The document outlines best practices for the maintenance and condition monitoring of boiler feed pumps (BFP), emphasizing the importance of preventive and predictive maintenance methods to ensure operational efficiency and longevity. It details various maintenance types including breakdown, preventive, reliability-centered maintenance, and the use of a computerized maintenance management system (CMMS) for tracking. Additionally, it covers troubleshooting procedures and technical specifications of the BFP, highlighting key maintenance activities and the importance of shaft alignment.

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

6. BFP EXTERNALS

7. BFP INTERNALS

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.

12. 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

17. Procedure for cartridge
replacement

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.

19. Boiler feed pump Log Book

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

22. Thank You