NATIONAL THERMAL POWER CORPORATION OPERATION DIVISION FORMAL DOCUMENTATION SYSTEM OPERATION GUIDANCE NOTE- OGN/OPS/MECH/026

Issue No. : 1 Date : Feb, 97

THE CARE AND MAINTENANCE OF PUMPS

Approved for Implementation by ....................................... Director (Operation) Date :...................................... Enquiries to : Executive Director, Operation Services

THE CARE AND MAINTENANCE OF PUMPS

CONTENTS Page Nos 1.0 2.0 3.0 3.1 3.2 3.3 4.0 4.1 4.2 4.3 5.0 5.1 5.2 5.3 5.4 6.0 6.1 6.2 7.0 8.0 Introduction Superseded Documents Records of Pump Status Objective Information required Transfer Engineering Aspects of Plant Operation Objective General requirements for all pumps Specific requirements for feed pumps Plant Maintenance and Modification Objective Maintenance Activities Refurbishment/replacement Schemes Responsibilities Life Assessment Objective Condition Monitoring Review References 1 2 2 2 2 4 4 4 4 6 8 8 9 9 9 9 9 9 10 10

Page - 1 OGN/OPS/MECH/026 Issue - 1

THE CARE AND MAINTENANCE OF PUMPS

1.0

INTRODUCTION Pumps are subjected to a wide range of operating condition with frequent stops and starts. Proper care and maintenance of pumps is vital for the achievement of good Unit availability and performance. This Guidance Note recommends procedures intended to achieve reliable operation and minimise `whole life' costs by:

1.1

Establishing the pedigree and recording the status of components so as to provide a basis for assessing their future capability. Optimising operational behavior and thereby minimising the rate of component deterioration. Determining the rate of component deterioration so that any remedial action required to achieve operating targets can be implemented on a planned basis at the optimum time. Ensuring that routine maintenance and any remedial action employed give the greatest overall benefit. This document applies to all large centrifugal pumps, i.e. turbine driven feed pumps, electric driven start/standby feed pumps, extraction pumps, DC heater lift pumps, condensate booster pumps, HP heater drain pumps, boiler circulating pumps and main CW pumps. In some cases, such as low merit or life limited plant, it may be appropriate to delay implementation of these procedures, or permanently exclude items of plant from them.

1.2

1.3

1.4

Page - 2 OGN/OPS/MECH/026 Issue - 1 2.0 3.0 3.1 SUPERSEDED DOCUMENTS : Nil RECORDS OF PUMP STATUS Objective To provide a database for Engineering and other Production interests. 3.2 Information Required The pump status record should contain details of the design intent, manufacture, operational history, maintenance and modification of each pump. 3.2.1 Original Design Intent a) b) c) d) Pump type i.e. Name of Manufacturer, Type, and Serial no. Operating limits Specified life, number of starts and duty running hours. General arrangement, detail drawings and assembly details e.g. fits and clearances of pump assembly, support structure and associated' pipework of sufficient detail for all overhaul and repair purpose. Technical data for each pump assembly in sufficient detail for performance investigations and operation monitoring, including the minimum net positive suction head required.

e)

3.2.2

Manufacturing Information a) Casing, shaft and impeller material specification and heat treatment details. Casting, forging numbers where appropriate.

Page - 3 OGN/OPS/MECH/026 Issue - 1 b) c) 3.2.3 Procedure for welding and heat treatment of all major welds. Works test data.

Operational History a) b) c) d) Date of installation Operating hours, numbers of hot, warm and cold start till date. Current operating hours for cartridges or major components Service performance test and vibration survey data (including original and post overhaul "fingerprints") Details of any abnormal conditions Problems and failures experienced.

e) f) 3.2.4

Inspection and Maintenance a) b) Dates of overhauls/inspections Summaries of findings in each case including: Components or locations inspected Method of inspection e.g. mechanical measurement visual, MPI, ultrasonics,

c)

Results e.g. clearance and NDT data Action taken

Components replaced or relocated with dates

Page - 4 OGN/OPS/MECH/026 Issue - 1 d) e) 3.2.5 Date of next planned overhaul Legging specification

Modifications Dates and details of all modifications, including substantiation and approval details where relevant.

3.3

Transfer When a pump leaves site for storage or ultimate installation elsewhere, the Station General Manager should transfer a copy of the database to the receiving location.

4.0 4.1

ENGINEERING ASPECTS OF PLANT OPERATION Objective To identify the parameters requiring limits in order to minimise component deterioration without compromising plant flexibility.

4.2 4.2.1

General Requirement for all Pumps Vibration The routine monitoring of pump vibration can give early warning of impending mechanical failure. Bearing vibration levels at design duty or repeatable alternative datum load should be monitored at monthly intervals for feed and condensate system pumps and at a maximum of 6 month intervals for other pumps. The frequency of monitoring should be increased if vibration levels change. Base-line measurements "fingerprints" should be made on first commissioning and immediately after overhauls. Test vibration results can then be compared with fingerprints to identify and diagnose developing problems.

Page - 5 OGN/OPS/MECH/026 Issue - 1 Vibration severity will be assessed from the overall R.M.S. velocity of the full velocity wave form. "Alarm" and "warning" levels are to correspond to the "unsatisfactory" and "just satisfactory" categories given in ISO 3945 (Ref 1). These categories correspond to velocities of 11 mm/s and 4.5 mm/s respectively. At the "warning" level the Plant vibration specialist should be informed of the vibration level. At the "alarm" level urgent advice should be sought from Head of condition monitoring group at station, on the continued operation of pump as severe damage may be taking place. The validity of the Certificate of Calibration for the instrumentation used should be confirmed and recorded on the test log sheet. 4.2.2 Bearing Temperature Bearings should be operated at all times at temperatures within the limits recommended by the manufacturer using the installed instrumentation. The temperatures should be clearly displayed and recorded in a way suitable for future analysis and audit purposes. The format of the display and the method of logging should be compatible with the relevant Control and Instrumentation Codes of Practice. 4.2.3 Net Positive Suction Head Cavitation is the source of in-service damage to pump internal components and causes a reduction in the pump operational performance both on throughput and efficiency. It is particularly prevalent on extraction pumps, feed pump suction stages and on axial or mixed flow pumps. To limit cavitation damage the Net Positive Suction Head (NPSH, the difference between the static pressure and the vapour pressure at the pump suction) should exceed the NPSH required. The NPSH required should form part of the technical data contained in the record of pump status. For condensate and feed system pumps, inlet pressures and

Page - 6 OGN/OPS/MECH/026 Issue - 1 temperatures should be monitored in service. Suitable instrumentation tapping points may have to be installed. Operation Services can provide technical advice. The suction head should be periodically measured and recorded in a way suitable for future analysis/audit purposes. The format of the display and method of logging should be compatible with the relevant Control and Instrumentation Codes of practice. 4.3 Specific Requirements for Feed Pumps The requirements are in addition to those listed in para 4.2. 4.3.1 Pump Casing Distortion When feed pumps are taken off-load, cooling results in an increase in top to bottom temperature differentials, causing the pump casing to "hog". If it is not possible to bar a main feed pump within three minutes of coming to rest, the pump should not be restarted until the difference between the top and bottom body temperature is less that the value specified by the manufacturer or, if no value is specified, 10 deg C measured at the casing surface by contract thermometers or thermocouples if fitted. The lagging of the pump bodies should be regularly checked and maintained. 4.3.2 Overspeed/Governor Test for Turbine Driven Pumps Guidance on procedures for operating, testing and maintaining governors, overspeed trips and control valves is given in OD/OPS/SYST/003 (Reference 2). The guidance given there in should be followed in the case of boiler feed pump turbines. Overspeeding results in higher than normal rotational speed and therefore undesirable stresses in rotating assemblies. In the case of feed pumps it can also cause excessive pressures within the pump casing and special procedures and test frequencies may be desirable to take account of these

Page - 7 OGN/OPS/MECH/026 Issue - 1 factors. These may include disconnection of the pump from the turbine prior to testing overspeed trips, in which case the increased sensitivity of the turbine should be considered most carefully before testing commences. Any special procedures used should be derived in consultation with the manufacturers. 4.3.3 Leak-off parameters A test to confirm the correct operation of all feed pump leak off valves at their design set points should be carried out: When the pump is being returned to service after overhaul. At least one per annum.

The test should include and off-load visual inspection of the leak-off valve operation to ensure that the valves are moving freely over their full travel. Leak-off flows should be measured as part of the test and compared with the design values. Any instruments used for these tests should have valid test certificates, details of which should be recorded with the test results. Leak-offs may be speed, flow or temperature operated. The exact test procedure to be used will depend upon the system, and advice from the manufacturer. Operation Services should be consulted, if necessary, to determine a suitable procedure. This will involve running-up the pump, using normal operating procedures, to a point slightly below the leak-off set point and then in small increments until the leak-off valves shuts. The pumps should then be run under steady state conditions, above the point at which valve should open on falling flow, for at least 15 minutes. After this the pump should be run down in small increments until the valve opens. The pump speed, feed flows, temperatures and, if possible, leak-off flows at which the valve should open on falling flow for at least 15 minutes.

Page - 8 OGN/OPS/MECH/026 Issue - 1 Results should be recorded in a way suitable for future analysis and audit purposes. 4.3.4 Thrust Balance Water Excessive wear or damage at thrust location should be regarded as being indicative of a possible thrust load problem and Field Engineering should be contacted to arrange the installation of monitoring instrumentation. Water pressure at the balance drum outlet or within the balance disc chamber should be monitored together with the water flow in the balance return line, to provide a guide to the general condition of the balance device. If suitable instrumentation is fitted, pressures and flows should be measured: When the pump is being returned to service after overhaul. At least once per annum.

It suitable instrumentation is not fitted, arrangements should be made to install instrumentation and carry out this monitoring only if repeated problems are experienced with the thrust balance device. 5.0 5.1 PLANT MAINTENANCE AND MODIFICATION Objectives a) b) To identify the content and timing of maintenance activities To outline a procedure for formulating repair/refurbishment schemes. To identify the considerations regarding the introduction of modifications.

c)

Page - 9 OGN/OPS/MECH/026 Issue - 1 5.2 Maintenance Activities These activities should initially be carried out in agreement with the plant manufacturer's recommendations and to the quality assurance standards applicable to the particular pump. They should, in addition, take account of the results of previous inspections and problems identified in similar plant elsewhere. Where agreement cannot be achieved further action should be taken as described in Section 5.4. 5.3 Refurbishment/Replacement Schemes If adequate standards of reliability cannot be attained due to, e.g. design shortfalls or output is limited for other reasons, consideration should be given to an appropriate refurbishment or replacement scheme. approach should be based on economic and programme considerations. 5.4 Responsibilities The Station General Manager should develop a maintenance policy for all pumps. 6.0 6.1 LIFE ASSESSMENT Objectives To define a methodology for determining the degree of pump degradation and identify the actions required to assure continued safe, reliable and efficient operation. 6.2 6.2.1 Condition Monitoring General Requirements All the factors identified in Section 4.0 should be used to determine the condition of the pump and as part of the life assessment. Additional information should be obtained from a pump efficiency test.

Page - 10 OGN/OPS/MECH/026 Issue - 1 6.2.2 Pump Efficiency Pump efficiency should be assessed: After return from overhaul. Annually

Tests should be recorded out in accordance with BS 599 (Reference 3) and BS 5316 (Reference 4). The class of test to be applied, as defined in BS 599, shall be agreed with Plant Engineering. The result should be recorded in a way suitable for future analysis and audit purposes. 7.0 REVIEW The Executive Director, Operation Services will be responsible for reviewing this Guidance Note on a 2-yearly or as necessary. 8.0 8.1 REFERENCES ISO 3945:1977, Mechanical Vibration of Large Rotating Machines with Speed Range from 10 to 200 rev/sec - Measurement and Evaluation of Vibration Severity In Situ. Procedures for Testing and Maintenance to Overspeeding of prime Movers, OD/OPS/SYST/003. BS 599: 1966, Methods of Testing Pumps BS 5316 Part 2:1977, part 3 : 1988, acceptance Tests for Centrifugal Mixed Flow and Axial Pumps. Avoid Excessive

8.2

8.3 8.3