Performance of the BFPs after rectification of CCI Drag Make Recirculation valves passing Prepared by KODANDAPANI VUDUGUNDLA ADE/TURBINE MAINTENANCE/RTPP
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Performance of the BFPs after rectification of CCI Drag Make Recirculation valves passing
Prepared by
KODANDAPANI VUDUGUNDLAADE/TURBINE MAINTENANCE/RTPP
,
RC Valve Details
Type : CCI Drag 100DR 4X4 GLOBE VALVEPr class 2500 ANSI
Design pr -320kg/cm2, Temp-180CMax seat leakage-5cc/min
valve Trim -24 stage disc stack
MAINTAIN LIQUID LUBRICATION INSIDE PUMP INTERNALS
MAINTAIN MINIMUM FLOW(125T) THROUGH PUMP TO AVOID FLASHING OF WATER
AVOID PUMP SEIZURE
VALVE OPENS AT 100 T BFP SUCTION FLOW VALVE CLOSES AT 220T BFP SUCTION FLOW
IMPORTANCE OF RECIRCULATION VALVE
NRV
At 6 mts
LOCATION OF VALVE
At 21 mts
FEED WATER INLET TAPPING FROM BFP DISCHARGE
FEED WATER OUTLET TO DEAERATOR
RC VALVE INTERNALS
HIGH FEED FLOWHIGH MOTOR AMPERAGE
PUMP VIBRATIONSDAMAGING OF NRV IN RC LINE
OUTAGES OF PUMP
PROBLEMS FACED
Dismantled all RC valvesFound damaged Seat Ring & Plug
Replaced with new one & Reassembled
Spare parts usedPlug assembly ,Seat ring ,Guide
bushing balance seal and soft goods.
WORKS ATTENDED
DAMAGED PLUG
DAMAGED PORTION
DAMAGED SEATDAMAGED PORTION
FLEX GASKET
SEAT RING
PLUG ASSEMBLY
GUIDE BUSHING
BALANCE SEAL
STEM
PLUG
BONNET METAL SEAL
DISK STACK
BALANCE SEAL
FLEX GASKET
SET OF RC VALVE INTERNALS
PERFORMANCE OF PUMPSAFTER RECTIFICAION AT FULL LOAD
BFP-5A BFP-5B BFP-5CFEED FLOWT/HR
CURRENTAMPS
FEED FLOWT/HR
CURRENTAMPS
FEED FLOWT/HR
CURRENTAMPS
PREVIOUS
364 306 370 315 355 310
PRESENT 342 297 332 292 344 300
CURRENTSAVING
9 A 23 A 10 A
ENERGY SAVING Per Day
2099 KWH 5363 KWH 2322 KWH
SAVING COST/Day @ Rs 5/-
10,494.00 26,818.00 11,658.00
REDUCTION IN POWER CONSUMPTION
REDUCTION IN FEED FLOW
REDUCTION IN PUMP VIBRATIONS
REDUCTION OF NOISE IN RC PIPE LINE
ELIMINATING DAMAGING OF NRV
RESULTS
Purchase of Spares including service chargesRs 40 Lakhs
Average Energy Loss/Year in RupeesRs 120 Lakhs
Pay Back period is with in 4 Months
Guarantee period of spares is one year
COST ANALYSIS
CONCLUSIONThe BFP recirculation valve is one of the most severe duty valve in the plant.
If this valve does not perform up to expectations, it can cause severe pump damage, degraded unit performance or even bring a unit offline
THANK YOU
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