4.13 Pumping hot liquids 4.13.

1 General High demands are made on pumps which are to be used for pumping hot liquids in heating and heat transfer installations. The pump must: Have a high level of operational reliability, as loss of the pump means shutdown of the entire plant. Be suitable for the temperature of the media, without the need for external cooling of the pump bearings and mechanical seals. An external cooling system not only increases the capital investment for the additional cooling pipework and control, but also the operating costs of removing the heat and providing cooling water.

1 2 3 4 Fig. 4.13.01

Heating unit Consumer Circulation pump Expansion tank

Schematic of a heat transfer installation

Heat transfer liquids can be: water for temperatures in the range t = 75 to 230C and for specific applications up to 300C heat transfer oils, mineral based, e.g. Mobiltherm, Essotherm and similar for temperatures from t = 100 to 340C synthetic heat transfer liquids, e.g. Diphyl and Dowtherm for temperatures from t = 100 to 400C.

162

For handling these heat transfer media, single stage volute casing pumps, which have been specially developed for the application, are mainly installed. Because of the variation of physical properties of the heat transfer liquids, e.g. vapour pressure, the design of hot water pumps is different to that for heat transfer oils or equally, synthetic heat transfer liquids.

Fig. 4.13.02

Comparison of the vapour pressure curve of water with a synthetic thermal transfer liquid.

4.13.2 Pumping hot water 4.13.2.1 Water up to 110C This application is most typical for hot water heating systems. For circulations up to a flowrate of approx. Q = 60 m3/h and heads up to H = 10m the first route is to use a canned motor pump, i.e. a heating circulation pump, sealless with media flooded rotor. For higher flowrates or heads, conventional pumps with uncooled stuffing box or mechanical seal are installed (see section 4.13.3). Standard PN10 water pumps to EN733 are typical for these applications.

163

The pumps can be baseplated, or for space saving, of monoblock or in-line design. 4.13.2.2 Water from 110 up to 160C For heating systems with inlet temperatures up to 160C it is similarly possible to install standard PN10 water pumps to EN733 / DIN 24 255 with uncooled balanced mechanical seals. Internal circulation, ensures that the mechanical seal is lubricated by the pumped medium thus preventing dry running. In an installation where the minimum temperature difference above the vapour temperature (tmin 10C above boiling point) cannot be guaranteed, then a throttle device must be installed in the circulation line to maintain sufficient pressure in the seal housing so as to prevent vaporisation.

Fig. 4.13.03

Conventional pump with uncooled mechanical seals

4.13.2.3 Water from 160 up to 230C Even in this temperature range it is possible to run the pump uncooled. However it is necessary to fit the mechanical seal at the cold drive end of the pump and to protect the seal housing by a heat barrier, as shown in Fig. 4.13.04. Even with inlet temperatures up to 230C with this design, the temperature in the mechanical seal will not exceed 100C. 4.13.2.4 Water from 230 up to 311C In this temperature range the requirements outlined in the introduction, which are placed on an uncooled design, can no longer be met, so that constructions with cooled mechanical seals must be selected. Up to a temperature of 290C, the method of positioning the mechanical seal in the cold end is used with a cooled housing cover and counter face. A cooling sleeve between the pump and the mechanical seal housing, reduces thermal transmissions.
164

For water temperatures >290 < 311C an integral pumping ring in the mechanical seal, sets up a circulating flow through an external heat exchanger. This construction is shown in Fig. 4.13.05

Fig. 4.13.04

Pump with uncooled seal at the cold end

Fig. 4.13.05

Pump with cooling sleeve and cooled mechanical seal.

165

4.13.2.5 Materials for hot water circulating pumps The selection of materials for hot water circulation pumps is primarily dependent on temperature and pressure. When selecting the pump and materials, the permitted operating pressure of the pump and the required operating pressure and temperature in the specification should be considered. The selection of flange ratings (PN) is made in accordance with the permitted pressure/temperature regulations for the material. The following diagrams show the permitted pressure/temperature limits for different materials or groups of materials at different nominal pressures, when handling hot water. Using the diagrams Figs. 4.13.06 to 08 and table 4.13.01, a suitable material can be selected, for a particular operating or design pressure and temperature.

Fig. 4.13.06

Pressure/temperature limits for a flange in cast iron (GG25 to ENGJL-250) according to EN1092-2.

1. Limit for pumps in chemical industry installations according to VDMA 24 276 2. Limits for circulation pumps DN 200 according to EN 12953-2 and TRD 108 3. Limits for feed pumps (according to TRD 108) (TRD = German technical regulations for steam boilers)

166

Hot water in heating and hot water plants does not generally represent a corrosion risk due to its pre-treatment. The material selection is therefore only dependent on temperature and pressure. Pumping hot water in power station systems, does require consideration of the chemical nature as well as the temperature and pressure. With an alkaline operation with pH > 9.5 and for pressure up to 63 bar, there is no corrosion danger. For lower pH values, higher operating pressures or neutral pH or a combination of conditions, the use of ferritic chrome steel with at least 12% Cr is recommended.

Fig. 4.13.07

Pressure/temperature limits for a flange in ductile (SG) iron (GGG40 to EN-GJS-400-15) according to EN1092-2.

1. Limits for circulation pumps and feed pumps (according to TRD 108)
167

Fig. 4.13.07

Pressure/temperature limits for a flange in cast steel (GS-C25 to 1.0619, GP240GH) according to EN1092-1.

Table 4.13.01 Materials for hot water circulating pumps t > 230 to 311 C (Example of a pump range for boiler circulation) Max. operating data Flange Material 1) 2) tmax. C pmax. bar PN 255 50 63 1.4008 270 63 63 1.7706 3) 280 70 100 1.4931 3) 290 80 100 1.4317 - V1 311 110 160 1.4317 - V2 1) Max. housing pressure pmax. = entry pressure + zero flow head 2) Flange to EN 1092-1 3) Cast steel to TRD 103 4) V1 = Heat treatment stage 1: 0,2%- tensile strength = 550 N/mm 5) V2 = Heat treatment stage 2: 0,2%- tensile strength = 830 N/mm
168

4) 5)

4.13.3

Pumping heat transfer oils and synthetic heat transfer liquids up to 400 C Heat transfer installations and their circulation pumps are subject to standards and guidelines. Pumps which have a shaft seal mounted at the cold end drive side and a thermal barrier, with the bearing housing thermally separate or a moveable seal cartridge meet these standards for inlet temperatures up to 350C. The pumps can be baseplated as shown in Fig. 4.13.09, or for space saving, of monobloc or in-line design.

Fig. 4.13.09

Heat transfer oil pump with mechanical seal to EN 733

To meet increasingly stringent standards, reflecting concern about environmental pollution and requirements for safety, the sealless pump is being used more and more for this application. In particular for synthetic heat transfer liquids, which are classified as health hazards, the use of magnetically coupled and canned motor pumps is widespread. Such pumps are suitable for inlet temperatures up to 400C. For more information see section 4.11 Leak-free pumps. Fig. 4.13.10 shows a heat transfer oil pump with a heat barrier and magnetic coupling in a compact monoblock construction. The materials for the pump casing need to be durable. Ductile cast iron with spheroidal graphite e.g. 400-18-L to ISO 1083 (GGG-40.3 to DIN 1693) for inlet temperatures up to 350C and heat stable cast steel e.g. GP240GH to EN 10213-2 (GS-C 25 to DIN 17 245) for inlet temperatures up to 400C, have proven reliable and are widely used.
169

Fig.4.13.10

Heat transfer oil pump with a heat barrier and magnetic coupling in a compact monoblock construction

Table 4.13.02 Properties of various heat transfer liquids Heat transfer liquids organic base Glycol (water-free) mineral oil base naphtha base mineral oil base paraffin base synthetic base Isomer mixture Temperature range C 20 200 40 250 150 320 150 400 Density kg/dm 1.114 1.028 0.861 0.725 0.781 0.670 0.968 0.774 Vapour pressure mbar < 0.1 50 0.02 5000 0.1 40 19.3 5300 Viscosity mm/s 150 2.1 8.4 0.60 2.3 0.60 1.1 0.30

170