This deals with Boiler feed pumps used in power plants .
contains details about the KHI and FK series pumps , technical parameters and maintenance prctices followed for these pumps
1. BEST PRACTICES FOR CONDITION
MONITORING AND MAINTENANCE OF BOILER
FEED PUMP
V.Gautham
BE Power NPTI
MBA SIMSREE(2014-16)
2. INTRODUCTION
Function of BFP – transport water from feed
storage tank to boiler drum through H.P heater,
F.R.S and economizer
Types of BFP – KHI and FK series
Need for maintenance
3. AIMS AND OBJECTIVES OF
MAINTENANCE OF BFP
To maintain BFP at its maximum
operating efficiency
To safeguard investment
To help management in taking
decisions
Make best use of resources.
Maintain plant parameters
4. TECHNICAL DETAILS OF BFP
Pump type: FK 6D30
Flow rate: 398 cum/hr
Speed: 5075 rpm
Input Power: 2558 kw
Efficiency: 81 %
Min. RC flow: 100 tonnes/hr
No. of stages: 6
8. Maintenance
The BFP is a critical auxiliary which has to
work continuously.
Maintenance types :
Breakdown maintenance
Preventive
Reliability centered maintenance
Condition monitoring
Computer management maintenance
system(CMMS)
9. BREAKDOWN MAINTENANCE
Breakdown maintenance involves the repair or
replacement of equipment and components after
they have failed.
Activities which are undertaken when the BFP
stops working come under breakdown
maintenance
s.n Clearance between Clearance(in mm)
01.
Impeller wearing-Casing wear
0.4
ring/Diffuser wear ring.
02
Balance drum-Restriction bush.
0.24
03.
Total axial float.
8.0
04.
Thrust/Axial bearing clearance
0.25 to 0.40
05.
Journal bearing clearance (Top
0.15 to 0.18
clearance)
06.
Interference of thrust collar & shaft
0.09
10. Preventive maintenance
It includes cleaning, inspection, oiling and
retightening
It is the work done primarily to rectify the effects of
normal wear in pump.
The usual intervals of preventive maintenance are:
Daily
Monthly
Quarterly
Half yearly
Annually
11. Predictive maintenance
It includes the following -
Visual and sound monitoring
Contaminant or debris monitoring
Performance and behaviour monitoring
thermograph monitoring
Shock pulse monitoring.
Vibration monitoring.
13. COMPUTERIZED MAINTAINANCE
MANAGEMENT SYSTEM
It is a type of management software that performs
functions in support of management and tracking of
operation and maintenance activities.
Historical tracking of all work orders generated which
become sortable by equipment, date ,person
responding etc.
Tracking of scheduled and unscheduled maintenance
activities.
Storing of maintenance procedures as well as all
warranty information by component.
Storing of all technical documentation or procedures by
component.
14. CMMS BENEFITS
Detection of impending problems before
a failure occurs resulting in fewer
failures.
Achieving a higher level of plant
maintenance activities that enables a
more efficient use of staff resources.
Maintaining optimal equipment
performance that reduces downtime and
results in longer equipment life.
15. Shaft alignment
Shaft Alignment – Shaft alignment is the
process of matching the centerline of two
shafts. There is a one driving and another
one is driven shaft.
Misalignment -It is the deviation in the
centerline and plane of two shafts.
Radial misalignment
Axial misalignment
Combined misalignment
16. Motor
Pump
Radial misalignment
Motor Pump
Axial or angular misalignment
Motor
Pump
Combined misalignment
18. BFP PERMISSIVES
1. Deaerator level normal(2375mm).
2. BFP suction valve open.
3. Auxiliary oil pump on lube oil pressure
more than 2.5 kg/cm2.
4. Discharge valve closed, recirculation valve
open.
5. Working oil temperature less than 130˚C.
6. Differential temperature across feed pump
suction and discharge less than 12˚C.
21. Troubleshooting
Sr.
no
Symptom Possible cause Action
1. Pump does not
deliver rated
quantity
•Pump not upto rated
speed
•Restriction in delivery
pipe work or incorrect
•Blockage in impeller or
casing
•High fluid viscosity
• Increase speed
• Clear obstruction
or rectify error in
pipe work
• Remove half
casing and clear
obstruction
• Check the
recommended
viscosity
2. Bearing
overheating
•Defect in lubricating oil
system
•Bearing warn out of
misaligned
•Misaligned of pump
•Check lubricating oil
system (pr.>2.5kg/cm)
•Examine bearings
•Check the alignment