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Boiler Feed Pump

Basics & Its Construction

Boiler Feed Pump- Heart of


the Power Plant.
How to choose a pump for
Power Plant.

SYSTEM HEAD
It is the total head of a system against
which a pump must operate.
Total System Head= (Total static head
from supplying level to discharge level+
Discharge pressure) (Suction Pressure+
Friction losses+ Entrance & Exit losses)

BOILER FEED PUMPS ST-1


POWER - 3.5 MW
CURRENT 361 Amp
SUPPLY 6.6 KV,
3, 50 Hz
SPEED 1485 RPM

BFP scheme
Hydraulic
coupling

Resilance
coupling
MOTOR

Main p/p
Booster p/p

Motor speed-1485 rpm


Booster p/p speed-1485 rpm
Main p/p speed- 4750 rpm

BFP FW scheme
Transfer line
MP

BP
MOTOR

strainer

R/C v/v
To D/A

NRV

Suction v/v
Discharge v/v

WHY Recirculation ?
For minimum FW flow.
To avoid churning
BFP discharge header

180 kg

180 kg
A

0 kg
B

To D/A

100kg
181kg

BFP(stage-1)
Specification
No-3 nos(2X 50%)
Main Pump-8 stage centrifugal Pump
Type-Motor driven
Motor-6.6 KV
Motor speed -1485 rpm, 3500 KW.
Booster Pump-single stage
centrifugal

Main pump
M/S Wier Make. Model-FK8D30.
Eight stage horizontal centrifugal pump
of the barrel casing design.
The pump internals are designed as a
cartridge, which can be easily removed
for maintenance without disturbing the
suction and discharge pipe work, or the
alignment of the pump and the turbo
coupling.

BFP
MAJOR COMPONENTS

BOILER FEED PUMP CARTRIDGE


Shaft
Impellers
Diffusers
Ring Sections
Suction Guide
Discharge Cover
Bearing Housings
Bearing Brackets
Journal Bearing
Thrust Bearing
Mechanical Seals

Mechanical seal

P/p casing

Tungsten
carbide
(rotating)

Carbon steel(static)

O ring

P/p shaft

BFP Sealing system


Mechanical seals are used in MP &
BP
Mechanical
sealwater
cooling used
arrangement
in main
p/p
Clarified
for seal
cooling
Clarified water used
for cooling of DM water

DM water running in closed ckt

Mechanical seal
cooler

Cold DM cooling water

Clarified o/l
Hot DM
cooling water

Thrust balancing
Balancing disc is provided in main
p/p
Balance leak off pr-16 ksc.

Balancing Drum.
Due to differential pressures acting on the impeller the rotating
assembly is subjected to axial thrusts. The balance drum located
at the non-drive end is designed to keep these forces
neutralised and only the residual thrust remains, which is taken
up by thrust bearing.
The main components of hydraulic balancing arrangement are
the balance chamber machined in discharge cover, the balance
drum secured to the shaft and balance drum bush fitted in the
bore of discharge cover.
The thrust caused by the suction pressure acting on the area
inside the wear ring on inlet side of each impeller is overcome
by much greater thrust caused by the discharge pressure acting
on the equivalent area on the outlet side of each impeller.
The resultant thrust is therefore towards drive end of pump.
Thrust force varies with load on the pump but hydraulic balance
arrangement will reduce its effect enabling residual thrust to be
taken by fitting pads of thrust bearing.

BFP Bearing Arrangements


Main p/p
- DE side-journal bearing.
- NDE side-journal & trust bearing.
Booster p/p-p/p - DE side-journal bearing.
- NDE side-journal & trust
bearing.
Hydraulic coupling - 10 bearings(4
thrust bearings, rest-journal
bearings).

Journal bearing

Bearings
Journal bearings

Lub oil

White metal liner(babbit metal)


Thickness-0.5 mm

shaft

Flexible Coupling

Lub
oil
scheme
MOP(connected to gear box)
NRV

AOP motor

AOP

2 no lub oil cooler


Raw water from
ARCW discharge

Oil tank

Lub oil filter


Return from bearing
Booster p/p bearings

Oil header

Motor bearings

Main p/p brg

When BFP is in S/B condition motor driven AOP is in service


(Cut in Pr-1.2 Ksc), for cooling of bearings, because S/B BFPs
suction v/v is always in open condition & feed water temp.
coming from dearator is around 166 Deg C. So BFP metal &
Brg. temp. should be always around 160 Deg C, which
required cooling even BFP in S/B condition.
AOP discharge pressure- 3 Ksc.
When we give start command to BFP motor driven cut out in
auto at 2.3 ksc pr(gear driven MOP will supply lub. oil to
bearings .
Lub Oil Used in BFP- Servo Prime 46

Meshes with
HC gear

Main-Motor
driven shaft

Meshes with LO
and WO pump
gear

Coupled with
driven shaft

Auxiliary
Lube oil
pump
Lube oil
Working oil
pump

Gear box
Gear box & Hydraulic
coupling

Resilance
coupling
MOTOR

Main p/p
Booster p/p

Gear box
1

2
Lub oil p/p
Working oil p/p
7
9
8
10

Lub oil tank

* Gear Ratio- 1: 3.3

Hydraulic coupling

Working oil scheme


WC p/p

Working oil
make up

Hydraulic coupling

Regulation
control
drain
Cold working oil
Hot working oil

LUB OIL TANK


WOC

Cooling water
From ARCW
Working oil cooler(2 in number)

Lub Oil header

Lub Oil P/P

To all bearings

Gear
Aux Lub oil P/P
Motor

Motor

Coupling

Coupling
Scoop
Tube

Main
Pump

Working Oil P/P


Oil
Regulating Chamber
Variable speed thermo coupling
Working oil cooler

Coupled with
driven shaft

Auxiliary
Lube oil
pump
Lube oil
Working oil
pump

Hydraulic Coupling in BFP

Hydraulic Coupling Oil Used- Servo Torque-10

Working oil & Hydraulic coupling


Hydraulic coupling used for regulaing BFP speed.
Hydraulic coupling is combination of pump & turbine
By changing scoop position we can control the Main p/p
speed thus we can control the flow of main p/p

P/p

Shaft
Connected
To motor

Space filled up
with oil

turbine

Driven shaft
connected
To main p/p
Scoop tube
scoop

Meshes with
motor side gear

HYDRAULIC
COUPLING

Connected
to pump
shaft

Turbine of Hydraulic
Coupling: Coupled with
main pump shaft

Hydraulic Coupling bearing Assembly

Slot to
fit
Scooptube

Motor cooling

2 cooling fans are provided at the both ends of motor


Cooling air fans sucks cold air which cools motor
stator /rotor
Hot air is cooled by water in the cooler(2 no of cooler
provided)
Cooling water coming from Aux.
Raw cooling water
Motor cooler
p/p(ARCW p/p)discharge header

Cooling water

Hot air

Cold air
BCW
v/v

To WO
cooler

Motor rotor

Motor cooler

Motor stator

BFP MOTOR

Drain

End Cover

Cooler

Cooler

Tray

Tray

Drain

Stator
Rotor

Bearing

Fan

Stator

Fan

Bearing

Siphon Drain

BFP motor cooler

Sealing system
Mechanical seals are used in MP &
BP
Mechanical
seal cooling
arrangement
in main
Clarified
water
used for
sealp/pcooling
Clarified water used
for cooling of DM water
Mechanical seal
cooler

DM water running in closed ckt


Cold DM cooling water

Clarified o/l
Hot DM
cooling water

Mechanical seal

P/p casing

Tungsten
carbide
(rotating

Carbon steel(static)

O ring P/p shaft

Mechanical seal

BFP parameter
UCB parameter

Normal value

BFP current 290-300amp


BFP flow
340 ton/hr
BFP(MP) discharge pr 180 kg
D/A pr 6.5 ksc
BFP suction temp
167 degree
BFP suction strainer DP
0.07
Drum level
+50 mm

Local parameter
Lub oil pr
3 ksc
Lub oil cooler in service
Lub oil temp cooler I/l/O/L

normally one
60/40 degree

Local parameter

Normal value

Working oil pr

1.4 ksc

Working oil cooler in service


Working oil temp cooler I/l/O/L

normally one
120/75 degree

Hydraulic coupling max bearing temp


Motor air temp
50 degree
Clarified water pr
3.5 ksc
Balance leak off pr
BP suction pr 8 kg
MP suction pr 16 ksc

16 ksc

65 degree

BFP starting permissive


D/A level normal>800 mm
Suction v/v open
R/C v/v open
Bearing p/p& motor temp normal(<75 degree)
Lub oil pr normal(>1.5 ksc)
Cooling water pr normal>3 ksc
Suction pr adequate

Protection

P/p & motor bearing temp hi-hi(>85 degree)


Hyd coupling oil temp Hi-Hi(>130 degree)
Lub oil pr low-low(<0.8ksc)
Main p/p suction pr low(<8 kg)
BFP flow hi-hi(>430 ton/hr-1 minute time delay)
EPB pressed
Electrical protection

BFP Protections
Sr.
Parameters
No.

Alarm
Value

Trip Value /
Remarks

Motor [DE/NDE] bearing temperature

75C

85C

Main pump [DE/NDE] bearing


temperature

75C

85C

< 1.2 Ksc

< 0.8 Ksc


(Time delay 5
sec)

90C

> 130C

< 12 Ksc

< 8 Ksc

450 T/hr

450 T/hr
(Time delay 55
sec)

550 mm

400 mm

Lube oil pressure low

Working oil temp Hi-Hi

BFP running & Main pump suction


pressure low

BFP Flow Hi-Hi

Deaerator level low-low

Emergency Push Button Pressed

BFP Isolations
1. Ensure that pump is in stopped condition.
2. Get the main motor breaker isolated ( Electrical
isolation).
3. Close discharge valve and isolate its electrical supply .
4. Close the suction valve .Ensure there is no rise in
suction press.
5. Open suction strainer, booster pump casing, discharge
line and main pump casing drain valves.
6. Open the transfer line vent, booster pump vent.
7. Close the manual recirculation valve at deaerator level.

BFP Normalisations
1. Physically check that work is complete and all men and
materials are removed from site.
2. Get the electrical supply of AOP normalised.
3. Ensure that one lube oil cooler and one working oil
cooler are charged from oil and water side.
4. Check oil level ( It should be more than 50 %)
Start AOP, observe lube oil pressure (It should be more
than 2.5 ksc) and oil filter DP (It should be less than 0.5
ksc).Check return oil flow in all bearings.
5. Open motor cooling inlet/outlet valves .

BFP Normalisations
6. Ensure booster pump,transfer line & recirculation line
vents open , Close all drains. (To avoid pressurisation of
pump).
7. Charge clarified water to mech seal coolers and jacket
cooling.

Ensure clarified water Pressure is more than 3

ksc .
8. Open manual recirculation valve at deaerator and
ensure recirculation control valve is open. Also ensure air
supply to recirculation control valve.
9. Crack open suction and observe the discharge through
the vents. Close the vent valves after venting is over.

BFP Normalisations
10. Open suction valve fully and ensure the suction
pressure is adequate.
11. Get the discharge valve and its integral bypass valves
supply, BCW valve supply normalized .
12. Open its discharge valve from UCB, Ensure there is no
reverse rotation of the pump.
13. Get the main motor electrically normalised.

BFP Lube Oil Filter Change


Over.
Two lube oil filters provided in BFP Main pump.
1. No charging line provided.
2. No venting provided in both lube oil filters.
Lube oil filter chocked alarm provided in alarm fascia.
(Lube oil filter chocked at DP > 0.5 Ksc)
BFP tripping on lube oil pressure low-low at 0.8 Ksc,
Time delay- 5 seconds.

Hydraulic Coupling
Pointer, T shape
bottom

Match Yellow Mark on


Handle & Nut

Lube oil
Filter-A
in-service

For Lube oil filter change over moves the handle in this

Hydraulic Coupling
Match Yellow Mark on
Handle & Nut

Pointer, T shape
bottom
Lube oil
Filter-B
in-service

For Lube oil filter change over moves the handle in this

BFP Lube Oil Filter Change


Over.
During
Changeover :Place the handle over nut by matching the Yellow Mark.(Half
Yellow mark on Nut & Half Yellow mark on handle)
Slowly rotates the change over handle (180 degree) so that
the pointer (bottom part of T) provided in the nut always
moves towards the Hydraulic coupling side.
When pointer moves towards Hydraulic coupling- both filters
remain in service in pointer mid position.
When pointer moves opposite to Hydraulic coupling- both
filters became out of service in pointer mid position.
The pointer (bottom part of T) shows the Lube oil filter inservice.
Observe the rise in DP of filter to be taken in service.

Drum level control


DP control
When BLI <20% low range CV i/s , drum level control is
single element control it see only drum level)
When BLI>20% it becomes 3-element control. steam
flow, feed water flow& drum level)
Hi range CV try to maintain drum level. (CV
opening<100% )
BFP scoop try to maintain
DP range CV
Low

BFP

Drum
FR
S

DP
Drum level controlled by 1) FRS CV 2)BFP

Drum level control(stage-I)


Initially there was DP control
Now there is two control
1)DP control
2)Scoop control

In Scoop control auxiliary power is saved ,as


BFP draw less power

DP control
If drum level increase CV throttle,
DP increase(>4 KSC)
BFP master DP set point is 4 ksc
BFP master try to maintain 5 ksc
DP
BFP scoop will reduce

Scoop control
Drum level is controlled directly by
BFP scoop.
FRS CV=100% open
DP maintained zero
When load <70% scoop control to
DP control take place

BFP isolation/normalisation
1-Booster p/p strainer drain
2-Booster p/p casing vent
3-transfer line drain
4-transfer line vent
5-main p/p casing drain
6-discharge line drain
7-recirculation line drain