs of wear or damage,
and renew as necessary.
Examine the oil seals for wear or deterioration and renew
as necessary.

General
Examine all studs, nuts and bolts for any signs of
damage or deterioration. Renew as necessary.
All joints and O rings, anti-extrusion rings and
Garlock seals should be renewed on assembling.
All dowel pins must be clean and free from damage.
Worn or damaged dowels must be renewed.
All keys must be a good fit in their keyways. worn or
damaged keys must be renewed.
Examine the components of the coupling flexible
elements assemblies and coupling bolts for wear or
damage and renew as necessary.

Clearances Feed water


Pump

Clearance between
journal bearing and
pump shaft
Oil throwers and oil
guards
Ring section wear rings
and impeller
Diffuser wear rings and
impeller
Balance drum and
balance drum bush
Last stage diffuser and
discharge cover(axial)
Total axial clearance in
thrust bearing
Ring section and
impeller (axial)
Diffuser and impeller
(axial)
total axial clearance,
thrust pads removed

Column 1
0.140/0.215

Column 2
0.26

0.350/0.410

0.47

0.410/0.490

0.675

0.410/0.490

0.675

0.410/0.490

0.675

1.23/2.27

--

0.4

By inspection

--

--

--

Clearances Booster Pump


Clearance
Journal bearing and
shaft
Impeller and casing
wear ring
Thrust collar and
thrust bearing
pads(axial clearance)
Impeller and casing
wear ring
(axial clearance)
Rotating assembly
total axial movement
(thrust pads removed)

Column 1

Column 2

0.08/0.10

0.18

0.56/0.72

1.18

0.30/0.50

By inspection

2.0(D.E.)
6.0(N.D.E.)

8.0

Troubleshooting
Symptom
(1) Pumpset fails to start

Possible Cause
(a)Failure of electrical
supply.
(b) Motor fault.
(c) Starter fault.
(d) Seizure in the pumpset.

(e) Pumpset in Trip


condition.
(2) Pumpset performance (a) motor or electrical
low
supply fault.
(b) Direction of rotation
incorrect.
(c) Excessive wear in
booster pump or feed
pump internals.
(d) Fault in minimum flow
system.
(e) Pressure stage pump
speed low.
(f) Pump suction pressure
low.

Solving Action
Check supply.
Check motor.
Check starter.
Disconnect each element
in turn at the couplings to
locate the seizure.
Overhaul as necessary
Investigate cause. Reset
trip.
Check motor and electrical
supply
Check direction of rotation.
Dismantle pump and
examine the internals.
Overhaul as necessary.
Check system
Check setting and
operation of turbo
coupling.
Check suction conditions.

(3) bearings overheating

(4)
Pumpset
excessive power
duty

(a)Insufficient or
contaminated lubricating oil.
(b) Misaligned of pump and
turbo coupling.
(c) bearing worn or
misaligned
(d) Incorrect grade of
lubricating oil.
requires (a) Discharge pressure low
to meet (b) Friction between rotating
and stationary pump
components.
(c) Excessive internal
clearances in pump
(d) Incorrect installation of
mechanical seals.

check the oil supply


Check alignment
check up the bearing
Check grade of oil
Check flow rate
Check clearances
Check clearances
Examine seals

(5) pump
seizes

overheats

or (a) pump running dry.

Check that the inlet isolating


valve id open and that
strainer is clean. Check that
the booster pump discharge
pressure is normal.
(b) Internal friction in pumps Check clearances
(c) Insufficient or incorrect Check oil supply and grade
grade of lubricating oil.
(d) Defects lubricating oil Check oil system
system
(e)
Bearings
worn
or EXamine bearings
misaligned
(f) pumpset misaligned
Check alignment
(6) Excessive noise and /or (a) Rotating assembly out of Indentify
element
of
vibration
balance.
pumpset causing fault and
check the dynamic balance
of the rotating assembly.
(b)
Excessive
coupling Check alignment
misalignment.
(c) bearing worn
Examine bearings
(d) Holding down bolts slack. Check bolts
(e) Excessive pump internal Check clearances
clearances
(f) Suction pressure lost
Check suction system
(g) Coupling damaged
Check up the coupling
(h) Sympathetic vibration Check adjacent pipework
from
incorrectly
fitted and supports.
pipework.
(i) Minimum flow system Check minimum flow system
fault

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