Design Features Of CEPs

Vertical, multistage, single/multi-shaft

Can type construction without suction nozzle
Double suction first stage impeller for minimum NPSHR
Balancing holes and tilting pad thrust bearing for axial thrust
Submerged bronze line bearings
Shaft sealing by mechanical seals
Compatible materials for stationary and rotating parts
 Comparison Of Typical Parameters Of CEP

S.NO PARAMETER 500MW 660MW 800MW 1000MW

SUB
CRITICAL
SUPER CRITICAL UNITS

1 Pump Duty 3x50% 3x50% 3x50% 3x50%

Motor Motor
2 Arrangement Motor driven Motor driven
driven driven

3 Flow Rate 800 1015 1210 1500

4 Head (MLC) 275 345 350 360

Sectional View Of 500MW CEP
Sectional Assembly of MHI CEP
Sectional View Of MHI CEP
 Major parts of CEP
Impeller and casing:
The first stage impeller is specially designed with double suction type to
avoid cavitation. Other stages consist of single suction impeller with balance
holes in the shroud to reduce the axial thrust. The casings consist of suction
bell, 1st stage casing, stage bowls, discharge bowl. The renewable casing wear
rings are provided in all these casings.

Shaft:

The shaft is made of 13% chrome forged stainless steel. Hard chrome plating is
applied on the shaft surfaces contacting to impellers, in order to facilitate
disassembly and reassembly of the impeller.
 Major parts of CEP
Top casing:
The top casing guides the condensate water to pump’s barrel pit and guides
pumped water passing through the column pipes to the horizontal pipe.

Shaft seal:

Mechanical seal is used for shaft seal. To reduce the pump discharge pressure
to the gland, a balance hole leading to the suction chamber is provided at the
lower side of glance to reduce pressure up to an optimum value. On the other
hand, vacuum is formed in the pump when the pump is kept in rest during
operation of plant. In this case sealing water to the stuffing box avoids air
suction from the gland.
 Major parts of CEP
Bearing:
The downward thrust from the impeller hydro-back pressure and the weight
of rotating parts is supported by a thrust bearing mounted on the top of pump
which is applied with a water cooled.
The radial bearing is a submerged type made of copper alloy casting, circular
plain bearing with off-set arc shape to avoid unstable vibration due to whorl
phenomena in water. There are 8 radial bearings in the pump ,i.e in suction bell
mouth, 1st stage casing, stage bowls, discharge bowl & column pipes. During
operation water is automatically circulated through the longitudinal groove
provided on the sliding surface to lubricate the bearing.
 Major parts of CEP
Column pipe:
In order to ensure normal pump operation without any cavitation, the pump
shall has a proper suction head (available NPSH= Net positive suction head). The
column pipes are provided between discharge bowl for last impeller stage to
top casing to discharge pipe for the purpose that the pump is installed at lower
level keeping a proper suction head.
Sectional View Of CEP Thrust Bearing
Sectional View Of CEP Mechanical Seal
 Assembly Procedure-CEP
CEP-Clearances and Float values

S No. Description Clearances mm (DIA)

1 Between Shaft & Submerged Bearing at 0.135 - 0.185
suction bell mouth
2 Between Shaft & Submerged Bearing at 0.195 - 0.260
bowl and column pipes
3 Between Impeller and casing rings 0.390 - 0.494
4 Total Thrust Bearing clearance 0.05 - 0.10
5 Total Float 13 (10 Min)
6 Lift up dimensions 6.5 (5 Min)
Schematic Drg. Of CEP CW, Vent & Mech. Seal Outlet
Connections
Assembly Procedure-CEP-1st & 2nd Step
Assembly Procedure-CEP- 3rd Step
Assembly Procedure-CEP-4th Step
Assembly Procedure-CEP- 5th Step
 Assembly Procedure-CEP (step 4 & 5)
Outer casing, Pump and Thrust bearing pedestal

Install Outer casing (Suction and Discharge side shall be checked)

and Pump on Sole Plate.
Confirm the center level and orientation of suction and discharge as per drawing.
Check Suction and discharge thrust bearing pedestals and
install the thrust bearing pedestal on the sole plate.
Check the elevation and level of the upper surface of the thrust bearing pedestal
if required shims shall be inserted between the outer casing and sole plate.
Elevation tolerance ± 3 mm and level is <0.05 mm/ Mtr.
 Assembly Procedure-CEP (Step-6)
Shaft axial movement

Set the eye bolt on the shaft end.

Lift the pump rotor and measure the shaft axial movement.
Shaft axial movement i.e total float shall be 10-13 mm).
 Assembly Procedure-CEP (Step-7)
Mechanical seal Installation

Lock the screw-socket and set free lock nut.

Put the mechanical seal through the shaft with a key and nut lock LH.

“Don’t fix the Mechanical seal at this moment”

 Assembly Procedure-CEP (Step-8)
Thrust Bearing Plate Installation

Put the thrust bearing base plate through the shaft

“Don’t fix the thrust bearing base plate at this moment”
 Assembly Procedure-CEP (Step-9)
Alignment between Rotor and Casing

•Set the rotor at center of the casing through the Mechanical seal cover with Centering tool-1.
•Tighten the bolt (01- D) between the mechanical seal collar (25) and the pump casing.
Ensure orientation of piping as per drawing before fixing.
•Set the Centering tool-1 on the mechanical seal.
•Through this mechanical seal can be matched to the centre of the casing and
centre of the rotor can be matched to the centre of mechanical seal.
 Assembly Procedure-CEP (Step-10)
Alignment between Rotor and Casing

•Set the centering tool-2 on thrust bearing base plate to ensure rotor in center position.
•If centering tools 1 & 2 are not perfectly matching adjust the thrust Bearing and
base plate thrust bearing pedestal if required.
•After complete adjustment of thrust bearing base plate tighten the bolt between
thrust bearing base plate and thrust bearing pedestal.
Suction direction shall be marked on thrust bearing pedestal and uninstall the tool-2.
•Put the thrust bearing through the shaft and lift up the rotor by half of the shaft
axial movement based on the total float.
•“Don’t use Thrust Bearing nut to lift the rotor and use eye bolt setting on the shaft end”
•Assemble the thrust bearing on thrust bearing base plate.
Ensure orientation of auxiliary piping as per Drawing.
Assembly Procedure-CEP (Step-11)
Fixing of thrust nut
 Assembly Procedure-CEP – Step-12)
Setting the Mechanical Seal

Uninstall the centering tool-1.

Tighten lock nuts of mechanical seal with special hook spanner until the nut contacts sleeve.
Finger tighten the nut on the shaft threads till it goes easily.
Tighten the Screw – soc set Dcollar (POS 944.16) and slide out the Plate-Set(POS 266)
Tighten the ‘ Bolt-Hex head S.washer (POS.900.05). This shall be tightened fully to avoid
falling and rubbing running condition.
 Assembly Procedure-CEP (Step-13)
Installation of Motor Pedestal and Motor

• Install the Motor pedestal on Thrust bearing pedestal.

• Upper surface of Motor pedestal shall be
within +- 3 mm.
• Install the Motor on the Motor pedestal.
 Assembly Procedure-CEP (Step-14)
Pre centering between Pump and Motor

Carry out preliminary centering between the pump shaft and motor shaft.
Tolerances : Dia & Axial not more than 5/100 & 3/100 mm TIR respectively.

Measure the shaft distance in order to decide the thickness of adjusting ring.

Thickness can be machined based on hub position.

 Assembly Procedure-CEP (Step-15)
Installation of Adjusting Ring and Coupling hub

After machining the thickness of adjusting ring install to the shaft.

Install the coupling hubs of pump and motor shaft.
Confirm the alignment between Coupling Hub for pump and motor.
Tolerances : Dia & Axial not more than 5/100 & 3/100 mm TIR respectively.
Before join between the pump rotor and motor rotor, the motor shall be
operated independently to confirm direction of rotation.
 Assembly Procedure-CEP
Installation of Accessories

Install Suction Strainers and Differential pressure Gauge and Transmitters.

Piping to be installed

Installation of Instruments.

Fill the Thrust bearing with lubricant oil

(Change every 10,000 operating hours, Recommended oil Grade
ISO VG 32. & Oil capacity 7.5 litres.

CW qty for Thrust bearing is 1000 L/H CW inlet temp 38 C/ 6 bar

Max load on thrust Bearing- 115 KN

 Assembly Procedure-CEP
Final centering

After completion of piping connection, Carry out final centering

at coupling faces between the pump and motor again and compare
with preliminary centering record.
Tolerances : Dia & Axial not more than 5/100 & 3/100 mm TIR respectively.

Operational procedure.
Running preparation and inspection
Starting procedures
Normal Operation procedure
Starting and Standby procedure
Maintenance and Inspection procedures
Daily and annual inspection
Periodical overhaul/inspection
Maintenance during long term shut down
Recommended maintenance intervals and expected parts life
Sample records format
Failure and causes disassembly and reassembly procedures.
 Assembly Procedure-CEP
Operation Procedure-Alarams and Trips

Most of pump failures occur at the initial start-up of the plant or when restarting
the pump after a long term shut down, both of which are directly concerned
with problem of scale or foreign material entering into the sliding and close clearances
parts of the pump, and pump suction head decreases due to the suction strainer blockage.

As these failures generally occur within first month or so, special attention to
the flushing and to the provision of a strainer of an adequate mesh size in the pump
suction strainer are essential pre-start up considerations.

Detailed operational procedure and inspections are provided in the CEP O&M manual.
Permissives, Alarms and Trip values are indicated below for the safe operation of the pump.
Before starting ensure the all conditions are activated.

Conditions when CEPs are at rest:

• Circuit breakers of the drive motor of CEP
shall be in OFF position.
• Suction & RC Valve shall be kept open.
• Discharge valve shall be kept closed.
 Assembly Procedure-CEP
Operation Procedure-Alarams and Trips

Permissive condition for CEP start:

•Oil level in thrust bearing gauge glass is above normal.
•CW is available to the thrust bearing.
•Valve in suction vent line(Balancing line) to condenser shall be locked
in OPEN condition.
•Power supply to drive motor is available (through logics)
•The solenoid valve in discharge vent line to the condenser shall be
OPEN condition.
•Suction valve to be kept fully open (Limit switch in SV shall be used)
•Condenser hot well level not low.
•CEP discharge valve to be in closed condition.

Start up of CEP:
•If the all permissive conditions are fulfilled, the pump can be started.
When the pump is attained pre-set pressure of more than 22kg/cmsq,
discharge valve will be open automatically.
•Discharge vent solenoid valve shall close after starting of the pump
with a time delay of 2 minutes.
 Assembly Procedure-CEP
Operation Procedure-Alarams and Trips

Stand By CEP:
•When one/two CEPs are operating, third CEP kept as stand-by.
When pump is kept as stand-by, its selector switch shall be in AUTO position
and its discharge valve shall OPEN only when the discharge header pressure after NRV
is not less than 22kg/cmsq and sustained for 5 seconds.
All other conditions indicated in the permissive shall be fulfilled
for the stand by pump also. The stand by kept on AUTO, it shall come in to operation if
any of the following conditions occur.

•Running pump trips

•Disch header pressure is less than the pre set value of 26kg/cmsq for 10 seconds.

•When the running pump trips due to LOW-LOW level in condenser hot-well, it should
not be possible to start the STAND-BY pump.
 Assembly Procedure-CEP
Operation Procedure-Alarams and Trips

Thrust brg thrust pad metal Temp 90 ⁰C 95⁰C

Thrust brg journal pad metal Temp 85⁰C 90⁰C

Thrust brg oil Temp 80⁰C -

Motor bearing temp 80⁰C 90⁰C
Motor winding temp 110⁰C 130⁰C
CEP Vibration 7 mm/sec 7.6 mm/sec
Suction strainer DP 750mmWc 1000mmWc
300T/Hr with a time
Flow through pump very low
delay of 5 seconds

CEP discharge pressure very low 26 Kg/cmsq.

Hot well levels falls low &

(+) 1.845 M (+) 1.495 M
low-low level
Suction valve not open. Trip