GENERIC METHOD STATEMENT YATESMETER PUMP PERFORMANCE EVALUATION TESTS FOR BOILER FEED PUMPS

AE M S L t d . , T h e E n e r g y C e n t r e , F i n n i m o r e In d u s t r i a l E s t a t e , O t t e r y S t . M a r y , D e v o n . E X1 1 1 NR ~ Tel.: +4 4(0) 140 4 81 229 4 ~ Fa x: +4 4(0) 140 4 81 260 3 ~ ~ w w w. Y a t e s me t e r . c o . u k ~

Title

Method Statement

Boiler Feed Pump

Client

1 OVERVIEW
The purpose of this document is to describe the procedures followed during a typical Yatesmeter Pump Test on a high pressure Boiler feed pump. By measuring the temperature differential produced across a pump, a Yatesmeter determines the efficiency of the unit by exploiting the principles of thermodynamics. This method of measurement is highly accurate and the results can be used to perform pump condition monitoring, flow meter calibration, system optimisation and energy management.

2 CONFIGURATION

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Title

Method Statement

Boiler Feed Pump

Client

EQUIPMENT
The AEMS test equipment is fully portable and consists of the following: Yatesmeter Computer Power Monitor (If electric driven) Strobe Temperature Probes Pressure Transducers All equipment is regularly tested to conform to the latest legislation governing the use of Portable Equipment.

3 METHOD OF INSTALLATION
3.1 YATESMETER

The Yatesmeter is powered by either a 240Volt power supply or 110Volt supply. Outside of the UK and North America the unit is normally configured to 240VoltsAC. The Yatesmeter is positioned adjacent to the pump and the temperature and pressure transducers are attached and the sensors connected to the pump as follows:

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Title

Method Statement

Boiler Feed Pump

Client

The temperature probes need to be installed into thermowells in the suction delivery pipework. There are pressure valves in the pump pipework and the suction and delivery pressure transducers will be attached to these via push fit connectors provided as part of the test. It is normal to fit goose necks into the tappings prior to testing these are also supplied as part of the test. All fittings and transducers are rated to the pressures and temperatures required.

3.2

POWER METER

During the test procedure it is necessary to monitor the input power to the motor drive this is done by attaching a Power Meter to a 5 Amp secondary circuit fed from the primary voltage through a voltage transformer and through current transformers via an instrument circuit. The data from the Power Meter is either read in real time into the Yatesmeter via a data lead or logged remotely via a computer and the input power keyed in manually at each test point. AEMS use the following Powermeters : True 3 watt meter method 2 watt meter method 1 watt meter method The power meter connects shown are for a two watt meter method.

3 PHASE 3 WIRE 110V Phase to Phase

Voltage Inputs VR VY VB CT Inputs RIN ROUT YIN YOUT BIN BOUT

B
0 11 V

110V
0V

R
11

Earth Fuses

Voltage Transformer
S1 S2 P2

R Y B

P1

S1 P1

S2 P2

to load

Current Transformers

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Title

Method Statement

Boiler Feed Pump

Client

TEST PROGRAMME
Activity Set up equipment and attach transducers and power monitoring equipment Calibrate temperature probes Run Pump at open valve Normal operating point Test Point 1 Change operating condition Test Point 2 Change operating condition Test Point 3 Change operating condition Test Point 4 Change operating condition Test Point 5 Change operating condition Test Point 6 Duration 2 hours

30 mins 30 mins

30 mins

30 mins

30 mins

30 mins

30 mins

Total Time Note

5 hours

At least one test point should be taken with the second pump running All points are subject to operational constraints

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Title

Method Statement

Boiler Feed Pump

Client

PUMP MONITORING

3.3

CALIBRATION

The probes and transducers can be attached while the pump is running. Once attached a calibration of the temperature probes is undertaken which necessitates the reversal of the temperature probes, once only from the suction to the delivery pipework i.e. the delivery probe starts off in the suction pipework and is reversed to its final destination in the delivery pipework halfway through the calibration procedure and the suction probe is similarly reversed. The calibration procedure is done at a constant pump speed.

3.4

TEST POINTS

The following parameters are taken at each test point: Pump Efficiency Flow Head Power to Motor / Pump Delivery Pressure Suction Pressure Motor Efficiency Velocity Head Absolute Water Temperature Differential Temperature Across Pump Note: The characteristics for the pump would be charged by varying the speed of the pump, or by changing the number of pumps in parallel.

(a)

Where possible the test is undertaken with the pump running in its system on its own. Where this is not operationally possible the first point should be with the pump on its own (approx 5 mins) but subsequent points can be taken with a pump or pumps in parallel.

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Title

Method Statement

Boiler Feed Pump

Client

Requirements prior to testing 1. Do the electric motors have variable speed drives. 2. If there are no VSDs how can the operating state be changed. 3. If we use our own power monitoring equipment would it have to be logged remotely or could we run a data cable between the starter and the pump position (up to 200m length). 4. Can we run a single pump on its own. 5. What is the availability of the pumps i.e. is there any restriction on the period or the time of day for the testing. 6. On the high pressure side of the pump does the gate valve used for pressure have a pressure bleed off capability.

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Client:

Method Statement

Sulzer

Station:

CASE STUDIES The following case studies are extracts from actual tests on Boiler Feed pumps and boosters. One was undertaken in the UK and the other within a Nuclear facility in The USA.

MAIN PUMPS AND BOOSTER PUMPS 101, 201 AND 302. PUMP PERFORMANCE
The following table lists the pump performance achieved on-site at the maximum flow rate for each pump referred to the rated speed of 5100 rpm. The data below is displayed in metric units. Pump No. Main 101 Main 201 Main 302 Booster 101 Booster 201 Booster 302 Pump Head (m) 1725.06 2124.56 1525.89 560.80 534.46 480.40 Shaft Power (MW) 8.071 8.088 8.061 3.426 4.627 6.559 Pump Efficiency (%) 83.5 83.0 71.6 76.1 56.5 32.1 Pump Flow (m3/hr) 1671.8 1352.2 1618.0 1869.2 1972.7 1763.2

The data below is displayed in US units Pump No. Main 101 Main 201 Main 302 Booster 101 Booster 201 Booster 302 Pump Head (ft) 5659.63 6970.34 5006.18 1839.90 1753.49 1576.12 Shaft Power (HP) 10818.94 10841.46 10804.96 4593.16 6202.74 8792.78 Pump Efficiency (%) 83.5 83.0 71.6 76.1 56.5 32.1 Pump Flow (USgpm) 7361.3 5954.1 7124.5 8230.9 8686.5 7763.9

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Method Statement

Sulzer

Station:

OBSERVATIONS / RECOMMENDATIONS
Table 0-1 and Table 0-2 below show a comparison of the manufacturers test data with the data taken during the test by AEMS on 22/07/2003 - 24/07/2003. The comparison is carried out at constant head. Pump Head (ft) 5659.65 6970.34 5006.23 Pump Current As-new Head Pump Pump (m) Efficiency Efficiency 1725.06 83.5 84.1 2124.56 83.0 85.0 1525.9 71.6 82.5 Table 0-1: High certainty results Pump Current As-new Head Pump Pump (m) Efficiency Efficiency 560.80 76.1 80.2 534.46 56.5 78.9 480.40 32.1 76.4 Table 0-2: Low certainty results % Change in Pump Efficiency -0.7 -2.4 -13.2

Pump No: 101 Main 201 Main 302 Main

Pump No: 101 Booster 201 Booster 302 Booster

Pump Head (ft) 1839.90 1753.48 1576.12

% Change in Pump Efficiency -5.1 -28.4 -58.0

Pumps 101 Main is in good condition with efficiency shortfall of 0.7%. It can be seen from the pump curve created by AEMS that the pump operates close to BEP. Pump 101 Booster is considered to be in reasonable condition with an efficiency shortfall of 5.1%. However it can be seen from the pump curve that the operating head is higher, at the observed flow rate, than the manufacturers curve. The operating point is to the right of BEP. Pump 201 Main is in good condition with an efficiency shortfall of 2.4% at constant head. It can also be seen from the pump curve generated by AEMS that the pump operates close to BEP. Pump 201 Booster displays an efficiency shortfall of 28%. This appears very low but can be seen to be operating far to the right of BEP. The head verses flow rate performance is also in excess of the manufacturers curve which is probably due to tighter internal tolerances because of the temperature of the pumped fluid. Pump 302 Main shows an efficiency shortfall of 13.2% at constant head. There is a reduction in the head / flow rate performance, which is reflected in a reduction in pump efficiency. The differential temperature for pump 302 Booster could not be measured directly. For this reason the certainty in the efficiency determination is low. The calculated value is 32% which should be regarded as an indicator. It is recommended that the pump set 302 should be refurbished and new tappings installed for the booster pumps closer to the pump which will give more objective and accurate test results. The tappings in the delivery pipe work should be before the common header to eliminate any influence from the second booster pump in the set.

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Method Statement

Sulzer

Station:

4 GENERAL DETAILS
4.1 SYSTEM DESCRIPTION
The boiler feed pump system consists 3 pairs of booster and main pumps. The feed pump configuration is numbered as 101, 201 and 302. During the testing AEMS monitored the performance of 101 booster, 101 main, 201 booster, 201 main, 302 booster and 302 main; a total of six pump tests. The pump sets are configured with the booster and main pump operating off a common shaft, driven by a steam turbine.

4.2 PUMP AND MOTOR DETAILS

M AI N PUM PS
PUMP DETAILS Pump Manufacturer: Type: Arrangement: Duty Head Duty Flow Speed Serial No: 101 201 302 Year of Manufacture: Ingersoll Rand 10x16CA5 Multi stage 1999.5 m 1398.9 m3/hr 5100 rpm N/A N/A N/A N/A

BO OS T E R PUM PS
PUMP DETAILS Pump Manufacturer: Type: Arrangement: Duty Head Duty Flow Speed Serial No: 101 201 302 Year of Manufacture: Ingersoll Rand 10x16CA 621.8 m 1334.2 m3/hr 5100 rpm N/A N/A N/A N/A

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TABLES OF RESULTS (METRIC): MAIN PUMP 101

AEMS Test Data (22/07/2003 - 24/07/2003) Suctn Head (m) 375.92 548.13 648.67 700.53 Delivery Head (m) 1453.06 1829.66 2175.62 2430.73 Pump Head (m) 1077.14 1281.53 1526.95 1730.20 Pump Efficiency (%) 83.5 85.7 87.9 85.4 Volumetric Flow Rate (m3/hr) 1321.0 1000.8 1204.0 1368.7 Mass Flow Rate (kg/s) 314.97 232.54 276.45 322.46 Shaft Power (MW) 3.982 3.408 4.703 6.401 Rotational Speed (rpm) 4030 3905 4374 4744

AEMS Test Data referred to 5100 rpm Pump Head (m) 1725.06 2185.88 2075.90 1999.62 Pump Efficiency (%) 83.5 85.7 87.9 85.4 Shaft Power (MW) 8.071 7.591 7.456 7.953 Pump Flow Rate (m3/hr) 1671.8 1307.1 1403.9 1471.4

Manufacturers Test Data Pump Head (m) 1691.64 1996.44 2279.90 2407.92 2516.12 2590.80 2651.76 2682.24 Pump Efficiency (%) 84.0 85.0 81.0 72.5 60.0 44.0 24.0 0.0 Shaft Power (MW) 8.724 8.721 8.709 8.221 7.785 7.288 6.838 Pump Flow Rate (m3/hr) 1589.7 1362.6 1135.5 908.4 681.3 454.2 227.1 0.0

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Method Statement

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TABLES OF RESULTS (METRIC): MAIN PUMP 201

AEMS Test Data (22/07/2003 - 24/07/2003) Suction Head (m) 557.50 591.32 Delivery Head (m) 1895.08 1977.83 Pump Head (m) 1337.57 1386.51 Pump Efficiency (%) 81.1 83.0 Volumetric Flow Rate (m3/hr) 920.5 1092.3 Mass Flow Rate (kg/s) 221.68 260.49 Shaft Power (MW) 3.582 4.264 Rotational Speed (rpm) 3898 4120

AEMS Test Data referred to 5100 rpm Pump Head (m) 2289.7 2124.6 Pump Efficiency (%) 81.1 83.0 Shaft Power (MW) 8.022 8.088 Pump Flow Rate (m3/hr) 1204.4 1352.2

Manufacturers Test Data Pump Head (m) 1691.64 1996.44 2279.90 2407.92 2516.12 2590.80 2651.76 2682.24 Pump Efficiency (%) 84.0 85.0 81.0 72.5 60.0 44.0 24.0 0.0 Shaft Power (MW) 8.724 8.721 8.709 8.221 7.785 7.288 6.838 Pump Flow Rate (m3/hr) 1589.7 1362.6 1135.5 908.4 681.3 454.2 227.1 0.0

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TABLES OF RESULTS (METRIC): MAIN PUMP 302

AEMS Test Data (22/07/2003 - 24/07/2003) Suction Head (m) 381.29 562.93 647.97 751.21 Delivery Head (m) 1356.42 1848.67 2102.71 2458.90 Pump Head (m) 975.13 1285.74 1454.74 1707.70 Pump Efficiency (%) 71.6 73.7 77.9 74.8 Volumetric Flow Rate (m3/hr) 1293.4 1169.8 1197.8 1403.5 Mass Flow Rate (kg/s) 308.68 271.87 274.69 321.37 Shaft Power (MW) 4.118 4.644 5.028 7.190 Rotational Speed (rpm) 4077 4267 4475 4956

AEMS Test Data referred to 5100 rpm Pump Head (m) 1525.89 1836.74 1889.47 1808.37 Pump Efficiency (%) 71.6 73.7 77.9 74.8 Shaft Power (MW) 8.061 7.930 7.443 7.835 Pump Flow Rate (m3/hr) 1618.0 1398.2 1365.1 1444.3

Manufacturers Test Data Pump Head (m) 1691.64 1996.44 2279.90 2407.92 2516.12 2590.80 2651.76 2682.24 Pump Efficiency (%) 84.0 85.0 81.0 72.5 60.0 44.0 24.0 0.0 Shaft Power (MW) 8.724 8.721 8.709 8.221 7.785 7.288 6.838 Pump Flow Rate (m3/hr) 1589.7 1362.6 1135.5 908.4 681.3 454.2 227.1 0.0

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Method Statement

Sulzer

Station:

CASE STUDY 2 TEST PROCEDURE DESCRIPTION The temperature probes were inserted into thermowells. One in the suction pipework of the booster pump and the other in the delivery pipework of the high pressure pump. The reversal method was used to determine the precise zero for the temperature probe pair. The pressure in the suction to the booster pump and the delivery of the high pressure pump was measured using pressure transducers which had been calibrated immediately prior to the test. The power supplied to the drive was measured by the Yates Power Meter which was connected in the 2-wattmeter configuration in the switchgear panel, the power data being logged to a computer every minute. The speed of the motor shaft was measured using an optical tachometer. The speed of the high-pressure pump was calculated using the gearbox ratio of 4.021 . Test points for the construction of the pump performance curves were taken by altering the flow through the pump (which adjusted the speed), the following parameters being recorded: a) b) c) d) e) f) Differential Temperature across Pumping System Absolute Temperature of Water Suction Pressure Delivery Pressure Input Power to Drive Motor Speed

The Yatesmeter calculates the Pump Head from the suction and delivery pressures, corrected for velocity head and the height difference between the suction and delivery pressure transducers. It then computes the Pump Efficiency from the Differential Temperature across the pump, and further calculates the Flow Rate from the Input Power and the Drive Efficiency. The drive efficiency values have been computed for each input level, based on an estimated drive efficiency of 91%

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Method Statement

Sulzer

Station:

INSTRUMENTATION LAYOUT The diagram below shows the position of the instrumentation used on site. The arrows show the flux of information in the system.

Computer 1

HT YM Ts (T004) Td (T002) Station Flowmeter

Pressure Logger 1 (P200)

Booster
Tachometer Computer 2 Power meter

Motor and Driver

G/B

Boiler Feed Pump

Pressure Logger 3 (P204)

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MANUFACTURERS SPECIFICATIONS PUMP SPECIFICATION Service Data Medium handled Boiler feed water demineralized Service temperature 151.5 C Density 0.9155 kg/dm3 Booster Pump Manufacturer Type Year Serial No. Rate of Flow Pump inlet pressure Pump outlet pressure Pump power input Speed High Pressure Pump Manufacturer Type Year Serial No. Flow Min rate of flow Opening point Closing point Pump inlet pressure Pump outlet pressure Take off flow Take off pressure Pump power input Speed Work temperature Hours Run: KSB YNKN 300/200 1983 2-218-631 415/1 607.5 m3/h 4.88 bar 10.312 bar 110.0 kW 1470 rpm

KSB CHTA 50/6 1983 2-218-631 416/1 607.5 m3/h 125.0 m3/h 135.0 m3/h 175.0 m3/h 9.8623 bar 228.577 bar 23.6 m3/h 122.24 bar 4608 kW 5920 rpm 151.5 C 74,415

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MOTOR AND GEARBOX SPECIFICATION 3-phase motor Manufacturer Type Year Serial No. Power rating Voltage (Y connection) Current Cos Speed Frequency Rotor Insulation Class Other details Siemens 1 TM 3640-8DE02 1982 D 80 32 208 804 6600 / kW 6600 6600 V 608 / 677 A 0.89 / 0.88 1489 / rpm 1487 50 Hz 3400V 1100/1230 A F IP54 Slipping IPR 44 - air 1.5 m2/s 2mbar temperature 42C cooling air - inlet water 5331 l/min IEC 34

VDE0530/72 Gearbox Specification Manufacturer Type Year Serial No. Power rating Speed

BSH RP 32X 1983 501038/6 5432 1470 / 5912 Ratio 4.021

kW rpm

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Method Statement

Sulzer

Station:

SITE LAYOUT (NOMINAL VALUES)

Pressure: 4.88 bar ( 50 m) Pressure: 10.312 bar ( 105 m) to 9.86 bar ( 100 m) Pressure: 228.577 bar ( 2330 m)

Flow: 607.5 m3/h ( 169 l/s) Service temperature: 150C

Booster

Motor

G/B

Boiler Feed Pump

Power: 4608 kW

Power: 110 kW

Speed: 1740 rpm

Speed: 5920 rpm Driver

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Method Statement

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RESULTS

The results are presented firstly in tabular format and then in graphical format. The results are true hydraulic performance and include no allowances for the losses, e.g. bearings, gearbox, or radiation. The manufacturers data has been corrected for water temperature and the efficiency calculated from the summation of the heads and shaft powers for each pump.

TABLES OF RESULTS Test data

Differential Temp. (mK) 2970.6 2957.3 3125.3 3382.3 Absolute Temp. (C) 148.151 146.912 147.056 147.149 Suction Pressure (MPa) 0.563 0.545 0.547 0.555 Delivery Pressure (MPa) 20.895 20.800 20.813 20.960 Total Head (m) 2240.3 2229.2 2230.4 2234.5 Pump Flow (m3/h) 529.1 623.0 468.9 409.6 Power to Driver (kW) 3825.1 4501.7 3484.1 4089.1 Pump Speed (rpm) 5404 5544 5295 5235 Pump Efficiency (%) 85.85 85.57 83.26 80.03

Data speed corrected to 5920 rpm

Total Head (m) 2688.4 2541.0 2787.3 2857.2 Pump Flow (m3/h) 579.6 665.2 524.2 463.2 Power to Drive (kW) 5028.1 5478.3 4867.4 4586.3 Pump Speed (rpm) 5920 5920 5920 5920 Pump Efficiency (%) 85.85 85.57 83.26 80.03

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Client:

Method Statement

Sulzer

Station:

CONCLUSIONS / RECOMMENDATIONS. Despite the Boiler Feed Pump having run for 74,415 hours it would appear to be in very good condition showing no signs of wear.

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