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SULZER PUMPS

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"SULZER"





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7. Pump Design
Booster Pump
Yes

No
a.) Casing

No

Main Pump
Yes

- Barreltype

b.) Pump Internals


Booster Pump

1.
2.

Booster Pump

Main Pump

No. of
failures

No. of
failures

No. of
failures

No. of
failures

(total)

( per
year)

(total)

(per year)

Shaft seal failure


Vibration
- Pump max .shaft vibr. at BEP.a)... .. p/p
max. bearing vibr. at .....mm/s p/p
- Piping
- Foundation

3.

Axial balancing device failure

4.

Journal bearing failure

5.

Cavitation damage

6.

Impeller breakage

7.

Rapid wear of rings

8.

Unstable head curve

9.

Broken or damaged shaft

10

Thrust bearing failure

Main Pump

12.

Leaking gakets

13

Bent casing or shaft ( pump seizure )

14.

Cracked diffusers

15.
16.

diffuser
volute

SULZER - PUMPS

List of failures:

Failure Group

11. Oil / water contamination

Segmental(ring sectional) type- Horizontal split

- Diffuseror volutedesign

12

Excessive gear coupling wear


Occurance of water hammering
Other failure

double volute

Power Generation

- First stagesingleor double suction


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1st stage single suction


1st stage double suction

Checklist
Component Analysis

Booster Pump

Pump

) BEP = best efficiency point

Notes:
Main

- Impellerfixation
shrunk
sliding fit
- Impeller arrangement
:

Boiler Feed Pumps

1 st stage

1 st stage

BCP
Boiler
Turbine
Feedwater
Tank

Generator
Condenser

BFP
CEP
CWP




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Project-Study



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Modernisation of Boiler Feed Pump Aggregates for


Power Stations

The study comprises

The necessity for Modernisation


Measures to improve the reliability and
availability of pumps and accessories
Technical advantages of upgraded
equipment against old installations and

Evaluation of economic efficiency.

Power Stations :

kk Gres

8 x 300 MW

kk

8 300

kk Gres

7 x 150 MW

kk

7 150

Country :

xxxxxxxxx

Operating authority :

xxxxxxx

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xxxxxxxx

xxxxxxx

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380-185/200)
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"Sulzer".


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( 600, 850, 1150, 1500)


"SULZER"

8

[ bar ]



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"SULZER"

350
300
250
PE 600

PT 850

PT 1150

PT 1500

200
150

HPT 300-400/6s

HPT 150-300/7s
HPT 300-315/6s

HPT 350-400/7s

100

"Sulzer"

50

200

400

600

800

1000

1200

1400

1600

1800
[ t/]

"Sulzer"

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Q
H
n
T

=
=
=
=

207
1162
2960
125

m3/
m
1/
C

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11


6 500
, 1981 1989 .
- 2 50%
. 78%,
- 20 25.000 .
7500 . .
200.000 . .
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942 m3/
2616 m
5676 1/.
170 C
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"SULZER"

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15,
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Test Results
Results of Vibration Measurements at Site

veff = 0,9 - 1,1 mm/s

Results of Efficiency Measurements at Site


[%]

Measurement Results

86
84

Guarantied

82
80
Original Pump

78
600

700

800

900

1000
Q [t/h]

= 84,5 - 85,5 %

13

M
M
M


(300 )




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1159 m3/h
3321 m
5045 rpm
170 C

h = 84,2 % (SULZER)
h = 72,5 % (
)

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1.16 years

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"Voith"

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750 t/
370 bar ( )
4830 1/.
217 C

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- 217 C.
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2.

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SUDIS = Sulzer Diagnostic System





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Plant

Country

No.off

Blyth P.S.

G. Britain

12

HPTL 54 & 56-7s

Booster

Blyth P.S.

G. Britain

HPT 32-5s

Start-up Pump Casing rehabilitation, joint

Fawley P.S.

G. Britain

NPTX 40

Booster

Mech. seal, protection plate

Kingsnorth P.S.

G. Britain

NPTX 40

Booster

Mech. seal, protection plate

Tilbury P.S.

G. Britain

HPT 32-2s

Start-/Standby NDE carbon bearing

West Thurrock P.S.

G. Britain

HPT 42-4s

Main Feed
Pump

Full cartridge retrofit

Wylfa P.S.

G. Britain

HPT 54-2s

Main Feed
Pump

Partial cartridgisation

Pembroke P.S.

G. Britain

HPT 37-4s

Feed Pump

Casing rehabilitaion, seal upgrade

Maasbracht P.S.

Netherlands

HPTpok 32-25-4s

Start-up BFP

Mech. Seal instead of Floating Rings

Maasbracht P.S.

Netherlands

HPT pok 55-5s

Main Feed
Pump

Static Seal of Delivery Cover

Le Havre P.S.

France

HPT 45

Main Feed
Pump

Mech. Seal instead of Floating Rings

Porcheville P.S.

France

HPTpok 45-5s

Main Feed
Pump

Mech. Seal instead of Floating Rings

Kardia P.S.

Greece

HPTpok 28

Main Feed
Pump

Mech. Seal instead of Floating Rings

Obrenovac P.S.

Yugoslavia

HPTpok 28

Main Feed
Pump

Mech. Seal instead of Floating Rings

Dunamenti P.S.

Hungary

HPTpok 28

Main Feed
Pump

Mech. Seal instead of Floating Rings

Gardanne P.S.

France

HPT 32 X

Main Feed
Pump

Mech. Seal instead of Floating Rings

Amer VII P.S.

Netherlands

HPTpok 35-5s

Main Feed
Pump

Mech. Seal instead of Floating Rings,


Balance drum

Kriel P.S.

South Africa

HPTpok 32-5s

Main Feed
Pump

Elimin.of Shaft Threads, Tie Rods

GKW Mannheim

Germany

ME 200-360/6

Main Feed
Pump

Installation of complete redesigned


Pump

Sostanj P.S.

Slovenia

HPT pok 28-8s

Main Feed
Pump

Retrofit of Rotor and Shaft, Mech.


Seals

Netherlands

HPTpom 28-20

Main Feed
Pump

Change to Balance Drum

Germany

12

HPT 300-3156s/33A

Main Feed
Pump

Installation of Complete Pull-out Block


into Existing Case

Tilbury P.S.

Great Britain

HPT 30-5st

Start and
Standby

Major re-design of NDE with carbon


Bearings

Wylfa P.S.

Great Britain

HPT 54-2st

Main Feed
Pump

Basic Cartridgisation

Buggenum P.S.
Jnschwalde P.S.

Pump-Type

Designation

Modifications
Gland sleeve

20



Country

No.off

Mobil Coryton

Plant

Great Britain

HPT 28-7st

Main Feed
Pump

Major re-design of bearings with


mechanical seals

Poolbeg P.S.

Eire

HPT 28-7st

Main Feed
Pump

Basic Cartridgisation, Mech.Seals and


Material upgrades

Great Island P.S.

Eire

HPT 28-7st

Main Feed
Pump

Basic Cartridgidation and material


upgrades

North Wall P.S.

Eire

KSB

Main Feed
Pump

Hydraulic modification (7% increase)

Kilroot P.S.

N-Ireland

M/P

Main Feed
Pump

Hydraulic upgrade converting 50%


pump to 100%

Tuanku J-Afar P.S.

Malaysia

HPTLX

Main Feed
Pump

Bearing re-design, material upgrade

Isle of Grain P.S.

Great Britain

HPT 45-2st

Turbo Feed
Pump

Re-design gland and seal areas

Dungeness P.S.

Great Britain

HPT 45-2st

Turbo Feed
Pump

Hydraulic upgrade and seal re-design

Russia

22

HPT 300-400/6s

Main Feed
Pump

Installation of Complete Pull-out Block


into Existing Case

Hong Kong

12

HZB 253/640

Booster Pumps Mechanical seals and protection plates

Poolbeg P.S.

Eire

HZB 253/640

Booster Pump Mechanical seals

Aghada P.S.

Eire

HZB 253/640

Booster Pump Mechanical seals

Australia

HPT 30-4st

50% Duty
Pumps

Mechanical seals

Great Britain

HPT 48-6st

Turbo Feed
Pump

Hydraulic upgrade, bearing and seal


re-design

Gaisburg Co-Gen
P.S.

Germany

MC 100 - 14

Main Feed
Pump

Product lubricated bearings, Permavor

Gardabani

Georgia

HPT 300-400/6s

Main Feed
Pump

Installation of Complete Pull-out Block


into Existing Case

India

40

KHI 200

Main Feed
Pump

Hydraulic Upgrade (72% ---> 80% )

Mosenergo
Castle Peak P.S.

Muja P.S.
Drakelow P.S.

BHEL

Pump-Type

Designation

Modifications

21


Permavor R

.

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PERM VOR R

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6000 /

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PermAvor

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. PERMAVOR
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(CSS)
50

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119034 , . , 4

(095) 234 9877

(095) 234 9671


email: Moscow@sulzer.com
www.sulzerpumps.com