PUMPS

RITESH KUMAR CONSTRUCTION , M6K221 MECHANICAL ENGGINEER

Ritesh Kumar M6K221

Centrifugal pump
When impeller rotates ,it spins the liquid in cavities between

and give centrifugal acceleration. As cavity is diverging type so it converts velocity energy in pressure energy. When fluid leaves impeller it passes through volute casing which convert rest velocity energy in pressure. When liquid leaves impeller a vacuum is created which sucks liquid in pump.

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Possible arrangements
Series Parallel

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Booster pump
ITEM EFFINENCY NUMBER OF STAGE TEMPERATURE DESITY FLOW RATE HEAD NPSH POWER CONSUMED SPEED centigrade Kg/m3 m3/h meter meter KW r/min UNIT % Quantity 80.84 1 166.7 900.59 ITEM

Boiler feed pump

UNIT % Quantity 81.32 5 centigrade Kg/m3 m3/h meter meter KW r/min 166.7 900.59 35.5 1771.9 31.63 233.9 4686 EFFINENCY NUMBER OF STAGE TEMPERATURE DESITY 533.3 FLOW RATE 79.6 4.98 128.7 2986 HEAD NPSH POWER CONSUMED SPEED

Why booster pump before main pump ?

Well reason is minimum head needed for boiler feed pump is higher ,So booster pump is there to provide fluid at higher suction head.

Why both feed pumps are in parallel ?

To increase volume flow rate of system

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Net positive suction head (NPSH)

Minimum pressure head that pump need at suction side

for trouble free operation of pump.

Cavitations Water starvation

NPSHa is net positive suction head available

NPSHr is net positive suction head required

NPSHa must be greater then NPSHr

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NPSH calculation
NPSH = Ha+ Hs Hvp Hf Ha Atmospheric head. Hs Static head in meter of fluid level in suction vessel to pump center line Hvp Vapor head of fluid in meter at a temperature. Hf Friction head in meter of piping and connection.

That is why piping ,valve , pump installation must be as per drawing

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Erection sequence
Elevation Foundation check

Packer plate erection

Pre alignment checks Alignment Grouting

Surface chipping
Blue matching

Blue matching of machines feet , packer plates and wedge plate to 80% contact area.
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Packer plates and leveling device (wedge plates)

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Wedge plate
Packer plate

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Erection of packer plates

Blue matching Placing Leveling standards
Manufacturer standard

Leveling
Individual leveling Co planarity of plates

International standards

API 61O pumps - 200m per meter ASME purpose pumps - 400m per meter

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Change in elevation after grouting

Before grouting After grouting

If above happens then leveling and blue matching will be done simultaneously to avoid soft footing in future.

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Preliminary checks
Coupling half runout
Soft footing Bearing

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Runout check
Runout standards
Shaft speed Maximum runout 0.13 mm

0-1800 rpm

1800-3600 rpm

0.08 mm

3600+ rpm

0.05 mm

Maximum times these standards are provided by manufacturer

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Ways of detecting soft foot

Dial indicator shims

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Checking procedure
Dial indicator
First tight the bolt Place dial indicator Loose bolts See dial show less then 0.06

shims
Check gap between foot and

pedestal by shims at four sides of foot.

mm.

Repeat this for all foots

Eliminating soft footing is most time consuming and skilled job. Machines on maximum occasion have vibration problem due soft footing This is very much a trial and error method because every time you need to put shims as per calculation and check for soft footing till you eliminating.

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Example of soft footing

This condition is outcome of

bad blue matching, leveling and complaining of packers

Reasons of soft footing

Insufficient contact between machine foot and pedestal. Noncoplanarity foot or pedestal .
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Alignment basics

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Types of misalignments

Measured in mm

Measured in degree of angle

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Calculation of angular misalignment

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Alignment methods
Face to Rim method Reverse indicator method

There other method to align shafts but these are predominantly used. Reverse indicator method is more accurate then Face to Rim method.
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Face to Rim method

Advantage of Face to Rim method above reverse indicator method , it can be used for alignment when rotating both shaft is not possible

Both shafts are moving so facial reading is going to be effected. To overcome ,we are using two extra dial indicator .
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Set of readings

Making compensation for shaft movement is important .

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Other arrangement used in Face to Rim method

Axial reading = A1- A2/2

Why compensation is this?

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Dimension required

Accuracy of Face to Rim method depends on diameter at which facial reading is taken.
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How to align
Electrical machines have magnetic center , so motor shaft first

needs to be positioned to it magnetic center , only then alignment is done. With above mentioned formula calculate position of Driver and Driven machine inboard and outboard foots. Find out movement of inboard and outboard foots to make shafts collinear and coplanar. This can easily be done by using graph paper Individuals do it on hit and trial basis but by using above process can be done in less time.
Magnetic center of electric machines is specified by manufacturer 25

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Interpretation of dial reading in 3-D view

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Example

Page 361
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Reverse indicator method

Same process of finding movement of Drive and Driven machine inboard and outboard foot to align shafts we follow here.
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Why to rotate both shaft

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Alignment specification
Most of time provided by manufacturer

Depends on coupling ,speed and power.

NTPC allowable tolerance Parallel misalignment
Output of rotor in KW Coupling Speed rpm
Below 400 (mm) 400-1000 (mm) Over 1000 (mm)

Angular misalignment
Output of rotor in KW Coupling Speed rpm
Below 400 (mm) 400-1000 (mm) Over 1000 (mm)

2500-4000

0.01 0.025 0.04 0-01 0.015

0.02 0.04 0.06 0.02 0.03

0.03 0.06 0.10 0.03 0.04 Rigid coupling Flexible coupling

2500-4000
1300-2500 Below 1300 2500-4000 Below 2500

0.02
0.06 0.08 0.02 0.03

0.03
0.07 0.10 0.03 0.04

0.04
0.10 0.15 0.04 0.05

Flexible coupling

1300-2500 Below 1300

Rigid coupling

2500-4000
Below 2500

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Alignment procedure of machine with hydraulic variable speed coupling

Find magnetic center of motor
Find offset required between shafts through

manufacturer drawing. Find coupling maximum tolerable miss alignment. While doing alignment keep in mind piping strain. Following above mentioned we do alignment.

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Example 135MW Vedanta plant

Magnetic center 35mm specified by manufacturer.
Coupling maximum tolerable misalignment

Maximum axial misalignment is 4mmm without angular misalignment. Maximum axial misalignment is 1.85x2mm with o.75 x 2seconds angular misalignment. Above shown coupling is a metal membrane type mechanically flexible coupling

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Drawing showing offset required in alignment.

Top view

Side view

Cross sectional view of journal bearing

Why alignment ? Vertical offset different load on bearing ( Shaft weight ) and opposite rotation of shaft. Horizontal offset Horizontal load produced by gears and both shaft are rotating in opposite direction

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Coupling
Flexible coupling
Mechanically flexible

Rigid cleaning

Chain coupling Gear coupling

Metallic membrane/disk

Flexible membrane and disc type coupling Leaf spring type coupling

Elastomeric coupling
There is a belief that we need to align machine shafts to coupling tolerable misalignment, but this will reduce coupling life . A professional methodology is to align machine as accurate possible so that it can accommodate running time misalignment .

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Mechanical flexible coupling

Pin drive type coupling

Gear type coupling

Chain type coupling

Gear type coupling has been used to couple gear drive and HCSD (GEHO) pump used in 135 MW Vedanta plant

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Mechanical membrane or disk coupling

Leaf spring type coupling Flexible disc and membrane type coupling

This coupling has been used in boiler feed pump and all fans to couple shafts

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Elastomeric flexible coupling

Metal ribbon

This coupling has used to couple shafts of mixing tank agitator of 135MW Vedanta power plant.

This coupling has used to couple shafts of motor and gear box shaft of HCSD (GEHO)pump of 135MW Vedanta power plant.

This coupling has used to couple shafts of paddle mixture of ash handling plant of 135MW Vedanta power plant.

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Coupling half insertion methods

Coupling hub, key and key ways must be inspected

keeping damage and dimension as per drawing.

heating and then inserting coupling is also a method installing coupling half.

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Hydraulic expander and pusher assembly

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Hydraulic variable speed drive

Purpose using this is to supply variable amount of water

at variable pressure as per boiler requirement. HVSD helps in saving energy.

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Thank you

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