PROJECT : BELLARY UNIT 1 500 MW PROBLEM :TDBFP A HIGH VIBRATION OF PUMP BEARING OBSERVATION : TDBFP 1A of Bellary Unit 1 500

500 MW was experiencing high vibration of the bearing at pump drive end with increase of speed of the TDBFP. Vibration measurement and analysis were carried out on the pump at different speeds from 3000 4000 rpm. The vibrations of drive end bearings of feed pump was about 7 mm/sec. upto 3600 rpm and increased to 30 40 mm/sec. at 4000 rpm with oscillation. Scanning of the pedestal indicated that the pump support vibration was in the range of 6 mm/sec. and the pump bearing vibrations were reaching 30 40 mm/sec. Suction discharge piping and the spring below the deck were inspected and corrections made as below: Hanger supports missed during installation , was provided and the cold settings of the supports were checked and corrected. Vibration values of the pump drive end bearing was observed to be normal upto 4000 rpm and reaching 30 40 mm/ sec. beyond 4500 rpm. (Vibration readings Annexure A ) Pumps Engineering of BHEL/Hyderabad recommended replacement of pump drive end bearing to observe the vibrations. Marginal reduction in vibration level was observed (Vibration readings Annexure B ).

As the vibration were still beyond operating limits, replacement of pump cartridge from mandatory spares was carried out with BHEL / Hyderabad supervision. The cartridge was removed from the barrel and the cartridge was dismantled, as the pump did not rotate after charging DM water. Spiral metal chips was observed in stage 2 hub side and were removed. The impeller hub and diffuser ring were dressed up and polished. The impeller components were assembled and the total float was measured as 7.6 mm. The cartridge was reinserted into the barrel and after centering, an offset in the taper pin hole was observed. This was corrected by reaming and alignment was completed. After coupling and admitting of DM water, pump was not rotating freely. Steam rolling of TDBFP A was carried out, after discussion with BHEL/Hyderabad and the pump was taken into service. The pump is in normal operation. (Vibration readings Annexure C ). CONCLUSION: Piping supports was observed to have significant effect on vibrations. It is necessary to ensure that the pump is free of loading from suction and discharge piping at the time of final connections. The pumps were observed to have metal chips, causing the problem of high vibrations. It is necessary to check and ensure that no foreign material entry is possible both at the works during manufacture and at site during erection.

Annexure A
Speed 4500 RPM Bearing Velocity in mm/sec (Peak) Vertical 10.67 7.76 Horizontal 3.84 3.60 Axial 2.86 2.77

BFP Drive End BFP Non-Drive End

Before changing Drive End Journal Bearing Speed 4378 RPM BFP Drive End Vertical Bearing Velocity in mm/sec (Peak) 11.68 07.59

Annexure B

BFP Non-Drive End Vertical

After changing Drive End Journal Bearing Speed- 4250 RPM BFP Drive End Vertical Bearing Velocity in mm/sec (Peak) 10.33 03.11

BFP Non-Drive End Vertical

Annexure C
Speed 4686 RPM BFP Drive End Vertical Vertical Bearing Velocity in mm/sec (Peak) 01.58 02.11

BFP Non-Drive End