Maintenance report of Condensate Extraction Pump (KSB)

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Condensate Extraction Pump MaintenanceReport

January 19~24, 2012

Prepared byAshik Ahmed

Maintenance EngineerIn a Multinational Power Plant

Email: [email protected],[email protected]: +880-173-0059920

January 19~24, 2012

CCCOOONNNDDDEEENNNSSSAAATTTEEE EEEXXXTTTRRRAAACCCTTTIIIOOONNN PPPUUUMMMPPP MMMAAAIIINNNTTTEEENNNAAANNNCCCEEE RRREEEPPPOOORRRTTT 222000111222

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EQUIPMENT NO: CN-M-PP-001-C EQUIPMENT NAME: CONDENSATE EXTRACTION PUMP

INTRODUCTION

The condensate extraction pump is located near hot well. This pump discharge goes to gland steam condenser than HRSG LP drum & some portion again enters condenser for recirculation.

SOME MAJOR DATA’S OF CEP ARE AS FOLLOWS:-

January 19~24, 2012


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MAINTENANCE WORK: DISASSEMBLY

Maintenance work of the pump started after safe handover of the pump. First the piping joints of the pump were removed and then the motor was

removed by 16 ton crane. Then the pump was removed and it was made horizontal with the help of crane.

The pump brought to the workshop by a truck and dismantling work begins.

January 19~24, 2012


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First number punch mark was provided in every segment. One group started to dismantle from impeller side and another group started to dismantle mechanical seal & bearing housing with cooler. **Bearing Cooler fluid- Water, Flow Rate:-0.54 M3/Hr,Prs:- 3~5 Barg,Temp: 40°C.** Then the old trust roller bearing (Part No: -324) was removed from housing & centering sleeve (Part No: -526).

January 19~24, 2012


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After dismantling the clearances of wearing rings and bearings were measured.

Impeller wearing ring clearances were found in allowable range. But the clearance between bearing sleeve & bearing bush (05 nos) were found above of nominal range. So decision was made to change 5 no’s bearing bushes (Part No: -545) & 2 no’s of sleeves.

I) Spacer sleeve (Part No:-525.91) and II) Bearing sleeve (Spider – Middle) (Part No:-529.21). **Even though the sleeves OD were in normal range, those were replaced due to some scratches on the outer surface**

January 19~24, 2012


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January 19~24, 2012


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IMPELLER WEARING RING CLEARANCE (FOUND OK) Suction side

Wearing Ring ID

Impeller Suction Side

Impeller Neck OD

Clearance Discharge side

Wearing Ring ID

Impeller Discharge Side

Impeller Neck OD

Clearance

Suction Casing

228.2 1st Impeller

227.78 0.42 Suction Casing

N.A 1st Impeller

N.A N.A

1st Stage Casing

228.04 2nd Impeller

227.79 0.25 1st Stage Casing

228.04 2nd Impeller

227.74 0.30

2nd Stage Casing

227.98 3rd Impeller

227.79 0.19 2nd Stage Casing

228.03 3rd Impeller

227.74 0.29

3rd Stage Casing

228 4th Impeller

227.79 0.21 3rd Stage Casing

227.98 4th Impeller

227.74 0.24

4th Stage Casing

228.05 5th Impeller

227.79 0.26 4th Stage Casing

227.96 5th Impeller

227.74 0.22

January 19~24, 2012


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**Please note that although the sleeves OD’s (02 No’s) were in normal range ,those were replaced due to some scratches on the outer surface ** Sleeves are as follows:- Spacer Sleeve (Part No:-525.91) & Bearing sleeve (Spider II – Middle) (Part No:-529.21).

BEARING BUSH & SLEEVE CLEARANCE

OLD NEW Pump Bowl

Pump Bowl Bush ID

Stage Sleeve

Bearing Sleeve OD

Clearance Pump Bowl

Pump Bowl Bush ID

Stage Sleeve

Bearing Sleeve OD

Clearance

1st Stage 105.25 1st 104.75 0.5 1st Stage 105.01 1st 104.75 0.26

2nd Stage

105.54 2nd

104.75 0.79 2nd Stage

104.99 2nd

104.75 0.24

3rd Stage

105.74 3rd

104.75 0.99 3rd Stage

105.0 3rd

104.75 0.25

4th Stage

105.57 4th

104.75 0.82 4th Stage 105.01 4th

104.75 0.26

5th Stage

105.6 5th

104.75 0.85 5th Stage 105.0 5th

104.75 0.25

Throttle Bush ID

Spacer Sleeve OD

Clearance Throttle Bush ID

Spacer Sleeve OD

Clearance

105.06 104.71 0.35 105.06 104.71 0.35

Spider Bearing Bush ID

Bearing Sleeve OD

Clearance Spider Bearing Bush ID

Bearing Sleeve OD

Clearance

I 100.02 99.74 0.28 100.02 99.74 (Reused) 0.28

II 100.05 99.75 0.30 100.05 99.75 0.30

January 19~24, 2012


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SHAFT RUN-OUT The shafts run-out’s are follows:

0.01 0.00 0.01 0.00 0.02 0.01 0.01 0.00 0.01

PUMP SHAFT (part no:- 211)

0.02 0.00 0.01 0.02 0.02 0.03 0.03 0.04 0.00 0.02 INTERMEDIATE SHAFT (part no:- 212)

0.02 0.00 0.03 0.02 0.01 0.03 0.04 0.02 0.00 0.02

Top shaft (part no:- 213)

Maximum run-out was found 0.04 mm only.

January 19~24, 2012


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ASSEMBLY

After installing the new bearing bushes on the bush holders, those were tighten properly by 03 no’s of new hexagon socket cap screw.

Bearing (Part No:-324) was then installed in centering sleeve (Part No:-526) by induction heater @125°C.

January 19~24, 2012


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After finding all the required clearances OK, we had started the pump assembling work. We had used the BFP special stand for vertical assembly of the pump.1st we had put a 5 mm rubber gasket on the stand for avoiding damage. While assembling we were very careful about the punch marks & o-rings. Then the pump bowls {I) Part No:-112.03(1 No), II) 112.02(3 No’s), III) 112.01(1 No)} were assembled with the suction ring (Part No:-10-4) on the pump shaft (Part No- 211). After completion of the work, we had put down the assembly from the stand.

January 19~24, 2012


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Then pump shaft (Part No:-211) was then coupled with intermediate shaft (Part

No:-212) through split muff coupling (Part No:-853).Then the column pipe (Part No: 711.01) was connected with pump bowl no 5(Part NO: 112.03).

The spider bearing-I(Part No:-383) was then inserted in the intermediate shaft & the shaft was connected with top shaft (Part No:-213) by split muff coupling.

Then the column pipe (Part No: 711.02) was linked with column pipe (Part No: 711.01) by spider bearing-II (Part No:-383).

Then the throttle bush (Part No: 542) was installed in distributor casing (Part No: 10-1) .

Top shaft (Part No:-213) was then inserted in distributor casing through spacer sleeve (Part no:-525.91).

After completing the work we took the pump to the site and assembled with the base.

Then the mechanical seal (Part NO:-433) was then installed with shaft seal housing (Part No: 441). Mechanical seal stuffing box bolts were kept loose & the locking pins was tighten properly.

January 19~24, 2012


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Then the thrower (Part NO:-507.91) was slide over the top shaft (Part No: 213). The bearing housings (Part No: 350.81 &82) were then installed along with gasket(400.81).

After installing the splash ring the bearing cover (Part NO:-360.81) was then installed.

January 19~24, 2012


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Then lower the pump rotor to bottom position by means of adjusting nut

(924) until the impeller touch against the pump housing. Then raise the rotor to its top abutment & measure the axial clearance

accurately. The rotor must lift by a dimension A= 6 mm± 0.5 mm from the bottom abutment. The rotor was lifted finally at 5.6 mm.

Find the nearest tapped holes & holes for tapper pin(560.91) by slightly turning the adjusting nut. Then insert the taper pins (560.91) & fasten.

Then insert the split ring & tighten the thrower by 03 cap screws.The segmental ring (4 pcs) as then inserted & Mechanical seal bolts were then tighten .The mechanical seal locks were then removed.

Then Pump coupling hub was inserted by heating through induction heater @125°C.

January 19~24, 2012


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All pipe connections, auxiliary pipes then fitted. The Motor was then installed on position. Alignment was performed afterward. The data are:-

Then the pump & motor was then coupled. Then All piping joints were fixed

with the pump casing.

OBSERVATION AFTER START UP: After startup vibration data was measured and everything found ok. The Pump had been commissioned successfully on 24.01.2012 around 16:00 hrs. The data are as follows:-

Suction Pressure: -0.80kg/cm2, Discharge Pressure: 18.5kg/cm2. Vibration was within 1.0 mm/s (RMS) and Bearing Temperature is 46.80°C

Initially there was some intermittent whistling noise, observed near the Mechanical Seal area, which was being generated due to air ingress into the system, it disappeared gradually.

January 19~24, 2012


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CONSUMED SPARE PARTS: SERIAL PART NO DESCRIPTION QTY

USED 01 ST-CN-M-PP-001—BRNG-01 CEP TAPER ROLLER

BEARING ,PART NO -324 1

02 ST-CN-M-PP-001—BUSH-01 CEP BEARING BUSH ,PART NO -545.21

2

03 ST-CN-M-PP-001—BUSH-02 CEP BEARING BUSH ,PART NO -545.01

5

04 ST-CN-M-PP-001-O-RING-12 CEP O-RING , PART NO -412.21

4


1


6


1


1


1

10 ST-CN-M-PP-001—SEAL-01 CEP MECH SEAL PART NO:-433

1

11 ST-CN-M-PP-001—SLVE-03 CEP SPACER SLEEVE PART NO:-525.91

1

12 ST-CN-M-PP-001—SLVE-07 CEP BEARING SLEEVE PART NO:-529.21

1

13 ST-CN-M-PP-001—SCRW-01 HEXAGON SOCKET CAP SCREW PART NO -91461

15

14 NO CODE (IT WAS FABRICATED FROM RUBBER SHEET)

FLAT GASKET 326X370X3 MAT: NBR65

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Maintenance report of Condensate Extraction Pump (KSB)

Technology

pump shaft

pump discharge

nd stage impeller casing

nd stage casing

rd stage impeller casing

casing impeller

stage throttle bush

disassembly maintenance