CASE STUDY

Equipment & Location: Boiler Feed Water Pump # A

Dates of Checking’s: 20th, 25th January & 3rd February 2006

Instruments used: Vibration Data Collector/Analyser, Model Easy-Viber

Abstract of Case: All of a sudden Seizure of the Pump and Tripping of Unit due to Over Current, created panic in
the mind of Operational Staff. Earlier recorded Vibration Levels did not indicate any abnormal
thing in the Motor and Pump Unit. Inspection of the Pump Rotor revealed that two bolts had
entered in the Pump Casing and one of those had stuck in between the Impeller locking the
rotor, which had seizure of the rotor.

Equipment Specifications: Pump - Boiler Feed Water Pump # A, Make Flowserve, Model ECPJ 25-200, Driver
Electric Motor, Discharge Press 49.61 bar, Max Condition Flow Rate 75.6 m3/Hour,
Suction Min/Max Press 2.35/7.013 bar, Head at Rated Capacity 507.3 m, Seal Type
Mechanical, Seal Make Flowserve, Seal Model 5A (U) 4X, Diameter of Suction Line 8
inch, Diameter of Discharge Line 4 inch, Head Max 610.6 m, Speed 2,950 rpm,
Impellers Diameter 236 mm, Impellers Material 12% Chrome. Coupling Flexible Type.

Vibration Data: The following readings of the Vibration Levels were available in the recorded Data Base.
Actual Date Velocity BC Value Displacement Accelera
Point No. &
as per mm/sec Microns pk- tion G
Direction
Calendar rms pk pk
th
20 Jan 2006 1-Vertical 0.2375 0.08
th
20 Jan 2006 1-Horizontal 0.6678 0.06
th
20 Jan 2006 1-Axial 0.3320 0.04
th
20 Jan 2006 2-Vertical 0.3201 0.03
th
20 Jan 2006 2-Horizontal 0.6420 0.03
th
20 Jan 2006 2-Axial 0.3206 0.04
th
20 Jan 2006 3-Vertical 1.175 0.20
 20th Jan 2006 3-Horizontal 1.486 0.16
20th Jan 2006 3-Axial 0.4333 0.28
20th Jan 2006 4-Vertical 1.537 0.58
20th Jan 2006 4-Horizontal 1.112 0.48
20th Jan 2006 4-Axial 0.4278 0.36
25th Jan 2006 2-Horizontal 0.08 0.071546
25th Jan 2006 2-Axial 0.3426 0.04 0.7983 0.093649

Vibration Analysis: All of a sudden Seizure of the Pump and Tripping of Unit due to Over Current, created panic in
the mind of Operational Staff. While checking the earlier recorded Vibration Levels, which did
not indicate any abnormal thing in the Motor and Pump Unit. It was decided for dismantling of
the Pump Assembly for the Internal Inspection of the Pump Rotor.

Actions/Observations: There was no indication of any abnormality form the earlier recorded vibrations. Hence, the
motor was decoupled for doing free run check-up, which was found satisfactory confirming the
problem with the pump rotor. The coupling was found in good satisfactory condition. Finally, a
decision was taken to dismantle the pump. The mechanical seals also were found in the good
condition. Observed that after complete stripping of the pump assembly, revealed that two bolts
had entered in the Pump Casing and one of those had stuck in between the Impeller locking
the rotor, which had caused seizure of the rotor.

Conclusion: Seizure of the Pump Rotor could be indicated and prevented by the Motor Over Current Trip
System by avoiding further damages to Pump Impeller, Coupling and Motor due to the Over
Load Effects. The available Vibration Records could not reveal any abnormality within the Unit.
Ultimately, Inspection of Pump Rotor could reveal the exact cause of Seizure/Locking of the
rotor. Hence, all the Planned and Systematic Activities carried out can help in resolving the
problems by avoiding further Catastrophic Damages to the Machines without any Unscheduled
Shutdowns and Production Losses thereof.
SPECTRA REPORT (Dated: 20th Jan. 2006)

SPECTRA REPORT (Dated: 20th Jan. 2006)

SPECTRA REPORT (Dated: 20th Jan. 2006)

SPECTRA REPORT (Dated: 20th Jan. 2006)

SPECTRA REPORT (Dated: 20th Jan. 2006)

SPECTRA REPORT (Dated: 20th Jan. 2006)

SPECTRA REPORT (Dated: 20th Jan. 2006)

SPECTRA REPORT (Dated: 20th Jan. 2006)

SPECTRA REPORT (Dated: 20th Jan. 2006)

SPECTRA REPORT (Dated: 20th Jan. 2006)

SPECTRA REPORT (Dated: 20th Jan. 2006)

SPECTRA REPORT (Dated: 20th Jan. 2006)

SPECTRA REPORT (Dated: 25th Jan. 2006)

SPECTRA REPORT (Dated: 25th Jan. 2006)

SPECTRA REPORT (Dated: 25th Jan. 2006)

SPECTRA REPORT (Dated: 25th Jan. 2006)

SPECTRA REPORT (Dated: 25th Jan. 2006)

SPECTRA REPORT (Dated: 25th Jan. 2006)

 SPECTRA REPORT (Dated: 25th Jan. 2006)

SPECTRA REPORT (Dated: 25th Jan. 2006)

Date: 2005/11/05 16:08, Overall = 0.071546 g RMS, BC = 0.08, Shaft Speed =2,970.0 RPM, Bearing =NDH 8513
SPECTRA REPORT (Dated: 25th Jan. 2006)

SPECTRA REPORT (Dated: 25th Jan. 2006)