1.

Condensate Extraction Pumps (CEP)

Purpose:

Condensate Extraction Pumps are responsible for returning condensate from the condenser
hotwell back to the feedwater system, maintaining the water/steam cycle.

Annual Maintenance Procedure:

 1. Electrical System Checks:

o Inspect and test motor insulation resistance (Megger Test).
o Perform motor winding resistance checks to ensure balanced phases.
o Check motor terminal connections for tightness and corrosion.
o Verify operation of motor protection relays and controls.
 2. Mechanical Components:
o Disassemble the pump casing and inspect the internal components (impeller,
volute, casing) for signs of wear, erosion, or corrosion.
o Perform bearing checks: Measure bearing clearance, inspect for wear, and
replace if necessary.
o Shaft alignment check: Verify the motor-pump shaft alignment using a laser
alignment tool, adjusting the coupling as needed.
o Inspect and replace mechanical seals and gaskets.
o Lubricate motor bearings with high-temperature grease or replace oil for oil-
lubricated bearings.
 3. Impeller Inspection:
o Inspect the impeller for signs of pitting, corrosion, or damage.
o Measure impeller wear ring clearance and replace the wear ring if it exceeds
manufacturer recommendations.
o Clean the impeller and remove any deposits or scaling.
 4. Coupling Inspection:
o Check the coupling alignment and condition of the coupling components
(flexible elements, bolts, keys).
o Replace any worn-out components.
 5. Vibration Analysis:
o Conduct a vibration analysis to detect imbalances, misalignment, or bearing
wear.
o Compare current data with baseline readings to detect any changes in vibration
patterns.
 6. Flow and Pressure Testing:
o Perform flow and pressure tests to ensure the pump operates within its design
parameters.
o Compare performance with historical data to detect efficiency losses.
Inspection Procedure:

 Daily/Weekly: Visual inspections of the pump for leaks, unusual noises, vibrations, or
misalignment.
 Monthly: Conduct temperature checks on the pump housing and bearings to detect
abnormal heating.
 Annually: Full disassembly, inspection, and repair/replacement of critical components as
listed above.

2. Feedwater Pumps

Purpose:

Feedwater pumps deliver feedwater to the boiler, maintaining water flow under high pressure
and temperature.

Annual Maintenance Procedure:

 1. Electrical System:
o Motor insulation resistance testing (Megger) and motor winding resistance
testing.
o Inspect electrical connections for corrosion and tightness.
o Test the motor cooling fan for proper operation.
 2. Mechanical Components:
o Check pump alignment with motor, recalibrate if needed.
o Inspect and lubricate or replace pump bearings.
o Inspect the pump casing, volute, and impeller for wear or cavitation damage.
o Replace or recondition the mechanical seals.
o Inspect and clean impeller blades, replace if erosion or cavitation damage is
found.
 3. Hydraulic and Pressure Systems:
o Perform a hydraulic performance test to verify pump flow and pressure.
o Test the discharge pressure and compare with design data to ensure it meets
operational needs.
 4. Lubrication System:
o Inspect and replace lubrication oil and oil filters in the pump and motor
lubrication systems.
o Clean lubrication reservoirs and check for contaminants or signs of oil
degradation.
 5. Heat Exchangers (if applicable):
o Inspect any auxiliary cooling systems (like oil coolers) and clean or replace
filters as needed.

Inspection Procedure:
  Daily/Weekly: Visual inspection for leaks, unusual vibrations, and temperature
anomalies.
 Monthly: Check oil levels and inspect for oil contamination.
 Annually: Perform a full pump teardown to inspect internal components (bearings, seals,
impeller, casing, and wear rings).

3. Boiler Circulating Pumps

Purpose:

Boiler circulating pumps maintain water circulation within the boiler to ensure heat is transferred
efficiently.

Annual Maintenance Procedure:

 1. Electrical Checks:
o Test motor insulation and motor winding resistance.
o Check electrical terminations and the operation of motor protection devices.
 2. Mechanical Inspections:
o Disassemble the pump casing to inspect for corrosion, cavitation, or erosion
damage on the impeller, volute, and casing.
o Measure and inspect bearing clearances, replace bearings if necessary.
o Inspect the shaft for wear or damage and check for any signs of misalignment.
o Check the mechanical seal and replace if leakage or wear is observed.
o Shaft alignment should be checked and adjusted using precision laser alignment
tools.
 3. Impeller and Wear Rings:
o Check the impeller for signs of damage or excessive wear.
o Measure the wear ring clearance and replace if it exceeds the manufacturer’s
tolerance.
 4. Vibration Analysis:
o Perform a vibration analysis to detect any signs of misalignment or bearing
wear.
o Compare with baseline data to ensure no significant increase in vibration levels.
 5. Performance Testing:
o Conduct a flow and pressure test to ensure the pump is delivering the required
flow and head pressure as per design parameters.
o Compare current test results with historical data to identify any decline in
performance.

Inspection Procedure:

 Daily/Weekly: Visual inspection of pump casing, seals, and shaft coupling.

 Monthly: Check bearing temperatures and vibration levels.
  Annually: Full teardown, inspection, and refurbishment.

4. Main Cooling Water Pumps

Purpose:

Main cooling water pumps circulate cooling water from the cooling tower or natural source to
the condenser.

Annual Maintenance Procedure:

 1. Electrical Inspection:
o Conduct megger testing of the motor windings and verify motor protection
systems are functioning.
o Check electrical terminations and inspect for corrosion or wear on connections.
 2. Mechanical Inspection:
o Inspect pump casing and check for cavitation, corrosion, or erosion damage.
o Perform bearing inspection: Check for abnormal wear and replace bearings if
required.
o Verify that the shaft coupling is in good condition and properly aligned.
o Lubricate or replace bearings, ensuring the lubrication system is functioning
correctly.
 3. Hydraulic and Performance Checks:
o Conduct a performance test to verify that the pump is delivering the required
flow rate and pressure.
o Compare performance with the design specifications and historical data.
 4. Impeller and Wear Rings:
o Inspect the impeller and wear rings for wear or damage.
o Replace the wear rings if they are beyond the acceptable clearance range.
 5. Seals and Gaskets:
o Inspect mechanical seals and gaskets for wear or leakage, replacing them if
necessary.

Inspection Procedure:

 Daily/Weekly: Visual checks for leakage, noise, and vibration.

 Monthly: Check pump performance and motor temperatures.
 Annually: Full inspection and overhaul of key components (bearings, seals, impeller,
casing).
5. Firewater Pumps

Purpose:

Firewater pumps ensure a continuous supply of water for fire suppression systems.

Annual Maintenance Procedure:

 1. Electrical Checks:
o Conduct motor insulation testing and check the motor protection system.
o Test all electrical terminations for tightness and integrity.
 2. Mechanical Inspection:
o Perform full inspection of pump casing for any signs of corrosion, wear, or
erosion.
o Inspect and lubricate or replace bearings.
o Inspect the impeller for wear and damage and replace if necessary.
o Test and inspect the shaft alignment between motor and pump.
 3. Performance Testing:
o Perform a flow test to verify the firewater pump can meet the required flow and
pressure.
o Ensure the pump starts automatically when needed by testing the fire protection
control systems.
 4. Seals and Gaskets:
o Replace any mechanical seals and gaskets that show signs of wear or leakage.

Inspection Procedure:

 Weekly/Monthly: Regular no-flow start tests to ensure the pump starts automatically.
 Annually: Full overhaul of the pump, including motor, impeller, seals, and casing
inspection.

General Recommendations for Critical Pump Maintenance in CCPP:

 Documentation: Maintain detailed records of maintenance activities, including all

inspection data, performance tests, and repairs.
 Personnel Training: Ensure that maintenance personnel are trained on the specific
pumps they work with and can identify early signs of pump degradation.
 Scheduled Shutdowns: Plan annual maintenance during scheduled plant shutdowns to
minimize disruptions to operations.
 Predictive Maintenance: Use data from vibration analysis, thermography, and oil analysis to
plan future interventions more effectively and reduce unplanned downtime.