Sulzer Pumps

HPT Multistage Barrel Casing Boiler Feed Pump

The Heart of Your Process

Sulzer Pumps
Sulzer Pumps is one of the world leaders in state-of-the-art pumping solutions. Combining engineering and application expertise, Sulzer Pumps solutions add value and strengthen the competitive position of its customers. Thanks to a global network of manufacturing facilities, sales offices, service centers and representatives, we are able to provide fast responses to customer needs. Through its extensive experience in providing innovative solu tions to business partners, Sulzer Pumps is a well-recognized player in the following industries: Oil and Gas Hydrocarbon Processing Pulp and Paper Power Generation Water General Industry Chemical Process Industry HPT Global Manufacturing Facilities

Suzhou, China

Elandsfontein, South Africa

Leeds, UK

HPT Efficient and Reliable

HPT radially split barrel-casing pumps are specifically designed for boiler feed applications in thermal power stations. These pumps are optimized to provide high availability and high efficiency operation over an extended period of time, thus reducing operating and maintenance costs. Their robust construction and tolerance of changing conditions makes them particularly suitable for cyclic operation. The pumps efficiency is a result of its advanced hydraulic design and therefore does not rely on the use of close internal clearances. This is
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also the case for the rotordynamic design, which ensures low vibration by providing a high degree of damping throughout the life of the pump, even with the clearances worn to their maximum values. Although the HPT is a well-established design, with many years of reliable operation, it has been continually updated to take advantage of technological developments. These include developments in precision casting, sealing technology and materials, as well as the application of Finite Element (FE) analysis and state-of-the-art manufacturing techniques.

HPT Pump

Optimized Thermal Design

The HPT benefits from an optimized thermal design which: allows operation under cyclic conditions, without any need for pre-warming minimizes thermal distortion to avoid the reduction of internal clearances handles thermal stresses thanks to a selection of high strength materials ensures secure sealing under all transient conditions thanks to graphite stationary seals
Computerized analysis to optimize temperature distribution under various conditions

Shaft Seal Option

Cooling jacket decreases temperature in seal chamber Air barrier avoids heat transfer from hydraulic pump parts to sealing area Mechanical seal Thermosleeve with air gap Cold condensate injection Bleed-off for high suction pressures, without bleed-off for low suction pressures Cold condensate injection

Hot (~180 C)

Cool (~60 C) Drain Drain

Single Mechanical Seal Minimal leakage Low energy consumption

Fixed Throttle Bushing Simple and reliable design Less sensitive to dirt and flashing

With Floating Rings Moderate leakage

HPT Design Features and Options

Barrel design incorporates many design features resulting from Sulzer/EPRI research contract Maximum safety due to double casing design Pipework connections remain undisturbed during disassembly Barrel casing design provides maximum rigidity and accepts high pipe loads Top or bottom facing nozzles welded or flanged; can be positioned to suit the planned installation layout

Full cartridge pull out for rapid changeover

Axial thrust compensation by balancing piston to avoid damage during transient conditions Long operating life regardless of the operating mode Design features to eliminate the need for prewarming in most installations Fully rated double acting tilting pad thrust bearing

Design of close running clearances Optimized labyrinthhigh efficiency and good rotordynamic behavior Radial groovesincreased radial stiffness, reduced effect on rotor tilting and good rotor dynamic behavior Swirl break at balancing piston to maintain rotor stability even when internal clearances are worn

Centerline mounting

Removal of bolts, coupling hub, piston and thrust collar by means of a common hydraulic pump to simplify maintenance and reduce cartridge replacement time

Precision casting in chrome nickel steel Optimization of hydraulic profiles Kicker stage available

 Optional intermediate take-off possible

Integral impeller wear rings for longer life dimensioned to allow re-machining several times Double suction first stage available

Pure graphite stationary seal rings at external joints Bearing housing fixed to pump cartridge through 360 Bearing provides high stiffness and damping to minimize shaft movement Anti-whirl journal bearings

E-P o-rings at internal joints

Forged, low alloy steel barrel casing as standard; designed for long term cycling operation and to resist erosion-corrosion without the need for overlays High strength material to accept thermal shock Other materials possible to suit customer requirements Sliding pads to maintain alignment during thermal movements

Optional Double Suction

Optional Kicker Stage Kicker stage flow

Kicker stage forged design for flow < 50 m3/h Kicker stage cast design for flow >= 50 m3/h Shaft forged in chrome nickel steel Low L/D ratio Stable operation without critical speed problems Reduced vibration levels Balance drum leakage flow Main discharge flow

HPT Features
Integral Cartridge Design Step 1 Advantages The cartridge is completely assembled outside the barrel case Prior to installation of the cartridge, the mechanical seals are set, the rotor is radially and axially adjusted and the axial thrust bearing clearance is set Quick cartridge changes for increased productivity Cartridge support for increased safety Cartridge includes the shaft, coupling hub, static and dynamic hydraulic parts, shaft seals, radial bearings and thrust bearing, balancing system, suction and delivery cover

Suspended and supported on rollers at the drive end (DE)

Step 2

Suspended for re-rigging

Step 3 Final Installation

Rotor Design Advantages Shrunk on parts allow for high rotor balancing quality Shrunk on parts avoid fretting corrosion and minimize stress concentrations Shrunk on parts avoid loose parts on shaft during operation and result in lower vibration

Rotor
Shrunk on thrust collar, oil press fit Shrunk on balance drum, oil press fit Shrunk on coupling, oil press fit, parallel stepped or taper fit

Impellers are shrunk on, have keys for torque transmission and use split ring for thrust loading

Diffuser and Impeller Design Advantages Precision castings High efficiency Small hydraulic unbalance Thick impeller shrouds High strength for high head Natural frequency away from resonance, thus avoiding shroud breakage Diffuser Continuous channel diffuser High efficiency Impeller
Continuous channel diffuser Thick impeller shrouds Precision castings

Stage 1

Stage 2

Stage 3

Stage 4

Tightening System for Delivery Cover Studs Advantages Accurate tensioning to required pre-load Fast cartridge change
Set up Tensioning Tool Tension Stud Bolt Turn Nut Release Tensioning Tool

Pressure Retaining Parts Advantages Hydro test (1.5 x or 1.3 x pD) of each pressure casing provides high safety Analyzed with proven codes for high reliability: German vessel code AD, standard ASME section VIII, Division 1, optional Finite Element (FE) for selected cases

FE Model
Diffuser

Sulzer Test Facilities

Sulzer Leeds, UK Up to 18 MW electric motor at full speed (24,000 hp) Electric capacity up to 45 MW (60,300 hp) 18MW (24,000 hp) inverter + increasing gearbox with multiple ratios Flow capacity up to 20,000 m3/h (88,000 USgpm)

Sulzer Mantes, France Up to 10 MW electric motor at full speed (13,400 hp) Electric capacity up to 10 MW (13,400 hp) Increasing gearbox with multiple ratios Flow capacity up to 70,000 m3/h (300,000 USgpm)

Sulzer Suzhou, China Up to 11 MW electric motor at full speed (14,700 hp) Electric capacity up to 16 MW (21,400 hp) 12 MW VFD, output frequencies from 15 Hz to 100 Hz Flow capacity up to 15,000 m3/h (66,000 USgpm)

Sulzer Portland, USA Up to 15 MW electric motor at max speed 6,000 rpm (20,000 hp) Electric capacity up to 15 MW (20,000 hp) Multiple speed options and elevated temperature testing capability. Flow capacity up to 13,600 m3/h (60,000 USgpm)

Elandsfontein, South Africa Up to 4 MW electric motor at half speed (5,360 hp) Electric capacity up to 4 MW (5,360 hp) Various increasing and reduction gearbox with multiple ratios up to 2.5 MW Flow capacity up to 15,000 m3/h (66,000 USgpm)

HPT Performance Range

Capacity Q (USgpm) Head H (m) 10,000 1,000 10,000 Head H (ft)

10,000

1,000 100

1,000 3 Capacity Q (m /h)

10,000

Operating Data
Metric Units Pump sizes Capacities Heads Powers Temperatures Speeds up to 4,150 m /h
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U.S. Units From 150260 to 500505 up to 18,300 USgpm up to 13,800 ft up to 63,700 hp up to 430 F up to 6,750 rpm

up to 4,200 m up to 47,500 kW up to 220 C

Materials
Part Barrel casing Delivery cover Impeller Diffuser Stage casing Suction casing Shaft Balance drum Stationary wear parts Stud Static seals (internal) Static seals (external) DIN material 10 Cr Mo 9 10, forged 10 Cr Mo 9 10, forged G-X 5 Cr Ni 13 4 G-X 5 Cr Ni 13 4 G 17 Cr Mo 9 10 A 217 Gr WC 9 X 4 Cr Ni 13 4 X 20 Cr Ni 17 2 X 20 Cr Ni 17 2 36 Ni Cr Mo 16 Ethylene-Prpylene Pure Graphite ASTM material A 182 Gr F22 A 182 Gr F22 A 743 Gr CA-6MN A 743 Gr CA-6MN G-X 5 Cr Ni 13 4 A 743 Gr CA-6NM A 182 Gr F6MN A 276 Type 431 A 276 Type 431 High strength High fatigue resistance At least 50 HB hardness difference High erosion resistance High strength Good pressure / Thermal resilience Advantage High erosion resistance Good thermal transient properties High erosion resistance Good cavitation resistance

References

Pulau Seraya Power Station, Singapore HPT 150-260/1d / 5 stage Pump 441 m3/h (1,941 USgpm) at 2,154 m (7,067 ft) 2,890 kW (3,875 hp) at 6,364 rpm Neurath, Germany HPT 500-505-6s 4,117 m3/h (18,113 USgpm) at 3,961 m (12,991 ft) 47,343 KW (63,488 hp) at 4,845 rpm Neurath BoA 2 & 3 are lignite fired power plants with optimized system engineering located in Germanys region of North Westphalia. Developed according to the latest available technology and the best practices in the industry, the BoA 2 & 3 plants benefit from considerable improvements compared to older plants. The plant is a 2 x 1,100 MW lignite-fired power plant (electrical power output) and has been commissioned in January 2012. The HPT pump provided by Sulzer is the biggest boiler feed pump in Europe. It has a capacity of 887 kg/s at 332 bar discharge pressure (including booster pump) and 185 C feed water temperature. The electrical efficiency of the power plant is over 43%, which is, as of today, the worlds highest efficiency for a lignite fired power plant. The emission level of CO2 should be reduced by 6 million tons per year compared to older plants. On top of carbon emissions, specific SO2, NOX and dust emissions should also be significantly reduced.

Schwarze Pumpe, Germany HPT 350-440 / 5 stage Pump 3,165 m3/h (13,926 USgpm) at 4,100 m (13,448 ft) 35,833 KW (48,050 hp) at 5,795 rpm

Waigaoqiao 3, China HPT 500-505-5s Pump 3,867 m3/h (17,050 USgpm) at 3,457 m (11,342 ft) 36,258 kW (48,600 hp) at 4,717 rpm

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Maintaining and Improving Pump Performance

Sulzer Pumps Customer Support Services The continuous availability and high operating performance of pumps is the key target for our customer support service organization. Through our highly experienced personnel and application knowledge, we provide a full range of innovative service solutions to our customers to keep their pumps running including: Spare Parts Field Services Repair Services Retrofits Maintenance Agreements Operation Agreements Flexibility With services ranging in scope from supplying a spare part to operating the pump under contract, we are uniquely placed to make your process run smoother. A dedicated team of our services specialists based at either our manufacturing facilities or one of over 60 service centers located around the world is dedicated to maintain the performance of our customers pumps and associated equipment. This service is not just limited to Sulzer products, all the pumps our customers operate can benefit from the support of Sulzer Pumps.

Network of Locations
Divisional Headquarters Manufacturing Facility Customer Support Service Center (CSS) Sales Office 11

www.sulzer.com

E00616 (2) en 2.2013 (1,000), Copyright Sulzer Pumps This brochure is a general presentation. It does not provide any warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our products. Directions for use and safety will be given separately. All information herein is subject to change without notice.