CONSTRUCTION AND OPERATION OF BOILER FEED PUMP

General : The high-pressure boiler feed pump is a very expensive machine, which can comply with in operation and efficiency of the feed pump does not only depend on the correct design and careful manufacturing in the works, but also on the reliable operation and maintenance. Therefore, it is important that the operating and maintenance staffs are acquainted with these instructions properly in time. They should know perfectly the operation of the boiler feed pump to be able to find out the cause of defect. The causes of any adverse running of the feed pump found in the beginning may be easily removed without endangering the operation of the power plant and also without the expensive dismantling. Any damage resulting due to the ignorance of the operating instructions will not be the responsibility of the manufacturer even if it occurs during the guarantee period. 1.0 Description of the feed pump : The high pressure feed pumps of barrel type satisfy in all respects the latest developments the stated requirements, only with a careful and skilled maintenance. The safety

achieved for the design and operation of the feed pumps. It consists of the pump barrel, into which is mounted the inside stator together with the rotor. The high-pressure cover along with the balancing device closes the hydraulic part. The suction side of the barrel and the space in the high-pressure cover behind the balancing device are closed along with the balancing device and with the stuffing box casings. The bracket of the radial bearing of the suction side and the bracket of the radial and thrust bearings of the discharge side are fixed to the lowpressure covers. The entire pump is mounted on a foundation frame. The hydraulic coupling and two couplings with coupling guards are also delivered along with the pump. The watercooling and oil lubricating connections are provided with their accessories. All the instruments necessary for observing the performance of the feed pump are mounted on the pump, on local panel and on the piping. 1.01 Rotor: The rotor of boiler feed pump consists of the shaft, impellers, distance bushes, throttle bush, balancing disc, supporting rings, stuffing box bushes, nuts for holding the stuffing box bushes, the disc of axial bearing with the lock nut, nuts for securing the coupling, shaft keys and lubricating rings. For obtaining shrunk fitting of the impellers on the shaft, the impellers are first heated and then assembled. For this purpose, stepped diameters are provided on the shaft. On each stepped diameter two impellers are mounted. The axial thrust of the rotor is taken up by the balancing disc, which is keyed, to the shaft. The axial expansion of the rotor part is limited to the extent of dilation gap that exists between the throttle bush and the supporting ring. This dilation gap should diameters, the throttle bush and stuffing box bushings is up to be within the limit of 0.2 to 0.3 mm. The maximum run out of the assembled rotor, at the sealing impeller 0.06 mm. The impellers are statically balanced and the rotor as a whole is dynamically balanced within the permissible
253

unbalance according to the standards of the works. Prior to dynamic balancing of the rotor, the deflection of the rotor due to its self weight is also measured. The deflection of the rotor due to self weight moves in the limits of 0.04 to 0.12 mm. All the measurements carried out on the rotor including the actual clearances at the sealing rings are entered in passports delivered with every feed pump. The rotor is supported on The necessary centering of rotor is done with the perfect concentricity of the stuffing box gland bush the throttle bush in the throttle space, a suitable change is made on the set of shims below the centering keys of the low pressure cover. In order to maintain the concentricity of the centering diameter diagonally opposite to each other, by removing from one place and positioning at the other. 1.01 Inside stator : The inside stator consists of stage bodies, the diffusers and rotor. The diffusers are centrally mounted in the stage bodies. They are secured against rotation, by locating pins. Stage bodies are fitted with wearing rings at the place where it is likely to come into contact with the wearing rings of impeller, and the wearing rings are secured to the stage bodies with the help of screws. The entire inside stator is connected to the barrel. The nuts at the ends of these bolts are tightened in order to pre stress the bolts to suit the working pressure and they are secured with the help of locking washers. During the operation of the pump and especially while putting the pump into operation, shocks are developed in the pump which effect the connecting bolts and the connecting bolts being as discharge side. On the suction side, a key fitted and screwed on to the inlet stage a key is provided which is fitted by a screw. This key will slide along the key way in barrel. On the discharge side also, the outlet stage is supported on the barrel by key and keyway arrangement on the supporting block welded to the barrel. The the suction side of the barrel and by aligning the high pressure cover to the end diffuser. While the pump is in operation, the inside stator will get heated earlier than the pump barrel together with the high pressure cover. This means that the expansion of the inside stator owing to temperature will be more that the expansion of the barrel and of the high pressure cover. A dilation gap of 6 mm is therefore maintained between the end diffuser an the high pressure cover. The sealing surfaces of the individual stages are accurately lapped using a fixture, and they seal metal. Therefore it is important that the sealing surfaces should not be damaged especially while dismantling the pump. If they are damaged, they must be relapped in order to obtain the perfect mating surfaces. 1.02 Mechanical seal : The design of the feed pump incorporates Mechanical seal. The mechanical seal eliminates the losses of feed water in stuffing box. Working ability of the feed pump increases. With the mechanical seal, cooling of stuffing box space should be perfect.
254

two

part

bearing

shells.

The

brackets

are

connected

to

the

low

pressure

covers.

with

the

bore

of

the

stuffing

box

casing

and

for

obtaining

the

concentricity

of

on

the

keys,

shims

are

replaced

from

the

centering

keys,

which

are

subjected

to

torsion,

the

inside

stator

is

secured

from

the

suction

side

as

well

centering

of

the

inside

stator

is

carried

out

by

aligning

the

inlet

stage

to

Cooling is carried out by the circulation of water by means of a pumping ring through a cooler. Cooling of the stuffing box space is different from the seal cooler. Even after stopping of the pump stuffing box cooling should be continued. Coolers are designed to keep the stuffing box space temp. below 80 0C. Pump need not be removed from base frame to replace mechanical seal. To replace mechanical seal on discharge side, dissemble thrust bearing, and bearing brackets along with bearing shells. To replace mechanical seal on the suction side, dissemble the coupling along with intermediate piece and bearing brackets along with the shells. Follow the seal disassembly and assembly instructions strictly. 2.0 Function of the feed pump : The water with the given operating temperature should flow continuously to the pump

under a required head. It passes through the suction branch into the intake spiral and from there it is directed into the first impeller. After leaving the impeller it passes through the diffusing passages of the diffuser, where the kinetic energy is converted into potential energy. Afterwards if flows over to the guide vanes to the inlet of the next impeller eye. This procedure repeats from one stage to the other till it passes through the last impeller and the end diffuser. Thus the feed water at the outlet of the last stage attains the required discharge head. A small part of the feed water, i.e. about 5% which is not calculated to the guaranteed delivery capacity, is taken off from the space behind the last impeller for the operation of the automatic balancing device to balance the hydraulic axial thrust of the pump rotor. The feed water passes through the balancing device and comes into the space behind the balancing disc. Feed water is taken from this space to the feed water tank. It is evident from the function of the balancing disc, as it disturbs the hydraulic equilibrium. Therefore the equalizing piping must have sufficient flow capacity. For a safe operation of the balancing device the pressure difference between the suction and balancing leak off should not exceed more than 5 atmospheres. 3.0 Balancing device : Balancing system of the pump takes up the entire axial thrust of the rotor, by means of

the balancing disc. Balancing device is an important aspect of the pump as far as the design and material selection is concerned. Balancing disc fitted to the high pressure cover by mans of the tightening flange and bolts with nuts which are locked by washers. Axial sealing gap is formed between the bearing disc and the balancing disc. Contact surfaces of bearing disc and balancing disc are mutually lapped against each other. Sealing of the individual parts is metal to metal. Full pressure developed by the last impeller is not carried on to the balancing device but throttled by means of the taper bush mounted on the shaft before the balancing disc.
255

device

consists

of

balancing

disc,

secured

to

the

shaft

and

bearing

The feed water passes through the taper bush, through the axial sealing gap. The axial sealing gap is approximately 0.10 mm. Balancing disc can be dismantled without extensive dismantling of the pump in case of damage to the balancing device. 2.0 Lubrication system : The feed pump consists of two radial sleeve bearings and one thrust bearing. All the

bearings are force lubricated by the main oil pump or the auxiliary oil pump or the hydraulic coupling. The thrust bearing is located at the free end of the pump. The feed pump drive motor consists of two sleeve radial bearings. The hydraulic coupling consists of four radial bearings and two tilting pad thrust bearings. Before the start of the pump main motor, lubrication to the various bearings is supplied through the auxiliary oil pump. Once the main motor attains a particular speed after start, the main oil pump of the hydraulic coupling takes over and the auxiliary oil pump is tripped automatically. The details of the switching 'ON' and switching 'OFF' of the oil pumps are dealt in the hydraulic coupling operating instructions and to be followed strictly. Two coolers are provided in the oil system. One for the working oil and the other for lubricating oil. The pressure of oil before the radial bearing should be a minimum of 0.8 atg to 1.0 atg and for the thrust bearing 0.5 atg. Before putting the lubrication system into operation all the oil lines and bearings should be clean. The following instructions should be followed for flushing of the oil system. 2.01 1) 2) 3) 4) 5) 6) Flusing of oil system : The oil pipes are cleaned thoroughly by means of wire brush. After mechanical cleaning the pipes are steam washed with steam of pressure 8 atg and 250
0

A coating of lubricating oil is given to the pipes after steam washed with steam washing against corrosion. After cleaning, the pipes are assembled in position. Fill Servo Fluid - 10" oil upto the mark indicated, through a 50 micron filter. Remove the top halves of the bearings, tilt the bottom half bearings, such that the oil hole in the bearing housing will allow free flow of oil through the system and protect the journal by covering with cloth and thin sheet of metal.

7) 8) 9)

Oil filter and bearings housings are to be cleaned. Mount all the instruments in the oil system. Heating of the oil during flushing is done by inserting steam coil or by heating elements. The oil flushing can be started by switching on the auxiliary oil pump. After the first 4

hrs of flushing the filters should be checked and put back. The choking of filters in the initial stages will be more and it should be cleaned from time to time and put back. The oil temperature during flushing is maintained at about 50-60 oil flushing is stopped. After flushing is completed, the oil tank and coolers are drained cleaned and fresh oil is filled.
256
0

. After ensuring that filters are not getting choked

2.02 1) 2)

Thrust bearing of feed pump : Quantity of oil required for each radial bearing - 7.5 lts/min Quantity of oil required for thrust bearing - 42 lts/min. For kingsbury thrust bearing. 12 lts/min. for Mitchell thrust bearing.

257