Pump Guidelines

Condensate Pump Application and
Maintenance Guide
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Condensate Pump Application and
Maintenance Guide
1000052
Final Report, August 2000
EPRI Project Manager

M. Pugh
EPRI 3412 Hillview Avenue, Palo Alto, California 94304 PO Box 10412, Palo Alto, California 94303 USA
800.313.3774 650.855.2121 askepri@epri.com www.epri.com
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CITATIONS
This report was prepared by
Fossil Maintenance Application Center (FMAC)

1300 W.T. Harris Blvd.
Charlotte, NC 28262
This report describes research sponsored by EPRI.
The report is a corporate document that should be cited in the literature in the following manner:
Condensate Pump Application and Maintenance Guide. EPRI, Palo Alto, CA: August 2000.
1000052.
iii
REPORT SUMMARY
This guide provides information to personnel involved with the maintenance of condensate
pumps and motors, including good maintenance practices, planning, predictive and preventive
techniques, and troubleshooting guidance. It provides insight to experienced personnel as well
as basic information, guidance, and instruction to personnel recently assigned to condensate
pump/motor maintenance.
Background
Condensate pumps (sometimes called hot well pumps) provide the motive force for transporting
condensate from the condenser hot well through the piping, valves, and equipment to the
preheating sections of the feedwater system in power plants. Condensate pump maintenance
issues rank high in surveys of fossil maintenance personnel.
Objective
To help member personnel deal with maintenance issues on this critical power plant
component
To provide technical information to plant personnel on proper selection and installation of
equipment, equipment and component operation, failure mode analysis, and maintenance
recommendations with a view to optimizing equipment operating life
Approach
This guide is structured to provide a basic understanding of background information relating to
condensate pumps in power plants. This information was used as a foundation for understanding
the elemental aspects of pump operation and maintenance that are important for personnel
involved in the operation, maintenance, and troubleshooting of this type of pump. Experienced
utility and industry personnel provided input into the development of this guide.
Results
The resulting guide presents a thorough discussion of system application considerations; pump
selection guidelines; potential failure modes; preventive, corrective, and predictive maintenance
practices; troubleshooting guidelines; and key operation factors. The contents of the guide will
assist plant personnel in reducing the costs associated with condensate pump maintenance and in
improving pump reliability.
v
EPRI Perspective
Condensate pump problems represent major expenditures for power plant operators in the form
of lost generation as well as labor and parts. This guide provides power plant maintenance
personnel with information to help improve component reliability through a better understanding
of critical components of pump operation and maintenance. It also provides guidelines on
investigating and troubleshooting problems that arise during inservice operation and normal,
planned maintenance activities.
1000052
Keywords
Pumps
Maintenance
Reliability
vi
EPRI Licensed Material
ACKNOWLEDGMENTS
This guide was developed by the Fossil Maintenance Application Center (FMAC) and the
following Technical Advisory Group (TAG):
Russell Briggs MEAG Power

Jerry Helderman IPL
Mike Jones IPL
Andy Lagerstrom OPPD
Val Muylle IPL
Dave Olney Duke Energy
Dave Reherman IPL
Lew Shuster TVA
Vic Varma Consultant
FMAC and the TAG were supported in this effort by
Black & Veatch

8400 Ward Parkway
P.O. Box 8405
Kansas City, MO 64114
Principal Investigator
J. Singleton
vii
CONTENTS
1 INTRODUCTION.................................................................................................................. 1-1
1.1 Purpose .................................................................................................................... 1-1
1.2 Organization.............................................................................................................. 1-1
1.3 Pop Outs ................................................................................................................... 1-2
2 GLOSSARY......................................................................................................................... 2-1
2.1 Pumps....................................................................................................................... 2-1
2.2 Motors....................................................................................................................... 2-6
2.3 Maintenance ............................................................................................................. 2-7
2.4 Tests ......................................................................................................................... 2-7
3 CONDENSATE SYSTEM DESCRIPTION ........................................................................... 3-1
4 CONDENSATE PUMP APPLICATION................................................................................ 4-1

4.1 System Configuration and Pump Type ...................................................................... 4-1
4.2 Pump Sizing Considerations ..................................................................................... 4-2
4.2.1 Flow Capacity....................................................................................................... 4-2
4.2.2 Total Developed Head .......................................................................................... 4-3
4.2.3 Net Positive Suction Head (NPSH) ....................................................................... 4-5
4.2.4 Number of Pumps................................................................................................. 4-5
4.2.5 Flow Control Method ............................................................................................ 4-6
4.2.5.1 Throttle Valve Control................................................................................... 4-6
4.2.5.2 Variable Speed Control ................................................................................ 4-7
4.2.5.3 Comparison of Control Methods ................................................................... 4-8
4.3 Pump Design Parameters and Characteristics .......................................................... 4-8
4.3.1 Shape of Pump Characteristic Curve.................................................................... 4-9
4.3.2 First-Stage Impeller Design .................................................................................. 4-9
4.3.3 Pump and Can Length for Vertical Pumps .......................................................... 4-10
ix
4.3.4 Materials of Construction .................................................................................... 4-11

4.4 Pump Specifications, Guarantees, and Shop Testing.............................................. 4-11
4.4.1 Specifications ..................................................................................................... 4-11
4.4.1.1 Pump Type and Arrangement..................................................................... 4-11
4.4.1.2 Operational Requirements.......................................................................... 4-12
4.4.1.3 System Design Conditions.......................................................................... 4-12
4.4.2 Guarantees......................................................................................................... 4-12
4.4.3 Shop Testing ...................................................................................................... 4-13
4.4.4 Specification Check Sheet.................................................................................. 4-13
4.5 Other System Design and Configuration Issues ...................................................... 4-13
4.5.1 Condenser Hot Well Suction Connection ............................................................ 4-13
4.5.2 Suction Piping Design......................................................................................... 4-13
4.5.3 Recirculation....................................................................................................... 4-14
4.5.4 Seal Water Supply.............................................................................................. 4-14
4.6 Common Misapplications ........................................................................................ 4-15
5 TECHNICAL DESCRIPTIONS OF PUMPS AND MOTORS ................................................ 5-1

5.1 Vertical Centrifugal Can Type Pumps........................................................................ 5-1
5.1.1 Impellers............................................................................................................... 5-4
5.1.1.1 Impeller Attachment...................................................................................... 5-8
5.1.2 Bowl ................................................................................................................... 5-10
5.1.3 Wearing Rings .................................................................................................... 5-10
5.1.4 Column............................................................................................................... 5-12
5.1.5 Shaft................................................................................................................... 5-14
5.1.6 Shaft Sleeves ..................................................................................................... 5-14
5.1.7 Bearings ............................................................................................................. 5-15
5.1.7.1 Sleeve Bearings ......................................................................................... 5-15
5.1.7.2 Antifriction Ball Bearings............................................................................. 5-15
5.1.7.3 Thrust Bearings .......................................................................................... 5-18
5.1.8 Stuffing Box ........................................................................................................ 5-19
5.1.8.1 Packing ...................................................................................................... 5-19
5.1.8.2 Mechanical Seals ....................................................................................... 5-21
Types ................................................................................................................. 5-22
Single Seal, Inside Unbalanced .......................................................................... 5-23
Single Seal, Outside Unbalanced ....................................................................... 5-23
x
Single Seal, Balanced......................................................................................... 5-24

Double Seals ...................................................................................................... 5-25
5.1.8.3 Comparison of Packing and Mechanical Seals ........................................... 5-25
Packing .............................................................................................................. 5-25
Mechanical Seals ............................................................................................... 5-25
5.1.9 Couplings ........................................................................................................... 5-26
5.1.10 Discharge Heads ............................................................................................. 5-30
5.1.11 Suction Can ..................................................................................................... 5-32
5.2 Horizontal Centrifugal Pumps.................................................................................. 5-33
5.2.1 Impellers............................................................................................................. 5-33
5.2.2 Casing ................................................................................................................ 5-34
5.2.3 Wearing Rings .................................................................................................... 5-34
5.2.4 Shaft................................................................................................................... 5-35
5.2.5 Shaft Sleeves ..................................................................................................... 5-35
5.2.6 Stuffing Boxes .................................................................................................... 5-36
5.2.7 Bearings ............................................................................................................. 5-36
5.2.8 Couplings ........................................................................................................... 5-36
5.3 Electric Drive Motors ............................................................................................... 5-37
5.3.1 Technical Description ......................................................................................... 5-37
5.3.2 Motor Components ............................................................................................. 5-40
5.3.2.1 Motor Components Overview ..................................................................... 5-40
5.3.2.2 Bearing Systems ........................................................................................ 5-43
Bearing Types .................................................................................................... 5-44
5.3.2.3 Lubrication Systems ................................................................................... 5-50
Oil Lubrication .................................................................................................... 5-51
Grease Lubrication ............................................................................................. 5-51
Lubricant Requirement ....................................................................................... 5-51
Grease Fill .......................................................................................................... 5-53
6 FAILURE MODE ANALYSIS ............................................................................................... 6-1

6.1 Survey Results .......................................................................................................... 6-1
6.2 EPRI Report AP-2071 ............................................................................................... 6-2
6.3 NERC-GADS Data .................................................................................................... 6-4
xi
7 PUMP OPERATION ............................................................................................................ 7-1

7.1 Startup ...................................................................................................................... 7-1
7.1.1 Initial Pump Startup or Startup Following Maintenance or Repair ......................... 7-1
7.1.2 Normal Startup ..................................................................................................... 7-3
7.1.2.1 Start Permissives ......................................................................................... 7-3
7.1.2.2 Operation of Discharge Isolation Valves ....................................................... 7-4
7.1.3 Limitations for Repeated Start Attempts ............................................................... 7-5
7.2 Pump Operation ........................................................................................................ 7-5
7.2.1 Basics of Pump Operation .................................................................................... 7-5
7.2.2 Operation at Increased FlowPump Runout ......................................................... 7-9
7.2.3 Operation at Decreased FlowMinimum Recirculation........................................ 7-11
7.2.4 Reverse Rotation................................................................................................ 7-13
7.3 Shutdown ................................................................................................................ 7-14
7.3.1 Normal Shutdown ............................................................................................... 7-14
7.3.1.1 Plant Shutdown .......................................................................................... 7-14
7.3.1.2 Individual Pump Shutdown ......................................................................... 7-14
7.3.2 Trip Conditions ................................................................................................... 7-14
7.3.2.1 Unit Trip...................................................................................................... 7-14
7.3.2.2 Pump Trip................................................................................................... 7-15
7.3.3 Prevention of Air Entry Following Shutdown ....................................................... 7-15
8 PERFORMANCE MONITORING ......................................................................................... 8-1

8.1 Performance Monitoring System ............................................................................... 8-1
8.2 System Components ................................................................................................. 8-1
8.2.1 Data Acquisition.................................................................................................... 8-1
8.2.1.1 Data Collection Methods .............................................................................. 8-2
8.2.2 Monitored Parameters .......................................................................................... 8-2
8.2.3 Performance Calculations..................................................................................... 8-3
8.2.3.1 Total Developed Head.................................................................................. 8-3
8.2.3.2 Net Positive Suction Head ............................................................................ 8-5
8.2.3.3 Pump Flow ................................................................................................... 8-5
8.2.3.4 Pump Efficiency............................................................................................ 8-5
8.2.3.5 Pump Vibration............................................................................................. 8-5
8.2.4 Data Storage ........................................................................................................ 8-5
8.2.5 Data Analysis ....................................................................................................... 8-5
xii
9 CONDENSATE PUMP MAINTENANCE PRACTICES ........................................................ 9-1

9.1 Predictive Maintenance ............................................................................................. 9-5
9.1.1 Vibration Monitoring.............................................................................................. 9-5
9.1.2 Performance Monitoring ....................................................................................... 9-7
9.1.3 Oil Analysis........................................................................................................... 9-8
9.1.4 Infrared Thermography ......................................................................................... 9-8
9.1.5 On-Line Motor Monitoring ..................................................................................... 9-8
9.2 Preventive Maintenance............................................................................................ 9-9
9.2.1 Calibrations .......................................................................................................... 9-9
9.2.2 Packings and Seals .............................................................................................. 9-9
9.2.3 Operational Rounds.............................................................................................. 9-9
9.2.4 Periodic Motor Testing........................................................................................ 9-10
9.3 Corrective Maintenance .......................................................................................... 9-11
9.3.1 Equipment Isolation ............................................................................................ 9-13
9.3.2 Removal ............................................................................................................. 9-13
9.3.3 Pump Disassembly............................................................................................. 9-14
9.3.4 Disassembly of Bowl Assembly .......................................................................... 9-15
9.3.5 Inspection and Cleaning ..................................................................................... 9-17
9.3.6 Impellers............................................................................................................. 9-17
9.3.7 Bowls.................................................................................................................. 9-18
9.3.8 Shaft................................................................................................................... 9-18
9.3.9 Bearings ............................................................................................................. 9-19
9.3.10 Parts Preparation ............................................................................................. 9-19
9.3.11 Pump Reassembly ........................................................................................... 9-20
9.3.12 Packing and Mechanical Seals ........................................................................ 9-21
9.3.12.1 Packing .................................................................................................... 9-21
9.3.12.2 Mechanical Seals ..................................................................................... 9-23
10 TROUBLESHOOTING..................................................................................................... 10-1
10.1 Troubleshooting of Pump Operating Symptoms ...................................................... 10-1
10.2 Troubleshooting of Pump Components ................................................................... 10-8
10.3 Mechanical Seal Troubleshooting.......................................................................... 10-11
10.4 Troubleshooting Vertical Induction Motors............................................................. 10-12
xiii
11 TRAINING AND PERSONNEL QUALIFICATIONS ......................................................... 11-1

11.1 Basic Training Requirements .................................................................................. 11-1
11.2 Approach to Training ............................................................................................... 11-2
12 REFERENCES ................................................................................................................ 12-1
A NERC-GADS DATABASE REPORTS ................................................................................A-1
B CONDENSATE PUMP SPECIFICATION CHECK SHEET..................................................B-1
C LISTING OF KEY INFORMATION ......................................................................................C-1
xiv
LIST OF FIGURES
Figure 3-1 Thermal Plant Condensate System........................................................................ 3-2

Figure 3-2 Combined Cycle Plant Condensate System........................................................... 3-3
Figure 4-1 Constant Speed Pump With Throttle Valve Control ................................................ 4-7
Figure 4-2 Variable Speed Drive Control................................................................................. 4-8
Figure 5-1 Condensate PumpVertical, Multistage, Wet-Suction, Can Type, With Single-
Suction First-Stage Impeller ............................................................................................ 5-2
Figure 5-2 Condensate PumpVertical, Multistage, Wet-Suction, Can Type, With
Double-Suction First-Stage Impeller ................................................................................ 5-3
Figure 5-3 Radial-Flow Impeller .............................................................................................. 5-4
Figure 5-4 Axial-Flow Impeller................................................................................................. 5-4
Figure 5-5 Mixed-Flow Impeller ............................................................................................... 5-5
Figure 5-6 Single-Suction Impeller .......................................................................................... 5-5
Figure 5-7 Double-Suction Impeller......................................................................................... 5-6
Figure 5-8 Enclosed Impeller .................................................................................................. 5-6
Figure 5-9 Open Impeller ........................................................................................................ 5-7
Figure 5-10 Semi-Open Impeller ............................................................................................. 5-7
Figure 5-11 Comparison of Pump Profiles............................................................................... 5-8
Figure 5-12 Impeller-to-Shaft Attachment Methods ................................................................. 5-9
Figure 5-13 Pump Bowl Assembly ........................................................................................ 5-11
Figure 5-14 Plain Flat Leakage Joint With No Renewable Parts............................................ 5-12
Figure 5-15 Single Flat-Casing-Ring Construction ................................................................ 5-13
Figure 5-16 Double Flat-Ring Construction ........................................................................... 5-13
Figure 5-17 Step-Type Leakage Joint With Double Rings ..................................................... 5-14
Figure 5-18 Pump Design With the Bearing External to the Discharge Head ........................ 5-16
Figure 5-19 Single-Row Deep-Groove Ball Bearing .............................................................. 5-17
Figure 5-20 Double-Row Deep-Groove Ball Bearing ............................................................. 5-17
Figure 5-21 Self-Aligning Double-Row Ball Bearing .............................................................. 5-17
Figure 5-22 Single-Row Angular-Contact Ball Bearing .......................................................... 5-18
Figure 5-23 Conventional Stuffing Box With Throat Bushing ................................................. 5-20
Figure 5-24 Conventional Stuffing Box With Bottoming Ring................................................. 5-20
Figure 5-25 Lantern Ring (also called Seal Cage)................................................................. 5-21
Figure 5-26 Basic Mechanical Seal ....................................................................................... 5-22
xv
Figure 5-27 Single, Inside Unbalanced Seal.......................................................................... 5-23

Figure 5-28 Single, Outside Unbalanced Seal....................................................................... 5-24
Figure 5-29 Single, Inside Balanced Seal.............................................................................. 5-24
Figure 5-30 Double, Inside Unbalanced Seals ...................................................................... 5-25
Figure 5-31 Coupling Arrangements ..................................................................................... 5-27
Figure 5-32 Split Rigid Coupling............................................................................................ 5-27
Figure 5-33 Gear Mechanically Flexible Coupling ................................................................. 5-28
Figure 5-34 Metal-Disk Material Flexible Coupling ................................................................ 5-28
Figure 5-35 Sleeve-Type Elastomer Coupling ....................................................................... 5-29
Figure 5-36 Sleeve-Type Clamped Elastomer Coupling........................................................ 5-29
Figure 5-37 Rubber Jaw Coupling......................................................................................... 5-30
Figure 5-38 Fabricated Discharge Heads Above Grade Suction ........................................... 5-31
Figure 5-39 Fabricated Discharge Heads Below Grade Suction............................................ 5-32
Figure 5-40 Sectional View Horizontal Centrifugal Condensate Pump .................................. 5-33
Figure 5-41 Single-Stage Axial (Horizontal) Split Case Pump ............................................... 5-34
Figure 5-42 Single-Stage Radial (Vertical) Split Case Pump ................................................. 5-35
Figure 5-43 Sleeve With an External Locknut and Impeller Key Extending Into the
Sleeve to Prevent Slip ................................................................................................... 5-36
Figure 5-44 Vertical Motor..................................................................................................... 5-38
Figure 5-45 Detail of a Rotor for a Squirrel-Cage Motor ........................................................ 5-39
Figure 5-46 Cutaway Drawing of an Open, Drip-Proof Squirrel-Cage Induction Motor .......... 5-40
Figure 5-47 Exploded View of an AC Motor .......................................................................... 5-42
Figure 5-48 Sleeve Bearing Details....................................................................................... 5-45
Figure 5-49 Oil Ring Detail .................................................................................................... 5-45
Figure 5-50 Single-Row, Double-Sealed Ball Bearing ........................................................... 5-47
Figure 5-51 Single-Row, Open Enclosure, Deep-Groove Ball Bearing .................................. 5-47
Figure 5-52 Single-Row, Double-Shielded Ball Bearing ........................................................ 5-48
Figure 5-53 Single-Row, Maximum Type Ball Bearing .......................................................... 5-48
Figure 5-54 Mounting Arrangements for Angular-Contact Ball Bearings................................ 5-49
Figure 5-55 Tilting Pad Thrust Bearing Runner ..................................................................... 5-49
Figure 5-56 Six-Shoe Thrust Bearing Without the Runner Installed....................................... 5-50
Figure 5-57 Six-Shoe Thrust Bearing With the Runner Installed............................................ 5-50
Figure 5-58 Equalized Support of Thrust Bearing Shoes....................................................... 5-50
Figure 5-59 Flow-Through Lubrication System...................................................................... 5-52
Figure 5-60 Lubrication System Used for Shielded Bearings................................................. 5-52
Figure 6-1 Condensate Pump Failure Data ............................................................................. 6-3
Figure 7-1 Single Pump Operation .......................................................................................... 7-6
Figure 7-2 Pumps Operating in Parallel................................................................................... 7-7
Figure 7-3 Condensate Pump Performance Curves ................................................................ 7-8
xvi
Figure 7-4 Condensate Pump Performance at Design Conditions........................................... 7-9

Figure 7-5 Condensate Pump Performance at Runout Conditions ........................................ 7-10
Figure 7-6 Condensate Pump Performance at Low Flow Conditions..................................... 7-12
Figure 8-1 Datum Plane for a Vertical Pump ........................................................................... 8-4
Figure 8-2 Datum Plane for a Horizontal Pump ....................................................................... 8-4
Figure 8-3 Condensate Pump Performance Data Trends........................................................ 8-6
Figure 9-1 Vertical Can-Type Condensate Pump .................................................................. 9-12
Figure 9-2 Packing Box......................................................................................................... 9-22
xvii
LIST OF TABLES
Table 4-1 Determination of Developed Head........................................................................... 4-3

Table 4-2 Common Misapplications ...................................................................................... 4-15
Table 5-1 Predominant Motor Components Summary........................................................... 5-43
Table 5-2 Bearing Application ............................................................................................... 5-46
Table 6-1 EPRI FMAC Member Plant SurveyCondensate Pump Problem Reports ............... 6-1
Table 6-2 MTTR Contribution Data ......................................................................................... 6-4
Table 6-3 NERC-GADS Data: Condensate Pump and Motor Failure Data, 19951998 .......... 6-5
Table 7-1 Checklist: Condensate Pump Startup, Initial Startup, or Startup Following
Maintenance.................................................................................................................... 7-2
Table 8-1 Representative Performance Trends and Indications .............................................. 8-7
Table 9-1 Condensate Pump Condition Assessment Checklist ............................................... 9-3
Table 9-2 Maintenance Task Template ................................................................................... 9-6
Table 10-1 Troubleshooting Pump Operating Problems........................................................ 10-2
Table 10-2 Troubleshooting Pump Component Problems ..................................................... 10-9
Table 10-3 Troubleshooting Mechanical Seals.................................................................... 10-11
Table 10-4 Troubleshooting Motor Problems....................................................................... 10-13
xix
1
INTRODUCTION
1.1 Purpose
This guide provides personnel involved with the maintenance of condensate pumps and motors
with useful information regarding the following:
Pump selection and application
Description of typical pumps and components
Basic operating guidelines
Good maintenance practices
Planning
Predictive and preventive techniques
Troubleshooting guidelines
1.2 Organization
This guide is divided into 12 sections and appendices:

Section 1 introduces the guides purpose and organization
Section 2 is a glossary of terms and abbreviations used in the guide and in typical condensate
pump literature
Section 3 describes typical power plant condensate systems
Section 4 discusses issues related to the selection and application of pumps for condensate
system service
Section 5 provides technical descriptions of pumps and motors typically used for condensate
service applications
Section 6 summarizes the significant causes of pump and motor failures as reported in
industry sources
Section 7 addresses typical startup, operation, and shutdown modes for condensate systems
and pumps, including initial startup of new pumps and startup of pumps following
maintenance
Section 8 describes current methods for monitoring the performance of condensate pumps
1-1
Introduction
Section 9 addresses typical practices for maintaining condensate pumps, including

recommendations and common industry practices
Section 10 discusses methodology for troubleshooting typical condensate pump/motor
problems and determining the root cause of the problems
Section 11 addresses recommended training and qualifications for personnel assigned the
responsibility of maintaining and repairing condensate pumps and related drive motors
Section 12 is a list of references used in the development of this guide and materials that
provide users of this guide with additional information
Appendix A includes additional data related to the failure analysis described in Section 6
Appendix B includes a check sheet for reference in specifying and purchasing condensate
pumps
Appendix C includes a listing of the Pop Outs used to identify key points throughout this
document
1.3 Pop Outs
Throughout this guide, key information is summarized in Pop Outs. Pop Outs are bold lettered
boxes which succinctly restate information covered in detail in the surrounding text, making the
key point easier to locate.
The primary intent of a Pop Out is to emphasize information that will allow individuals to take
action for the benefit of their plant. The information included in these Pop Outs was selected by
FMAC personnel and the consultants and utility personnel who prepared and reviewed this
guide.
The Pop Outs are organized according to three categories: O&M Costs, Technical, and Human
Performance. Each category has an identifying icon, as shown below, to draw attention to it
when quickly reviewing the guide.
Key O&M Cost Point

Emphasizes information that will result in reduced purchase, operating,
or maintenance costs.
Key Technical Point

Targets information that will lead to improved equipment reliability.
Key Human Performance Point

Denotes information that requires personnel action or consideration in
order to prevent injury or damage or ease completion of the task.
1-2
Introduction
Appendix C contains a listing of all key points in each category. The listing restates each key
point and provides reference to its location in the body of the report. By reviewing this listing,
users of this guide can determine if they have taken advantage of key information that writers of
the guide believe would benefit their plants.
1-3
2
GLOSSARY
2.1 Pumps
Allowable Operating Range - The flow range for operation of the pump at the specified speed
as limited by cavitation, heating, vibration, noise, shaft deflection, fatigue, or other criteria. This
range is a function of the impeller and pump design and is specified by the manufacturer.
Best Efficiency Point - The capacity and head at which the pump efficiency is at its maximum.
Bowl Assembly Efficiency - The ratio of the bowl output to the bowl assembly input, expressed
in percent. This is the efficiency that is usually shown on catalog rating charts.
Bowl Assembly Head (H1) - The energy imparted to the liquid by the pump bowl assembly,
expressed in feet or meters of liquid. It is the head developed at the discharge connection of the
bowl assembly per stage as shown on the curve in the pump manufacturers catalog.
Bowl Assembly Power Input - The power required by the bowls to deliver only a specified
capacity against bowl head, as follows:
Bowl Head x Capacity

(U.S. Units) Bowl hp =
3,960 x Bowl Efficiency
Bowl Head x Capacity

(Metric Units) Bowl kW =
366 x Bowl Efficiency
Bowl Output - Defined as QH1 3,960 for water having a specific weight of 62.4 pounds per
cubic foot (relative density of 1.0). It is expressed in horsepower (hp x 0.746 = kW) when Q is in
gallons per minute and H1 is in feet of water.
Capacity (Q) - The volume rate of flow through the pump per unit of time at the specified
suction conditions, such as gallons per minute.
Column Loss - The value of the head loss, expressed in feet or meters, caused by the flow
friction in the column pipe.
Datum or Grade - The horizontal plane that serves as the reference for head measurements. For
vertical pumps, this is usually also the elevation of that surface from which the weight of the
2-1
Glossary
pump is supported: normally the elevation of the underside of the discharge head or head base
plate or sole plate. For horizontal pumps, the datum is usually at the centerline of the pump shaft.
Discharge Head Loss - The value of the head loss expressed in feet or meters, caused by the
flow friction in the discharge head assembly.
Drawdown - The difference in feet or meters between the static liquid level in the condenser hot
well and the liquid level when pumping at required capacity.
Driver Efficiency - The ratio of the driver power output to the driver power input, expressed in
percent.
Driver Power Input - The power input to the driver, expressed in horsepower (hp) or kilowatts
(kW).
Driver Power Output - The power delivered to the pump shaft by the driver, expressed in
horsepower (hp) or kilowatts (kW). Also referred to as pump input power or brake horsepower
(bhp).
Friction Head (hf) - The head required to overcome the frictional resistance of a piping system
to flow of the liquid. It is dependent upon the size and type of pipe, flow rate, and nature of the
liquid.
Head - The value used to express the energy content of the liquid per unit weight of the liquid,
referenced to an arbitrary datum. In terms of foot-pounds or meter-kilograms of energy per
pound or kilogram of liquid being pumped, all head quantities have the dimension of feet or
meters of liquid.
Head Above Datum (Ha) - The head measure above the datum, expressed in feet or meters of
liquid, plus the velocity head at the point of measurement.
Head Below Datum (Hb) - The vertical distance in feet or meters between the datum and the
pumping water level.
Impeller Balancing - Correction of residual unbalance by removing or adding weight. May be

done by static balancing (also called single plane balancing), in which weight is added or
removed in one plane only, or by dynamic balancing (also called two plane balancing), in which
weight is added or removed in two correction planes. Dynamic balancing is accomplished by
spinning the impeller on a balancing machine.
Internal Recirculation - The reversal of a portion of the pump flow back through the impeller at
low flows. This recirculation is known as suction recirculation when it occurs at the inlet of the
impeller and discharge recirculation when it occurs at the impeller outlet. Internal recirculation
can produce cavitation damage to the impeller.
2-2
Glossary
Line Shaft Loss - The power, expressed in horsepower (hp) or kilowatts (kW), required due to
the rotational friction of the line shaft. This value is added to the bowl assembly input power to
predict the pump input power.
Maximum Allowable Working Pressure - The highest pressure at the specified pumping
temperature for which the pump casing is designed. This pressure must be equal to or greater
than the maximum discharge pressure. For some pumps (such as double suction, vertical turbine,
or multistage), the maximum allowable casing working pressure on the suction side may be
different from that on the discharge side.
Net Positive Suction Head (NPSH) - The total suction head in feet or meters of liquid absolute
determined at the suction nozzle and the referred datum minus the vapor pressure of the liquid in
feet or meters absolute. The NPSH available at the pump suction connection at a given operating
condition is denoted by NPSHa, and the NPSH required by the pump design to prevent cavitation
is denoted by NPSHr.
Normal Conditions - The point on the rating curve at which the pump normally operates. It may
be the same as the rated condition point, but it may be different because of the design head and
flow margins included in the pump specifications.
Overall Efficiency (wire to water) - The ratio of the energy imparted to the water by the pump
to the energy supplied to the drive motor; the efficiency of the complete pump and motor
assembly. Overall efficiency is equal to the total pump efficiency multiplied by the motor
efficiency.
Power - Expressed in units of horsepower (hp) or kilowatts (kW). One horsepower is equivalent
to 33,000 foot-pounds per minute, 2,545 Btu per hour, or 0.746 kW.
Pump Input Power - The power delivered to the pump shaft by the driver, expressed in
horsepower (hp) or kilowatts (kW). Also referred to as brake horsepower (bhp) or driver power
output.
Pump Output Power - The power imparted to the liquid by the pump, expressed in horsepower
(hp) or kilowatts (kW). Also referred to as water horsepower.
Pumping Liquid Level - The vertical distance in feet or meters from the datum to the level of
the suction water reservoir surface while the specified fluid flow is being drawn by the pump.
For condensate pumps, the suction water reservoir is the condenser hot well.
Rated or Specified Conditions - The specified capacity, head, net positive suction head, and
speed of the pump.
Setting - The vertical distance in feet or meters from the datum or grade to the centerline of the
first stage suction.
Shutoff - The condition where the pump is primed and running but delivering no flow.
2-3
Glossary
Specific Speed (S, NS, or Ns) - Defined as the speed in revolutions per minute at which a
geometrically similar pump would operate in order to deliver 1 gallon per minute at a total head
of 1 foot. Specific speed represents a correlation of pump capacity, head, and speed at optimum
efficiency and is indicative of the shape and characteristics of the impeller. Specific speed
numbers range from approximately 500 (representing radial flow impellers) to approximately
20,000 (representing axial flow impellers):
nQ 0.5
NS =
H 0.75
where
Q = gpm
n = pump speed in rpm
H = feet
Speed - The rate of rotation of the pump shaft, expressed in revolutions per minute (rpm) or
revolutions per second (rps).
Static Head - The vertical distance in feet or meters between the centerline of the pump
discharge connection and the surface of the liquid in the discharge vessel, and between the
centerline of the pump suction connection and the condenser hot well level.
Static Liquid Level - The vertical distance in feet or meters from the datum or grade to the
liquid level of the suction water reservoir (condenser hot well) surface under no-flow conditions.
Submerged Suction - A submerged suction exists when the centerline of the pump inlet is
below the level of the liquid in the suction reservoir (condenser hot well).
Submergence - For vertical pumps, the distance from the liquid level in the suction reservoir
(hot well) to the lip of the suction bell.
Suction Specific Speed (NSS or Nss) - An index number descriptive of the suction
characteristics of a pump:
n Q
N SS =
( NPSHr ) 0.75
where
Q = gpm
n = pump speed in rpm
NPSHr = feet
2-4
Glossary
The numerical value of suction specific speed is primarily a function of the impeller inlet design.
Lower numerical values are associated with better NPSH capabilities.
Total Discharge Head (hd) - The algebraic sum of the pressure in feet or meters of liquid
(measured at the pump discharge connection) and the velocity head at that point.
Total Head (H); Total Dynamic Head (TDH); Total Developed Head (TDH) - The measure
of energy increase per unit weight of the liquid, imparted to the liquid by the pump; the
difference between the total discharge head and the total suction head.
Total Suction Head (hs) - The algebraic sum of the pressure in feet or meters of liquid
(measured at the pump suction connection) and the velocity head at that point. The pump suction
connection is the point at which the suction piping is attached to the pump bowl assembly or its
enclosing vessel.
Total Pump Efficiency (water to water) - The efficiency of the complete pump minus the
driver, with all pump losses taken into account as follows:
Specified Pump Head x Capacity
Efficiency =
3,960 x Brake Horsepower
Total Pump Length (TPL) - For a vertical pump, the distance from the bottom of the discharge
head at grade to the bottom of the lowest part of the pump (including strainer if required). The
sole plate, if used, is considered part of the foundation; the measurement is to the top of the sole
plate.
Velocity Head (hv) - The energy of a liquid as a result of its motion at a specific velocity; the
equivalent head in feet through which the water would have to fall to acquire the same velocity.
In other words, the head necessary to accelerate the water:
v2
hv =
2g
where
g = acceleration of gravity
v = velocity of the liquid
The velocity head is usually insignificant and can be ignored in most high head systems but may
be significant in low head systems.
2-5
Glossary
2.2 Motors
Antifriction Bearing - A bearing incorporating a peripheral assembly of rotating elements used

to support and control the shaft of a motor. The rotating element can be ball or roller type.
Armature - The part of the motor containing the winding in which an alternating voltage is
generated by relative motion of a magnetic field. Armature is the stator of an induction motor or
a synchronous motor and the rotor of a dc motor.
Brush Holder - A structure that supports a carbon brush and enables it to maintain contact with
the sliding surface (commutator or slip ring).
Commutator - An assembly of conducting members insulated from one another, in the radial-
axial plane, against which brushes bear. Used to enable current flow from stationary to rotating
parts.
Die Cast Rotor - The rotor of certain induction motors in which rotor bars and short-circuiting
rings are manufactured as a single casting.
Fabricated Rotor Winding - The rotor winding of certain induction motors in which bars and
short-circuiting rings are made of copper, brass, bronze, or aluminum bars individually inserted
into rotor slots and brazed or welded to short-circuiting rings.
Field Winding - A winding on the rotating part of a synchronous motor which has the sole
purpose of producing the main electromagnetic field of the motor.
Form-Wound Stator Coils - Coils that are wound, shaped, and insulated before insertion into
stator slots.
Phase Separator - Insulation sheets placed between phases of random wound stator windings.
Pigtail - A stranded copper wire shunt that connects a carbon brush to a brush holder.
Random Wound - A method of manufacturing stator windings of motors rated 600 volts and
below in which round magnet wires are coiled into loops of correct dimensions and installed in
stator slots without forming or preinsulating.
Sleeve Bearing - A bearing with a cylindrical inner surface often made of carbon,
graphalloy, tin, zinc, lead, or an elastomeric material in which the journal of the rotor
shaft rotates.
Slip Ring (or Collector Ring) - A metal ring suitably mounted on an electric machine, through
which stationary brushes conduct current into or out of the rotor.
Slot Liner - A sheet of insulation used to line a slot before the winding is placed in it.
2-6
Glossary
Squirrel-Cage Induction Motor - An alternating current motor in which the primary winding
on the stator is connected to the power source, and a squirrel-cage secondary winding on the
rotor carries induced current.
Synchronous Motor - A motor in which the speed of operation is exactly proportional to the
supply frequency. A synchronous motor has field poles excited by direct current.
Thrust Bearing - A bearing designed to carry an axial load in order to prevent or limit axial
movement of the shaft or to carry the weight of a vertical rotor system.
Vacuum-Pressure Impregnation (VPI) - The filling of voids in a coil or insulation system by

withdrawing by vacuum, air, or solvent (if any) from the contained voids, admitting a resin or
resin solution, pressurizing, and finally curingusually with the application of heat.
Wound Rotor Induction Motor - Similar to the squirrel-cage induction motor, except that the
rotor carries a three-phase winding.
2.3 Maintenance
Condition-Based Maintenance (CBM) - A methodology for performing maintenance activities

based on the actual condition of the equipment rather than on the basis of fixed intervals or hours
of operation.
Corrective Maintenance - Activities performed in response to unsatisfactory equipment

conditions, including repair and replacement activities.
Predictive Maintenance (PDM) - A subset of preventive maintenance, referring to activities

performed to develop maintenance schedules according to equipment history or present
condition, testing or analysis techniques, or a combination of these two items.
Preventive Maintenance (PM) - Activities performed to prevent unsatisfactory equipment

conditions from occurring, or if they occur, to prevent them from accumulating, so that the need
for corrective maintenance is reduced.
2.4 Tests
AC Hi Pot Test (High Potential Test or Overvoltage Test) - A test that consists of the
application of an ac voltage higher than the rated voltage for a specified time (usually one
minute) for the purpose of determining adequacy against breakdown of insulation under normal
(rated) conditions.
DC Hi Pot Test (High Potential Test or Overvoltage Test) - A test that consists of the
application of a dc voltage higher than the rated voltage for a specified time (usually one minute)
for the purpose of determining adequacy against breakdown of insulation under normal
conditions. For equivalency of test, the DC Hi Pot Test is usually carried out at 1.7 times the AC
Hi Pot Test value.
2-7
Glossary
DC Step Voltage Test (DC Absorption) - A controlled overvoltage test in which designated
voltage increments are applied at designated times and the leakage current is recorded. Time
increments may be constant or graded.
EL-CID Test (Electromagnetic Core Imperfection Detection Test) - A low power, low core
flux level test used to search stator cores for hot spots. A Chattock coil is used to bridge adjacent
stator teeth. The coil is used to sweep the entire stator.
Infrared Thermography - A noncontact method of monitoring a piece of equipment using

thermal imaging equipment to detect and display a visual indication of the equipments
temperature differential pattern. The display is typically qualitatively compared with the
temperature pattern of an identical or similar piece of equipment under similar operating
conditions in order to detect areas where unusual amounts of heat are being generated due to
wear, misalignment, inadequate cooling, or similar conditions.
Insulation Resistance Test - A test for measuring the resistance of insulation under specified
conditions. The test is the quotient of a specified direct voltage maintained on an insulation
system divided by the resulting current at a specified time after the application of voltage under
designated conditions of temperature, humidity, and previous charge.
Partial Discharge Test - A test, responsive to the high frequency discharge, which only partially
bridges the insulation between conductors. The test is used to measure the relative discharge
intensity.
Polarization Index Test - The ratio of the insulation resistance of a motor winding measured at
one minute after voltage has been applied, divided into the measurement at ten minutes.
Power Factor Tip-Up Test - The difference in power factors measured at two different
designated voltages applied to an insulation system, with other conditions being constant. This
test is used mainly as a measure of discharges, and hence of voids within the system at the higher
voltage.
Resistance Measurement Test - A measurement of the stator winding resistance with a Kelvin
Bridge type of measurement device to determine poor connections within the winding or at the
winding terminations.
Side-Band Analysis - A technique for analyzing stator current in induction motors with Fast
Fourier Transform equipment to determine the presence or absence of broken rotor bars.
Surge Comparison Test - A test for evaluating the integrity of turn insulation in the stator
winding by transmitting electrical pulses from twin capacitors into two different phase coils and
comparing the damped oscillating current wave shapes on the oscilloscope of the test equipment.
Ultrasound Test - A test that listens for ultrasonic noise produced by antifriction bearings to
determine if deterioration may be occurring. Ultrasonic frequencies are selectively monitored. A
1012 dB increase provides warning of bearing failure before changes in temperature or
vibration develop. This test equipment can also be used to detect partial discharges in stator
windings.
2-8
3
CONDENSATE SYSTEM DESCRIPTION
The purpose of the condensate system in an electric generating plant is to transport the
condensate from the condenser hot well to a higher-pressure vessel, which, among other
functions, serves as a suction reservoir for the boiler feed pumps.
In traditional coal-, oil-, or gas-fired power plants (thermal plants), the condensate system
generally includes a series of closed shell and tube type feedwater heaters, and the condensate is
delivered to a deaerating feedwater heater, as shown schematically in Figure 3-1. In a typical
combined cycle power plant, there are no external feedwater heaters. The condensate is delivered
either to a deaerator or, for plant designs that accomplish deaeration in the condenser, through
the low-pressure economizer section of the heat recovery steam generator (HRSG) to the low-
pressure drum, as shown schematically in Figure 3-2. The deaerator for a combined cycle plant
may be a free-standing vessel, or it may be furnished as a component of the HRSG and designed
to function with the low-pressure drum as the storage vessel.
3-1
Condensate System Description
Figure 3-1
Thermal Plant Condensate System
3-2
Figure 3-2
Combined Cycle Plant Condensate System
The condensate system in either type of plant typically includes the following:
Circulation of the condensate through the steam turbine gland steam condenser to cool and
condense the steam exhausted from the turbine steam seals system.
Provisions for maintaining the required minimum flow through the gland steam condenser
during startup and low load operation by means of a controlled recirculation line to the
condenser, located downstream of the gland condenser.
3-3
Provisions for maintaining the required minimum flow through each pump, either by
individual pump discharge recirculation lines to the condenser or through the gland steam
condenser minimum flow recirculation line.
Provisions for reducing the high condenser hot well water level by directing some of the
condensate flow to the condensate storage and makeup system or to the drain.
Provisions for increasing the low hot well water level by the addition of water from a
condensate makeup system.
Provision of water for other cycle uses, such as turbine exhaust hood cooling water spray or
desuperheating spray water.
Means for measuring and controlling the quantity of water delivered to the receiving vessel.
(Condensate flow is generally controlled to maintain the required water level in the deaerator
or drum, as applicable.)
Temporary or permanent performance test connections.
Condensate systems may also include the following:

Provisions for the addition of chemicals into the condensate flow to maintain water quality
Sample connections to allow monitoring of water chemistry
Pressure monitoring instrumentation
Provisions for pre-operational chemical cleaning of the system piping
Some additional features and functions of condensate systems for thermal plants may also
include the following:
Circulation of the condensate through an external drain cooler serving a low-pressure
feedwater heater or heaters located in the neck of the condenser
Provisions for diversion of the condensate flow through a condensate polishing system to
maintain water quality
The condensate pumps (sometimes called hot well pumps) provide the motive force for
transporting the condensate from the condenser hot well through the piping, valves, and
equipment to the receiving vessel.
3-4
4
CONDENSATE PUMP APPLICATION
Most users of this document will be concerned with maintaining pumps that have been in service
for a significant time. However, understanding the reasons for initial selection of a certain pump
for condensate system service may provide clues regarding ongoing operational problems that
could be related to the initial selection or changes in the system that affect pump operation. This
section also addresses common misapplications of condensate pumps and the results of these
misapplications.
The selection of a pump for power plant condensate system service requires the evaluation and
application of several important factors:
Configuration of system equipment and pump type
Pump sizing considerations
Pump operating and design conditions
Pump design parameters and characteristics
Other related equipment and system design and operating parameters
4.1 System Configuration and Pump Type
The most significant factor influencing the selection of the type of pump to be used for
condensate system service is the available net positive suction head (NPSHa), which, in turn, is
determined primarily by the configuration and location of the condenser. (NPSH is defined and
addressed in Section 4.2.3.)
Many older, smaller electric generating units were designed with top-supported condensers, with
the hot well elevated a few feet above the ground floor of the plant. This arrangement provided
sufficient suction pressure and NPSH to allow the use of horizontal multistage centrifugal
condensate pumps, which were typically located underneath the condenser. Horizontal pumps
are also used at some modern plants with air-cooled condensers.
However, current design plants and many older, larger units use bottom-supported condensers,
with the hot well located at or below the ground floor elevation. This arrangement has reduced
the NPSHa for the condensate pumps below the minimum requirements for horizontal pumps in
the size range required for condensate system service. This arrangement has also necessitated the
application of vertical multistage centrifugal pumps installed in suction cans embedded in the
ground floor. The suction can lengths are sized to provide adequate NPSH to the centerline of the
4-1
Condensate Pump Application
first-stage impeller for proper operation of the pumps. For this reason, vertical centrifugal can
type pumps are the predominant type used in power plant condensate system service today.
Key Technical Point

The type of pump required for condensate system service is primarily
determined by the NPSHa.
4.2 Pump Sizing Considerations
To properly select and specify a pump for condensate system service, the system designer must
accurately determine the following parameters:
Required flow capacity
Total developed head
Available NPSH
Number of pumps to be used
Flow control method
4.2.1 Flow Capacity
The design flow capacity for the condensate system is typically based on the condensate flow
requirements with the unit operating at maximum turbine heat balance conditions. This flow
should be increased to include additional water quantities that must be provided by the
condensate system, including the following:
Turbine steam seal flow
Steam bypass system desuperheater spray flows
Condenser spray curtain flows for steam bypass systems
Steam jet air ejector or vacuum pump flows
Turbine steam seal desuperheater flows
Boiler feed pump seal water injection flows
Sootblowing steam supply flow
Secondary air preheating flow
Condenser exhaust hood cooling spray flow
A margin of up to 5% of the total flow determined above is typically added to provide latitude
for future increase in the flow requirements as a result of any of the contributing factors. The
design point flow for a condensate pump will be the total flow divided by the number of pumps
to be in operation during normal maximum conditions (for example, half of the total flow per
pump if two 50% capacity pumps are being provided).
4-2
4.2.2 Total Developed Head
The design total developed head for each condensate pump at the design flow rate is calculated
by determining the difference between the condensate pump discharge head and the suction
head, as shown in Table 4-1. All intended operating scenarios should be reviewed to verify that
the worst-case flow and head conditions have been addressed.
Table 4-1
Determination of Developed Head
Total Suction Head
Formula Item Reference/Comments
Condenser pressure Based on the condenser operating

pressure at maximum turbine heat
balance condition.
+ Static head between the condenser hot Based on a low condenser hot well water
well water level and the centerline of the level.
condensate pump first-stage impeller
(horizontal pump) or pump base plate
(vertical pump)
- Friction loss between the condenser Friction loss in the pump suction piping
and the condensate pump suction from the condenser to the condensate
connection pump at maximum turbine heat balance
condition, including additional condensate
system flows, as applicable. Friction
losses in the pump are accounted for by
the pump manufacturer.
+ Velocity head The kinetic energy of the liquid (energy in

the water due to its velocity). Also known
2
as V /2g losses. Although typically this is a
very small number, it should not be
neglected in determining the condensate
pump suction head.
= Total suction head Pressure head (P/) + static head (Z) -

2
friction loss (hf) + velocity head (V /2g).
4-3
Table 4-1 (cont.)

Determination of Developed Head
Total Discharge Head

Deaerator or drum pressure Based on the deaerator or drum operating
pressure at maximum turbine heat
balance conditions.
+ Static head between the deaerator or Based on a normal water level maintained
drum level and the condensate pump in the deaerator storage tank or HRSG
first-stage impeller discharge (horizontal drum.
pump) or pump base plate (vertical
pump)
+ Friction losses between the condensate Friction loss in pump discharge piping
pump discharge connection and the from the condensate pump to the
deaerator or drum inlet deaerator or drum at maximum turbine
heat balance conditions, including
additional applicable condensate system
flows. Friction losses in the pump are
accounted for by the pump manufacturer.
+ Pressure losses for feedwater heaters, Feedwater heater pressure losses are
gland steam condenser, and other heat generally limited by heater design and
exchangers, as applicable specifications to approximately 50 psi (344
kPa) or less, depending on the number of
heaters. For other heat exchangers,
maximum pressure loss may be specified
by the system designer or determined by
the manufacturer.
+ Regulating valve pressure drop (for Based on the required pressure drop of
throttle valve controlled systems) the control valve for the required flow
control. Typically 2550 psi (172344
kPa).
+ Condensate polisher pressure drop (if Generally limited by condensate polisher
applicable) design and specification to approximately
80100 psi (552689 kPa)
+ Velocity head The kinetic energy of the liquid; also
2
known as V /2g losses. Typically, this is a
very small number.
= Total discharge head Pressure head (P/) + static head (Z) +
2
velocity head (V /2g) + equipment and
valve pressure losses + friction losses (hf).
Design Total Developed Head
Total discharge head
- Total suction head
= Total developed head
+ Design margin Typically 5% of the total developed head.
= Design total developed head 1.05 x total developed head.
(Black & Veatch, Power Plant Engineering, used with permission.)
4-4
4.2.3 Net Positive Suction Head (NPSH)
Because of the very low pressure available at the pump suction connection, accurate
determination of NPSHa is especially critical to the proper design, selection, and operation of
condensate pumps to prevent cavitation damage to the pump or suction piping.
NPSH is the difference between the pressure at the pump suction (in feet or meters absolute) and
the vapor pressure of the condensate as it arrives at the pump suction connection. The total
pressure available at the pump suction must be greater than the liquid vapor pressure to prevent
cavitation. Cavitation occurs when the pressure of the liquid is reduced to a value equal to or
below its vapor pressure. It is characterized by the formation of small vapor bubbles or pockets.
As these bubbles move along the impeller vanes to a higher-pressure area, they rapidly collapse.
The forces generated during the collapse of the vapor bubbles are high enough to cause minute
pockets of fatigue failure on the impeller surfaces. This action may be progressive and, under
severe conditions, can cause serious pitting damage to the impacted surfaces.
Calculation of the available NPSH for the condensate pump should be based on the most
conservative conditions, including maximum operating flow, lowest condenser pressure, low hot
well water level, and the highest condensate temperature.
A design margin of 12 ft (30.561 cm) is typically applied to the NPSH value. For determining
the NPSH, the margin is subtracted from the calculated value.
Key Technical Point

When specifying a condensate pump, be sure that the available NPSH is
calculated accurately and is based on worst-case operating conditions.
To determine the worst-case condition, evaluate the possible
combinations of low hot well water level, low condenser pressure, high
condensate temperature, and high condensate flow that can be
realistically anticipated in the operation of the plant. Base the specified
NPSH on the condition that provides the minimum NPSH at the pump
suction.
4.2.4 Number of Pumps
The most common arrangements for the number and capacity of condensate pumps are as
follows:
Two half-capacity pumps
Three half-capacity pumps
Two full-capacity pumps
Initial capital cost and system reliability issues are considered in the selection of the number and
capacity of condensate pumps for a specific application.
4-5
Where low capital cost is the overriding consideration, installation of two half-capacity pumps
may be selected. However, system and plant reliability would be compromised with this
arrangement, because failure of one pump would mean an immediate derating of the plant until
repairs were made and the pump was returned to service. The reliability aspect could be
improved by purchasing one complete, spare internal pump assembly. Then, should a pump
failure occur, the failed assembly could typically be removed and the spare assembly installed in
one to two shifts, which would limit the duration of the derating.
Key O&M Cost Point

To improve the reliability of a plant with two half-capacity condensate
pumps, consider the purchase of a complete spare internal pump
assembly. Having this assembly on-site would reduce the length of time
the plant is out of service or derated due to failure of a condensate
pump.
Installation of three half-capacity pumps or two full-capacity pumps would provide improved
reliability, as failure of one pump would probably not result in a temporary derating of the plant.
On failure of an operating pump, the standby pump would immediately start and maintain the
unit load. However, the obvious tradeoff is the higher initial cost of purchase and installation of
an additional half-capacity pump or larger full-capacity pumps.
4.2.5 Flow Control Method
4.2.5.1 Throttle Valve Control
Control of the flow delivered by the condensate pumps is typically provided by a throttle valve
installed in the condensate system piping. As shown in Figure 4-1, the head produced by the
pump is greater than the system resistance at any required flow (except for the flow at the design
point), and the difference in pressure is dissipated by the control valve. With this type of control
scheme, the condensate pumps are driven by direct-coupled constant speed motors, with throttle
valves downstream of the pump discharge providing the flow control.
4-6
Figure 4-1
Constant Speed Pump With Throttle Valve Control
4.2.5.2 Variable Speed Control
Another flow control method, although rarely used, involves the use of variable speed drivers to
match the pump discharge to the system resistance head. As shown schematically in Figure 4-2,
the speed of the pump is adjusted by the variable speed drive mechanism to shift the pump head
curve to match the system resistance at the required system flow. Variable speed operation can
be provided by constant speed motors driving the condensate pumps through variable speed
couplings or by variable speed drives.
4-7
Figure 4-2
Variable Speed Drive Control
4.2.5.3 Comparison of Control Methods
Throttle valve control is a relatively simple control method and provides reliable condensate
flow control with a relatively low initial cost. However, at any operating flow except the design
point, the discharge pressure produced by the pumpand thus the pump power consumptionis
higher than required to meet the system resistance, resulting in higher operating costs.
Variable speed control offers the advantage of lower operating costs than throttle valve control,
since the motor must only provide adequate energy to match the system resistance at the required
system flow. However, variable speed drive systems add significant complexity and are more
costly to install and maintain than throttle valve controlled systems.
4.3 Pump Design Parameters and Characteristics
Once the sizing parameters have been established, certain pump design parameters, operating
characteristics, and component selection criteria must be addressed by the system designer and
the pump manufacturer to ensure the selection of a pump that will provide good long-term
operation, performance, and reliability. These parameters and characteristics include the
following:
Shape of the pump characteristic (head-capacity) curve
4-8
First-stage impeller design

Determination of pump and can length (for vertical pumps)
4.3.1 Shape of Pump Characteristic Curve
The shape of the condensate pump characteristic curve (flow versus head) is important for good
pump and system operation. The curve should rise continuously from the design point to shutoff.
For stable parallel pump operation, the minimum rise in the pump head should be 20 to
25 percent. A lower rise to shutoff may be acceptable if an independent minimum flow
recirculation system is provided for each pump to guard against possible operation of a pump at
or near shutoff conditions.
The maximum rise should not exceed 40 percent. Selection of a pump with an excessively high
shutoff head could require installation of higher-pressure class valves and piping accessories,
which will increase the system cost.
Key Technical Point

The shutoff head for a condensate pump should be no less than 120 to
125 percent and no more than 140 percent of the design head.
The characteristic curve shapes for horizontal pumps typically provide a head rise from design
flow to shutoff within the 20 to 40 percent range. However, the curve shapes for vertical pumps
tend to be characterized by a higher head rise to shutoff than for horizontal pumps, and the
characteristic curve for a proposed vertical condensate pump should be closely reviewed to
verify that the head rise is within the acceptable range.
4.3.2 First-Stage Impeller Design
Proper design of the condensate pump first-stage impeller to eliminate cavitation problems is a
critical consideration for reliability in a condensate pump.
Foremost in the design of a condensate pump is the pump suction specific speed required (NSS).
The suction specified speed is an index number that is indicative of the suction characteristics of
the pump, primarily determined by the impeller design. In general, the lower the numerical value
of NSS, the less likely the pump is to have cavitation problems. The formula for calculating NSS
for a specific pump is provided in Section 2 of this guide. The Hydraulic Institute suggests that
NSS between 6,000 and 12,000 is typical for normal pump design and allows higher suction
specific speeds for special pump designs. For condensate pump service, the suction specific
speed allowance of 12,000 (based on total pump flow) has been found to be acceptable. Another
important parameter established for good condensate pump design is the limitation of the
peripheral velocity of the outer tip of the first-stage impeller inlet vanes to 65 ft (20 m) per
second. Most condensate pumps operate without cavitation if they meet these two separate but
related criteria.
Adherence to these limits typically ensures stable condensate pump operation from minimum
flow to pump runout. Suction specific speeds over 12,000 or first-stage impeller peripheral
4-9
velocities over 65 ft (20 m) per second may be permissible but tend to increase the minimum
flow for stable pump operation. Sensitivity to low flow operation results from separation of fluid
flow at the periphery in the inlet area. For example, suction specific speeds over 14,000 or
peripheral velocities over 75 ft (23 m) per second may require minimum pump flow in the range
of 50 to 60 percent of the design flow.
Key Technical Point

In order to ensure cavitation-free operation, verify that the
manufacturers first-stage impeller design is based on the following
criteria:
Suction specific speed less than 12,000
First-stage impeller peripheral velocity of less than 65 ft (20 m) per
second
If the design does not meet these criteria, the manufacturer should be
asked to provide evidence that the proposed design has a proven
inservice history of acceptable cavitation performance.
Because of the typically very low available NPSH, double-suction first-stage impellers are
frequently used for both vertical and horizontal condensate pumps. In a double-suction impeller
design, the fluid enters the impeller simultaneously from both sides, as opposed to entering from
only one side in a single-suction design. In addition, the greater suction area of a double-suction
impeller permits the pump to operate at a significantly lower suction head. Additional
descriptions of single- and double-suction impellers are provided in Section 5.
Proper design of the first-stage impeller based on the specified operating and design conditions is
the responsibility of the pump manufacturer. However, the purchaser or system designer could
include in the purchase specifications the requirements that the characteristics described above
be incorporated into the pump design or at least review these design features during bid
evaluations to further indicate that the proposed design is suitable.
4.3.3 Pump and Can Length for Vertical Pumps
Virtually all of the NPSH required (NPSHr) for a vertical condensate pump must be established
by the static head in the suction can. With the previously addressed suction specific speed and
peripheral velocity limitations, the pump manufacturer can then establish the required pump
NPSH and, in turn, the required condensate pump and suction can lengths. Typically, both are
established at the maximum pump flow at runout conditions. Most conservatively, the NPSHr to
prevent any reduction in the pump first-stage head at pump runout operation is used to determine
the length of the condensate pump.
However, it is important to note that the deeper the suction can setting, the longer the cantilever
for the pump (distance from the pump support at grade to the bottom of the pump). Problems
have surfaced because pump elements are so long that pulsations resulting from cavitation or
critical frequencies have caused pump and pump bearing failures. Alternatives to long
condensate pump designs are slower operating speeds, double-suction first-stage impellers, or
4-10
first-stage impellers specifically designed by the pump manufacturer to meet the NPSHa for a
shorter pump design. All of these factors must be evaluated by the pump manufacturer to arrive
at the most economical pump design to reliably meet the specified design and operating
conditions.
4.3.4 Materials of Construction
Selection of materials for condensate pumps will have a significant impact not only on the initial
cost, but also on how long the pump will be able to operate before one or more components must
be repaired or replaced in order to maintain acceptable performance levels.
While there is typically little variation in the materials used for vertical pump discharge heads
(carbon steel or cast iron), columns (carbon steel), shafts (stainless steel), and suction cans
(carbon steel) or for horizontal pump casings (cast iron or carbon steel) and shafts (stainless
steel), there are wider choices for the pump impellers.
The most common pump construction material combinations are designated as bronze fitted and
stainless steel fitted. Bronze fitted pumps are typically provided with bronze impellers and cast
iron bowls. Stainless steel fitted pumps have stainless steel first-stage impellers. Impellers for
additional stages may be stainless steel or cast iron. Bowls are typically cast iron.
Although the initial cost for a stainless steel fitted pump is higher than for a bronze fitted pump,
most new pumps are currently specified with stainless steel materials, which are more resistant to
cavitation damage. Also, if any cavitation damage does ultimately occur, weld repair methods
which can produce effective and long lasting repairs to stainless steel impellersare readily
available. Repairs to bronze impellers are generally limited to brazing procedures, which
generally do not provide repairs that are as effective or last as long.
4.4 Pump Specifications, Guarantees, and Shop Testing
4.4.1 Specifications
In the specification of a condensate pump, it is essential that the following information, which
affects the design, manufacturing, and operation of the pump, be provided to the pump
manufacturer.
Key Technical Point

Complete and accurate information regarding the application must be
provided to the pump manufacturer in order for the manufacturer to
provide a properly designed pump.
4.4.1.1 Pump Type and Arrangement
The specification should include the desired pump type, number of pumps required, location of
the pumps, and plant arrangement.
4-11
4.4.1.2 Operational Requirements
The specification should include the single or parallel operation requirements and a description
of the type of flow control that will be designed into the condensate system (regulating valve or
variable speed operation). It should also include requirements for the number of pumps in
parallel operation, as well as a short description of the anticipated startup/shutdown operation of
the pumps. System head curves or a table of head/flow values for single pump operation as well
as all parallel pump operating modes should be provided.
4.4.1.3 System Design Conditions
The following design conditions should be provided to the pump manufacturer:

Design capacity for each pump during parallel operation, at the minimum condenser hot well
level.
Total developed head, based on the design capacity and low condenser hot well level.
NPSHa, based on design capacity typically referred to as the pump support elevation and in
accordance with the worst-case condenser vacuum operating condition. Plant arrangement
and the condensate pump setting must be considered.
Condensate temperature, typically specified for the design conditions and at the maximum
required capability of the pump.
Allowable shutoff head.
Maximum suction specific speed for the first-stage impeller (see Section 4.3.2).
Maximum pump speed, typically specified at 1,200 or 1,800 rpm.
Water chemistry, including the anticipated concentration of each constituent of the
condensate (including pH).
4.4.2 Guarantees
The guarantees required from the pump manufacturer should be included in the specification.
Guarantees vary for each application and are often negotiated during contract development.
Some typical guarantees are as follows:
Design point capacity and head
Pump speed at design capacity and head
NPSH requirements at design and single pump runout operating conditions
Pump efficiency at design capacity and head
Power required at design point and maximum power requirement, generally at one-pump
runout conditions
Maximum shutoff head
4-12
Parallel and single pump operation in accordance with certified pump curves, including
operation during the starting and stopping of a parallel pump
No critical speeds near the pump operating speed
Sound level during operation
4.4.3 Shop Testing
Pump shop testing requirements should include tests to verify design capacity and head, NPSHr,
power requirements, efficiency, runout flow and head, and shutoff head. Sufficient operating
data (8 to 10 test points) should be collected to allow the plotting of an accurate performance
curve. Most pump manufacturers have adequate test facilities to handle the testing of condensate
pumps. Should this not be the case, prototype or field performance data should be required to
verify the condensate pump design and operating characteristics.
4.4.4 Specification Check Sheet
A condensate check sheet for purchase of pumps is included for reference in Appendix B.
4.5 Other System Design and Configuration Issues
4.5.1 Condenser Hot Well Suction Connection
Each pump suction connection on the condenser hot well should be equipped with an antivortex
device to prevent the formation of a vortex, which may induce air into the pump suction, causing
unstable operation, reduced flow capacity, or cavitation damage in the suction piping or in the
pump.
A raised barrier should also be provided around each suction connection to prevent any debris or
solid material that has collected on the hot well floor from carrying over into the pump suction
line.
4.5.2 Suction Piping Design
Because of the extremely low suction pressure available, minimizing the suction losses is critical
to maintaining adequate NPSH and preventing cavitation in the pump. To minimize the piping
friction losses, the suction pipe routing should be kept as short and direct as possible with a
limited number of fittings. It is especially important to minimize to the extent possible the piping
turns and elbows in different planes in order to prevent swirl. It is also recommended that the
condensate velocity in the suction piping should be limited to 4 ft (1.2 m) per second at the
maximum operating condition.
Each condensate pump should have an individual suction line from the condenser hot well.
Individual suction lines allow greater piping arrangement flexibility and are less likely to result
4-13
in NPSH problems resulting from the variable pressure drop that would be present in a common
header as the flow rate varies with plant load and operating conditions.
4.5.3 Recirculation
The condensate system piping must include provisions to allow the minimum required flow
through each pump and to meet the minimum cooling water flow requirement of the turbine
gland steam condenser.
Both functions are often served by a single recirculation line to the condenser, downstream of the
gland steam condenser. In this case, the line would be sized for whichever is higher: the gland
steam condenser minimum flow or the minimum flow requirement of the condensate pumps.
In some installations, separate individual recirculation lines from the pump discharge piping to
the condenser are provided for each pump.
4.5.4 Seal Water Supply
During normal plant operation, seal water for condensate pumps is typically supplied from the
pump discharge header. However, a second source of seal water must be provided in order to
maintain the seal water supply to the pumps during periods when the unit is not in operation.
This prevents ingress of air into the system through the pump seals. This second seal water
supply can be provided from the condensate system of other units or from another available
demineralized water source.
4-14
4.6 Common Misapplications
Misapplication of the factors described in Sections 4.2 through 4.5 can result in ongoing
problems with pump or system performance. Table 4-2 summarizes some of the more common
misapplications and the results of each.
Table 4-2
Common Misapplications
Misapplication Result
Overestimation of available NPSH Cavitation damage to the pump or suction

piping
Underestimation of required flow capacity Limitation of unit load
Overestimation of required flow capacity Pump operation is far from the best efficiency
point, possibly resulting in surging, cavitation,
noise, or vibration
Underestimation of total developed head Limitation of unit load
Undersizing of minimum recirculation line Damage to the pump due to cavitation,

overheating, etc.
Incorrect sizing or routing of suction line Inadequate NPSH, resulting in cavitation

damage
4-15
5
TECHNICAL DESCRIPTIONS OF PUMPS AND
MOTORS
Condensate pumps are either vertical centrifugal can type pumps or horizontal centrifugal
pumps. The following sections describe each type.
5.1 Vertical Centrifugal Can Type Pumps
Vertical centrifugal can type condensate pumps are the predominant type of pump currently used
in power stations. These pumps are typically selected from two types: vertical turbine or vertical
volute. Both types of vertical pumps are usually motor driven, wet-suction, multistage pumps
mounted in a barrel casing or can, with either single- or double-suction first-stage impellers, as
illustrated in Figures 5-1 and 5-2.
5-1
Technical Descriptions of Pumps and Motors
Figure 5-1
Condensate PumpVertical, Multistage, Wet-Suction, Can Type, With Single-Suction First-
Stage Impeller
5-2
Figure 5-2
Condensate PumpVertical, Multistage, Wet-Suction, Can Type, With Double-Suction First-
Stage Impeller
5-3
5.1.1 Impellers
Impellers are classified according to the major direction of flow in reference to the axis of
rotation of the impeller. Centrifugal pumps can have radial-flow impellers (see Figure 5-3),
axial-flow impellers (see Figure 5-4), or mixed-flow impellers (see Figure 5-5). Mixed-flow
impellers combine the principles of design of both radial-flow and axial-flow impellers.
Impellers are further classified as either single- or double-suction. Single-suction impellers (see
Figure 5-6) have a single inlet on one side, while double-suction impellers (see Figure 5-7) have
symmetrical inlets on both sides.
Figure 5-3
Radial-Flow Impeller
Figure 5-4
Axial-Flow Impeller
(Hydraulic Institute, used with permission.)
5-4
Figure 5-5
Mixed-Flow Impeller
Figure 5-6
Single-Suction Impeller
5-5
Figure 5-7
Double-Suction Impeller
The mechanical construction of impellers can be further defined as follows:

Enclosed impellers have shrouds or side walls that enclose the waterways (see Figure 5-8)
Open impellers do not have shrouds or side walls (see Figure 5-9)
Semi-open or semi-enclosed impellers have a single shroud, usually at the back of the
impeller (see Figure 5-10)
Figure 5-8
Enclosed Impeller
(Flowserve Corporation, used with permission.)
5-6
Figure 5-9
Open Impeller
Figure 5-10
Semi-Open Impeller
Impellers can also be classified by the shape of their vanes (see Figure 5-11):
Radial-vane impeller
Francis-vane or screw-vane impeller
Mixed-flow impeller
Axial-flow propeller or impeller
5-7
Figure 5-11
Comparison of Pump Profiles
5.1.1.1 Impeller Attachment
There are four primary methods for impeller-to-shaft attachment (see Figure 5-12):
Drive collet
Lock collet
Split ring and retaining ring (snap ring)
Lock collar
5-8
Figure 5-12
Impeller-to-Shaft Attachment Methods
The drive collet is the simplest of the four arrangements and is typically used on small units. It is
essentially a tapered collet that is driven between the shaft and the tapered fit of the impeller
bore. The drive collet assembly is not a controllable operation. The quality of the attachment
depends on the environment and the ability of the individual assembling the pump. If the collet is
not tight enough or if dirt or oil is present in the impeller or shaft fits, the impeller will slip under
load and pump performance will be adversely affected. The one advantage of the drive collet is
the lower initial cost.
5-9
The lock collet is similar to the drive collet except that a threaded nut is added on the small end
of the collet. This results in the collet having a tighter fit and higher reliability. Although the lock
collet has a tighter fit than the drive collet, it still has assembly problems and the possibility of
slippage under load.
The next arrangement uses a split ring/retaining ring combination to secure the impeller on the
shaft. The split ring transmits axial down thrust, and the retaining ring transmits axial up thrust.
Torque is transmitted by a key in the shaft. This method is substantially more reliable than the
drive and lock collets. The disadvantage of this design is that it requires two registered fits to
ensure tightness between the impeller and the shaft. Any manufacturing error will result in a
loose fit, causing the impeller to chatter during operation and increase overall pump vibration.
The last attachment method is a split collar device. The collar fits in a shaft groove and is
attached to the impeller hub by cap screws. Once again, torque is transmitted by a key in the
shaft. This design accurately places the impeller at the proper location and rigidly holds the
impeller under all operating conditions, including reverse rotation. This design is the
recommended method for impeller attachment.
5.1.2 Bowl
The liquid leaving the impeller has high kinetic energy and discharges into the pump bowl. The
bowl assembly (see Figure 5-13) contains axially disposed diffuser vanes to efficiently transform
this kinetic energy into pressure energy. The bowl can be fitted with wear rings and have one or
more bearings. The functions of the bowl are as follows:
Provide efficient energy recovery
Connect the suction bell and column
Support the shaft bearings
5.1.3 Wearing Rings
Wearing rings provide an easy and economically renewable leakage joint between the impeller
and the casing. A leakage joint without renewable parts is shown in Figure 5-14. Restoring the
original clearances in this design requires buildup of the worn areas through welding or other
means (followed by machining to the original clearances) or purchase of new parts.
5-10
Figure 5-13
Pump Bowl Assembly
(Goulds Pumps, used with permission.)
5-11
Figure 5-14
Plain Flat Leakage Joint With No Renewable Parts
(Karassick et al, Pump Handbook, used with permission.)
Provision of renewable wearing rings will, at an increased initial cost, improve the pump
refurbishment process during the life of the pump, thereby reducing maintenance costs (see
Figures 5-15 through 5-17). Wearing rings are available for enclosed impellers and bowls, which
provides a way to reestablish initial operating clearances and recover pump efficiency at the
lowest cost. For longer life, hard surfacing for wear rings is also available.
Wearing rings are an option typically offered by pump manufacturers. After consideration of
initial cost versus maintenance costs, the purchaser may decide to utilize them. Typically,
renewable stationary wearing rings are provided, while impeller wear rings are offered as an
option but not usually included.
5.1.4 Column
The column assembly is the spool piece connecting the bowl to the discharge head and may
consist of one or more sections. Column sections are flanged and provided with rabbet fits for
positive alignment. Column lengths depend on shaft construction type (open or closed).
For open line construction, the column length matches the bearing span to enable bearing
support through the use of a spider located at the flange (unless this length exceeds the
machining capability of the manufacturer and/or the handling capacity in the field) (see Figures
5-1 and 5-2).
5-12
Figure 5-15
Single Flat-Casing-Ring Construction
Figure 5-16
Double Flat-Ring Construction
5-13
Figure 5-17
Step-Type Leakage Joint With Double Rings
5.1.5 Shaft
The basic function of a pump shaft is to transmit the torques produced during startup and
operation of the centrifugal pump while supporting the impeller(s) and other rotating
components. The shaft must perform this function with a deflection that is less than the minimum
clearance between the rotating and stationary parts. Pump shafts can be rigid or flexible. A rigid
shaft design for a centrifugal pump is one with an operating speed that is lower than its first
critical speed. A flexible shaft is one with an operating speed that is higher than its first critical
speed. Condensate pumps are usually operated at 1,750 rpm (or lower) and have rigid shafts.
Specification of condensate pumps that have an operating speed lower than the first critical speed
is widely practiced.
In most U.S.-made vertical pumps, axial thrust is transmitted to the motor thrust bearing through
the line shaft. Shafting is precision machined for trueness, balance, straightness, and surface
finish to minimize shaft vibration and maximize bearing life.
5.1.6 Shaft Sleeves
Pump shafts are usually protected from erosion, corrosion, and wear at stuffing boxes, leakage
points, internal bearings, and in the waterways by renewable sleeves. The most common shaft
sleeve function is to protect the shaft from wear at a stuffing box.
Shaft sleeves are typically offered for vertical condensate pump service at the stuffing box or at
line shaft bearings.
5-14
5.1.7 Bearings
Bearings in centrifugal pumps maintain the shaft and rotating elements in correct alignment with
the stationary components under the action of radial and axial loads.
Three basic types of bearings are used in pumps: sleeve, antifriction ball, and thrust bearings.
Sleeve bearings can accommodate only radial loads. Antifriction ball bearings accommodate
radial loads, and some types can also accommodate axial thrust loads. Some special types of
bearings are designed to accommodate only thrust loads. Each type of bearing is described in the
following sections. Bearings used in motors are addressed in Section 5.3.
Vertical pumps used for condensate service are typically equipped with sleeve bearings at all
locations where there is relative motion between the shaft and a stationary component, including
the location at which the shaft passes through the pump casing, at each bowl, and (depending on
the shaft length) at additional locations where the manufacturers design requires intermediate
support. Turbine pumps often include an additional bearing located at the bottom of the shaft in
the suction bell. Figures 5-1 and 5-2 show typical bearing locations. Sleeve bearings for
condensate pumps are typically designed for lubrication by the pumped fluid.
At least one non-U.S. manufacturer uses an oil-lubricated ball bearing instead of the sleeve
bearing at the discharge head. The design places the bearing external to the pump discharge
head, as shown in Figure 5-18.
All vertical pumps require a thrust bearing to support the weight of the shaft, impellers, and the
unbalanced hydraulic thrust. In U.S. designs, this bearing is usually located in the motor or gear
drive, while most non-U.S. pump manufacturers incorporate the thrust bearing into the pump
directly under the driver.
5.1.7.1 Sleeve Bearings
Sleeve bearings consist of a bushing mounted inside a rigid cylindrical sleeve that provides
dimensional stability for the bushing. Bushings for condensate pump applications are typically
manufactured of a low-friction, long-wearing material such as carbon, graphalloy, or nitrile,
while the sleeve is typically manufactured of stainless steel.
5.1.7.2 Antifriction Ball Bearings
The most common antifriction bearings used on centrifugal pumps are ball bearings. The most
common ball bearings used on centrifugal pumps are as follows:
Single-row, deep-groove (see Figure 5-19)
Double-row, deep-groove (see Figure 5-20)
Double-row, self-aligning (see Figure 5-21)
Angular-contact, either single- or double-row (see Figure 5-22)
5-15
All of these bearings, except the double-row, self-aligning bearings, are capable of carrying
radial loads as well as limited axial (thrust) loads.
The self-aligning ball bearing (shown in Figure 5-21) is the most serviceable bearing for heavy
loads, high speeds, long bearing spans, and no end thrust. For these reasons, it is ideal for service
as a line bearing on a centrifugal pump. This bearing is not used for combined radial and thrust
loads.
The single-row, deep-groove ball bearing (shown in Figure 5-19) is the most commonly used
bearing for centrifugal pumps, except for larger size pumps. When the single-row, deep-groove
ball bearing is not capable of handling the loading, the double-row, deep-groove ball bearing is
used. Both bearings can handle radial and axial loads.
The angular-contact ball bearing is good for heavy thrust loads. The single-row type is good for
thrust in only one direction, while the double-row type can carry thrust loads in either direction.
Figure 5-18
Pump Design With the Bearing External to the Discharge Head
(Sulzer Pumps, used with permission.)
5-16
Figure 5-19
Single-Row Deep-Groove Ball Bearing
(NTN Bearing Corporation of America, used with permission.)
Figure 5-20
Double-Row Deep-Groove Ball Bearing
Figure 5-21
Self-Aligning Double-Row Ball Bearing
5-17
Figure 5-22
Single-Row Angular-Contact Ball Bearing
Ball bearings used in centrifugal pumps are usually lubricated with grease, although some
services use oil lubrication. Grease lubrication requires a minimum amount of attention and has
been proven to be satisfactory. However, it is important that proper greasing procedures be used
to provide adequate lubrication without overgreasing. Oil lubrication of bearings requires a
means to maintain an oil level in the housing. The proper oil level is typically at the middle of
the ball. Oil rings may be used to supply oil from the housing to the bearings.
5.1.7.3 Thrust Bearings
The type and size of thrust bearing used depends on the pump speed, thrust load, and required
bearing life. Thrust bearings fall into one of two general classes: antifriction (ball or roller) and
plate (tilting shoe).
Three types of antifriction bearings are used. Radial ball bearings are normally used in vertical
normal thrust motors. While this bearing is not specifically designed to carry thrust, it can
support light thrust loads without problems. Use of this bearing is usually restricted to small
pumps with low pumping heads.
Angular-contact ball bearings are the most commonly used thrust bearings for vertical pumps.
The thrust of a typical vertical pump can be carried by a single angular-contact bearing or, in
high-thrust applications, by two bearings in series (stacked bearings).
For the very high thrusts encountered with large, deep-setting or high-head pumps, a spherical
roller thrust bearing is sometimes used. It is a hybrid design, incorporating features from a ball
bearing and a roller bearing. The rollers are barrel shaped. This bearing has attained wide usage
in recent years because of its high thrust capacity.
The plate type thrust bearing is seldom used in the U.S., except for those applications with
extremely high thrust that are beyond the capabilities of angular-contact bearings or spherical
roller bearings. The plate type thrust bearing is used considerably more frequently throughout the
rest of the world and is known by many names. Kingsbury is the most widely used description in
the U.S., while Michell is frequently used abroad. It is also called tilting shoe, pivoted shoe, and
tilting pad, which describe its operation. Manufacturers of this type of bearing include
Kingsbury, General Electric, Waukesha, Union Diesel, and Glacier.
5-18
5.1.8 Stuffing Box
The stuffing box has the function of protecting the pump from leakage at the point where the
shaft passes through the pump casing. If the pump operates with a suction lift and the pressure at
the interior stuffing box end is below atmospheric (as is the case in most condensate pump
applications), the stuffing box prevents air leakage into the pump. If this pressure is above
atmospheric, the stuffing box prevents liquid leakage out of the pump.
On vertical pumps, the stuffing box is located in the discharge head for aboveground applications
and in the motor support for belowground applications. For condensate pumps, the stuffing box
is typically lubricated by the pumped liquid.
Two stuffing box sealing methods are typically employed: packing and mechanical.
5.1.8.1 Packing
The stuffing box is usually a cylindrical recess that can accommodate a number of packing rings
around the shaft or shaft sleeve (see Figures 5-23 and 5-24). If sealing of the stuffing box is
required, a lantern ring or seal cage can be added between equal numbers of packing rings (see
Figure 5-25) to allow injection of seal water. Compression of the packing by a packing gland
provides the desired fit on the shaft or shaft sleeve. The sealing liquid supplied to the stuffing
box usually comes from the pump discharge piping or an interstage point.
Stuffing box packing functions as a pressure breakdown device and must be somewhat elastic so
that it can be adjusted for proper operation. Packing must also absorb energy without failing or
causing damage to the shaft or shaft sleeve. It comes in numerous forms and materials and is
supplied in continuous coils of square cross-section or in preformed die-molded rings. The die-
molded packing rings are preferable because they are available to exact sizes and in sets. This
ensures an exact fit to the shaft or shaft sleeve and to the stuffing box bore, while also ensuring
equal packing density throughout the stuffing box.
5-19
Figure 5-23
Conventional Stuffing Box With Throat Bushing
Figure 5-24
Conventional Stuffing Box With Bottoming Ring
5-20
Figure 5-25
Lantern Ring (also called Seal Cage)
Recommended packing materials include a graphite impregnated Teflon coating or aromatic

polyimide.
5.1.8.2 Mechanical Seals
This Section is based on information provided by Goulds Pumps and ITT Industries and is used
with their permission.
A mechanical seal is a sealing device that forms a running seal between rotating and stationary
parts. The design of liquid handling equipment with rotating parts should include the
consideration of the use of mechanical seals.
The wide variety of styles and designs, together with extensive experience, allows the use of
seals on most pump applications.
A mechanical seal must seal at three points:

Static seal between the stationary part and the housing
Static seal between the rotary part and the shaft
Dynamic seal between the rotating and stationary seal faces
Figure 5-26 shows a basic seal with these components:

The stationary seal part is positioned in the housing with preload on the O-ring to effect
sealing and prevent rotation.
The rotating seal part is positioned on the shaft near the O-ring. The O-ring seals between the
rotating part and the shaft and provides resiliency.
5-21
The mating faces are precision lapped for a flatness of 3 light bands and a surface finish of 5
microinches (0.1 micrometer).
The spring assembly rotates with the shaft and provides pressure to keep the mating faces
together during periods of shutdown or lack of hydraulic pressure.
The driving member positions the spring assembly and the rotating face. It also provides the
positive drive between the shaft and other rotating parts.
As wear occurs between the mating faces, the rotating face must move along the shaft to
maintain contact with the stationary face. The O-ring must be free to move.
Figure 5-26
Basic Mechanical Seal
(Goulds Pumps and ITT Industries, used with permission.)
A mechanical seal operates as each basic component performs its duty. Liquid pressure in the
seal chamber forces the faces together and provides a thin film of lubricant between the faces.
The faces, selected for low frictional qualities, are the only rubbing parts. These basic
components are part of every seal. The form, shape, style, and design vary greatly, depending on
service and manufacture. The basic theory in the design, however, remains the same.
Types
Mechanical seals can be classified into the following general types and arrangements:
Single seals: Inside unbalanced, outside unbalanced, inside balanced (see Figures 5-27, 5-28,
and 5-29, respectively)
Double seals: Inside unbalanced (see Figure 5-30)
5-22
Single Seal, Inside Unbalanced
The single inside seal mounts on the shaft or sleeve within the stuffing box housing. The
pumpage is in direct contact with all parts of the seal and provides the lubrication for the faces.
The full force of pressure in the box acts on the faces and provides good sealing to
approximately 100 psig (689 kPa). This is the most widely used type for services handling clear
liquids. A circulation or bypass line connected from the volute to the stuffing box provides
continual flushing of the seal chamber.
Figure 5-27
Single, Inside Unbalanced Seal
Single Seal, Outside Unbalanced
This type mounts with the rotary part outside of the stuffing box. The springs and drive element
are not in contact with the pumpage, thus reducing corrosion problems and preventing product
accumulation in the springs. Pressures are limited to the spring rating, which is usually 35 psig
(241 kPa). Usually the same style seal can be mounted inside or outside. The outside seal is
easier to install, adjust, and maintain. A restricting bushing can be used to control leakage of
external sealing liquid into the pumpage.
5-23
Figure 5-28
Single, Outside Unbalanced Seal
Single Seal, Balanced
Balancing a seal varies the face loading exerted by the box pressure, thus extending the pressure
limits of the seal. A balanced rotating part uses a stepped face and a sleeve. Balanced seals are
used for pressures up to 2,000 psig (13, 790 kPa).
Balanced outside seals allow box pressure to be exerted toward the seal faces, thus allowing
pressure ranges to above 150 psig (1,034 kPa), as compared to the 35 psig (241 kPa) limit for the
unbalanced outside seal.
Figure 5-29
Single, Inside Balanced Seal
5-24
Double Seals
Double seals use two seals mounted back-to-back in the stuffing box. The stuffing box is
pressurized with a clear liquid from an external source. This liquid is circulated through the
double seal chamber at 1/4 to 1 gpm (0.016 to 0.063 L/s) to cool and lubricate the mechanical
seals. Double seals are used on solutions that contain solids, are toxic, or are extremely
corrosive.
Figure 5-30
Double, Inside Unbalanced Seals
5.1.8.3 Comparison of Packing and Mechanical Seals
Packing
When properly applied, packing can be a simpler, more economical, more reliable, and easier
maintenance choice than mechanical seals. The most important concept regarding packing is that
leakage is required across the packing to provide lubrication and cooling. Most packing problems
occur when maintenance personnel adjust the gland tightness to reduce or eliminate packing
leakage. Packing suppliers recommend leakage rates ranging from 30 to 60 drops per minute.
Mechanical Seals
When properly applied, mechanical seals can offer the following advantages over conventional
packing:
Reduced friction and power losses
Zero or limited leakage of product
Elimination of shaft or sleeve wear
Reduced maintenance
Ability to seal higher pressures
5-25
However, the disadvantages of mechanical seal use for condensate system applications include
the following:
Higher initial and replacement costs
More difficult installation
Sensitivity to vibration shaft alignment and wear of other pump components
More catastrophic failure mode than packing
Since mechanical seals are less forgiving of wear, vibration, and misalignment of other pump
components as compared to packing, repeated failures of mechanical seals may be indicative of
problems elsewhere in the pump. If a pump experiences multiple mechanical seal failures, be
sure to extend the analysis of the problem beyond the seal itself (see Section 10 for guidance on
troubleshooting seal problems). These characteristics of mechanical seals should be taken into
consideration before considering application of mechanical seals for an existing pump.
Key Technical Point

Mechanical seals are sensitive to pump vibration, alignment, and wear.
Repeated mechanical seal failures can be indicative of problems with
other pump components rather than the seal itself.
Mechanical seal installation must be completed after the pump rotor is installed to account for
shaft stretch. The mechanical seal must be relocated every time there is an axial change in shaft
position as a result of impeller or shroud wear.
5.1.9 Couplings
Coupling types used in pump drive systems can include rigid or flexible couplings. A coupling is
used wherever there is a need to connect a prime mover (motor) to a piece of machinery
(centrifugal pump). A rigid coupling is used to connect machines where precise shaft alignment
is required. Two common types of rigid couplings are used. One type consists of two flanged
members, each mounted on one of the connected shafts (see Figure 5-31). A second type is
known as the split rigid, which is split along its horizontal centerline (see Figure 5-32). A
common application for rigid couplings in the pump industry is in vertical drives, where the
prime mover (motor) is positioned above the pump. In this case, both machines can use a
common thrust bearing that is usually located in the motor. It should be noted that the use of
rigid couplings requires precise alignment of machine bearings because there is no flexibility
within the coupling to accommodate misalignment between shafts.
5-26
Figure 5-31
Coupling Arrangements
Figure 5-32
Split Rigid Coupling
Flexible couplings perform the primary function of transmitting torque between the motor and
the pump while accommodating the unavoidable minor misalignment between shafts. Numerous
designs for flexible couplings can be classified into two types: mechanically and material
flexible.
Mechanically flexible couplings accommodate misalignment between the two connected shafts
by means of clearances incorporated into the design of the coupling. The most commonly used
type of mechanically flexible coupling is the gear type coupling, shown in Figure 5-33.
5-27
Figure 5-33
Gear Mechanically Flexible Coupling
Material flexible couplings rely on the flexing of the coupling element to accommodate shaft
misalignment. The flexing element can be made of any suitable material, such as metal,
elastomer, or plastic, which has sufficient resistance to fatigue failure to provide acceptable life.
Examples of material flexible couplings are shown in Figures 5-34 through 5-37.
Figure 5-34
Metal-Disk Material Flexible Coupling
5-28
Figure 5-35
Sleeve-Type Elastomer Coupling
Figure 5-36
Sleeve-Type Clamped Elastomer Coupling
5-29
Figure 5-37
Rubber Jaw Coupling
The type of flexible coupling most suitable for a particular application depends on a number of
factors, including horsepower, speed of rotation, shaft separation, amount of misalignment, cost,
and reliability.
For condensate pump service, the selection of the coupling should not compromise the reliability
of the condensate pump. Typically, horizontal, centrifugal condensate pumps use rigid couplings.
Vertical condensate pumps typically use rigid adjustable couplings.
The most commonly used drive coupling is the rigid-adjustable coupling, as illustrated in
Figure 5-31. This design employs an adjusting nut between the pump and driver coupling hubs to
axially position the rotor.
5.1.10 Discharge Heads
The discharge head of a vertical pump functions to efficiently change the direction of flow of the
liquid from the vertical axis to the horizontal axis of the discharge pipe. The discharge head also
supports the pump stationary parts, houses the shaft-sealing device, and supports the motor. The
discharge head can accommodate all modes of drivers, including hollow shaft and solid shaft
motors, right angle gears, and vertical steam turbines. Discharge heads are available with
aboveground or belowground discharge and are constructed of cast iron or fabricated steel. Cast
iron discharge heads are used for low-pressure service not exceeding 175 psi (1,207 kPa). For
pressures exceeding 175 psi (1,207 kPa) or for applications requiring alloy construction,
fabricated discharge heads are used.
For condensate pumps in power plant service, fabricated carbon steel discharge heads are
typically used. See Figures 5-38 and 5-39 for typical discharge head designs.
5-30
Figure 5-38
Fabricated Discharge Heads Above Grade Suction
(Ingersoll-Dresser Pump Company, used with permission.)
5-31
Figure 5-39
Fabricated Discharge Heads Below Grade Suction
5.1.11 Suction Can
The barrel casing or suction can (sometimes referred to as the suction barrel) is designed to
provide pressure containment of the pumped liquid. For power plant condensate pumps, the
suction can is usually constructed of fabricated carbon steel.
5-32
5.2 Horizontal Centrifugal Pumps
While both horizontal and vertical condensate pumps can be used in power station condensate
systems, the predominant design uses motor-driven, vertical, multistage, wet-suction, can type
pumps with either single- or double-suction first-stage impellers. When horizontal pumps are
used, they may be either single-stage or multistage, depending on pressure requirements. See
Figure 5-40 for a typical horizontal centrifugal pump used in condensate pump service.
Figure 5-40
Sectional View Horizontal Centrifugal Condensate Pump
5.2.1 Impellers
For a discussion of pump impellers, refer to Section 5.1.1. Horizontal centrifugal condensate
pumps typically use straight (radial) vane impellers, and either single- or double-suction or a
combination (double-suction first stage, with single-suction impellers for additional stages).
In multistage pumps, single-suction, enclosed, radial-flow impellers are commonly used because
of the simpler design and lower initial cost compared to the double-suction impeller design.
5-33
5.2.2 Casing
The volute casing pump derives its name from the spiral shaped casing surrounding the
impeller(s). This pump casing collects the liquid discharged by the impeller and converts
velocity energy into pressure energy. Casings can be solid or split. A solid casing is a design in
which the discharge waterways leading to the discharge nozzle are all contained in one casting or
fabricated piece. Most end-suction, single-stage pumps are made of one-piece solid casings.
Split casings are made of two or more parts fastened together. Split casings can be axially split
(horizontal plane) (see Figure 5-41) or radially split (vertical plane) (see Figure 5-42). The
majority of single-stage pumps are of the volute casing type; however, both volute and diffuser
casings are used in multistage pump designs. Both axially or radially split casings are used for
multistage pumps. Typically, horizontal condensate pumps use the axially split casing design.
Figure 5-41
Single-Stage Axial (Horizontal) Split Case Pump
5.2.3 Wearing Rings
For information regarding wearing rings, refer to Section 5.1.3.
5-34
5.2.4 Shaft
For information regarding shafts, refer to Section 5.1.5.
5.2.5 Shaft Sleeves
For information regarding shaft sleeves, refer to Section 5.1.6.
Figure 5-42
Single-Stage Radial (Vertical) Split Case Pump
5-35
In medium-sized horizontal centrifugal pumps (such as those used for condensate pumps) with
two external bearings on opposite ends of the casing, the typical shaft-sleeve design uses an
external shaft nut to hold the shaft sleeve in position, with sleeve rotation prevented by a key (see
Figure 5-43).
Figure 5-43
Sleeve With an External Locknut and Impeller Key Extending Into the Sleeve to Prevent
Slip
5.2.6 Stuffing Boxes
For information regarding stuffing boxes, packing, and mechanical seals, refer to Section 5.1.8.
5.2.7 Bearings
Horizontal condensate pumps are typically designed with antifriction ball bearings supporting
the rotating element at each end of the pump casing.
Thrust bearings are typically not required for horizontal condensate pumps because the pump
impeller is usually designed to minimize unbalanced thrust loading.
The types of ball bearings typically used are described in Section 5.1.7.
5.2.8 Couplings
For information regarding couplings, refer to Section 5.1.9.
5-36
5.3 Electric Drive Motors
Motors used for driving condensate pumps, both in horizontal and vertical configurations, are
typically ac squirrel-cage induction motors. The following sections include a general description
of this type of motor and its components. Except as specifically noted, all descriptions are
applicable to both vertical and horizontal motors.
A cross-section drawing of a vertical motor typical of the type used for vertical condensate
pumps is illustrated in Figure 5-44.
More detailed information regarding electric motors can be found in Electric Motor Predictive
and Preventive Maintenance Guide, EPRI NP-2814-35.
5.3.1 Technical Description
The principal function of an electric motor is to convert electric energy into mechanical energy.
The conversion is accomplished by two main components: the stator and the rotor. Regardless of
the type and application of an electric motor, all motors have these two main components. The
stator is the stationary component, and the rotor is the rotating component. They are separated by
a small air-gap clearance to avoid mechanical rubbing.
The stator is generally composed of a winding, the frame, and the laminated steel punchings
(core iron). The stator coils can be random wound (loops of wire) or form wound (preformed
diamond shape) coils of magnet wire.
5-37
Figure 5-44
Vertical Motor
(Emerson Electric Company, used with permission.)
5-38
The rotor is usually made up of laminated steel punchings (core iron), coils or rotor bars,
shorting rings, and a shaft.
Squirrel-cage induction motors employ simple and rugged construction and are economical in
terms of initial and maintenance costs. They also have a proven record for long-term reliability.
The rotor winding of a squirrel-cage motor is usually embedded in slots near the outer surface of
the rotor. For larger motors, the winding is made up of uninsulated copper, copper alloy, or other
suitable bar or rod material embedded in the slots of the rotor punchings. The rotor bars or rods
extend beyond the ends of the rotor punchings and are connected by shorting rings to provide
closed loop current paths (see Figure 5-45).
Figure 5-45
Detail of a Rotor for a Squirrel-Cage Motor
Die-cast aluminum rotors perform similarly to copper bar rotors and are used because of their
economic advantage in fabrication cost. In either design, it is the rotor bar conductivity and
shape coupled with the stator winding design that determine the motor starting and running
characteristics.
Technical descriptions of squirrel-cage induction motors for various horsepower ratings are
provided below:
Horsepower ratings 200 and below: These motors are normally covered by NEMA
Standard MG-1 and typically have voltage ratings below 600 volts. They generally have die-
cast type rotors and random-wound stators. Enclosures for these motors are as follows:
Open, drip-proof
Totally enclosed, fan-cooled (TEFC)
Totally enclosed, air-over
NOTE: Some vendors offer TEFC motors rated above 200 hp.
A cutaway drawing of a squirrel-cage induction motor with a cast iron, open, drip-proof
enclosure is shown in Figure 5-46. The motor has antifriction bearings and a die-cast aluminum
rotor with integrally cast fan blades.
5-39
Figure 5-46
Cutaway Drawing of an Open, Drip-Proof Squirrel-Cage Induction Motor
Horsepower ratings above 200: These motors, typically 4,000 volts and above, have form-
wound stator coils and fabricated copper or alloy bar rotors. The enclosures for these motors
are as follows:
Open, drip-proof
Weather protected I
Weather protected II
Totally enclosed, water-cooled
Totally enclosed, pipe-ventilated
5.3.2 Motor Components
Three essential components make the operation of the electric motor possible:
The windings, which receive current from an electrical supply system
The active iron (stator and rotor cores), which provides a path for magnetic flux
The stator housing with structural support elements, which comprises the electric motor
The motor components of concern for motor maintenance programs include the following:
Features of the motor components
Bearing systems and applications
Lubricants and lubrication systems
5.3.2.1 Motor Components Overview
The stator housing protects and supports the stator core and windings. The support structure for
most electric motors consists of two end bells (bearing housings) and a stator frame. The stator
5-40
frame and end bells are often made of cast iron, fabricated steel, or in some instances, cast
aluminum. With horizontal motors, the stator housing with mounting feet usually doubles as the
mounting system for the motor. Vertical motors are usually anchored or supported by a lower
mounting flange on the bottom end bell. Rotor shafts are usually made of carbon or special steel
alloy.
The stator frame houses the stator core, which is made of stacked insulated laminated punchings,
with slots that allow for winding placement. The stator frame also provides support for brackets
and rings for the end turns of the windings. The end bells contain the bearings that allow for
correct positioning of the rotor with respect to the stator. Correct positioning of the rotor
maintains a sufficient and uniform air gap between the stator and the rotor. Often, enclosures of
large motors contain air baffles that aid in the ventilation of the coil, windings, and bearings.
The stator windings receive the applied voltage and are arranged to produce a rotating magnetic
field within the confines of the stator. These windings are made of magnet wire, which is formed
to make coils. The magnet wire is coated with an insulating material that provides the turn-to-
turn and phase separation. The coils are further insulated by layers of material that provide
electrical isolation from the stator core iron. The coil ends are brought out, connected, and
insulated to form the required series or parallel circuits.
Both stator and rotor cores are made of low loss, insulated laminations that are stacked, aligned,
and clamped. Thin laminations are used to reduce hysteresis and eddy current losses to minimize
core heating. When the motor is fully assembled, the rotor core is inside the stator core, and the
two are separated by an air gap. Magnetic flux passes across the air gap to complete the magnetic
circuit. The magnetic flux reacting with the induced current in the rotor conductors produces
torque, causing the rotor to rotate.
Design features for NEMA type squirrel-cage induction motors up to 200 hp, and 600 volts and
lower, include the following:
Stator:
Winding: Three-phase winding consisting of various insulating materials.
Conductors are made from insulated magnet wire.
Core: Stacked laminations, insulated with iron oxide, enamel, aluminum phos-
phate, or other insulating material.
Rotor:
Winding: Die-cast or fabricated
Shorting rings: Die-cast or fabricated
Core: Similar to stator core material
Shaft: Carbon steel or special steel alloy
Bearings: Antifriction (ball or roller) or, occasionally, sleeve bearings
Frame: Cast iron, die-cast aluminum, or sheet steel
Fan: Molded plastic, sheet metal, or cast metal alloy
5-41
Figure 5-47 shows an exploded view of a NEMA type, TEFC, squirrel-cage induction motor
with random-wound stator, a die-cast aluminum rotor, and antifriction bearings. The external fan
and fan cover are shown.
Design features for squirrel-cage induction motors above 200 hp, and 4000 volts and higher,
include the following:
Stator:
Winding: Three-phase winding consisting of insulated formed coils. Several resin
treatments (such as vacuum-pressure impregnation and resin rich) exist for these
systems.
Core: Laminated electrical grade steel sheets, insulated.
Figure 5-47
Exploded View of an AC Motor
5-42
Rotor:
Winding: Rotor bars of fabricated conductors made of copper, alloy, or
aluminum.
Core: Same as stator core.
Shaft: Carbon steel or special steel alloy.
Bearings: In some cases, antifriction bearings are used in motors up to 2,000 hp. Ring
lubricated sleeve bearings are used for most horizontal motors. Vertical motors often use
plate or pivoting shoe type thrust bearings.
Oil-lubricated bearings may have cooling coils in the oil reservoir. Water is
circulated through cooling coils to reduce oil temperature.
Frame: Usually fabricated from carbon-steel plates or cast iron.
Predominant components of squirrel-cage induction motors categorized by horsepower rating are

summarized in Table 5-1.
Table 5-1
Predominant Motor Components Summary
Die-Cast Rotor Bars

Antifriction Bearings
Form-Wound Stator
Fabricated Rotor
Random-Wound
Sleeve Bearing
Oil Lubricated
Grease Lube
Horizontal
3 Stator
3 Rotor
Vertical
Stator
Bars
Up to 200 hp X X X X X X X X X X
Above 200 hp X X X X X X X X X X
5.3.2.2 Bearing Systems
Bearings are a crucial element in the reliable operation of an electric motor. Bearings fall into
three major categories: sleeve, antifriction, and thrust bearings (which can be either antifriction
or plate type bearings). The type of bearings used in a motor depends on the motors service
requirements. Small motors typically use antifriction bearings. Large motors often use babbit
bearings; however, motors up to 2,000 hp have been designed with antifriction bearings. In
addition, large vertical motors incorporate a thrust bearing in their design. There are exceptions
to these generalities, however, and it is important for maintenance personnel to recognize bearing
types and their orientation.
5-43
Bearings are the major cause of failure for electric motors. All motor bearings are intended to
have some form of lubrication, and bearing life is dependent on correct and adequate lubrication.
Choice of lubricants depends on the following factors:
Type and size of the bearing
Operating temperature
Bearing load
Bearing fit-to-shaft and end bell
Motor speed
Environment (for example, humid, hot, dirty, high radiation)
Motor operating mode (continuous or standby)
Under continuous operation and normal load conditions, most antifriction bearings have an
average life expectancy of 510 years, whereas sleeve and thrust bearings, if properly
maintained, are considered to have indefinite life. However, the factors listed above can
significantly affect bearing life expectancy. Overlubrication can be as detrimental to the bearings
as underlubrication. Forcing too much grease or adding too much oil into a bearing reservoir will
lead to overheating of the bearing and may lead to incursion of the lubricant into the motor,
which results in damage to the windings. Therefore, it is important that the correct type, amount,
and frequency of lubrication be determined for each motor.
Large motors use oil-lubricated bearings because bearing size and speed exceed the limits for
grease. These bearings can be either antifriction or babbitted. Many of the identified bearing
failures relate to grease-lubricated bearings. Bearing types are related to bearing application
considerations rather than to motor types and are discussed below.
Bearing Types
The two principal types of self-lubricated bearings are antifriction (rolling element bearings) and
babbitted bearings. Most horizontal motors in the 1500 hp size range and some motors up to
2,000 hp use antifriction bearings. This type of bearing is lubricated by an oil reservoir or grease
that acts as an oil reservoir, gradually releasing oil to the bearing surfaces. Larger horizontal
motors usually have oil-film babbitted sleeve bearings (see Figure 5-48). These bearings have an
oil reservoir from which oil is drawn by oil rings (see Figure 5-49), and the bearings rotate on the
shaft and dip into the oil reservoir. The rings deposit oil on the shaft and the bearing surfaces.
Some large motors have force-fed lubrication supplied from a separate shaft-driven or motor-
driven pump.
5-44
Figure 5-48
Sleeve Bearing Details
Figure 5-49
Oil Ring Detail
The bearing types for horizontal and vertical motors are discussed below:
Antifriction Bearings: The basic difference in antifriction bearings is the type of rolling
element used in the bearing. The following types of rollers are in wide use today: ball,
cylindrical, spherical, and tapered. Small direct-coupled horizontal motors use ball bearings.
Roller bearings are capable of higher side thrust loading than ball bearings and sleeve
bearings.
Sleeve Bearings: The sleeve bearing for motors is normally a simple babbitt-lined steel
cylinder. Oil rings (usually made of bronze or brass) ride on and rotate with the shaft to carry
oil up from a sump beneath the bearing, letting the oil flow down onto the journal to spread
between the journal and bearing surfaces. Sleeve bearings are in wide use on larger motors in
power plants.
5-45
Since there are no statistical, standardized relations between load and life, sleeve bearings
(unlike the antifriction type) are often expected to last indefinitely. Experience has shown,
however, that degradation of lubrication systems, vibration, and poor shaft alignment can lead to
sleeve bearing wear and eventual failure.
Thrust Bearings: Thrust bearings of most vertical motors having large diameters and rotor
weight (such as condensate pump motors) use oil-lubricated disc or tilting pad bearings that
have babbitted surfaces. Vertical motors rated up to 2,000 hp may use antifriction bearings as
thrust bearings in single, double, or triple arrangements, depending on thrust loading.
Table 5-2 shows how bearings are typically applied, depending on horsepower.
Table 5-2
Bearing Application
Horizontal
Direct-
Connected Vertical
200 hp and below
200 hp and below

200 hp to 2,000
200 hp to 2,000
hp
hp
Antifriction ball type X X X X
Antifriction roller type X
Sleeve bearing ring lubricated X X
Sleeve bearing oil bath X X
Sleeve bearing, force-fed lubrication X
Thrust bearing antifriction, ball oil-lubricated X X X
Thrust bearing antifriction, ball grease-lubricated X X
Thrust bearing tilting pad X
Thrust bearing disc type X
Ball bearings are provided in a variety of configurations for requirements of load, speed, thrust,
and lubrication design:
Sealed bearings prevent foreign material entry into the bearing. These bearings are usually
not designed to be relubricated. The bearing has a prefilled grease level in its enclosed
reservoir (see Figure 5-50).
Single-row, deep-groove, double-shielded bearings combine the bore and outside diameter of
single-row bearings with the width of double-row bearings for wider area in contact with
5-46
shaft and housing. This style is often used with aluminum housings. Extra width provides
extra grease capacity. Deep-groove ball bearings tolerate moderate thrust loads (see Figures
5-51 and 5-52).
Single-row maximum type bearings are designed for heavy radial loads at moderate speeds.
A filling slot is milled into the inner and outer rings of the bearing. These bearings are used
with or without shields, depending on the application. Because of the filling slot, these
bearings have little thrust capability (see Figure 5-53).
Figure 5-50
Single-Row, Double-Sealed Ball Bearing
Figure 5-51
Single-Row, Open Enclosure, Deep-Groove Ball Bearing
5-47
Figure 5-52
Single-Row, Double-Shielded Ball Bearing
Figure 5-53
Single-Row, Maximum Type Ball Bearing
Angular-contact ball bearings carry a combination of radial and single direction thrust loads.
To carry thrust loads in both directions, these bearings are mounted in pairs with opposed
contact angles (see Figure 5-54).
Ball bearings for axial thrust loads can handle relatively high thrust loads where no radial
loads are present.
5-48
Figure 5-54
Mounting Arrangements for Angular-Contact Ball Bearings
Bearings with pivoted shoes, also called tilting pads, are used in both horizontal and vertical
shaft applications. Figure 5-55 shows a runner for a tilting pad bearing. Figures 5-56 and 5-57
show a six-shoe tilting pad thrust bearing with and without the runner. The all-steel runner is
fixed to the rotating shaft and its rider on the six shoes with babbitted surfaces. The pads tilt to
allow an oil wedge to form on the surface that supports the weight of the shaft assembly via the
runner. Figure 5-58 shows schematically how the individual thrust bearing shoes provide an
equalized support system.
Figure 5-55
Tilting Pad Thrust Bearing Runner
5-49
Figure 5-56
Six-Shoe Thrust Bearing Without the Runner Installed
Figure 5-57
Six-Shoe Thrust Bearing With the Runner Installed
Figure 5-58
Equalized Support of Thrust Bearing Shoes
5.3.2.3 Lubrication Systems
All motors have lubrication systems for bearings. Bearing life is primarily limited by the
adequacy of the lubricant. The type and quality of the lubricant depend on bearing type, size,
operating temperature, load, and motor speed. Bearings may be self-lubricated or force-fed
lubricated.
5-50
Oil Lubrication
Oil lubricated bearings are either submerged in an oil bath for vertical motor applications or
coated with oil by a slinger or oil rings. Oil viscosity selection is based on bearing loading.
Vertical motors with antifriction thrust bearings use fairly low viscosity oil. A heavily loaded
spherical roller thrust bearing uses higher viscosity oil.
High operating temperatures will promote oil deterioration. Some motors use cooling coils to
limit bearing operating temperatures and retard oil degradation. Oil analysis should be used to
periodically monitor the lubricant for degradation of physical properties or the presence of
bearing wear. Equipment manufacturers should be consulted when determining the correct oil
(for example, viscosity and additives) for each application. However, in situations where this
information may not be accessible, equipment qualification reports and lubricant companies are
also good sources for lubrication information.
Grease Lubrication
Grease performs the following functions:

Maintains a film of oil between the rotating and stationary surfaces within the bearing, thus
minimizing friction between them
Cools surfaces so that friction heat does not damage the parts or the lubricant
Aids in flushing out microscopic particles broken away from bearing parts by wear or high
surface stress
Prevents corrosion
Limits dirt or chemical contamination
Lubricant Requirement
The amount of lubricant needed to maintain an oil film on bearing parts is extremely small. At
the proper viscosity, less than one thousandth of one drop of oil can properly lubricate a ball
bearing on a 2-inch (50.8-mm) shaft running at 3,600 rpm. In setting up grease lubrication
maintenance programs for motors, it is important to understand the workings of the following
types of antifriction bearings:
Unshielded bearings (see Figure 5-51): These are used when the lubricant system is arranged
for flow-through greasing. In the system shown, grease enters one side of the bearing and
leaves from the other side. This is intended to aid the discharge of old grease from the
bearing during lubrication. The wide inner cap fit along the shaft helps keep grease from
being forced into the motor interior (see Figure 5-59).
5-51
Figure 5-59
Flow-Through Lubrication System
Shielded bearings (see Figures 5-60 and 5-52)

Single-shielded bearingsshield facing the motor exterior: This assembly is
common when an inner bearing cap is used to hold the bearing in place. The cap
acts as a grease seal to prevent leakage, and the side of the bearing that is left
open facing the cap allows the bearing to purge excess grease into the cap
reservoir. Unfortunately, overgreasing will fill up the cap reservoir and cause the
grease to be forced between the cap and the shaft and inside of the motor.
Figure 5-60
Lubrication System Used for Shielded Bearings
5-52
Single-shielded bearingsshield facing the motor interior: This bearing is

customarily used when there is no inner cap. The shield is needed to help prevent
internal grease leakage.
Double-shielded bearings (see Figure 5-52): These bearings are used when there
is a need to retain the lubricant in the bearing more efficiently and to minimize the
intrusion of contaminants into the bearing. Regreasing this type of bearing
arrangement is more difficult because the grease cannot be pushed into or forced
out of the bearing as easily as in the case of an open- or single-shielded bearing.
Because of this, regreasing intervals are usually longer, and the amount of
lubricant added to the grease cavity is less. In a non-hostile environment, with a
proper greasing program, a double-shielded bearing should have approximately
the same useful life as an open- or single-shielded bearing.
Sealed bearings (see Figure 5-50): These bearings are made to prevent lubricant
(and dirt) inflow as well as lubricant escape. They are not usually designed to be
relubricated. The use of sealed bearings should be evaluated on a case-by-case
basis. This evaluation should take into account motor characteristics, operating
environment, and accessibility.
Grease Fill
The most common recommended grease fill percentage in a bearing grease cavity is 50 percent,
although there are published ranges from 25 to 75 percent. The partially filled cavity allows for
thermal expansion of the grease without it being forced into the motor through clearances
between the shaft and the inner bearing cap.
The fill plug and drain plug of 90 percent of bearing housings are located on the same side of the
bearing (usually the side of the bearing facing away from the motor). This design usually
employs shielded bearings.
5-53
6
FAILURE MODE ANALYSIS
Condensate pumps are typically very reliable and require minimal attention other than normal
maintenance. Consequently, little published information exists regarding industry experience and
failure statistics for condensate pumps.
While developing this guide, EPRI FMAC conducted a limited survey of its member plants to
determine members experience with condensate pump problems. The following sources also
provided information regarding condensate pump problems:
Component Failure and Repair Data for Coal-Fired Power Units, EPRI AP-2071: 1981.
North American Electric Reliability CouncilGenerating Plant Availability Data System
(NERC-GADS).
6.1 Survey Results
Table 6-1 lists the condensate pump problems reported by survey respondents along with the
sections of this guide that address each problem.
Table 6-1
EPRI FMAC Member Plant SurveyCondensate Pump Problem Reports
Percent of Replies
Problem Reporting the Problem Reference Sections
Alignment 5 10.1, 10.2
Oxygen ingress 30 4.5.4, 7.3.3
Mechanical seals 30 5.1.8.2, 5.1.8.3, 9.2.2, 9.3.12,

10.3
Bearings 30 5.1.7, 5.3.2.2, 9.3.9, 10.1,

10.2
Lubrication systems 0 5.1.7.2, 5.3.2.3, 9.1.3
Balance/vibration 25 9.1.1, 10.1, 10.2
Motor 30 5.3, 9.1.5, 9.2.4, 10.4
Shaft bushing wear 10 10.1, 10.2
Variable speed drive 5 n/a
6-1
Failure Mode Analysis
The highest percentage of the condensate pump problems reported was related to oxygen leakage
into the pump, mechanical seals, bearings, and motors. A slightly lower percentage of problems
was related to balance and vibration.
The survey results did not differentiate between problems that resulted in equipment failures or
plant trips and those that were ongoing maintenance problems that did not result in outright
failures. Follow-up contacts with plant personnel indicated that few of the reported problems
resulted in complete failure.
6.2 EPRI Report AP-2071
In 1981, EPRI published AP-2071, a topical report that presented failure rates and average
restoration times for various coal-fired power plant components. Although the report is several
years old, current information indicates that the basic information regarding the types of failures,
relative frequency, and restoration time following a failure is still valid for plants at least 20
years old.
The results are presented in Figure 6-1, which is a reproduction of the condensate pump data
page from AP-2071. Figure 6-1 also includes the relative frequency reported for each failure
mode, the average time to restore to service (including logistic, repair, and system shutdown and
startup times), and the contribution to the mean time to restore (MTTR). The MTTR contribution
is defined as the relative frequency of failure divided by 100 and multiplied by the total restore
time.
A review of the information presented in Figure 6-1 shows the following:

The average time between condensate pump failures is five years. This equates to
approximately 23 failures per million operating hours.
The MTTR a condensate pump to operation following a failure is approximately 36 hours.
The failure modes reported with the highest relative frequency are bearing failure and
impeller/bowl failure. Cavitation/erosion problems represent the second highest relative
frequency.
Motor failure represented the lowest reported relative frequency, but restoration of a motor
following a failure required the longest time.1
1
Refer to the last paragraph of Section 6.3 regarding low cost motors frequently used in recently designed power
stations.
6-2
Figure 6-1
Condensate Pump Failure Data
(Source: EPRI Report AP-2071)
6-3
Table 6-2 presents the MTTR Contribution data, including the relative impact of each failure
mode in terms of the likelihood of failure and the time required to restore the equipment to
operation.
Table 6-2
MTTR Contribution Data
Failure Mode Description Relative Impact* (%)
Pump motor 10.5
Bearing failure 9.4
Coupling failure 4.5
Impeller/bowl failure 42.6
Cavitation/erosion 28.4
Shaft failure 4.6
(Relative Frequency of Failure / 100) x Total Re store Time

* Re lative Im pact = x 100
Mean Time to Re store
This indicates that the failure modes most likely to have the greatest impact on pump downtime
are impeller or bowl failure and repair of cavitation or erosion damage.
6.3 NERC-GADS Data
The NERC-GADS database provides statistical information regarding overall plant availability
and information regarding plant outages and required plant derating attributable to specific plant
equipment. The statistical data are based on information voluntarily reported to NERC by 178
utilities in the United States and Canada, representing investor-owned, municipal, state,
cooperative, provincial, and federal segments of the industry.
Although failure data and plant derating data are available for specific plant equipment items, the
database provides no detailed information regarding the specific causes of the problems. The
failure rates (occurrences per unit-year) and lost generation rates (lost generation hours per unit-
year) include losses from all forced and scheduled outages.
Information was retrieved from the database regarding the number of failures and the equivalent
lost hours and lost megawatt hours from 1995 through 1998, attributable to condensate pump and
condensate pump motor problems for 969 coal-fired units of all sizeswith ages ranging from
zero to 60 years. In order to check for differences between newer and older plants, the data were
sorted on the basis of age, for plants up to 30 years old and for plants 3160 years old.
The information retrieved from the NERC-GADS database is summarized in Table 6-3. The
reports from which the data were summarized are included for reference in Appendix A.
6-4
Table 6-3
NERC-GADS Data: Condensate Pump and Motor Failure Data, 19951998
Equivalent Lost
Generation Hours Equivalent Lost Megawatt-Hours
Average Average
Number of Occurrence per Unit- Loss per Loss per
Component Occurrences per Unit-Year Per Occurrence Year Occurrence Unit-Year
All units 060 years old (969)
Condensate pump 808 0.216 16.437 3.543 4,173.280 899.422
Condensate pump motor 235 0.063 14.530 0.911 5,316.303 333.244
Units 030 years old (338)
Condensate pump 476 0.359 13.876 4.977 5,121.634 1837.150
Units 3160 years old (631)
Condensate pump 332 0.137 20.110 2.757 2,813.591 385.678
6-5
Review of the data presented in Table 6-3 confirms that condensate pumps and motors have very
low failure rates compared to other power plant components, and the cost of the outages in terms
of lost generation is not high relative to other components and equipment. For example, the
failure frequency of boiler feed pumps is approximately twice as high as that for condensate
pumps. The outage time for a boiler feed pump failure is also much longer, resulting in a greater
loss of generation.
Although it might be expected that older equipment would exhibit more frequent failures, Table
6-3 shows that failure rates for both pumps and motors is significantly higher for plants 30 years
old or less than for plants 3160 years old. This may reflect the recent trend for design and
construction of turnkey power plants in which low capital cost is a major factor. For these plants,
the condensate pumps and motors are often lower cost items, and are more standardized products
rather than the more highly engineered utility grade equipment generally purchased for power
plant applications in earlier years. Although the failure rates for the newer plants are higher, the
data show that significantly more time is required to return a pump in an older plant to service.
However, the average time for restoration of motors is similar, regardless of the age of the plant.
6-6
7
PUMP OPERATION
This section addresses typical issues and procedures related to condensate pump and condensate
system startup, operation, and shutdown. Particular emphasis is placed on procedures and
precautions for initial startup of a new pump or startup of an existing pump following
maintenance. A brief overview of normal startup, operation, and shutdown is also included to
review some of the basic principles of pump operation and to highlight certain system operating
conditions that may be potentially detrimental to pump operation or longevity.
This general description cannot address all possible condensate system and condensate pump
design features and operating requirements. It is imperative that the personnel operating the
pumps be familiar with the recommendations of the pump and motor manufacturers and with all
system operating procedures for their specific system and equipment.

Before attempting to operate unfamiliar equipment, consult the
manufacturers operating and maintenance manuals and system
operating procedures.
7.1 Startup
7.1.1 Initial Pump Startup or Startup Following Maintenance or Repair
For the initial startup of a new pump following installation or for startup of an existing pump
following maintenance/repair involving partial or complete disassembly of the pump and/or
piping, care must be taken to ensure that the following basic issues have been addressed:
Is everything correctly assembled and connected?
Is the flow path free of obstructions?
Are all pump and motor bearings properly lubricated?
Are the pump casing and piping purged of air and filled with water?
Are all related system valves in the position required for pump startup?
Are all control and protective devices functioning properly?
Table 7-1 provides a detailed checklist of typical items to be addressed prior to pump startup.
Note that additional checks and verifications may be required for specific equipment. The
7-1
Pump Operation
manufacturers operating and maintenance manuals should be consulted for additional

requirements.
Table 7-1
Checklist: Condensate Pump Startup, Initial Startup, or Startup Following Maintenance
Pump, hot well, and piping (including suction strainer) are free of debris and
_____ obstructions.
Motor power leads are correctly installed and properly sequenced for correct rotation.
(Verify the connection sequence with wiring diagram or bump motor before
_____ connection to pump to verify proper rotation.)
_____ Pump and motor are correctly aligned.
Mechanical connections, including shaft coupling and piping connections, are installed
_____ correctly and are tight.
_____ Base plate or foundation bolt connections are tight.
Protective devices (for example, overcurrent devices) are connected and functioning
_____ properly.
_____ Grounding connections are properly installed and tight.
_____ Motor and pump bearings are properly lubricated.
Pump is free to rotate. (Rotate by hand if possible to verify that there is no binding or
_____ rubbing.)
_____ Packing is correctly adjusted (where applicable).
_____ Seal water flow is available (where applicable).
System (including suction line, pump casing/can, discharge piping, and all heaters and
equipment) is filled with water, and air has been vented back to the condenser above
_____ the hot well water level.
_____ Suction isolation valve is open.
_____ Minimum recirculation flow path is available and functioning.
_____ Discharge valve is in correct position for start.
_____ Other system valves are properly lined up for pump start.
Equipment and switchgear have been released for operation in accordance with plant
_____ safety and operating procedures.
The system (including pump, piping, and heaters) must be completely filled with water and
purged of air for proper operation and protection of the pump.
7-2
Pump Operation
Key Technical Point

Allowing a pump to run dry will very quickly cause extensive damage.
Be certain that the pump and piping are completely filled with water
before starting following initial installation or reassembly.
Because the condensate pump and suction piping are typically located below the normal
operating water level in the hot well, the suction piping, the pump can or casing, and the
discharge piping up to the discharge isolation valve can generally be filled by gravity with water
from the condenser hot well. The suction isolation valve and pump and piping vent valves are
opened, the discharge isolation valve is closed, and water is allowed to flow from the hot well
into the piping and pumpthus displacing the air.
For initial startup of a new plant, a temporary cone type strainer is often provided to protect the
pump by capturing any construction debris that may remain in the condenser hot well or pump
suction piping. After the system has been verified to be clean, the strainer is usually removed. In
some systems, a basket type strainer is provided. Following initial startup, the basket will often
be removed to reduce the pressure loss in the suction piping. However, following work on the
condenser or the suction piping, the basket may be reinstalled prior to starting the pumps again to
collect any debris that may be present.
During the initial run following startup, flow, suction temperature, suction and discharge
pressure, motor current, voltage, speed, vibration levels, and bearing temperatures should be
closely monitored to verify that the equipment is functioning properly.
Key Technical Point

Monitor the flow, pressures, temperatures, motor current, and vibration
levels closely any time a pump is started following disassembly or
maintenance. Be prepared to shut down the pump immediately if the
measured quantities indicate a problem, especially if the suction or
discharge pressure drops to zero.
7.1.2 Normal Startup
Normal pump startup conditions include starting the first or primary condensate pump during
plant startup and starting the standby pumps in response to increases in condensate flow demand
or failure of the primary pump. Startup of the first pump is initiated as part of the plant startup
sequence. Starting of additional pumps is generally initiated by the condensate system controls in
response to decreasing deaerator storage tank or LP drum level (as applicable) with the primary
pump(s) already in operation and flow control valves at or near wide open.
7.1.2.1 Start Permissives
During a plant startup, a start of one of the condensate pumps will be initiated in the pre-
established sequence of events. When the start signal is received, the control system verifies that
7-3
Pump Operation
the conditions required to allow a safe pump startup (start permissives) are met prior to allowing
the pump to start. Typical pump start permissives include the following:
Suction valve is open
Seal water pressure is above the minimum requirement
Condenser hot well water level is above the minimum requirement
Deaerator storage tank or LP drum water level is below the maximum allowable level
Motor trip lockout relay is reset
Bus differential lockout relay is reset
Discharge valve position is correct for start
If all permissives are met, the pump will be allowed to start. However, if one or more are not
met, a fail to start or similar message will be delivered, and the cause of the failure must be
addressed before the pump will be allowed to start in the automatic mode.
Individual pumps may also be started manually for checkout or maintenance purposes
independent of plant operation. However, in the manual mode, some of the start permissives may
be bypassed. It is the responsibility of the operator to verify that all conditions required for safe
startup and operation of the pump are met before a pump start is initiated manually.

Some or all start permissives may be inoperable in the manual operating
mode. When starting a pump in the manual mode, verify that all
conditions for a safe startup are met to prevent injury to personnel or
damage to equipment.
7.1.2.2 Operation of Discharge Isolation Valves
Most pumps used for condensate system service have power curves that rise from shutoff (no
flow) to rated capacity (see Section 7.2). In order to reduce the starting load on the pump drive
motor, initial flow through the pump should be limited. This may be accomplished by starting
the pump against a closed discharge valve. If another pump is already in service and the system
is pressurized, the discharge check valve will limit the flow until the pump builds adequate
pressure to lift the disk off the seat. Current plants are often designed to start the first pump with
the discharge isolation valve open but with the main flow control valves closed, and flow is
limited to that allowed through the minimum recirculation line.
In some condensate systems, the discharge isolation valves are power operated to allow their
operation to be coordinated with pump startup and shutdown. For automated pump startup
sequences, control systems are often programmed to begin opening the discharge valve at the
same time a start signal is sent to the pump motor in order to minimize the operating time at no
flow or very low flow conditions. Whether or not operation of the valve is automated, the valve
should be opened as soon as the pump reaches operating speed in order to prevent damage due to
operation of the pump below the minimum required recirculation flow (see Section 7.2).
7-4
Pump Operation
For systems with manual valves, the start sequence should include verification that additional
pumps are in operation or that the flow through the main header is shut off and that the flow path
through the minimum recirculation line is open.
7.1.3 Limitations for Repeated Start Attempts
If pump or system problems require a number of start attempts within a relatively short time, the
operator should be aware of possible limitations on the allowable number of motor starts within a
specified period.
Starting current for the drive motor is very high and causes significant heating of the motor
windings. The manufacturer may limit the number of starts in order to allow sufficient cooling
between starts to prevent damage to the motor windings. This limitation may be stated in the
system operating manuals or in the equipment manufacturers operating and maintenance
manuals. Whether or not there is a stated limitation, each motor should be equipped with a
protective relay or device that monitors winding temperature and trips the motor (or does not
allow the motor to start) if the winding temperature reaches a preset upper limit.
The following typical start limitation scenario was included in a condensate system operating
manual for a large coal-fired power plant:
Motor may undergo two successive cold starts
Motor must cool for at least 20 minutes after two successive cold starts or after one hot start
7.2 Pump Operation
7.2.1 Basics of Pump Operation
A pump with a specific impeller diameter operating at a given constant speed exhibits a fixed
performance characteristic (head vs. flow) curve. The point on this curve where the pump
operates depends on the characteristics of the system in which it is operating. The characteristic
curve for the system is typically referred to as the system head curve or system resistance curve.
The system head curve is determined by the resistance of the system to flow at various flow rates
(system friction losses) and the fixed losses or gains (static head). In other words, a pump will
operate at the flow and head condition represented by the point where the pump performance
curve intersects the system head curve, as illustrated in Figure 7-1.
7-5
Pump Operation
Figure 7-1
Single Pump Operation
7-6
Pump Operation
For applications with two or more pumps operating in parallel, the system characteristic curve is
determined by adding the pump capacities at each value of pump head. The intersection of the
pumps combined system characteristic curve with the system head curve is the operating point.
Figure 7-2 shows the pump characteristic curve for a two-pump system with one pump in
operation and the combined characteristic curve for both pumps operating in parallel.
Figure 7-2
Pumps Operating in Parallel
7-7
Pump Operation
As described in Section 4, a condensate pump is sized to provide a specified flow and total head
at the pumps rated speed. These design (or rated) flow and head conditions are normally
selected based on an operating point on the system head curve at or near which the pump is
expected to operate most of the time. The specific pump selected for the application will have its
peak efficiency at or near these rated conditions, and its performance is represented by a set of
characteristic curves (see Figure 7-3).
Figure 7-3
Condensate Pump Performance Curves
7-8
Pump Operation
Figure 7-4 shows the system head curve at the design condition superimposed on the pump
characteristic curves. As seen in the figure, the pump efficiency at the design point is very near
the peak of the efficiency curve, and the efficiency decreases as the flow deviates significantly in
either direction from the design point. For system operating conditions that require the pump to
operate at a flow significantly higher or lower than the design flow, precautions may be required
in order to prevent damage to the pump, as described in the following sections.
Figure 7-4
Condensate Pump Performance at Design Conditions
7.2.2 Operation at Increased FlowPump Runout
Under certain system operating conditions, such as one-pump operation in a system designed for
operation of two or more pumps in parallel, a pump may be required to operate at a flow
significantly higher than the design flow.
For example, to maintain plant load as high as possible when only one partial capacity pump is
available, the condensate flow control valve would be moved to its full open position to reduce
the friction loss and allow increased flow. Under this condition, the pressure loss across the
control valve would be much lower than normal. Since the total flow through the system would
be much less than the two-pump design flow, the system friction losses, which are proportional
7-9
Pump Operation
to the square of the flow, would also be significantly reduced. The result would be that the
system head curve would be lowered, as illustrated in Figure 7-5.
Figure 7-5
Condensate Pump Performance at Runout Conditions
Figure 7-5 shows that as the total system head is reduced, the pump flow will increase beyond
the design point. As the flow increases, the NPSH required at the pump suction increases, and
the available NPSH may be inadequate to prevent cavitation. The required pumping power
increases, which may overload the drive motor.
The operating condition defined by the maximum anticipated discharge and the lowest
anticipated head is defined as the pump runout condition. Ideally, this one-pump operating
condition or other similar conditions will have been considered in defining the runout condition
for the initial specification and design of the pump, the motor sizing will be adequate to prevent
overload, and the first-stage impeller design will be adequate to prevent cavitation. To prevent
cavitation damage during high flow operating conditions, the pump suction pressureas well as
the water temperature at the pump suctionshould be monitored to verify that the actual suction
pressure is not less than the vapor pressure at the measured suction temperature in order to
prevent reduction of the NPSH below the pumps requirements.
7-10
Pump Operation
Key Technical Point

When operating a pump at runout conditions, monitor the suction
pressure and temperature closely to avoid damage due to cavitation
caused by reduction of the NPSH below the pumps minimum
requirements.
Most drive motors are equipped with protective relaying devices (overcurrent relays or
overtemperature relays) to prevent damage to the pump motor due to overload conditions. It is
imperative that these protective devices are maintained in good operating condition.
7.2.3 Operation at Decreased FlowMinimum Recirculation
During system startup, low load operation, deaerator storage tank or boiler drum fill, or similar
conditions, a condensate pump will be required to operate at a flow much lower than the design
flow, as illustrated in Figure 7-6. As described in Section 7.2.1, the pump discharge flow is a
function of the system resistance. Depending on the required function and flow path, the system
resistance will be increased by throttling either the main condensate control valves or separate
control valves in the fill lines.
7-11
Pump Operation
Figure 7-6 shows that as the flow decreases and head increases, pump efficiency decreases,
pumping power requirements are reduced, and NPSHr is reduced.
Figure 7-6
Condensate Pump Performance at Low Flow Conditions
The pump manufacturer will define a minimum permissible flow below which the pump should
not be operated. A primary factor in determining this minimum flow is heating of the water in
the pump.
Pump efficiency is a measure of the ratio between the power supplied to the pump by the drive
motor and the power actually used to move the water. Most of the power difference between the
pump input and the work performed in pumping is converted into heat energy and transferred to
the water being pumped. Operation of a condensate pump at very low flows increases the
temperature of the pumped water, which may result in flashing of the water within the pump.
Sustained operation at this condition will damage the pump. Therefore, the manufacturer will
determine a minimum permissible flow rate that must be maintained in order to keep the
temperature of the fluid in the pump below its saturation temperature.
Overheating is not the only factor to consider in determining the minimum allowable flow.
Depending on the pump design, operation of the pump at low capacity may also increase noise,
7-12
Pump Operation
hydraulic pulsation, and rapid deterioration of the impeller. These effects are caused by internal
recirculation in the impeller as a result of a mismatch between the inlet vane angle and the liquid
flow direction at the low flow velocity.
To avoid damage, the pump must not be allowed to operate for any significant period of time at a
flow below the minimum allowable flow established by the manufacturer. In order to prevent
such operation, the condensate system is normally designed to include a flow path from the
condensate pump discharge piping to the condenser. This design ensures that the flow through
the pump will be above the minimum flow requirements under all operating conditions. It is
important to verify that this minimum recirculation line, the control valves or orifices, and all
controls are functioning properly when operation of a pump at low flow is required.
Key Technical Point

Never allow a pump to operate for extended periods at flows below the
minimum allowable recirculation flow established by the manufacturer.
7.2.4 Reverse Rotation
Under certain conditions, it is possible for condensate to flow backwards through an idle pump
and rotate the pump in the reverse direction.
Condensate pumps are typically provided with suction isolation valves (either gate or butterfly
valves), discharge check valves, and isolation valves (usually gate valves). As discussed in
Section 7.1.2.2, the discharge isolation valves can be either manual or motor operated valves,
depending on owner preference. The pump can run backwards at up to runaway speed if (1) it is
not provided with a nonreversing device (usually located in the motor) and (2) reverse flow from
the system through the pump occurs due to failure of the discharge isolation valve to close
following pump shutdown (in the case of motor operated discharge valves) or failure of the
discharge check valve.
Under the extreme case of full reverse flow, attempting to start a pump experiencing reverse
rotation will cause the motor to experience a prolonged overload condition. This occurs because
the motor must overcome the reverse flow and rotation by decelerating the pump, momentarily
stopping the pump, and then accelerating the pump to normal speed. The duration of this
transient condition will be longer than the normal starting time, and the motor current will be
higher than normal current demand. The motor protection devices will probably disconnect the
motor from the power supply before normal operation can be realized. Starting a pump under this
extreme case could result in pump or motor damage. Failures of this type are generally
uncommon in condensate systems. In the case of a leaking check valve, full reverse flow will
probably not occur, so the effects of attempting to start the motor under this reduced condition
will be lessened.
Reverse flow through the standby pump can adversely impact system pressure, deaerator or drum
level, and hot well level. In the case of significant reverse flow, the operator will be alerted to the
problem by degradation of system pressure, low water level in the drum or deaerator, and high
water level in the condenser hot well.
7-13
Pump Operation
Periodic preventive maintenance of the system check valves or provision of motor operated
discharge gate valves coupled with a coordinated pump and discharge valve startup sequence can
help minimize the possibility of reverse flow through an idle pump.
7.3 Shutdown
7.3.1 Normal Shutdown
7.3.1.1 Plant Shutdown
During a normal plant shutdown, the condensate pumps are taken out of service as part of a pre-
established shutdown sequence. A typical simplified shutdown sequence is described below:
1. As load on the turbine generator is gradually reduced, the condensate flow demand is
reduced, and the condensate flow control valve(s) modulate(s) toward the closed position.
2. For systems with multiple partial capacity pumps, all but one of the pumps will be shut down
as flow demand drops to a point where flow from one pump can adequately provide the
required flow.
3. As the condensate flow control valve nears its closed position, the minimum recirculation
valve opens to maintain adequate flow through the pump and gland steam condenser.
4. The condensate pump motor is stopped.
5. If the pump is equipped with a power operated discharge valve, the valve will typically be
automatically closed as the pump is shut down.
7.3.1.2 Individual Pump Shutdown
An individual pump may also be taken out of service manually, either for inspection and
maintenance or to rotate another pump into service to equalize operational time.
As long as the unit load is adjusted to accommodate the reduction in flow caused by taking a
pump out of service, or a standby pump is started and ready to pick up and maintain the required
flow, removal of a pump from service should provide a reasonably seamless transition with
minimal upset to the system and plant operation.
7.3.2 Trip Conditions
7.3.2.1 Unit Trip
In the event of a unit trip, the condensate system will continue to operate to ensure condensate
flow for required services during the time it takes for the steam turbine to coast to a stop.
7-14
Pump Operation
Required services may include boiler feed pump seal water, turbine seal steam desuperheater
spray water, LP turbine exhaust spray water, and gland condenser cooling water.
If multiple condensate pumps are operating when the unit trips, auxiliary power is typically
supplied to both pumps. The operator would manually take one pump out of service and operate
with only one pump during the coast down period.
The sequence of pump shutdown events is essentially the same as for a normal shutdown.
7.3.2.2 Pump Trip
A trip may be initiated for all operating condensate pumps or for an individual pump if certain
monitored conditions exceed pre-established limits for safe operation.
Conditions that may initiate a condensate pump trip include the following:
Condenser hot well level falls below normal low operating level
Pump motor stator winding temperature rises above normal high operating range
Pump motor bearing temperature rises above normal high operating range
Bus lockout relay trip
Motor temperature relay trip
Motor overcurrent trip
Vibration level rises above the allowable limit
If a condensate pump is tripped due to problems related to the pump (for example, high vibration
or high motor temperature) rather than system problems (for example, low hot well water level
or high feedwater heater water level), a standby pump will automatically be started to maintain
unit load. If the trip is due to problems related to the condensate system and therefore plant
operation, a plant trip will be initiated. The conditions that would typically initiate a plant trip
will initiate an alarm before the monitored parameter reaches a critical level in order to allow the
plant operators time to address the situation without tripping the plant.
7.3.3 Prevention of Air Entry Following Shutdown
When a pump is shut down with the condenser under vacuum conditions, air will tend to be
drawn into the pump through the packing or mechanical seal. To prevent the entry of air, proper
sealing of the packing area should be verified. For pumps with packing, proper adjustment of the
packing to obtain a tight seal should be verified.
If the pump is equipped with mechanical seals, seal water is usually supplied from the pump
discharge header. When the pump is in standby status with the system operating, seal water will
be available from the operating pump(s). An auxiliary source of seal water supply should be
provided for use during plant startup and other times when seal water is not available from the
pump discharge header.
7-15
Pump Operation
Air can also enter the condensate system through improperly sealed mechanical connections on
the pump or piping system. All bolted or threaded connections should be checked periodically to
verify that bolts are properly torqued, threads are adequately sealed, and gaskets are in good
condition.
Key O&M Cost Point

Prevention of air entry for a shut-down pump is important in reducing
O2 ingress into the condensate system and the resulting effects.
7-16
8
PERFORMANCE MONITORING
Key O&M Cost Point

Performance monitoring can contribute to increased equipment
reliability and thus increased plant availability.
Monitoring of pump performance parameters can detect changing operational characteristics that
may indicate a degradation in the pumps performance due to increasing wear or a developing
problem. Performance monitoring can be used as a component of a preventive maintenance
program (as described in Section 9) and as a failure analysis tool.
This section provides an introduction to basic performance monitoring concepts and methods as
well as data collection and analysis.
8.1 Performance Monitoring System
A performance monitoring system creates a real-time and historical record of the performance of
a condensate pump by collecting and analyzing pertinent data and calculating performance
parameters determined from the data and from manufacturer design information.
A performance monitoring system can be simple or complex. An effective system can be as

simple as a manually kept log of periodic instrument readings, or as complex as a dedicated on-
line system with data acquisition and performance calculation and trending capabilities. The
following sections describe the basics of various systems.
8.2 System Components
8.2.1 Data Acquisition
Acquisition of data is the first step in monitoring the performance of a condensate pump. Data
can be collected and stored by various methods. Regardless of the method selected, it is critical
that data be regularly and systematically collected and stored in a form that can be readily
retrieved for review and analysis.

In order for any performance monitoring system to be effective, it must
be based on performance data that are collected regularly and
systematically.
8-1
Performance Monitoring
8.2.1.1 Data Collection Methods

Data Logginga data log is a manually generated table of instrument readings. Data logs
may be generated by plant personnel recording readings from local instruments during
operator rounds of the plant or instrument readings displayed on screens in the control room.
The data may be manually entered on log sheets or entered into a computerized spreadsheet.
DCS Systemsdata can be collected and recorded from parameters already monitored by the
plants distributed control system (DCS). The DCS collects data from remote sensors in the
plant, displays information in the control room, controls equipment based on built-in logic,
and, in some cases, can store or print plant data for reporting purposes. A report can be set up
to retrieve and present the desired condensate pump performance data.
On-Line Data Storage and Retrieval Systemspump performance parameters can be
monitored and captured by a separate on-line data storage and retrieval system. On-line data
systems differ from DCS systems in that the on-line systems are not required to control plant
operations. The systems can be configured to access and store data from multiple DCS or
equipment logging systems. They can be configured to provide simple or complex
calculations and typically provide remote access to the plant data over a computer network.
8.2.2 Monitored Parameters
The list of performance parameters that may be monitored includes the following:
Pump flow
Pump suction pressure
Pump suction temperature
Pump discharge pressure
Pump discharge temperature
Pump vibration
Motor input power
Motor voltage
Motor current
Motor speed
Bearing temperature
The parameters actually measured vary from plant to plant. Based on the information provided
by respondents to the EPRI survey conducted in conjunction with the preparation of this guide
and on an informal survey of additional power plant operators, the parameters most often
monitored are:
Condensate flow
Pump and motor bearing temperatures
8-2
These parameters are typically monitored by the DCS. When an abnormal condition is detected,
an alarm is sounded to call the abnormal condition to the attention of the operators.
8.2.3 Performance Calculations
The list of performance parameters that may be calculated from the monitored parameters
includes the following:
Total developed head (TDH)
NPSH requirements
Flow (if not measured)
Hydraulic power
Efficiency
Vibration analysis
8.2.3.1 Total Developed Head
The pumps TDH may be calculated from the measured suction and discharge pressures.
Adjustments must be made to account for the suction and discharge velocity heads and the height
of the pressure measurement devices from the pump datum plane (see Figures 8-1 and 8-2).
8-3
Figure 8-1
Datum Plane for a Vertical Pump
Figure 8-2
Datum Plane for a Horizontal Pump
8-4
8.2.3.2 Net Positive Suction Head
The NPSHa at the pump suction may be calculated by deducting the vapor pressure for the water
temperature at the pump suction from the measured suction pressure.
8.2.3.3 Pump Flow
If not measured, the condensate flow can be estimated by relating it to the measured feedwater
flow by a thermodynamic heat and mass balance of the total steam cycle.
8.2.3.4 Pump Efficiency
The efficiency of the pump is calculated from the calculated TDH, mass flow rate, and the
measured input power supplied to the pump:
Hydraulic Power (kW) = TDH (ft) * Mass Flow (lbm/s)/550 * (gc/g) * 0.7457
Pump Overall Efficiency (%) = Hydraulic Power (kW)/Actual Power Supplied (kW) * 100
8.2.3.5 Pump Vibration
Vibration monitoring is covered in more detail in the preventive maintenance and predictive
maintenance programs described in Section 9.
8.2.4 Data Storage
Typical computer-based performance monitoring applications store data for a predetermined

length of time, based on exception reporting or fixed time intervals. Information that is beyond
the time range is downloaded to an acceptable backup storage device or printed to a hard copy.
Data can also be stored in manual logs that are transferred to a spreadsheet or program for data
analysis.
8.2.5 Data Analysis
A performance monitoring system also provides a user interface to assist in the retrieval of
measured and calculated data. Data retrieval interfaces include custom-built data interfaces and
commercial database or spreadsheet tools. These data can be presented in either tabular or
graphical form.
Plant level analysis of the collected or calculated data is required to evaluate the condition of the
equipment, which can then be used to make equipment improvement recommendations or to
alert plant personnel of possible problems before a failure. Evaluation of the measured and
calculated data over a period of time can detect changes in performance characteristics that may
indicate developing problems.
8-5
Figure 8-3 is a graphical representation of selected monitored and calculated condensate pump
performance parameters from an actual on-line monitoring system.
In this example, the system is set up to monitor and calculate the required parameters hourly. The
load on this plant varies considerably, as shown by the wide range of pressure and power values
plotted. This means that it would be difficult to detect any deterioration of pump performance by
evaluating performance parameters at any given hour or day. However, when trend lines are
superimposed on the hourly plots of data over the monitored period, it can be seen that the
measured pump discharge pressure has decreased and the measured motor input power has
increased, while the calculated pump efficiency has decreased.
Monitoring data trends similar to those illustrated in Figure 8-3 can help detect deteriorating
pump condition or developing problems. Some representative trends that can be tracked by a
performance monitoring system and the possible conditions indicated by the trends are included
in Table 8-1.
Figure 8-3
Condensate Pump Performance Data Trends
8-6
Table 8-1
Representative Performance Trends and Indications
Noted Trend Possible Indication
Reduction in TDH Pump wear, including increased clearances

and/or impeller degradation
Reduction in suction pressure; constant Plugging of suction strainer

condenser pressure
Increased motor current or power; steady Pump wear

discharge flow
Increased bearing oil temperature with Worn bearing

constant ambient temperature
8-7
9
CONDENSATE PUMP MAINTENANCE PRACTICES
Traditional power plant maintenance practices included inspecting, cleaning, and maintaining
equipment on a rigorous time-based schedule. These practices generally kept the equipment
functioning well, but were costly in terms of personnel and maintenance budget. Today, few
plants have the staff and resources available to follow this approach.
Consequently, there may be a tendency to focus on the equipment that requires the most attention
and provide maintenance for other generally reliable equipment, such as condensate pumps,
only on an as-needed basis. In the short term, this approach may appear to save resources, but in
the long run may be costly if a piece of equipment that has been largely ignored deteriorates,
wears out, or fails. The cost of an equipment failure may include not only the cost of repairing or
replacing the equipment, but also the cost of lost generation if the failure results in a plant
shutdown or derating.
A recommended alternative approach for routine maintenance is condition-based maintenance

(CBM). CBM is designed to maintain plant equipment based on its condition instead of on a
fixed timeline or hours of operation. CBM minimizes potential failures by looking for signs of
impending failure, thereby optimizing maintenance costs. The goal of CBM is to maximize the
maintenance cycle of the equipment while minimizing the risk of a plant shutdown or load
reduction due to equipment failure. At the same time, a CBM program allows for better
maintenance planning of spare parts and labor.
Key O&M Cost Point

Condition-based maintenance is designed to minimize potential failures
by looking for signs of impending failure, thereby optimizing
maintenance costs.
Predictive (PDM) and preventive (PM) maintenance are integral parts of a CBM program to
minimize unscheduled and costly corrective maintenance. PM and PDM are used to assess the
condition of the equipment to decide what work is needed and when it is required. When
assessing equipment condition, it is important that all information pertaining to that piece of
equipment is available. This information includes vibration data, performance data, oil analysis,
thermography data, estimated hours of operation, number of starts, information from the last
overhaul, work orders, inspection information, work performed, and any other PDM and PM
completed.
Plant personnel will be able to make informed decisions regarding the best way to maintain
equipment at an optimal cost if there is a greater quantity and quality of pump information
available. A condition assessment checklist can be used to collect pertinent data and information.
The checklist incorporates the necessary information to assess the overall condition of the pump
9-1
Condensate Pump Maintenance Practices
and motor. The following sections discuss PDM, PM, and corrective maintenance associated
with condensate pumps and motors.
A condensate pump condition assessment checklist can be used to gather data so that plant
personnel can make better decisions about equipment maintenance needs. A sample checklist is
provided in Table 9-1.
9-2
Table 9-1
Condensate Pump Condition Assessment Checklist
Vibration
Date: / / Condition: Excellent ( ) Good ( ) Fair ( ) Poor ( )
Data Collection X ampl. X phase Y ampl. Y phase Comments
Motor top brg
Motor axial --- ---
Motor bottom brg
Base top
Base bottom
Base axial --- ---
Discharge pipe
Suction pipe
Performance
Date / / / / / / / / / / / /
Net load
Pumps operating (A, B, both)
Suction strainer diff pressure
Hot well level
Hot well temperature
Condensate flow
Deaerator level
Feedwater flow
Lube Oil Condition
Date / / / / / / / / / / / / / /
Cleanliness code
% Water
Preventive Maintenance
Date Results Date Results
Hot well level alarm calibration / / / /
Condensate flow calibration / / / /
Hot well level trip calibration / / / /
Minimum flow device calibration / / / /
Inspect/grease seal / / / /
Inspect/grease coupling / / / /
Check coupling alignment / / / /
Operator Checklist
Date Results Date Results
Seals / / / /
Noise / / / /
Piping / / / /
Winding temperature / / / /
Motor amps / / / /
Brg metal temperature / / / /
Oil levels / / / /
Pump suction pressure / / / /
Pump discharge pressure / / / /
Suction strainer diff pressure / / / /
9-3
Table 9-1 (cont.)

Condensate Pump Condition Assessment Checklist
Motor Condition
Date / / / / / / / / / / / /
Stator winding temp
Motor amps
Brg metal temp - top
Brg metal temp - bottom
Equipment History
A Pump Date Results
Last overhaul / /
/ /
/ /
Work performed / /
/ /
/ /
/ /
/ /
Work outstanding / /
/ /
/ /
/ /
/ /
B Pump Date Results
Last overhaul / /
/ /
/ /
Work performed / /
/ /
/ /
/ /
/ /
Work outstanding / /
/ /
/ /
/ /
/ /
Motor Diagnostics
Date A Motor Results Date B Motor Results
Supply voltage / / / /
Running current / / / /
Motor speed / / / /
Bearing metal temperature / / / /
Winding temperature / / / /
Insulation resistance / / / /
Polarization index / / / /
Current analysis / / / /
DC hi pot (step) / / / /
Winding resistance / / / /
9-4
A maintenance task template as shown in Table 9-2 recommends the frequency of maintenance
tasks. Frequency of tasks will vary due to the criticality, duty cycle, and severity of the service
condition of the equipment. For example, a unit with 100 percent capacity pumps will have a
different maintenance strategy than a unit with two 50 percent capacity condensate pumps.
Plant personnel should develop a maintenance strategy based on how the equipment will be
maintained, what predictive and preventive methods will be used, how and how often the
information will be assessed, and what the determining factors are for an overhaul or pump
shutdown.
Key Technical Point

Develop a strategy on maintaining plant equipment. Each piece of
equipment, especially critical equipment, should have its own strategy.
9.1 Predictive Maintenance
Predictive maintenance (PDM) includes (but is not limited to) the following:
Vibration monitoring
Performance monitoring
Oil analysis
Thermography
On-line motor monitoring
9.1.1 Vibration Monitoring
Vibration monitoring should be performed routinely to establish baseline data for rotating
equipment. A vibration analyzer should be utilized to determine the significance of the vibration.
Newer technology analyzers will determine a vibration signature, and the data can be
downloaded to a software program to keep a history and determine alarm points for action.
9-5
Table 9-2
Maintenance Task Template
1 2 3 4 5 6 7 8
Critical Yes X X X X
No X X X
Duty Cycle High X X X X X
Low X X X
Service Condition Severe X X X X
Maintenance Task Mild X X X X
Predictive Maintenance
Vibration monitoring See Section 9.1.1 6W 6W 6W 6W 6W 6W 6W 6W
Performance monitoring See Section 9.1.2 1Y 1Y 1Y 1Y 1Y 1Y 1Y 1Y
Oil analysis See Section 9.1.3 3M 3M 3M 3M 3M 3M 3M 3M
Thermography See Section 9.1.4 1Y 1Y 1Y 1Y 1Y 1Y 1Y 1Y
Preventive Maintenance
Calibrations See Section 9.2.1 1Y 1Y 1Y 1Y 1Y 1Y 1Y 1Y
Packing and seal lubrication See Section 9.2.2 1Y 1Y 1Y 1Y 1Y 1Y 1Y 1Y
Operational rounds See Section 9.2.3 Daily Daily Daily Daily Daily Daily Daily Daily
Motor testing See Section 9.2.4 1Y 1Y 1Y 1Y 1Y 1Y 1Y 1Y
Corrective Maintenance
Pump overhaul See Section 9.3 AR AR AR AR AR AR AR AR
Packing and seal replacement See Section 9.3.11 AR AR AR AR AR AR AR AR
AR - As Required
W - Weeks
M - Months
Y - Years
9-6
No matter what technology or equipment is used, it is essential to analyze data to determine

vibration characteristics of the component in order to assess its condition.
Key Technical Point

For vertical pumps, vibration will show up as motor vibration.
Inaccessibility to a pump forces vibration assessment from the motor.
Data should always be gathered at the same locations on the equipment to allow direct
comparison of data gathered over a period of time. These measurement locations should be
permanently marked. Due to the inaccessibility of vertical condensate pumps, vibration for
pumps of this type will show up as motor vibration and may be diagnosed through readings
collected from accessible locations such as the motor, motor base, and piping. Vibration data
should be collected at the following locations:
Motor (top and bottom bearings) in line with and 90 degrees to the discharge piping
Axial reading on top of the motor
Motor pedestal (top and bottom bearings) in line with and 90 degrees to the discharge piping
Discharge piping (if accessible) in the relational direction of motor readings
Vibration data should be collected every six weeks. For peaking units, data should be collected at
least at the beginning and end of the peak period. This will allow ample time to establish a
baseline for the peak season should deficiencies arise and to address deficiencies while the unit is
not in demand.
9.1.2 Performance Monitoring
Performance monitoring is necessary to determine whether the pump is performing well enough
to meet flow requirements for the condensate system. Many different tools can be used to
accomplish this task, whether a distributed controls system or an operator with a checklist is
used. It is not necessary to have an elaborate system to monitor pump performance.
If available, the following parameters should be measured and recorded to assess condensate
system performance versus plant performance:
Hot well level
Hot well temperature
Condensate flow
Deaerator or drum level
Feedwater flow
Net load
Number of pumps in operation
9-7
Monitoring pump performance over a period of time will enable the detection of degradation and
will facilitate the decision regarding the best time to overhaul the pump and regain lost pump
capacity. Section 8 discusses what, when, and how pump performance should be monitored. It is
important to understand that degradation in performance does not necessarily mean that the
pump is ready for an overhaul. System flow requirements should be calculated, and as long as
requirements are being met, an overhaul can be postponed. Monitoring the rate of degradation
will enable more accuracy in predicting when the pump will be unable to sufficiently meet flow
requirements and when to schedule an overhaul.
9.1.3 Oil Analysis
Vertical condensate pump line shaft bearings are normally lubricated by condensate, but motor
bearings and bearings for horizontal pumps are often lubricated with oil.
Oil analysis is an accurate tool in determining the condition of the equipment and lubricant. It is
important to evaluate the oil for water content, particulate count, and particulate makeup. Oil
degradation occurs primarily by contamination, which is caused by water, dirt, bearing wear, and
condensation. Chemical breakdown, caused primarily by overheating, also leads to oil
degradation. Due to the criticality of the condensate system, it is recommended that oil samples
be analyzed every three to six months. If contamination problems exist, more frequent analysis
should be performed until the problem is resolved and the oil is within cleanliness specifications.
9.1.4 Infrared Thermography
Infrared thermography provides a method for noncontact detection of temperature patterns in a

component or piece of equipment that may indicate developing problems or impending failures.
Thermography can be used to detect motor problems (the entire motor, including the terminal
box, should be inspected), coupling misalignment, packing wear or installation problems,
inadequate bearing lubrication, and other problems that may not otherwise be indicated by a
hands-on check of the equipment or by normal instrumentation.
More detailed information regarding thermography can be found in EPRI NP-73, Infrared
Thermography Guide, Revision 2.
9.1.5 On-Line Motor Monitoring
An advanced technology is available to monitor the motor condition while it is operating. The
parameters monitored include, but are not limited to, the following:
Motor starting current
Overvoltage/undervoltage indication
Voltage measurement
Percent voltage imbalance
Percent current imbalance
9-8
Percent kilowatt imbalance

Bus frequency measurement
Voltage spikes or dips
Current spikes or dips
Ground indication
Motor startup time
Motor running hours
Although the cost of the technology may be prohibitively high in many applications, condensate
motors frequently have stator temperature indication and bearing metal temperatures. These
measurements can be used to monitor motor condition. Stator temperature measurement should
be utilized to prove that motor heaters are operational during shutdowns and one-pump
operation.
9.2 Preventive Maintenance
9.2.1 Calibrations
To ensure proper protection and accurate monitoring, calibration of condensate system protective
and measurement devices should be completed annually. These devices include hot well level
alarms and trips, minimum flow transmitters or switches, discharge and suction pressure
indications, and condensate flow transmitters.
9.2.2 Packings and Seals
Some packing arrangements require periodic greasing that should be performed at least annually.
Many packing arrangements are self-lubricating and do not require additional lubrication.
Packing must maintain a small leakage rate for cooling. The sealing mechanism should be
visually inspected during normal daily operator rounds to detect any abnormalities or
maintenance necessary. See Section 9.3.12 for information about maintenance of seals and
packing.
9.2.3 Operational Rounds
Operations staff play a significant role in assessing equipment condition because of their
knowledge and understanding of the equipment and how its performance changes. Operators
performing routine daily rounds or observations of the equipment will be able to detect changes
in sounds, vibrations, pressure indication, and packing leakoff.
9-9
9.2.4 Periodic Motor Testing
Periodic motor testing is recommended to reduce the risk of motor failure and to improve the
equipment assessment process. The following tests and inspections are recommended because of
their trendability and nondestructiveness:
Supply Voltagethese data help determine abnormal motor performance and winding
overheating conditions. Although routine voltage verification is not required, baseline
voltage data should be recorded under normal operating conditions and is recommended to
be checked at intervals of 18 to 24 months. This information can be used for comparison
during future abnormal events.
Running Currentrecorded values of running current can help determine overload or other
abnormal operating conditions. Baseline currents should be recorded for all three phases and
trending values at 6- to 12-month intervals for continuously operated motors or 12- to 24-
month intervals for intermittently operated motors.
Motor Speedthis information serves as a backup to running current as a measure of motor
load. Baseline data should be recorded and checked again at 24- to 48-month intervals for
continuously operated motors.
Bearing Temperaturethis information is recorded to determine if the bearings are
performing in the manner in which they were designed to operate for long bearing life. For
continuously operated motors, bearing temperatures should be recorded at 6- to 9-month
intervals.
Winding Temperaturethese data are analyzed for excessive temperature that can cause
premature aging of the winding insulation. The recommended period for recording is 6 to
12 months. Data should be correlated with running current, voltage, and vibration level.
Insulation Resistancethis simple test provides basic information, such as whether the
insulation is clean and dry. It tests motor cables, motor leads, and winding. Recommended
test periods are 24 to 36 months for low voltage motors (600 volts and lower) and 12 to
18 months for medium voltage motors (above 6007200 volts).
Polarization Indexthese data are recorded in conjunction with the insulation resistance test
for medium voltage motors. The test interval is the same (12 to 18 months). A polarization
index of 2 or higher is usually considered good. An index lower than 2 requires further
investigation and may require a dc step voltage hi pot test.
Current Analysisthis test indicates the presence of broken rotor bars or short-circuiting rings
in squirrel-cage rotors. After the initial benchmark tests, the recommended time for
performing this test is 36 to 60 months for medium voltage motors and 60 to 72 months for
low voltage motors. The longer period for low voltage motors is due to their use of die-cast
aluminum rotors, which, when driving pumps, are not likely to develop rotor problems. This
test can be used to investigate rotor vibration problems caused by cracked rotor bars or short-
circuiting rings that produce vibration only under load.
DC Hi Pot (Step)this test is recommended for medium voltage motors on a 36- to 60-month
schedule. The minimum recommended test value is 1.9 times the rated line-to-line voltage.
This test value ensures that the motor has enough voltage-withstand capability to survive a
line-to-ground failure of another motor on the same bus. A line-to-ground failure can raise
9-10
the neutral voltage of other motors (and the line-to-line voltage of two phases). Multiple
motor failures can result from a single line-to-ground fault if the motors have weak windings.
Motor Vibrationbecause of the importance of maintaining a low vibration level for motor
well-being, the relatively high incidence of bearing failures (see Section 6), and the
sensitivity or rotor vibration to indicate bearing problems, misalignment, damaged parts, and
electrical imbalance, it is recommended that motor vibration be checked at 6- to 9-month
intervals.
Oil Analysisoil analysis can be helpful in determining bearing performance and possible
deterioration. Periodic checks for oil color, viscosity, and acidity can aid in preventing or
anticipating bearing failure. Section 9.1.3 covers oil analysis in more detail.
Winding Resistancewinding resistance can be taken when the insulation resistance
measurement is made: at 12- to 18-month intervals for medium voltage motors. This test is
more significant for motors subject to conditions that foster corrosion of motor connections,
such as outdoor locations.
9.3 Corrective Maintenance
Eventually, repairs will need to be made to the pump and/or motor as CBM indicates. Repairs
will consist of removal, disassembly, replacement of worn parts, reassembly, and installation.
The following sections describe a typical removal, repair, and reinstallation sequence for a
vertical can-type condensate pump. A cutaway view of a multistage vertical condensate pump is
shown in Figure 9-1. The pump and motor manufacturers O&M manuals should always be
consulted for specific procedures and precautions applicable to the equipment.
The repair process should be performed in a clean area with sufficient space to lay out the parts
in order of disassembly. Cleanliness throughout the repair process is important. This is a close
tolerance, high-speed machine and should be handled as such.
9-11
Figure 9-1
Vertical Can-Type Condensate Pump
9-12
9.3.1 Equipment Isolation
It is important that proper lockout/tag-out procedures are followed to prevent injury or

equipment damage from energy sources.

Follow proper lockout/tag-out procedures when working on any piece of
equipment to prevent injury or equipment damage.
1. Close suction and discharge valves and tag.
2. Lock out power supply to driver and tag.
9.3.2 Removal
1. Disconnect all electrical connections and tag.
2. Matchmark mating components.
3. Disconnect any external auxiliary piping connections.
4. If a sleeve is used, loosen the mechanical seal from the shaft.
5. Disconnect the driver shaft from the pump shaft by removing the fasteners from the flanged
coupling. This will allow the pump shaft and impellers to drop down. If the coupling has a
spacer, remove the lower set of fasteners only.
6. Remove the bolts that attach the driver to the discharge head.
7. Lift the driver off of the pump and set it on wooden supports. Be sure that the supports are
high enough to clear the shaft and shaft coupling.
8. Disconnect the discharge piping from the pump.
9. Remove anchor bolts (or nuts). If the pump has a suction can, remove the nuts attaching the
discharge head to the suction can.
10. Lift the pump vertically until pump suction clears the base.
11. Cover the opening in the foundation.
12. Lower the pump into a horizontal position on a suitable support in an area suitable for
disassembly.
9-13
Key O&M Cost Point

Vibration problems following reassembly of a pump are frequently
caused by reassembling coupling halves with one half rotated relative to
its position prior to disassembly. Matchmarking coupling halves prior to
disassembly will facilitate reassembly in the same relative position, and
may help avoid expenditure of time and effort diagnosing and correcting
vibration problems.

If more than minor repairs are anticipated, it is recommended that the
pump be taken to a shop or other clear area with a smooth floor and
overhead lifting equipment.
9.3.3 Pump Disassembly
Key Technical Point

As disassembly proceeds, matchmark mating components to facilitate
reassembly of the components in the same relative position.
1. Remove the adjusting nut from the pump shaft. The nut may have left-hand threads. Remove
the pump half of the flanged coupling with the key from the pump shaft.
2. Unbolt the mechanical seal housing and throttle bushing housing.
a. For mechanical seals mounted directly to the shaft, remove the mechanical seal housing
and slide the seal over the shaft. Remove the seal drive collar and throttle bushing
housing.
b. For mechanical seals mounted on a sleeve, remove the mechanical seal housing and seal
as one unit (be sure that set screws in the drive collar are loose). Remove the throttle
bushing housing.
Key Technical Point

Before proceeding with disassembly, make sure that the discharge head
and bowl assembly are supported independently of one another.
3. Remove the top column from the discharge head. The nuts are located just under the
discharge head. Remove the discharge head, being careful not to damage or bend the shaft
extending through the discharge head.
9-14
Key Technical Point

If more than one length of column pipe is involved, each column pipe
and shaft should be matchmarked to keep the shaft extensions the same
during reassembly.
Key Technical Point

Caution: When using wrenches on shafting, always place the wrenches
on the same side of the shaft to avoid excess side strain on the shafting.
Care should always be taken so that exposed lengths of shafting are not
bent or otherwise damaged.
4. Remove the head shaft and coupling if they have not been removed earlier (left-hand
threads).
5. Remove the bearing retainer by slipping it over the shaft. Any nicks or burrs on the shaft
should be removed before removing the bearing retainer.
6. Remove the column pipe by unbolting at the nearest joint from the top of the pump.
7. Each time a line shaft coupling is exposed, the line shaft and coupling should be removed by
holding the lower line shaft and turning the coupling (line shaft threads are left-hand).
Bearing retainers should be removed after the line shaft coupling. Before lifting the bearing
retainer out of the register in the flanged column, remove any nicks or burrs on the shaft.
8. Repeat Steps 6 and 7 for each piece of column pipe removed.
9.3.4 Disassembly of Bowl Assembly
When disassembling the bowl assembly, always number and tag all bowls and impellers for ease
of reassembly.
Although the following procedure describes disassembly with the bowl assembly in the
horizontal position, disassembly and reassembly may be performed with the assembly either in
the horizontal position or upside down in the vertical position, using the motor base to support
the assembly. An advantage of assembly and reassembly in the vertical position is that the
components are less likely to become cocked relative to each other. However, care must be taken
to ensure that components are attached or supported so that they will not disengage and fall off
when the assembly is inverted.
9-15
Key Technical Point

Consider disassembly and reassembly of the bowl assembly upside down
in the vertical position, supported by the motor base. Components are
less likely to become cocked relative to each other. However, be sure that
components are either attached or supported such that they will not
disengage when the assembly is inverted.
1. Lay the bowl assembly in the horizontal position and block evenly.
2. Remove the suction bell (or case) plug, if supplied.
3. Measure the end play.
a. Push the shaft down until the impeller(s) seat(s) against the bowl(s).
b. Mark the shaft position.
c. Pull the shaft up until the impellers hit.
d. Record the distance traveled (end play = _____).
4. Remove the shaft coupling (threads are left-hand).
5. If a discharge case is supplied, remove discharge case fasteners and slide the discharge case
off of the shaft.
6. Remove bowl fasteners and slide the top intermediate bowl off of the shaft.
Key Technical Point

Do not allow the weight of bowls or impellers to rest on an unsupported
shaft.
7. Remove the impeller.
a. Put the shaft up so that the impeller is not against the bowl seat.
b. Remove the fasteners.
c. Slide the impeller down the shaft.
d. Remove the split thrust rings.
e. Slide the impeller off of the shaft.
f. Remove the straight key from the shaft.
9-16
8. Repeat Steps 6 and 7 until all intermediate bowls and impellers have been removed.
9. Slide the suction bell off over the bottom end of the shaft.
10. If a sand collar is supplied, loosen the set screw and slide the sand collar off of the shaft.
Dress the shaft where it was marred by the set screw.
9.3.5 Inspection and Cleaning
After disassembly, all components should be thoroughly cleaned and examined for physical
defects, wear, corrosion, and damage. When repairing a bowl assembly that has been in service
for several years, the physical condition or strength of all parts such as cap screws, bowls, and
bowl threads must be carefully checked.
Key O&M Cost Point

Worn and degraded parts should be replaced to improve equipment
reliability.
When attempting to rework any part, extreme care must be taken to maintain alignment of
mating parts and as new tolerances.
9.3.6 Impellers
Clear all passageways and check for signs of damage from abrasion or corrosion. Replace any
impeller that shows signs of excessive wear.
Check impeller running clearances against as new tolerances as listed in the manufacturers
O&M manual. If clearances exceed the manufacturers tolerances, wear rings should be installed
to obtain correct tolerances. If the original unit was furnished with bowl and/or impeller wear
rings, they may be removed by pressing or machining. If the original unit did not have wear
rings, the impeller hub outside diameter (OD) and bowl inside diameter (ID) must be machined
to accept them. Recommended press fits data should be obtained from the manufacturer.
Replacement wear rings may be furnished semifinished if ordered separately. Bowl wear rings
will require machining of the bore after they have been pressed into the casting. Impeller wear
rings will require machining of the OD after they have been pressed onto the casting. Finish on
wear ring surfaces must be smooth and in accordance with manufacturers allowable roughness
values.
Check the perpendicularity of the ends of the impellers with the centerline of the bore. Correct
any discrepancies to within the manufacturers recommended tolerances.
9-17
Check the impeller bore and shaft diameter to ensure correct fit within the manufacturers
tolerances. Correct any discrepancies.
9.3.7 Bowls
Clear all passageways and check for signs of damage from abrasion or corrosion. Minor weld
repairs may be made, but excessive wear may warrant bowl replacement. Be sure to check for
erosion at the webbing.
Check bowl-to-bowl fit for both concentricity and dimension and, if required, correct to within
the manufacturers tolerances.
9.3.8 Shaft
Check the shaft for pitting, wear, and straightness. Shaft damage is usually best corrected by
replacing the shaft.
Always check the total indicated runout of the shaft on disassembly. Rechecking the runout prior
to reassembly is also a good idea if significant time has passed since disassembly, as changes
may have occurred due to damage in storage, handling, or transit.
The shaft must be straight and within the manufacturers tolerances. If the shaft is not straight, it
must be straightened or replaced. If the deflection is gradual over a considerable length, it may
be possible to straighten the shaft by supporting it on two blocks straddling the crooked section
and applying pressure to the high side to deflect the shaft in the opposite direction. If the shaft
has a sharp crook (dogleg), it is recommended that the shaft be replaced because the shaft will
not always remain straight.
Although it is possible to straighten a bent shaft, it should be recognized that there are risks
associated with doing so. In some cases, a shaft that has been mechanically straightened will tend
to return to its deformed state following reinstallation. This generally occurs after the shaft has
been in operation for a period of time and has been subjected to typical vibration and temperature
cycles associated with normal pump operation.
If the deformation returns, the resulting costs and impacts can be extensive. In addition to the
costs associated with disassembly and reassembly of the pump and replacement of the shaft,
costs are likely to be incurred for replacement or repair of other damaged pump components,
including bearings, seals, and wearing rings. Depending on the severity of the shaft deformation
and ensuing damage, impellers and bowls may also require repair or replacement. In addition to
the direct repair and replacement costs, the costs associated with the equipment downtime and
possible plant derating (with resulting lost generation) could be significant and should also be
considered.
9-18
Key O&M Cost Point

Although it is possible to straighten a bent pump shaft, recognize that
there are risks associated with doing so. A bent shaft may tend to return
to its deformed state following reinstallation, resulting in damage to
other pump components, disassembly/reassembly costs, and equipment
downtime, with possible plant derating and lost generation.
9.3.9 Bearings
Check all bearings for total clearance over the shaft. It is recommended that all bearings
indicating visual wear be replaced. In addition, any bearing whose running clearance exceeds
as new tolerances by more than 50 percent should be replaced (refer to the manufacturers
O&M manual). Rubber bearings should always be replaced when servicing a pump.
Bronze, epoxy, carbon, and hard-backed rubber bearings are pressed into their respective bores.
They can either be pressed out or machined on the ID until the wall is thin enough to collapse.
Some rubber bearings are the snap-in or glue-in type. These can be removed by prying inward on
the outside of the bearing to collapse it. If the bearing bore of the housing is heavily scarred or
corroded, the part should be replaced or reworked to provide a true bore for the bearing.
Replacement bearings are designed to be pressed into housings so bores will shrink to as new
tolerances. Check the bore of bearings after pressing and ream as necessary to ensure as new
tolerances.
9.3.10 Parts Preparation
Before proceeding with assembly, thoroughly clean all bolts, nuts, threaded connections, and
mating faces and apply pipe joint compound. Clean up any burrs with a file or emery cloth.
Cleanliness and proper lubrication are required to guarantee ease of reassembly and proper
pump operation. Check the shaft for straightness and remove all burrs or nicks. Even if the shaft
is new, has been previously straightened, or was checked for runout on disassembly, it is
recommended that it be rechecked at this point to ensure that damage has not occurred in transit
or handling.
Check clearances on all replacement parts on receipt to properly reassemble and minimize
turnaround on wrong parts.
9-19
9.3.11 Pump Reassembly
1. Insert the shaft into the suction bell. Adjust so that the bottom of the shaft is even with the
bottom of the suction bearing.
2. Place the straight key in the key seat of the next impeller to be assembled.
3. Slip the impeller over the shaft and key and seat it in the suction bell or bowl.
4. Semi-open/additional stages only: slide shims over the shaft and insert into the impeller hub
until the shims match the level of the circular keyway in the shaft. Be sure that all impellers
are seated against their respective bowls.
Key Technical Point

Shims are used for semi-open impellers to ensure that all impellers seat
against their respective bowls. There is no need to shim the first stage of
semi-open bowl assemblies or any stage of enclosed bowl assemblies.
5. Adjust the shaft so that the circular key seat is just above the hub of the impeller.
6. Insert the split thrust rings into the circular key seat with the counterbored holes away from
the impeller.
7. Align the holes in the thrust rings and impeller. Insert fasteners and tighten evenly.
8. If the pump was supplied with a sand collar, install it using the following procedure:
a. Remove the shaft from the suction bell.
b. Slide the sand collar with set screw onto the shaft.
c. Reinsert the shaft into the bell as before. Make sure the impeller is seated.
d. Pull the sand collar against the suction bell hub.
e. Tighten the set screw.
9. Slide the intermediate bowl onto the shaft and mate it with the suction bell or bowl. On
bolted bowl assemblies, rotate the bowl to align its ribs with the bell ribs.
10. Insert and uniformly tighten fasteners on flanged bowls. Use heavy chain tongs to tighten
threaded bowls.
11. Repeat Steps 2, 3, 4 (if applicable), 5, 6, 7, 9, and 10 until all bowls and impellers are
reassembled.
9-20
12. If a discharge case was supplied, slide it over the shaft and mate it with the top intermediate
bowl. Install and tighten fasteners (flanged construction) or tighten using chain tongs
(threaded construction).
13. Grasp the shaft and rotate by hand to check for binding. Also check shaft end play against
the value recorded during disassembly.
14. If the suction bearing was originally grease packed (bronze bearing with plug), repack with
insoluble grease. Work the shaft up and down after greasing to remove excess grease.
Remove enough grease to allow insertion of the plug without forcing the shaft up.
15. Install the suction bell plug and tighten.
16. Screw the shaft coupling onto the shaft.
17. Check all bolts and nuts for tightness. If a threaded discharge case bearing is used, check it
for tightness.
18. Threaded construction only: drill a hole into each flange joint. Insert drive pins into the holes
to secure the joints.
19. Reassemble the pump to the driver and align. More detailed information regarding alignment
of vertical pumps can be found in EPRI TR-112449, Shaft Alignment Guide.
20. Reconnect all external auxiliary piping connections.
21. Reconnect electrical connections.
9.3.12 Packing and Mechanical Seals
9.3.12.1 Packing
A better understanding of packing function can be gained by observing what happens in a

stuffing box when a pump is in operation. To illustrate, a simple stuffing box designed for six
rings of lubricated, braided packing will be used (see Figure 9-2).
Initially, the packing is snugged up by means of the gland. Then, as the pump goes into
operation, the fluid being handled will flow through the slight clearance between the moving
parts and the packing and act as a lubricant for the packing. At this point, the first difficulty can
arise. Seeing this leakage, an inexperienced mechanic may be inclined to tighten the packing
gland nuts and, instead of making just a slight adjustment, will tighten the nuts to eliminate the
leakage. Having succeeded in eliminating the leakage, an unacceptable side effect has been
produced: the packing will run dry, creating frictional heat.
At this point, the saturant in the packing begins to melt and flow outward and thus supply the
vital lubricant needed to prevent burning the packing and scoring the shafts. Then, as the packing
readjusts itself, some volume of packing is lost, and pumped fluid leakage reoccurs.
9-21
Figure 9-2
Packing Box
When the packing has been compressed to the point that the gland is about to contact the upper
face of the packing container, remove the gland, add one extra packing ring, and readjust. If this
fails to reduce the leakage, remove all of the packing rings and repack with new rings.
To properly adjust the packing leakage, allow the pump to run for 15 minutes, and if the leakage
rate is more than desirable, take up one-eighth turn on the gland nuts. The packing adjustment is
made with the pump running. Before making another adjustment, allow the packing to equalize
against the increased pressure and the leakage to gradually decrease to a steady rate. (Flowserve
Corporation, used with permission.)
Key Technical Point

Pump packing must leak slightly to ensure proper lubrication and
cooling.
For the first few days, the packing will run a little warmer until it has burnished in. The leakage
rate will often reduce by itself during this time.
Metallic and plastic packings are good for temperatures to at least 450F (230C). Note that even
if the leakage is warmer than the fluid being pumped, the packing is not necessarily being
damaged.
Periodic inspections of leakage should be performed, but tightening of gland nuts should be
avoided unless absolutely necessary. Overtightening wears out packing prematurely and causes
scoring and damage to the shaft.
9-22
9.3.12.2 Mechanical Seals
Key O&M Cost Point

Maintaining a spare seal or seal kit on-site provides for almost
immediate repair/replacement, thus improving plant reliability and
availability.
Considering the many variables encountered in mechanical seal applications, it is recommended

that the local mechanical seal service representative be contacted for assistance. It is also
recommended that all mechanical seal installations be backed up with a spare mechanical seal
kit. Maintaining a spare seal or seal kit on-site allows almost immediate repair or replacement.
There are also special seal cartridge designs that permit removing a complete cartridge and
replacing it with a new one. Old cartridges can be repaired and placed back on the shelf ready for
use. Worn bearings can set up vibrations, which may cause mechanical seal failure.
9-23
10
TROUBLESHOOTING
Key O&M Cost Point

A structured troubleshooting approach is important for quick
identification of problems in order to promptly effect repairs and return
components to service.
The following information regarding maintenance and troubleshooting of problems associated

with centrifugal condensate pumps is restricted to commonly used pump types for condensate
service. This is due to the wide variation in pump types, ranges in size, and differences in design,
materials of construction, and system design philosophy. The pump and motor manufacturers
instruction manuals must be carefully considered by plant engineering, operation, and
maintenance personnel prior to performing any operation and maintenance activity.
The information presented in this section is intended to be used as a guide to troubleshooting

possible pump operation problems. If a check of the suggested solutions does not clarify and cure
the problem, the best action is to contact the pump manufacturer. The manufacturers experience
with similar applications should enable them to suggest an immediate solution or a technique for
diagnosis and resolution of the problem.
For additional information regarding troubleshooting of pump problems, see EPRI TR-114612,
Pump Troubleshooting, Volumes 1 and 2.
10.1 Troubleshooting of Pump Operating Symptoms
Table 10-1 provides a summary of problems that may be noted during operation or attempted
operation of the pump, as well as probable causes and suggested remedies.
Some operating problems are more likely to occur during initial pump startup and operation or
startup and operation following maintenance. These problems are denoted by a checkmark in the
column in the table labeled S. Other problems that are more likely to occur after the pump has
been in operation for a period of time are denoted by a checkmark in the column labeled O.
Problems that can occur at any time are indicated by checkmarks in both columns.
10-1
Troubleshooting
Table 10-1
Troubleshooting Pump Operating Problems
(Diagnostic checks that can be made with the pump on-line are indicated in bold type.)
Symptom Probable Cause Remedy S O

Insufficient pressure Impeller trimmed Check impeller
incorrectly dimensions
(new pump or
replacement impeller).
Wrong rotation Check rotation.
Incorrect impeller Check impeller lift. Reset
adjustment (lift) to manufacturers
recommendations.
Installation of incorrect Check impeller against
impeller (that is, left-hand manufacturers drawings
impeller in lieu of right- and specifications for
hand impeller or impeller pump.
with the wrong number of
vanes)
Speed too slow Check voltage.
Suction valve throttled or Check valve position.
closed
Impeller loose Disassemble pump.
Repair impeller.
Clogged impeller or Check impeller and
foreign material in pump pump internals. Remove
pluggage.
Entrained air in pump Check for air in-
leakage.
Leaking joints or bowl Check for leaks.
casings Repair as needed.
Cavitation Listen for
characteristic sound of
cavitation (steady
crackling at pump
suctionsounds like
rocks passing through
pump).
Modify system
operation to avoid
operating pump at this
condition for extended
periods.
Wear rings worn Check wear rings.
Replace/repair as
needed.
10-2
Troubleshooting
Table 10-1 (cont.)


No liquid delivered or insufficient Recirculation valve not Check valve position.
capacity open
Impeller trimmed Check impeller
incorrectly dimensions
(new pump or
replacement impeller).
Suction valve throttled or Check valve position.
closed
Wrong rotation Check rotation.
Insufficient submergence Check submergence.
Consult manufacturer.
Insufficient NPSH Check NPSH.
Consult manufacturer.
Incorrect impeller Check impeller lift. Reset
adjustment (lift) to manufacturers
recommendations.
System pressure or flow Perform system
requirement higher than analysis.
design
Barrel or discharge not Check vent.
vented
Driver inoperative Check driver.
Speed too slow Check motor voltage
and amps.
cavitation (steady
crackling at pump
suctionsounds like
pump).
Modify system
operation to avoid
periods.
Impeller loose Disassemble pump.
Repair impeller or
replace sheared key.
Impeller or bowl plugged Disassemble pump.
Check for pluggage.
No liquid delivered or insufficient Leaking joints Check joints.
capacity Repair leaks.
Strainer or suction pipe Check strainer and pipe.
clogged
Low hot well water level Check water level.
10-3
Troubleshooting
Table 10-1 (cont.)


Shaft broken or Verify shaft integrity.
unscrewed
Internal recirculation due Check motor amp draw
1

to worn wear rings or versus pump flow
other pump components Disassemble pump and
replace or rebuild
components as required.
Vibration Misalignment of pump Check pump alignment
casings, discharge head and correct.
column, bowls, or coupling
Discharge head Check discharge head
misaligned by improper and pipe.
mounting or pipe strain
Resonance: system Consult manufacturer.
frequency at or near pump
speed
Vane-pass vibration Check impeller against
caused by installation of manufacturers
impeller with the wrong requirements.
number of vanes
Coupling reassembled Check matchmarks.
with one half rotated Disconnect and
relative to its position reassemble in correct
before disassembly position.
Motor imbalance: Check motor.
electrical
Motor bearing not properly Check motor bearings.
seated or worn Repair as needed.
Motor drive coupling out of Check coupling.
balance or alignment Repair as needed.
Bent shafting Check shaft.
Clogged impeller or Check impeller.
foreign material in pump Remove any foreign
matter.
Vortex problems in hot Install anti-vortex device
well on suction connection.
Loose or improperly Check bolts and tighten
torqued motor or coupling if required.
mounting bolts
Distorted motor or pump Check base plate and
base plate repair if required.
10-4
Troubleshooting
Table 10-1 (cont.)


cavitation (steady
crackling at pump
suctionsounds like
pump).
Modify system
operation to avoid
period.
Check hot well level
suction. Check piping
for flow restrictions.
Impeller out of balance Balance impeller.
Worn pump bearings Check bearings.
Using too much power Speed too high Check speed and
motor power supply
voltage and frequency.
Improper impeller trim Check impeller
dimensions.
Lubrication oil too heavy Check for correct oil.
System head lower than Perform system
design analysis.
Improper impeller Check impeller
adjustment alignment.
Pump out of alignment Check alignment.
Adjust as needed.
Coupling out of alignment Check coupling
alignment.
Adjust as needed.
Bent shaft Check shaft for
straightness.
Tight bearing or packing Check bearing
temperature. Check
bearings and packing.
Adjust or replace as
needed.
Inadvertent flow losses Check position of
recirculation valve and
other system valves.
Worn pump Rebuild or replace
pump.
Damaged pump Rebuild or replace
pump.
10-5
Troubleshooting
Table 10-1 (cont.)


Abnormal noise Excessive fluid velocity in Check condensate flow
pipe system and compare with
system design flow.
Cavitation due to low Listen for
submergence or operation characteristic sound of
beyond maximum capacity cavitation (steady
rating crackling at pump
suctionsounds like
pump).
Modify system
operation to avoid
periods.
Check hot well level,
suction temperature,
and condensate flow.
Internal recirculation due Listen for
to operation at low flow characteristic sound of
recirculation (random
crackling noise with
high-intensity knocks).
Modify system
operation to avoid
periods.
Install piezometric
transducers to monitor
pressure pulsations.
Motor noise Check motor.
Pump bearing running dry Check bearings.
Impellers dragging on Check impellers and
bowl case bowls.
Foreign material in pump Check pump.
Remove foreign
material.
Pump operation far from Modify system operation
best efficiency point to avoid operating pump
under this condition for
extended periods.
Abnormal noise Broken column bearing Check bearing retainers.
retainers
Broken shaft or shaft Check shaft and
enclosing tube enclosing tube.
10-6
Troubleshooting
Table 10-1 (cont.)


Other loose, worn, or Perform vibration
defective components spectrum analysis.
Air in-leakage Worn or improperly Inspect packing.
adjusted packing Adjust or replace.
Improperly adjusted or Inspect seal.
worn mechanical seal Adjust or repair.
Leaking mechanical joints Check joint fasteners
on pump or piping and tighten as required.
Leaking expansion joint Check expansion joint.
Repair or replace as
required.
Excessive leakage from packing Improper packing Repack correctly.
procedure
Worn, incorrect type, or Repack with correct
defective packing grade for service.
Worn shaft or sleeve Remachine or replace
damaged parts.
Stuffing box packing overheating Improper packing Repack correctly.
procedure
Incorrect type of packing Repack with correct
grade for service.
Packing too tight Release gland pressure.
Readjust to proper
setting.
Insufficient lubrication Adjust gland to allow
proper amount of
leakage.
Packing wears prematurely Improper packing Repack correctly.
procedure
Incorrect type of packing Repack with correct
grade for service.
Insufficient lubrication Adjust gland to allow
proper amount of
leakage.
Shaft or sleeve damaged Remachine or replace
or worn parts. Consider upgrade
of sleeve material.
Abrasives in liquid Remove source of
abrasives or inject clean
liquid into stuffing box at
10 psi (69 kPa) above
stuffing box pressure.
Mechanical seal problems See Table 10-3.
1
Checking the current draw (amp draw) of a pump motor in conjunction with the pump flow is a good way to
diagnose certain pump operating problems.
10-7
Troubleshooting
The amp draw of the motor is an indication of the pump load. Under normal pump operating
conditions, the amp draw and flow are related as follows:
At minimum recirculation, the pump is moving a relatively small quantity of water, and the
motor amp draw is low
At higher pump flows, the amp draw is correspondingly higher
However, if the motor is drawing high amps while the pump is delivering little (if any) flow, this
indicates a problem internal to the pump, such as worn or damaged pump components or high
internal flow recirculation caused by operation at low flows.
Key Technical Point

The current (amperage) draw of the motor is an indication of pump
load. Checking the motor amp draw in conjunction with the pump
discharge flow can help diagnose certain pump operating problems. If
the relationship between measured flow and amps does not follow the
normal expected relationship (low flow, low amps or high flow, high
amps), this may point toward worn or damaged pump components or
internal recirculation.
10.2 Troubleshooting of Pump Components
Table 10-2 provides information to assist in diagnosing probable causes of pump component
problems based on the indications of wear, damage, or failure exhibited by the components.
10-8
Troubleshooting
Table 10-2
Troubleshooting Pump Component Problems
Symptom Probable Cause Remedy

Impellers
Wear on exit vanes and Abrasive action Replace impeller if excessive. Consider
shrouds coating or upgrading material.
Pitting on entrance vanes Cavitation Correct condition or upgrade material to
of impeller extend life.
Pitting on impellers and Corrosion, erosion, or Investigate cost of different materials
bowl casting recirculation versus frequency of replacements.
Wear on impeller skirts Abrasive action or excess Install new bearings and wear rings.
and/or bowl seal ring area wear allowing impeller skirts Upgrade material if abrasive action.
to function as bearing journal
Impellers set too high Check setting and adjust impellers
correctly.
Impeller end seal wear Improper impeller adjust- Install bowl wear rings. Adjust impeller
ment (impeller running on setting per manufacturers
bottom) recommendation.
Impeller loose on shaft Repeated shock load by Refit impellers. If collet mounted, consider
(extremely rare occur- surge in suction or discharge changing to key mounting.
rence) line (can loosen first or last
stage impellers)
Foreign material jamming Remove cause of jamming.
impeller (may break shaft or
trip overloads before
impeller becomes loose)
Differential expansion due to If collet mounted, consider changing to key
temperature mounted. Avoid sudden thermal shock.
Parts improperly machined Correct parts and refit (if necessary).
and/or assembled
Bearings
Premature bearing wear Abrasive action Consider conversion to fresh water flushing
on all bearings or pressure grease/oil
lubrication.
Bearing seized or galling Running dry without Check lubrication: look for plugged suction
on shaft lubrication or evidence of flashing.
Bearing failure or bearing High-temperature failure Check pump manufacturer for bearing
seized temperature limits. Generally temperature
limits are as follows:
Bronze: 175F (79C) maximum in water.
Synthetics: 125F (52C).
Carbon: 300F (100C).
Rubber: 125F (52C).
Excessive shaft wear Rubber bearings will swell in Change bearing material.
under rubber bearings high-temperature service
10-9
Troubleshooting
Table 10-2 (cont.)

Troubleshooting Pump Component Problems

Uneven wear on bear- Pump nonrotating parts Check mounting and discharge pipe
ings, uniform wear on misaligned connection and dirt between column joints.
shaft Correct misalignment, replace bearings, and
repair or replace shaft.
Uniform wear on bearings Abrasive action Replace parts, consider changing materials
and shaft or means of lubrication.
Uniform wear on Shaft runout caused by bent Straighten shaft or replace, clean, and
bearings, uneven wear on shafts, shafts not butted in assemble correctly.
shaft couplings, dirt or grease
between shafts
Shaft ends not properly Remachine to make faces parallel and
faced concentric.
Shaft and Couplings
Bent shaft Improper handling in transit Check straightness. Correct to meet
or assembly manufacturers tolerances or replace.
Shaft coupling unscrewed Pump started in reverse Shafts may be bent; check shafts and
rotation couplings. Correct rotation.
Shaft coupling elongated Motor started while pump Look for faulty check valve. Could also be
(necked down) running in reverse momentary power failure or improper
starting timers.
Corrosion Replace couplings.
Pipe wrench fatigue on Replace couplings.
reused couplings
Power being applied to Check for galling on shaft ends.
shafts that are not butted in
coupling
Broken shaft or coupling Can be caused by same See remedies for elongated coupling.
reasons listed for elongated
coupling
Can also be caused by See remedies for bearing seizure.
bearings seized due to lack
of lubrication
Foreign material locking Add strainers or screens.
impellers or galling wear
rings
Metal fatigue due to Check alignment of pump components to
vibrations eliminate vibration.
Improper impeller Refit impeller.
adjustment or continuous up
thrust conditions, causing
impeller to drag
Bowls
Wear on bowl vanes Abrasive action Coat bowls, upgrade material, or apply
rubber lining.
Wear on bell suction Cavitation Repair damage. Consider upgrade of
vanes material to extend life.
10-10
Troubleshooting
10.3 Mechanical Seal Troubleshooting
Because of the many variables encountered in mechanical seal applications, it is recommended

that plant personnel contact the local mechanical seal service representative for assistance in
addressing seal problems.
Table 10-3 provides information to assist in troubleshooting mechanical seal problems.

Table 10-3
Troubleshooting Mechanical Seals

Seal leaks steadily Faces not flat Check for incorrect installation dimensions.
Blistered carbon graphite seal 1. Check for gland plate distortion due to
faces overtorquing of gland bolts.
2. Improve cooling flush line, if overheated.
3. Check gland gasket for proper
compression.
4. Clean out any foreign particles between
seal faces. Relap faces, if necessary.
5. Check for cracks and chips at seal faces
during installation.
6. Replace primary and mating rings, if
damaged.
Secondary seals nicked or Replace secondary seals.
scratched during installation
Worn out or damaged O-rings Check for proper seals with seal
manufacturer.
Compression set of secondary Check for proper lead-in on chamfers, burrs,
seals (hard and brittle) etc.
Chemical attack (soft and Check seal manufacturer for alternate
sticky) materials.
Spring failure Replace parts.
Erosion damage of hardware Check seal manufacturer for alternate
and/or corrosion of drive materials.
mechanism
Seal squeals during Inadequate amount of liquid to 1. Flush line may be needed (if not in use).
operation lubricate seal faces 2. Enlarge flush line and/or orifices in gland
plate.
Carbon dust Inadequate amount of liquid to 1. Flush line may be needed (if not in use).
accumulating on lubricate seal faces 2. Enlarge flush line and/or orifices in gland
outside of gland ring plate.
Liquid film evaporating between Check for proper seal design with seal
seal faces manufacturer if pressure in stuffing box is
excessively high.
10-11
Troubleshooting
Table 10-3 (cont.)

Troubleshooting Mechanical Seals

Seal leaks See causes listed under Seal 1. See list under Seal leaks steadily.
intermittently leaks steadily 2. Check for squareness of stuffing box to
shaft.
3. Align shaft, impeller, and bearing to
prevent shaft vibration and/or distortion of
gland plate and/or mating ring.
Short seal life Abrasive particles in fluid 1. Prevent abrasives from accumulating at
seal faces.
2. Flush line may be needed (if not in use).
Use abrasive separator or filter.
Seal running too hot 1. Increase cooling of seal faces (for
example, by increasing flush line flow).
2. Check for obstructed flow in cooling lines.
Equipment mechanically Align properly. Check for rubbing of seal on
misaligned shaft.
10.4 Troubleshooting Vertical Induction Motors
Even though an electric motor is a reliable component, lack of maintenance and defects in
design, manufacturing, or workmanship can cause problems. None of the protective devices
available will provide maintenance or solve built-in motor defects, so it is worthwhile to know
when to suspect the motor. Fortunately, a motor will tend to exhibit some signs of distress prior
to a complete and catastrophic failure.
Table 10-4 provides information to assist in troubleshooting motor problems.
10-12
Troubleshooting
Table 10-4
Troubleshooting Motor Problems

Vibration Excessive motor or pump Rebalance.
unbalance
Misalignment or eccentricity of Check and correct.
rotating parts
Open bars in motor rotor Check and correct.
Mounting unstable or uneven Check and correct.
Faulty bearings (improperly Repair or replace.
seated, pitted from long periods
of idleness, fatigued)
Uneven motor air gap Readjust gap.
Operation of spring-loaded Replace with proper bearing.
spherical roller bearing motors
with insufficient thrust load
Oil whip Adjust oil level.
Loose or improperly torqued Check bolts and tighten if
mounting bolts required.
Distorted base plate Check base plate and repair if
required.
Motor noise Worn bearings Replace bearings.
Loose iron Check and correct.
Fan noise Normal noiseno likely
correction.
Vibration See Vibration above.
Bearing noise Bearing noise is a normal
phenomenon, but experience
will tell when noise exceeds
acceptable levels. Such
excessive noise should be
recognized as a symptom of
impending bearing failure.
Motor drive coupling problems Failure of cap screws that join Replace cap screws and
coupling halves torque properly. (Motors are
shipped with specially
hardened cap screws that
require proper torque values
when tightened to prevent
shearing. Overtightening puts
excessive stress on the cap
screw fasteners. Replacement
cap screws should be SAE
Grade 5 or equivalent.)
Unbalanced drive coupling Check and rebalance.
10-13
Troubleshooting
Table 10-4 (cont.)

Troubleshooting Motor Problems

Oil leaks Overfilling Reduce oil to proper level.
Foaming because of improper oil Change to correct oil.
Leaks at fitting Tighten or repair.
Cracked castings (rare) Repair or replace.
Motor bearing failures Plate bearing failures: failure of Disassemble and
oil film because of excessive clean/resurface. Verify thrust
thrust, rusting during storage, or loading and adequate cooling
lack of cooling water water supply.
Sleeve bearing failures: rusting Disassemble and
during storage, improper clean/resurface. Verify proper
lubricants lubricant.
Ball and roller bearing failure
other than normal wear:
a. Improper, contaminated, or a. Clean bearing and replace
deteriorated lubricants lubricant.
b. Excessive loading b. Determine actual loading.
Replace bearing with
properly sized bearing.
c. Repair or replace
c. Flat-spotting (false brinelling) damaged bearings.
during transportation or Properly secure during
storage transportation and rotate
shaft regularly during
storage to prevent
damage.
d. Disassemble and
d. Rusting clean/resurface.
e. Correct alignment.
e. Misalignment
Bearing overheating:
a. Overgreased a. Clean out and regrease.
b. Old grease b. Clean out and install new
grease.
c. Overloading c. Determine loading.
Replace bearing with
properly sized bearing.
d. Misalignment d. Correct alignment.
e. Inadequate grease e. Add grease to proper
level.
High-temperature breakdown of Install oil suitable for operating
lubricating oil temperature.
10-14
11
TRAINING AND PERSONNEL QUALIFICATIONS
Significant specialized training is generally not required for personnel who install and maintain
condensate pumps, drive motors, and related monitoring equipment. Most plants have personnel
readily available, either in-house or on a contract basis, who are qualified to install and maintain
this equipment. In general, maintenance personnel who hold first class mechanics credentials (or
equivalent) will already have the basic skills and knowledge required for proper condensate
pump installation and maintenance. Because condensate pump drive motors generally do not
incorporate unique or specialized features, personnel with first class electricians credentials will
have the skills and knowledge required to handle any necessary motor work. First class
technicians will normally have the basic skills and knowledge required for working with any
condition or performance monitoring equipment. However, as with any piece of rotating
equipment, personnel should become thoroughly familiar with the manufacturers
recommendations and guidelines for installation, handling, disassembly, reassembly, and
operation of the specific equipment items prior to beginning any major installation, maintenance,
or repair work.

Although highly specialized training is not required for working on
condensate pumps, become thoroughly familiar with the manufacturers
recommendations for the specific equipment prior to beginning any
major installation, maintenance, or repair work.
Additional specialized training may be advisable in the area of installation and maintenance of
mechanical seals. These seals are typically difficult to install correctly and require closer
attention to tolerances and cleanliness compared to most other mechanical equipment in a power
plant.
11.1 Basic Training Requirements
Installation and maintenance personnel should have training in the following areas of basic
equipment maintenance and handling:
Basic safety procedures
Plant-specific tag-out and operating procedures
Assembly and disassembly of rotating equipment, including checking and setting clearances
Rigging and lifting of large equipment
Alignment of rotating equipment
11-1
Training and Personnel Qualifications
General equipment checkout and startup procedures

General precautions regarding handling and cleanliness of equipment
Additionally, electricians responsible for handling motor and electrical devices should have
adequate training in disconnecting and reterminating high voltage electrical leads.
11.2 Approach to Training
Initial training of inexperienced personnel and training to provide continuing skill development
for experienced personnel can be effectively provided either by utilizing in-house resources or
the resources of equipment manufacturers or training specialists. Most plants utilize a
combination of both.
Typically, at a new facility, the manufacturer will be brought in to assist with the general training
of the operations and maintenance staff as part of the construction contract. It is during this phase
that pump fundamental design application, materials of construction, head-pressure relationships,
efficiency, hydraulics, and other technical details of the pumps are discussed.
One training session is usually devoted to the immediate concerns of the day-to-day operation
and maintenance of the pump. Typical subjects covered for the operators would include checks
required prior to putting the pump in service, specific areas to observe during operator rounds,
and procedures to follow during and after major component/system trips and other nonroutine
events.
Another session for maintenance personnel would cover the details of pump construction to
allow regular maintenance to be performed. Areas discussed would include procedures to
disassemble the pump for component replacement/checking, repack seals, install bearings, align
couplings, and install mechanical seals. An important part of the training would be a detailed
discussion of the troubleshooting overview presented with the manufacturer's pump manual. This
troubleshooting overview allows maintenance personnel to become familiar with problems
experienced with this specific pump that have been identified by other customers and methods to
repair those problems or how to follow a systematic approach to identify the root cause of the
problem.
Often, manufacturers will present certificates acknowledging the completion of their training, but
these are not recognized by any industry body and are not required to maintain the pump.
Many plants utilize the services of the mechanical seal manufacturer to address the specialized
attention that should be given to properly maintain and install the seals.
The plant may also choose to bring in a manufacturers representative to train the technicians on
the specifics of a monitoring system component or system. A certificate may be given, but there
is no requirement to do so.
In-house training should include supervised on-the-job assignments to affirm the principles
learned by studying the equipment manufacturers manuals and drawings or application of the
11-2
Training and Personnel Qualifications
lessons provided by the manufacturers representative during training provided on-site. This
training should be monitored and recorded by the plant training department with the intent of
ensuring a minimum competency level for all personnel on the different areas of pump
maintenance. Consistency of training methods also minimizes the human factor errors that can
affect equipment availability and cause uncertainty in root cause failure analysis.
Many plants have in-house training programs utilizing manufacturer-supplied instructional

material supplemented with operating and maintenance experience to make personnel aware of
the proper techniques and procedures to minimize the cost of maintenance and reduce the
likelihood of a pump failure.
Equipment suppliers may also provide alignment classes where the maintenance personnel are
instructed how to align rotating equipment in general. These classes are usually given by local
representatives and repeated as new personnel are hired or new techniques are devised.
11-3
12
REFERENCES
1. American National Standard for Centrifugal Pumps for Nomenclature, Definitions,

Application, and Operation. ANSI/HI 1.1-1.5-1994, Hydraulic Institute, Parsippany, NJ, and
American National Standards Institute, Inc., 1994.
2. American National Standard for Vertical Pumps for Nomenclature, Definitions, Application
and Operation. ANSI/HI 2.1-2.5-1994, Hydraulic Institute, Parsippany, NJ, and American
National Standards Institute, Inc., 1994.
3. Black & Veatch, Power Plant Engineering. Kluwer Academic Publishing, NY, 1996.
4. Deep Draft Vertical Centrifugal Pump Maintenance and Application Guide. EPRI, Palo Alto,
CA: April 1994. NP-7413.
5. DeLaval Turbine, Inc., DeLaval Engineering Handbook. McGraw-Hill, NY, 1970.
6. Electric Motor Predictive and Preventive Maintenance Guide. EPRI, Palo Alto, CA: July
1992. NP-7502.
7. Flowserve Corporation, Byron Jackson Vertical Pumps Operation, Maintenance, and

Problem Solving, Bulletin No. 2-510-8A.
8. Goulds Pumps, Inc., Goulds Pump Manual. Sixth Edition, Industrial Products Group, Seneca
Falls, NY, 1995.
9. Tyler G. Hicks and T.W. Edwards, Pump Application Engineering. McGraw-Hill, NY, 1971.
10. Ingersoll-Dresser Pump Company IB5023.CHP, Repairs - Product Lubricated - Mechanical

Seal Solid Shaft Driver.
11. Ingersoll-Dresser Pump Company IB6011.CHP, Repairs - Flange Column - Product

Lubricated.
12. Ingersoll-Dresser Pump Company IB7021.CHP, Repair of Bowl Assembly - Inspection and
Tolerances - Enclosed Impellers.
13. Ingersoll-Dresser Pump Company IB7052.CHP, Repair - Bowl Assembly - Keyed

Construction.
14. Ingersoll-Dresser Pumps, Pump Selection Manual. Second Edition, 1995.
15. Johnston Pump Company, Vertical Pump Troubleshooting Guide. 1994.
12-1
References
16. Johnston Pump Company, GEDa.28, Useful Definitions. May 1996.
17. Igor J. Karassick, Centrifugal Pump Clinic. Second Edition, Marcel Dekker, Inc., NY, 1989.
18. Igor J. Karassick, William C. Krutzsch, Warren H. Fraser, and Joseph P. Messina, Pump
Handbook. Second Edition, McGraw-Hill, NY, 1986.
19. KSB Centrifugal Pump Lexicon. Federal Republic of Germany, Second Edition, 1980.
20. Val S. Lobanoff and Robert R. Ross, Centrifugal Pumps Design & Application. Second
Edition, Gulf Publishing, Houston, TX, 1992.
21. M.T. Radio, IDP Form 75126, Selecting a Reliable Utility Grade Condensate Pump.
Ingersoll-Dresser Pump Company, 1995.
22. Preventive Maintenance Basis, Volume 12: Vertical Pumps. EPRI, Palo Alto, CA: July 1997.
TR-106857-V12.
23. A.J. Stepanoff, Centrifugal and Axial Flow Pumps. John Wiley & Sons, NY, 1948.
24. Sulzer Pumps, TTMC API 610 V, Vertical Can Pumps. W2030e.
25. Sam Yedidiah, Centrifugal Pump Users Guidebook. Chapman & Hall, NY, 1996.
12-2
A
NERC-GADS DATABASE REPORTS
This Appendix includes the NERC-GADS database reports from which the information in
Table 6-2 was extracted and summarized.
Three reports were retrieved: one for all fossil-fired units up to 60 years old, one for units up to
30 years old, and one for units 31 to 60 years old. Each of the reports is included in the following
pages.
Each report includes four pages:

x The first page identifies the age of the units included in the report as well as additional
descriptive data
x The second page provides statistical data, including the event type and cause code for pumps,
motors, and condensate system valves
x The third and fourth pages provide a listing of the number and age of the units included in the
report
The terms used in the tabular data on the second page of each report is defined as follows:
Forced Outage (FO) - An unplanned component failure or other condition that requires that the
unit be removed from service.
Maintenance Outage (MO) - The removal of a unit from service to perform work on specific
components that can be deferred but requires that the unit be removed from service before the
next planned outage.
Forced Derating (Fde) - An unplanned component failure or other condition that requires that
the load on the unit be reduced.
Scheduled Derating (Sde) - Removal of a component for scheduled repairs that requires a
capacity reduction before the next planned outage. Removal is scheduled in advance and has a
predetermined duration.
Reserve Shutdown (RS) - Period during which the unit is available for service but not
electrically connected to the transmission system for economic reasons.
FDRS - Forced derating during reserve shutdown.
SDRS - Scheduled derating during reserve shutdown.
A-1
NERC-GADS Database Reports
Unit-Year (U-Yr) - A summation of the age of each unit multiplied by the number of years
(including fractions of a year) from the commercial operation date to the close date of the study
period (the end of 1998).
Occurrences: Number - The number of events during the recorded period.
Occurrences: Avg/U-Yr - The number of occurrences divided by the number of unit-years.
Equivalent Hours: Lost/Occur - A summation of the equivalent unavailable hours (due to

outages or derating) for the plants evaluated divided by the number of occurrences.
Equivalent Hours: Lost/U-Yr - A summation of the equivalent unavailable hours (due to

outages or derating) for the plants evaluated divided by the number of unit-years.
Equivalent MW Hours: Lost/Occur - A summation of the product of the equivalent lost hours
times the net dependable capacity for each of the plants, divided by the number of occurrences.
Equivalent MW Hours: Lost/U-Yr - A summation of the product of the equivalent lost hours
times the net maximum capacity for each of the plants, divided by the number of unit-years.
Net Maximum Capacity (NMC) - The capacity a unit can sustain over a specified period when
not restricted by ambient conditions or equipment deratings, minus the losses associated with
station service and auxiliary electrical loads.
A-2
Data for Units 0 to 60 Years Old
A-3
A-4
A-5
A-6
A-7
A-8
A-9
A-10
A-11
A-12
B
CONDENSATE PUMP SPECIFICATION CHECK SHEET
1. Type [ ] Vertical Can Type

[ ] Horizontal Split Case
[ ] _______________________
2. Number of Pumps to be Provided
3. Fluid Temperature, qF
Design, for continuous service and performance
rating of pump
Maximum, for intermittent service
4. Design Capacity, gpm
5. Design Total Developed Head, ft
(For vertical pumps, TDH is referenced to pump base plate setting elevation. For horizontal pump,
TDH is referenced to centerline of shaft. Head loses through pump, including suction inlet losses
and column friction losses, are not included in this value.)
6. Allowable Shutoff Head, ft
Maximum
Minimum
7. Available NPSH, ft
Design
Single Pump Runout
(Available NPSH does not include losses from suction nozzle to impeller. For vertical pump, NPSH
is referenced to pump base plate setting elevation. For horizontal pump, TDH is referenced to
centerline of shaft.)
8. Elevations
Finished floor elevation
Centerline elevation of pump suction connection
Centerline elevation of pump discharge connection
9. Pump Casing Design Pressure [ ] Maximum Shutoff Head Plus 25 psi
[ ] _________________ psi
10. Pump Motor Speed, rpm
11. Pump First Stage Impeller Suction Type [ ] Single
[ ] Double
[ ] Manufacturers Option
B-1
Condensate Pump Specification Check Sheet
12. Maximum Peripheral Velocity of First Stage

Impeller, ft/sec
13. Maximum Suction Specific Speed of First Stage
14. Chemical Characteristics of Condensate
pH Range ______________ to ______________
Ammonia Residual, ppb ______________ to ______________
Hydrazine, ppb ______________ to ______________
Total Dissolved Solids Excluding Ammonia and
Hydrazine
Other
15. Operating Characteristics
Type of Control [ ] Constant Speed with Throttle Valve
[ ] Variable Speed
Parallel Operation Required [ ] Yes
[ ] No
Number of Pumps in Parallel Operation
Minimum Single Pump Runout Capacity Required
on Design Head/Capacity Curve Without Pitting,
Cavitation, or Excessive Vibration, gpm
Description of Anticipated Startup and Shutdown
Operation
16. Pump Location [ ] Indoors

[ ] Outdoors
17. Design Life, years
18. Number of Anticipated Annual Startups and
Shutdowns
19. Shaft Seals
Type [ ] Packed Stuffing Box
[ ] Mechanical Seal
[ ] Manufacturers Option
Seal Water Source (If Required) [ ] External
[ ] Self-Contained
Seal Water Temperature Range, qF ______________ to ______________
20. Equipment To Be Provided With Pump
[ ] Drive Motor
[ ] Variable Speed Equipment
[ ] Suction Strainer
[ ] Minimum Continuous Flow Recirculation Orifice
[ ] Provisions for Mounting Vibration Transducer on or Near Stuffing Box
B-2
Condensate Pump Specification Check Sheet
[ ] Vibration Monitoring Equipment

[ ] Spare Rotating Element
21. Drive Motor Power Supply (3-phase) _______________ Volts

_______________ Hz
22. System Head Curves Attached
Parallel Pump Operation, Drawing No.
Single Pump Operation, Drawing No.
B-3
C
LISTING OF KEY INFORMATION
The following list provides the location of key Pop Out information in this report.
Key O&M Cost Point
Section Page Key Point
4.2.4 4-6 To improve the reliability of a plant with two half-capacity condensate pumps,
consider the purchase of a complete spare internal pump assembly. Having
this assembly on-site would reduce the length of time the plant is out of
service or derated due to failure of a condensate pump.
7.3.3 7-11 Prevention of air entry for a shut-down pump is important in reducing O2
ingress into the condensate system and the resulting effects.
8.0 8-1 Performance monitoring can contribute to increased equipment reliability and
thus increased plant availability.
9.0 9-1 Condition-based maintenance is designed to minimize potential failures by

looking for signs of impending failure, thereby optimizing maintenance costs.
9.3.2 9-13 Vibration problems following reassembly of a pump are frequently caused by
reassembling coupling halves with one half rotated relative to its position prior
to disassembly. Matchmarking coupling halves prior to disassembly will
facilitate reassembly in the same relative position and may help avoid
expenditure of time and effort diagnosing and correcting vibration problems.
9.3.5 9-14 Worn and degraded parts should be replaced to improve equipment reliability.
9.3.8 9-18 Although it is possible to straighten a bent pump shaft, recognize that there
are risks associated with doing so. A bent shaft may tend to return to its
deformed state following reinstallation, resulting in damage to other pump
components, disassembly/reassembly costs, and equipment downtime, with
possible plant derating and lost generation.
9.3.12.2 9-19 Maintaining a spare seal or seal kit on-site provides for almost immediate
repair/replacement, thus improving plant reliability and availability.
10.0 10.1 A structured troubleshooting approach is important for quick identification of

problems in order to promptly effect repairs and return components to service.
C-1
Listing of Key Information
Key Technical Point
4.1 4-2 The type of pump required for condensate system service is primarily deter-
mined by the NPSH available.
4.2.3 4-5 When specifying a condensate pump, be sure that the available NPSH is
calculated accurately and is based on worst-case operating conditions. To
determine the worst-case condition, evaluate the possible combinations of low
hot well water level, low condenser pressure, high condensate temperature,
and high condensate flow that can be realistically anticipated in the operation
of the plant. Base the specified NPSH on the condition that provides the
minimum NPSH at the pump suction.
4.3.1 4-8 The shutoff head for a condensate pump should be no less than 120 to
125 percent and no more than 140 percent of the design head.
4.3.2 4-9 In order to ensure cavitation-free operation, verify that the manufacturers first-
stage impeller design is based on the following criteria:
x Suction specific speed less than 12,000
x First-stage impeller peripheral velocity of less than 65 ft (20 m) per

second
If the design does not meet these criteria, the manufacturer should be asked
to provide evidence that the proposed design has a proven inservice history of
acceptable cavitation performance.
4.4.1 4-10 Complete and accurate information regarding the application must be
provided to the pump manufacturer in order for the manufacturer to provide a
properly designed pump.
7.1.1 7-3 Allowing a pump to run dry will very quickly cause extensive damage. Be
certain that the pump and piping are completely filled with water before
starting following initial installation or reassembly.
7.1.1 7-3 Monitor the flow, pressures, temperatures, motor current, and vibration levels
closely any time a pump is started following disassembly or maintenance. Be
prepared to shut down the pump immediately if the measured quantities
indicate a problem, especially if the suction or discharge pressure drops to
zero.
7.2.2 7-12 When operating a pump at runout conditions, monitor the suction pressure
and temperature closely to avoid damage due to cavitation caused by
reduction of the NPSH below the pumps minimum requirements.
7.2.3 7-14 Never allow a pump to operate for extended periods at flows below the
minimum allowable recirculation flow established by the manufacturer.
C-2
9.0 9-2 Develop a strategy on maintaining plant equipment. Each piece of equipment,
especially critical equipment, should have its own strategy.
9.1.1 9-6 For vertical pumps, vibration will show up as motor vibration. Inaccessibility to
a pump forces vibration assessment from the motor.
9.3.3 9-13 As disassembly proceeds, matchmark mating components to facilitate

reassembly of the components in the same relative position.
9.3.3 9-14 Before proceeding with disassembly, make sure that the discharge head and
bowl assembly are supported independently of one another.
9.3.3 9-14 If more than one length of column pipe is involved, each column pipe and
shaft should be matchmarked to keep the shaft extensions the same during
reassembly.
9.3.3 9-14 Caution: When using wrenches on shafting, always place the wrenches on
the same side of the shaft to avoid excess side strain on the shafting. Care
should always be taken so that exposed lengths of shafting are not bent or
otherwise damaged.
9.3.4 9-15 Consider disassembly and reassembly of the bowl assembly upside down in
the vertical position, supported by the motor base. Components are less likely
to become cocked relative to each other. However, be sure that components
are either attached or supported such that they will not disengage when the
assembly is inverted.
9.3.4 9-15 Do not allow the weight of bowls or impellers to rest on an unsupported shaft.
9.3.11 9-19 Shims are used for semi-open impellers to ensure that all impellers seat
against their respective bowls. There is no need to shim the first stage of
semi-open bowl assemblies or any stage of enclosed bowl assemblies.
9.3.12.1 9-21 Pump packing must leak slightly to ensure proper lubrication and cooling.
10.1 10-7 The current (amperage) draw of the motor is an indication of pump load.
Checking the motor amp draw in conjunction with the pump discharge flow
can help diagnose certain pump operating problems. If the relationship
between measured flow and amps does not follow the normal expected
relationship (low flow, low amps or high flow, high amps), this may point
toward worn or damaged pump components or internal recirculation.
C-3
7.0 7-1 Before attempting to operate unfamiliar equipment, consult the

manufacturers operating and maintenance manuals and system
operating procedures.
7.1.2.1 7-4 Some or all start permissives may be inoperable in the manual operating
mode. When starting a pump in the manual mode, verify that all
conditions for a safe startup are met to prevent injury to personnel or
damage to equipment.
8.2.1 8-1 In order for any performance monitoring system to be effective, it must
be based on performance data that are collected regularly and
systematically.
9.3.1 9-11 Follow proper lockout/tag-out procedures when working on any piece of
equipment to prevent injury or equipment damage.
9.3.2 9-13 If more than minor repairs are anticipated, it is recommended that the
pump be taken to a shop or other clear area with a smooth floor and
overhead lifting equipment.
11.0 11-1 Although highly specialized training is not required for working on
condensate pumps, become thoroughly familiar with the manufacturers
recommendations for the specific equipment prior to beginning any major
installation, maintenance, or repair work.
C-4
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Condensate Pump Application and

Please read the License Agreement

Final Report, August 2000

EPRI Project Manager

(A) MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, (I)

(B) ASSUMES RESPONSIBILITY FOR ANY DAMAGES OR OTHER LIABILITY WHATSOEVER

ORGANIZATION(S) THAT PREPARED THIS DOCUMENT

Black & Veatch

This report was prepared by

Fossil Maintenance Application Center (FMAC)

This report describes research sponsored by EPRI.

Russell Briggs MEAG Power

FMAC and the TAG were supported in this effort by

Black & Veatch

3 CONDENSATE SYSTEM DESCRIPTION ........................................................................... 3-1

4 CONDENSATE PUMP APPLICATION................................................................................ 4-1

4.3.4 Materials of Construction .................................................................................... 4-11

5 TECHNICAL DESCRIPTIONS OF PUMPS AND MOTORS ................................................ 5-1

Single Seal, Balanced......................................................................................... 5-24

6 FAILURE MODE ANALYSIS ............................................................................................... 6-1

7 PUMP OPERATION ............................................................................................................ 7-1

8 PERFORMANCE MONITORING ......................................................................................... 8-1

9 CONDENSATE PUMP MAINTENANCE PRACTICES ........................................................ 9-1

11 TRAINING AND PERSONNEL QUALIFICATIONS ......................................................... 11-1

12 REFERENCES ................................................................................................................ 12-1

A NERC-GADS DATABASE REPORTS ................................................................................A-1

B CONDENSATE PUMP SPECIFICATION CHECK SHEET..................................................B-1

C LISTING OF KEY INFORMATION ......................................................................................C-1

Figure 3-1 Thermal Plant Condensate System........................................................................ 3-2

Figure 5-27 Single, Inside Unbalanced Seal.......................................................................... 5-23

Figure 7-4 Condensate Pump Performance at Design Conditions........................................... 7-9

Table 4-1 Determination of Developed Head........................................................................... 4-3

This guide is divided into 12 sections and appendices:

Section 9 addresses typical practices for maintaining condensate pumps, including

1.3 Pop Outs

Key O&M Cost Point

Key Technical Point

Key Human Performance Point

Bowl Head x Capacity

Bowl Head x Capacity

Impeller Balancing - Correction of residual unbalance by removing or adding weight. May be

v = velocity of the liquid

Antifriction Bearing - A bearing incorporating a peripheral assembly of rotating elements used

Vacuum-Pressure Impregnation (VPI) - The filling of voids in a coil or insulation system by

Condition-Based Maintenance (CBM) - A methodology for performing maintenance activities

Corrective Maintenance - Activities performed in response to unsatisfactory equipment

Predictive Maintenance (PDM) - A subset of preventive maintenance, referring to activities

Preventive Maintenance (PM) - Activities performed to prevent unsatisfactory equipment

Infrared Thermography - A noncontact method of monitoring a piece of equipment using

Condensate System Description

Condensate System Description

Condensate System Description

Condensate systems may also include the following:

4.1 System Configuration and Pump Type

Condensate Pump Application

Key Technical Point

4.2 Pump Sizing Considerations

4.2.1 Flow Capacity

Condensate Pump Application

4.2.2 Total Developed Head

Total Suction Head

Formula Item Reference/Comments

Condenser pressure Based on the condenser operating

+ Velocity head The kinetic energy of the liquid (energy in