BoilerFeedPump(BFP) Review

Presentation By, By Purushottam R.Mukkundi

Topics
BFP Introduction CrossSectionofBFP(Typical) TypicalLayoutofBFP WaterSteamCycle ProcessFlowDiagram SystemIsometrci ViewofHPFeedwater (Typical) PipeIsometricViewofHPFeedwater (Typical) BFPDesignCriteria NPSHConsideration Cavitation BFP TransientStudy TypicalMaterials RecommendedInstruments

BFP Introduction
BFPisamultistagepumpprovidedforpumpingfeedwatertoeconomiser. T Types of fBFPs BFP 1.Ringsectiontype: Thisisthepumpforsendinghighpressureandhigh temperaturefluidtotheboiler.Thetypesvarydependinguponthepressure.The singlecasingtypeisusedforthecombinedcycle,thesubcriticalsteampower generation,etc.

2.Barreltype:Thisisthemultistagepumphavingthedoublecasing,theinner casingcontainedintheoutercasing.Amongvariousboilerfeedwaterpumps,this pumpisadoptedforhighpressureandhightemperatureapplicationasinthe subcritial b i i l steampowergeneration. i Th Thed double bl casing i i isalso l called ll d"barrel "b ltype". " Asinthecaseofthesinglecasing,therearedifferencesinthewayofsplittingthe innercasing,andspecialfeaturesarethesame.

CrosssectionofBFP(Typical)

Typical yp Layout y ofBFP

WaterSteamCycle y ProcessFlowDiagram g ( (Typical) yp )

System y IsometricViewofHPFeedwater ( (Typical) yp )

Pipe p IsometricofHPFeedwater ( (Typical) yp )

BFPDesign g Criteria(Typical) ( yp )
DesignPoint: Thedesigncapacityofboilerfeedwaterpumpisspecifiedbydesign capacity it and dhead. h d The Th d design i capacity it is i based b donplants l t maximum i steam t flow fl requirements.Foralargecapacitypowerstation,thiswouldbethesteamturbine throttleflowatvalveswideopenand5%overpressure,plussteamorfeedwater removedfromandnotreturnedtotheflowpathbetweenboilerfeedpump suction ti and dturbine t bi throttle. th ttl For F example l steam t supplied li dto t processindustries i d ti likesugar,textileetc. DesignCapacity: Thefollowingarecontributingfactorsgenerallyconsideredinthedeterminationof boilerfeedpumpdesigncapacity TurbinethrottlesteamflowtypicallyatVWOand5%overpressureconditions Steamcyclemakeupflow Seamblowingsteamflow,ifapplicable Auxiliarysteamflow,ifapplicable Reheatsteamdesuperheatingflow,ifapplicable Anyothersteam/feedwater requirement(ex (ex.ForProcessapplication)
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BFPDesignCriteria(Typical)
DesignHead : Thetotaldevelopedheadforboilerfeedpumpiscalculatedbydeterminingthe diff difference b between t th theb boiler il f feed dpumpdi discharge h h head dand dsuction ti h head das shownintablebelow. BoilerFeedPumpTotalSuctionHeadDetermination Item Deaerator pressure Head a Comments Basedondeaerator operatingpressure@max. turbine b HBDconditions d Based onlowlow waterlevel instorage g tankofdeaerator. Thisincludes pipefriction loss,suctionfilter50% cloggedcondition(ve value) a Sumofaboveitems
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Max.Static headbetweendeaerator LLL andBFPimpeller p centreline Frictionlossbetweendeaerator andBFP suctionline TotalSuctionHead

BFPDesignCriteria(Typical)
BoilerFeedPumpTotalDevelopedHeadDetermination Item pressure Turbinethrottlep Mainsteamlinefrictionloss Head Comments a a Basedonturbinethrottlep pressureat maximumturbineheatbalanceconditions Basedonmaximumturbineheatbalance conditions.Typically,mainsteamline economicallysizedtorendera100200psi pressuredrop Determinedbythesteamgenerator manufacturer.Generallylimitedbythe plantdesignertoaneconomicallyfeasible valuebyspecification Determinedbythesteamgenerator manufacturerandlimitedbyspecification Basedonsteamgeneratorconfiguration

Superheater frictionloss

Economizerfrictionloss Staticheadbetweensteam drumwaterleveland economizerwaterinlet

a a

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BFPDesignCriteria(Typical)
Item Head Comments Staticheadbetweenthe a Basedonlocationoftheeconomizerinlet economizerwater inlet andPumpTotal elevation and theboiler feedpump Boiler Feed Developed Head Determination thecenterlineoftheboiler Elevation feedpumpimpeller Highpressurefeedwater heaterpressuredrop a Generallylimitedbyfeedwater heaterdesignand specificationsto50psior l d less depending di onth thenumber b of ffeedwater f d t heaters Basedonthefeedwater flowatmaximumturbine heatbalanceconditions

Frictiondropbetweenthe boilerfeedpump dischargeconnectionand theeconomizerinlet Totaldischarge g head Totaldevelopedhead Designmargin Designtotaldevelopedhead

a a

Sumoftheaboveitems Totaldischargeheadminustotalsuctionhead Typically5%ofthesubtotaloftotaldeveloped headabove

Sumoftheaboveitems
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BFPDesignCriteria(Typical)
InstallationData

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Sample p forBFPSizing gCriteria( (Typical)..conti yp )

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Sample p forBFPSizing gCriteria( (Typical)..conti yp )

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Sample p forBFPSizing gCriteria( (Typical)..conti yp )

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Sample p forBFPSizing gCriteria( (Typical) yp )

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NPSHConsiderations Cavitation
TheNPSHAmustexceedthepumps NPSHRortheliquidwillvaporizewithin th pumpimpeller. the i ll This Thi vaporization i ti of f theliquidiscalledcavitation. Cavitation can occur in many areas of the pump. The Th most common and d significant i ifi is within the impeller. In an area on the vane commencing a short distance form the vane tip, the static pressure can fall sharply, sharply before rising again further along the vane. If the local static pressure falls below the vapor pressure of the liquid being pumped bubbles (cavities) form and pumped, travel along the vane. As soon as they reach an area of higher pressure, the bubbles collapse suddenly. This is cavitation.

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NPSHAvailable ClosedsuctionsupplywithHead
NPSHavailableisafunctionofthe systeminwhichthepumpoperates.Itis theexcesspressureoftheliquidoverits vaporpressureasitarrivesatthepump suction. NPSHA=p+LH (VP+hf) Where: p=pressureinsuctionvessel LH=staticheightofliquidin suctionvesseltocenterlinepump VP=vaporpressureofliquidat pumpsuction hf =frictionallossesofliquidin suctionpiping

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NPSHRequired q
NPSHRequiredisphysicaldesignproperty ofeachpump.Itisdependentonthedesign ofthesuctioncasing, casing impeller impeller,capacities andspeeds.InBoilerFeedwater applications thegreaterthemarginbetweenNPSH availabletorequiredthebetterthepump canhandlesuctiontransientsoccurances. NPSHRequiredcanbeidentifiedinvarious ways: Incipient I i i cavitation i i Headdecreasebyacertainpercentage( 0%,1%,3%...) Efficiencylossbyacertainamount Erosionofaspecificmaterialquantityina unitoftime Exceedingofacertainnoiselevel Collapseoftheflow,i.e.totalcavitation
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NPSHRequired q
NPSHrequiredismeasuredontheteststand byreducingthesuctionpressureand measuringdischargepressure. pressure Incipientvaluesrepresenttheveryonslaught ofbubbleformationwithnoreductioninhead. NPSH0%valuesrepresentthebeginningof bubbleformationbutwithnoreductionin head NPSH1%valuesrepresentalargerandmore bubbleswithareductionofdischargeheadof 1%. NPSH3%valuesrepresentincreasing b bbl size bubble i and damountwith i hareduction d i ofdischargeheadof3%. NPSHtotrepresentsapumpinfullcavitation withasignificantreductionindischargehead, head heavyvibrationandnoise.
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NPSHConsideration

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BFPTransientStudy

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BFPTransientStudy
BecauseofthehighoperatingspeedstherequiredNPSHishighandrequires eitheradoublesuctionfirststageasaminimumoraseparateboosterpump. pump Aseparateboosterpumpprovidestheabilitytoprovideahighmarginbetween availableandrequiredNPSHwhichhelpsduringcertainsuctiontransient conditions.

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TypicalMaterials

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Recommended Instruments

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References
NationalPowerTrainingInstitute(NPTI)manualfor BoilerFeedPump. PowerPlantEngineeringbyBlack&Veatch. SULZERMultistageBarrelCasing Boilerfeedpumpbrochure.

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A Questions Any Q ti please l

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Thank You All

Fichtner ConsultingEngineers(I)Pvt.Ltd.

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