1

GkUNDlOS "#$%&'()
LNGlNLLklNG MANUAL
"*+,-./012 34025/-


6#7"#66("#7 89#%9:
CopyrighI 2009 GkUNDlOS ManagemenI AS. All righIs reserved.
CopyrighI law and inIernaIional IreaIies proIecI Ihis maIerial. No parI o Ihis maIerial
may be reproduced in any orm or by any means wiIhouI prior wriIIen permission rom
GkUNDlOS ManagemenI AS.
All reasonable care has been Iaken Io ensure Ihe accuracy o Ihe conIenI o Ihis maIerial:
Rowever, GkUNDlOS shall noI be held liable or any losses wheIher direcI or indirecI,
incidenIal or consequenIial arising ouI o Ihe use o or reliance upon on any conIenI o Ihis
maIerial.


75*5/12 ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; <
- 8oiler Iypes........................................................6
- 8oiler sysIem (lig. 3) ......................................7
34025/ =4>?4*5*.- ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;; @
- DeaeraIorsCondenser ..................................7
- Lconomizer ........................................................9
- Lconomisers in Ihe marine indusIry .....9
- Lconomisers in land based boilers .........9
- 8oiler pumps .................................................. 10
- 8oiler eed .................................................. 10
- CondensaIe pumps ................................. 13
- ShunI pumps ............................................ 14
AB1. 7/,*+C4- 4CC5/- ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;D@
- 8oiler problems ............................................. 21
- 8oIIom blow down.................................. 22
- Weekend shoI down ............................... 22
- ProducIion changes................................. 22
- Dosing ......................................................... 23
- leed pump sIarI-up ................................ 23
E,>?- 1*+ -0F0*G ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;HI
- Sizing ................................................................ 25
J1?4,/ .1K25 ;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;LM
1A8LL Ol CON1LN1S
6
LNGlNLLklNG MANUAL N 76#6(9:
75*5/12
1he producIion o sIeam and hoI waIer is one o Ihe
world's largesI indusIries. Grundos is pleased Io be
Ihe preerred supplier o pumps or boiler sysIems or
Ihese indusIries.
Grundos pumps are reliable, ehcienI and cover a
wide perormance range. As an experienced con-
sulIanI in Ihe implemenIaIion o boiler sysIems, we
engage in a process o close parInership and dialogue
Io hnd Ihe besI soluIion or your sysIem.
Grundos is a global enIerprise wiIh a worldwide ser-
vice neIwork. When you need exporI or on-Ihe-spoI
advice in a parIicular parI o Ihe world, we have Ihe
Iechnical experIise close by.
34025/ .O?5-
1hree main boiler Iypes exisI:
- RoI waIer boiler
- 1hermal oil boiler
- SIeam boiler
1he demands and Ihe sizing o Ihe pumps used or
Ihese boiler Iypes are very dierenI.
1he inserIed picIures aI Ihe righI side show some o
Ihe Iypical boiler consIrucIions used.
Rere you can see a cuI open drawing o Ihe mosI
common consIrucIion o a boiler used in Ihe manu-
acIuring indusIry. AI Ihe boIIom you see Ihe burner
chambers, which are surrounded wiIh waIer and aI
Ihe Iop Ihe smoke pipes. On Ihe side o Ihe boiler you
can see Ihe Iwo eed waIer pumps.
1his consIrucIion is Iypically seen in Ihe
marine, buI is also used in Ihe manuac-
Iuring indusIry:
A Iypical boiler consIrucIion in Ihe
manuacIuring indusIry:
LNGlNLLklNG MANUAL N 76#6(9:
1. RoI waIer boiler
RoI waIer boilers are normally used in room and buil-
ding heaIing. 1hese kinds o sysIems are suiIable or
discharge IemperaIures o up Io 140C. 1he advan-
Iage o hoI waIer over sIeam is IhaI Ihe energy loss is
much lower Ihan wiIh sIeam boilers. ligure 1 shows
how Ihe pumps are normally insIalled in a hoI waIer
boiler.
2. 1hermal oil boiler
ln hoI oil boilers, oil is used insIead o sIeam or wa-
Ier. 1he advanIage o oil is IhaI Ihe sysIem does noI
have Io be pressurised above 100C as wiIh waIer
and sIeam. Oil is sIill liquid in aImospheric pressures
o up Io 300C. ln conIrasI, waIer requires a pressure
o 85 bar Io avoid evaporaIing aI IhaI IemperaIure.
1he consIrucIion o Ihermal oil boilers and sysIems
is almosI idenIical Io IhaI o hoI waIer boilers.almosI
idenIical Io IhaI o hoI waIer boilers.
3. SIeam boiler
SSIeam is normally used in indusIrial process heaIing
due Io iIs high energy conIenI. SIeam is also used or
cleaning applicaIions and Iurbine generaIion. 1he
advanIage o sIeam over hoI waIer is iIs high energy
conIenI and abiliIy Io release energy during conden-
saIion. 1his also allows or very small heaI exchan-
gers.
34025/ =4>?4*5*.-
$515/1.4/-NP4*+5*-5/
DeaeraIor and condenser Ianks are only used in sIeam
boiler sysIems and noI in hoI waIer and hoI oil boilers
as uid is always in iIs liquid orm. 1he consIrucIion o
Ihese Iwo Iypes o Ianks is almosI idenIical, buI as Iheir
names indicaIe, Ihey are used or dierenI purposes.
1wo primary principles are used wiIh Ihis orm o
Iank design; Ihermal and vacuum.
Burner
Shunt
Forward
Return
Hot water
boiler End
Burner
Shunt
End
Forward
Return
Hot oil
boiler
lig. 1
lig. 2
lig. 3
Deaerator
Condensate tank
Condensate
pumps
Steamboiler
Feed pumps
Control
box
Level
sensor
Level
sensor
Control
box
Return
condensate
From water
treatment

E
E
Burner
7
8
LNGlNLLklNG MANUAL N 3Q":6( PQ8EQ#6#'&
1he Iank design used depends on Ihe Iype o boiler
being used. Lach principle also has dierenI pump
consIrucIion requiremenIs.
'B5/>12 ?/0*=0?25
A Iank using Ihe Ihermal principle is connecIed Io Ihe
aImosphere via a valve. 1his design is normally used
in smaller planIs. Rere, sIeam is used Io mainIain
Ihe Iank waIer IemperaIure aI around 105C, which
removes air rom Ihe waIer. A IemperaIure o 105`C is
needed because o Ihe air venI valve mounIed in Ihe
deaeraIor or condenser which needs an opening pres-
sure o approx. 0.2 bar, which provides a IoIal pressure
o 1.2 bar absoluIe. 1his means IhaI Ihe waIer will
boil aI a IemperaIure IhaI is a liIIle biI higher Ihan
Ihe usual 100`C where waIer normally boils in aImos-
pheric pressure. See also Ihe vapour pressure Iable aI
Ihe back o Ihis manual. 8esides Ihe air venI valve, a
vacuum breaker valve has also been mounIed Io en-
sure IhaI vacuum never occurs in Ihis Iank Iype. l Ihe
vacuum valve was noI mounIed, vacuum could occur
when cold make up waIer was added Io Ihe Iank.
J1=,,> ?/0*=0?25
Rere an e|ecIor pump is used Io creaIe a vacuum in
Ihe Iank. 1his causes Ihe Iank waIer Io sIarI boiling
even aI low IemperaIures. 1his in Iurn removes air
rom Ihe waIer. 1his principle is normally used in
sIeam Iurbine applicaIions.
$515/1.4/- RS0G; IT
A deaeraIor is used Io reduce oxygen (O2) and car-
bonic acid (CO2) levels in boiler eedwaIer Io proIecI
Ihe boiler againsI corrosion. lI is possible Io reduce
oxygen and carbonic acid levels Io abouI 0.02 mgl
o O2 and 0 mgl o CO2, depending on deaeraIor
consIrucIion.
P4*+5*-5/- RS0G; UT
A condenser ensures IhaI all sIeam is condensed be-
ore being pumped back inIo Ihe deaeraIor and Ihen
nternal steam distributor piping
nternal perforated pipe (water distributor)
Perforated trays
Low pressure steam
Boiler feed water (Recycled condensate and makeup water)
Air vent
Condensate
DEAERATOR
FEED TANK
Heating steam
Aeration steam
Deaerated water to
boiler feedwater pump
Trayed section vent
drain rollers
glass
level
gauge
Liquid level
Baffle
Baffle
Flanges
Steam
Condensate
Water outlet
Water inlet
To ejector
vacuum system
Baffle
Flanged
cover
plate
Tubesheet Tubesheet
lig. 4
lig. 5
inIo Ihe boiler. New IreaIed waIer is normally ed inIo
Ihe condenser.
6=4*4>0F5/
RisIorically, economisers have only been used in
large-scale power planIs. Rowever, Ihe demand or
more ehcienI boilers wiIhin Ihe manuacIuring in-
dusIry and marine indusIry means IhaI economisers
are now ar more commonplace.
An economiser is a heaI exchanger placed in Ihe
exhausI rom a boiler or in Ihe exhausI unnel o Ihe
main engine o a ship.
Pump requiremenIs dier greaIly, depending on
where Ihe economiser is insIalled.
LCONOMlZLk lN 1RL MAklNL (llG. 6)
keerring Io Ihe diagram below, Ihe circulaIion pump
has Io be sized Io Ihe pressure and IemperaIure in Ihe
boiler, which can easily be 20 bar and 170C. 8ecause
o Ihis, economisers eaIuring air-cooled Iop and
bearing ange may be required. 1he pump does noI
normally need Io be capable o delivering a high di-
erenIial pressure, as iI only has Io overcome Ihe pres-
sure loss in Ihe plaIe heaI exchanger (economiser).
LCONOMlSLkS lN LAND 8ASLD 8OlLLkS (llG. 7)
An economiser used wiIh a boiler locaIed on land
uses Ihe boiler's wasIe gases. 1he waIer circulaIed
above Ihe economiser is normally supplied by Ihe
main eed pump, buI can also be hIIed wiIh iIs own
circulaIion pump see lig. 7. 1he chimney will also in-
clude a bypass Io allow wasIe gases Io pass around
Ihe heaI exchanger.
1he consIrucIion diers rom marine design as Ihe
wasIe gases released rom Ihe main engine o a ship
are signihcanIly greaIer. Lnergy produced by marine
applicaIions oIen allow or Ihe generaIion o over-
heaIed sIeam ed direcIly rom economiser and ouI
inIo Ihe piping.
Deaerator
Steam
Circulation
Economize
Boiler
Burner
Feed pump
Condensate
Smoke from
main engine
Smoke to
chimney
Deaerator
Boiler
Burner
Feed pump
Condensate
Steam
Economize
Smoke from
main engine
Smoke to
chimney
lig. 6
lig. 7
9
10
34025/ ?,>?-
A range o pumps or dierenI boiler applicaIions
exisI. 1his secIion describes Ihe Iypical posiIioning o
Ihe various pumps and how Ihey are conIrolled.
1he mosI common boiler applicaIions are boiler eed,
condensaIe pumping, economiser circulaIion and
shunI pumps.
Sub-sysIem pumps such as dosing and waIer IreaI-
menI pumps also exisI.
8OlLLk lLLD
8oiler eeding can normally Iake place in Ihe
ollowing 4 ways:
- Ono conIrol
- 1hrough eed valve
- 1hrough eed valve and variable speed
- variable speed
All 4 meIhods will be described in Ihe ollowing.
1. Ono conIrol (lig. 8)
S,*=.04*
ln ono conIrol Ihe eed pump is swiIched ono
Ihrough a level sensor or a dierenIial pressure sen-
sor. When Ihe waIer level alls Io Ihe Pump on" level,
Ihe pump sIarIs pumping a large quanIiIy o relaIi-
vely cold waIer inIo Ihe boiler. 1his will reduce Ihe qu-
anIiIy o sIeam and cause Ihe sIeam pressure Io all.
1his is Ihe reason why ono conIrol causes variaIi-
ons in sIeam producIion. lI may also cause over-boi-
ling in Ihe boiler, which may cause waIer Io enIer Ihe
sysIem.

- lnexpensive
- Lasy Io insIall
- No bypass
$/1VK1=W-
- Poor sIeam qualiIy
Deaerator
Steamboiler
Feed pumps
Control
box
Level
sensor

Burner
lig. 8
LNGlNLLklNG MANUAL N 3Q":6( PQ8EQ#6#'&
11
2. 1hrough eed valve (lig. 9)
S,*=.04*
ln Ihis Iype o sysIem Ihe waIer level in Ihe boiler is
conIrolled by a eed valve, which is conIrolled by a
level sensor or a dierenIial pressure IransmiIIer
posiIioned on Ihe boiler.
1he eed valve conIrols Ihe waIer inIake, which is
ad|usIed according Io Ihe sIeam consumpIion. 1his,
however, requires IhaI Ihe eed pump is seI Io conIi-
nuous operaIion.
1his sysIem operaIes smooIhly and is ideal or all
Iypes o sIeam boilers, boIh small and large, and will
minimise Ihe risk o over-boiling.

- 8oiler eeding ad|usIed according Io
sIeam consumpIion, as described.
$/1VK1=W-
- 1he pump musI be seI Io
conIinuous operaIion (energy consumpIion)
- 8ypass
- 1he eed valve is expensive
- Pressure loss across Ihe eed valve
">?4/.1*.X
kemember Io size bypass according Io Ihe Ck pumps
min. ow which is 10 % o nominal ow or Ihe pump.
lI may be an idea Io sIop Ihe pump when Ihe valve is
closed. 1his requires, however, a signal rom Ihe valve.
3. 1hrough eed valve, variable speed. (lig. 10)
S,*=.04*
ln Ihis sysIem Ihe waIer level in Ihe boiler is conIrol-
led by a eed valve, which is conIrolled by a level sen-
sor or a dierenIial pressure IransmiIIer posiIioned
on Ihe boiler. 1he eed valve conIrols Ihe waIer inIake,
which is ad|usIed according Io Ihe sIeam consump-
Iion. 1his, however, requires IhaI Ihe eed pump is
seI Io conIinuous operaIion. 1his sysIem operaIes
smooIhly and is ideal or all Iypes o sIeam boilers,
Deaerator
Bypass
Steamboiler
Feed pumps
M
Control
box
Level
sensor
P

E
E
Burner
lig. 10
Deaerator
Steamboiler
Feed pumps
Bypass
Level
sensor
M

Burner
lig. 9

12
boIh small and large, and will minimise Ihe risk o
over-boiling.

- 8oiler eeding ad|usIed according Io sIeam con
sumpIion
- Lnergy savings on pump operaIion
- ConsIanI dierenIial pressure across Ihe eed valve
$/1VK1=W-
- 8ypass
- 1he eed valve is expensive
- Pressure loss across Ihe eed valve
">?4/.1*.X
kequiremenIs vary rom one counIry Io anoIher as
regards Ihe sizing o boiler eed pumps.
kemember Io size bypass according Io Ihe CkCv
daIa as well as Io min. ow. lI may be an idea Io sIop
Ihe pump when Ihe valve is closed. 1his requires,
however, a signal rom Ihe valve. lind ouI wheIher
variable speed conIrol o boIh pumps is required as
Ihis increases expenses, buI does noI provide Ihe
same exibiliIy as Io alIernaIing Ihe pump operaIion.
4. WiIhouI eed valve (lig. 11)
S,*=.04*
ln Ihis sysIem Ihe waIer level in Ihe boiler is con-
Irolled direcIly by Ihe variable speed pumps wiI-
houI using a eed valve. 1he pumps are conIrol-
led by a level sensor or a dierenIial pressure
IransmiIIer posiIioned on Ihe boiler. 1his way Ihe
waIer inIake is conIrolled according Io Ihe sIeam
consumpIion. 1his sysIem operaIes smooIhly and is
ideal or all Iypes o sIeam boilers, boIh small and
large, and will minimise Ihe risk o over-boiling.
Deaerator
Steamboiler
Feed pumps
Control
box
Level
sensor

E
E
Burner
lig. 11
LNGlNLLklNG MANUAL N 3Q":6( PQ8EQ#6#'&
13

- As described, boiler eeding ad|usImenI
according Io Ihe sIeam consumpIion
- Lnergy savings on pump operaIion
- No pressure loss across Ihe eed valve
- Money earned equal Io Ihe price o an expensive
eed valve
$/1VK1=W
- kequires precise and qualihed sIarI-up
">?4/.1*.X
- A minimum requency musI be dehned ensuring
IhaI Ihe pump can always overcome Ihe pressure
in Ihe boiler, and supply Ihe minimum ow or Ihe
pump. May be carried ouI wiIh Ihe min. curve" op-
Iion or Ihe pump.
- lI musI be ensured IhaI Ihe pump sIops when
sIeam consumpIion is zero. May e.g. be carried ouI
wiIh a high level swiIch rom Ihe boiler.
- 1he regulaIor area may be small. l Ihe level sensor
e.g. is 2 meIres and regulaIion Iakes place in an area
o |usI 20 cm corresponding Io approx. 2 mA, i Ihe
level sensor is 4-20 mA.
- 1he level signal is normally inverIed. 1his means
IhaI i you geI 20 mA rom Ihe level sensor, Ihe boi-
ler is ull and Ihen Ihe pump should sIop insIead o
speeding up.
CONDLNSA1L PUMPS
1. CondensaIe pumping ono (lig. 12)
S,*=.04*
1he pumps musI move Ihe eed waIer rom Ihe con-
densaIe Iank Io Ihe deaeraIor. 1his sysIem is Iypically
ono conIrolled Ihrough a level sensor posiIioned in
Ihe deaeraIor.
Deaerator
Condensate tank
Condensate
pumps
Level
sensor
Control
box
Return
condensate
From water
treatment

lig. 12
14

lnexpensive and easy Io insIall
">?4/.1*.X
kequiremenIs vary rom one counIry Io anoIher as
regards Ihe sizing o condensaIe pumps (Iwo pumps
musI always back each oIher up 100 %, requiremenIs
as Io over-sizing, eIc).
As Ihe disIance Io Ihe deaeraIor is Iypically only beI-
ween 2-5 m, Ihe pump musI have Ihe smallesI head
possible.
1he pump is Iypically locaIed righI nexI Io Ihe con-
densaIe Iank. 1he waIer IemperaIure may be up Io
95C and, Ihereore, caviIaIion may cause problems
in Ihis Iype o sysIem. ConsequenIly, a cusIomised Ck
Low NPSR is a hne choice.
9==5--4/05- /5Y,0/5+
Dosing pumps and waIer IreaImenI sysIem.
SRUN1 PUMP
1he requiremenIs o a shunI pump are normally high
ow and very low head. 1he shunI pump is Ihereore
normally made wiIh a 4-pole or 6- pole moIor Io geI
Ihe head down. ShunI pumps are normally single
sIage pumps.
1. Ono shunI pump (lig. 13)
S,*=.04*
1he shunI pump musI ensure IhaI Ihe reIurn Iempe-
raIure Io Ihe boiler does noI become Ioo low. l Ihe
dierenIial IemperaIure is high iI will sIress Ihe boi-
ler. 1he pump musI be sized according Io Ihe lowesI
reIurn IemperaIure, meaning IhaI iI is over-sized
mosI o Ihe Iime.

- lnexpensive and easy Io insIall
- Sae operaIion (ew componenIs)
!"#$%#
lig. 13
LNGlNLLklNG MANUAL N 3Q":6( PQ8EQ#6#'&
15
">?4/.1*.X
lnormaIion abouI Ihe correcI reIurn-pipe Iempera-
Iure Io be obIained rom Ihe boiler manuacIurer.
2. variable shunI pump (lig. 14)
S,*=.04*
1he pump musI ensure IhaI Ihe reIurn IemperaIure
Io Ihe boiler does noI become Ioo low. l Ihe die-
renIial IemperaIure is high iI will sIress Ihe boiler.
A variable speed pump may be Ihe correcI choice or
Ihis Iype o pump applicaIion. 1he pump musI be
insIalled wiIh a IemperaIure sensor regisIering Ihe
reIurn IemperaIure Io Ihe boiler, Ihereby ensuring a
consIanI IemperaIure.

- Always consIanI reIurn IemperaIure
- Lnergy savings
">?4/.1*.X
lnormaIion abouI Ihe correcI reIurn IemperaIure Io
be obIained rom Ihe boiler manuacIurer.
9==5--4/05- /5Y,0/5+
1emperaIure sensor, k100.
!
"
#$%&'%
lig. 14
16
LNGlNLLklNG MANUAL N AZ9' 7(%#$SQ& QSS6(&
17
AB1. 7/,*+C4- 4CC5/-
1. L pump soluIions
WiIh Grundos L-soluIion iI is possible Io opIimise
Ihe eed pumps wiIh Ihe soIware. leed pump opIi-
misaIion by means o soIware is used, e.g. because
Ihe pump curve is labile. See Ihe curve on hg. 15 or
an overview o Ihe curve and whaI problems iI may
cause.
As seen rom Ihe curve, iI is possible Io have 2 die-
renI ows on Ihe same seI poinI. PuI dierenIly, nor-
mal regulaIion o Ihe pump is required on one parI o
Ihe curve, i.e. greaIer ow and more speed, while on
Ihe oIher, inverse regulaIion is needed, i.e. less ow
and more speed. A normal regulaIor is noI capable o
conIrolling boIh and will become very unsIable which
can lead Io a poor sIeam qualiIy.
0
1
2
3
4
10
20
30
40
50
60
70
80
90
100
H
0
2
4
6
8
P2
0 1 2 3 4 5 6 7 8 9 10 11 12 Q(m/h)
(m)
(kW)
NPSH
(m)
CRN 10-10
Flow Range
nverse
Regulation
Normal
Set point
lig. 15
18
Grundos L-soluIions may be upgraded Io address
Ihis Iype o problem by increasing Ihe requency Io
55 Rz and increasing Ihe moIor slip. 1he moIor auIo-
maIically ad|usIs when iI alls below Ihe labile poinI
o Ihe curve. See hg. 16.
1he labile curve is noI a problem in all boiler planIs.
Normally iI is or can be a problem i Ihe eed pumps
are locaIed close Io Ihe boiler wiIh a small ricIion
loss as a resulI. ou would Ihereore normally never
see Ihis problem in Ihe marine indusIry or in oIher
places where Ihe pumps and boiler are placed ar
away rom each oIher.
2. NPSR
1o improve Ihe NPSR curves on Ihe Ck pump range
you can consIrucI Ihe pump wiIh an oversized inleI
chamber. See hg. 17 where you can also see Ihe resulI
o a low NPSR impeller and whaI eecI iI has on Ihe
NPSR value.
Standard
impeller
Low NPSH
impeller
LNGlNLLklNG MANUAL N AZ9' 7(%#$SQ& QSS6(&
lig. 16
lig. 17
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28
5
10
15
20
0
2
4
6
8
Q[m/h]
NPSH
[m]
H
[m]
QH 2900 rpm
1
QH 2900 rpm
1n
LOW NPSH
NPSH
19
3. Air-cooled Iop (lig. 18)
1he air-cooled Iop soluIion is used wiIh waIer Iem-
peraIures above 120C and up Io 180C. lor oil up
Io 240C.
1he air-cooled Iop -5?1/1.5- .B5 -512 =B1>K5/ C/4>
.B5 ?,>? KO 1* 10/[=4425+ =B1>K5/, generaIing an
insulaIing eecI similar Io IhaI o a Ihermos.
via a *1//4V ?1--1G5 K5.V55* .B5 ?,>? 1*+ .B5
10/[=4425+ .4?, a small quanIiIy o Ihe pumped liquid
ensures IhaI Ihe seal chamber is always hlled wiIh
liquid.
Air cooled Iop
lig. 18
20
4. Double shaI seal Mag-Drive
1he double shaI seal or Mag-Drive is used where
ingress o air Ihrough Ihe shaI seal may occur. 1his
phenomenon can occur when a seI o duIy sIandby
pumps pump waIer rom a vacuum Iank, which can
lead Io air ingress inIo Ihe pump during sIandby.
As Ihe diagram in hg. 19 illusIraIes, Ihis can be ad-
dressed by Iranserring some o Ihe waIer rom Ihe
pressurised side o Ihe non-reIurn valves back inIo
Ihe chamber beIween Ihe double shaI seals.
lllusIraIion o a pump Iop wiIh a double shaI seal arrange-
menI in hg. 20.
lnsIead o Ihe pump wiIh a double shaI seal arran-
gemenI, one wiIh a magneIically-driven shaI can
Vacuum Deaerator or
condensate tank
Duty standby
feed pumps
Return pipes to the
double shaft seal chamber

LNGlNLLklNG MANUAL N AZ9' 7(%#$SQ& QSS6(&
CkN 150 pump wiIh Double shaI seal :
lig. 19
lig. 20
21
also be used. See more in Ihe Grundos caIalogue
CusIom-builI pumps.
5. 8earing ange (lig. 21)
l Ihe inleI pressure is high, as wiIh an economiser
pump in a marine boiler insIallaIion, you may need Io
consider hIIing a bearing ange.
A bearing ange is an addiIional ange wiIh an
oversize ball bearing Io absorb axial orces in boIh
direcIions. 1he coupling parI o Ihe ange ensures
opIimum alignmenI.
34025/ ?/4K25>-
When discussing problems wiIh boilers and pumps
IhaI break down, some Iopics keep recurring. Some
o Ihem are menIioned here.
8O11OM 8LOW DOWN
A problem we oIen see in Ihe boiler business is ca-
viIaIion due Io boIIom blow down o Ihe boiler.
A boIIom blow down is when waIer is leI ouI rom
Ihe waIer reservoir in Ihe boIIom o Ihe boiler.
1he reason or doing Ihis blow down is IhaI suspen-
ded solids in Ihe waIer can be kepI in suspension as
long as Ihe boiler waIer is agiIaIed, buI as soon as
Ihe agiIaIion sIops, Ihe suspended solids will all Io
Ihe boIIom o Ihe boiler. l Ihe solids are noI remo-
ved, Ihey will accumulaIe and, given Iime, will inhibiI
Ihe heaI Iranser rom Ihe boiler hre Iubes, which will
overheaI or even ail.
1he normal meIhod o removing Ihis sludge is
Ihrough shorI, sharp blasIs using a relaIively large
valve aI Ihe boIIom o Ihe boiler. 1he ob|ecIive is Io
allow Ihe sludge Iime Io redisIribuIe iIsel so IhaI
more may be removed aI Ihe nexI blow down.
1he duraIion and requency o Ihe blow down vary
rom Ihe dierenI boiler manuacIurers.
lig. 21
22
1he pump problem sIarIs when Ihe blow down Iime
is so long IhaI Ihe pressure in Ihe boiler sIarIs Io all.
1his will or can resulI in Ihe eed pump running ouI o
curve which means IhaI Ihe required NPSR value or
Ihe pump will increase dramaIically. And Ihis resulIs
in caviIaIion and over Iime break down o Ihe pump.
WLLKLND SRO1 DOWN
Many o our cusIomers have producIions IhaI sIops
in Ihe weekend. 1his means IhaI Ihey also sIop Ihe
sIeam producIion over Ihe weekend and only keep
Ihe boiler aI a minimum IemperaIure Io be ready
Io sIarI up again. Row Ihey choose Io carry ouI Ihis
sIandby period is very dierenI rom cusIomer Io
cusIomer, buI oIen a liIIle amounI o sIeam is re-
cycled rom Ihe boiler Io Ihe deaeraIor Io keep IhaI
heaIed as well. lrom Iime Io Iime Ihey Ihen sIarI Ihe
boiler Io correcI Ihe levels in Ihe boiler and deaeraIor
and Ihis may cause problems boIh wiIh caviIaIion
and waIer hammer. CaviIaIion due Io a lower pres-
sure in Ihe boiler Ihan normal and waIer hammer
due Io Ihe column o waIer in Ihe pump being coo-
led down aI sIandsIill as iI is noI insulaIed. And when
Ihe pump is subsequenIly sIarIed you send a column
o cold" waIer Ihrough Ihe pipes resulIing in waIer
hammer in Ihe sysIem.
PkODUC1lON CRANGLS
OIen we see IhaI Ihe producIion changes over Iime
so Ihey someIimes use larger amounIs o sIeam Ihan
Ihe daIa available Io us during sizing o Ihe boiler.
1his may resulI in Iwo small pumps; meaning IhaI we
run wiIh Iwo big ows in Ihe pumps and because o
Ihis, a bigger NPSR is required.
OIen Ihe cusIomers also have dierenI operaIion
paIIerns Ihan Ihey inorm us abouI when we size Ihe
eed pumps. lor example we had a cusIomer who
once a monIh used sIeam or an hour Io clean his Iur-
bines. 1his resulIed in such high pressure drops in Ihe
boiler IhaI Ihe pump caviIaIed an hour every monIh.
LNGlNLLklNG MANUAL N AZ9' 7(%#$SQ& QSS6(&
DOSlNG
Normally no problems arise due Io Ihe way Ihe che-
micals used are being dosed inIo Ihe waIer. 8uI rom
Iime Io Iime we have seen an increase in Iear o Ihe
impeller i Ihe chemicals are being dosed direcIly in
ronI o Ihe eed pumps. 1his is because Ihe concen-
IraIion can be very high in Ihe pump due Io Ihe che-
micals noI having been mixed properly beore pas-
sing Ihe pump.
l iI is a large Ck wiIh bronze bearing iI is imporIanI
Io keep Ihe PR value in Ihe boiler waIer below 10 as
iI will oIherwise Iear down Ihe bronze. lI is usually
noI a problem as Ihe boiler manuacIurer also has
an inIeresI in keeping Ihe PR value aI approx. 8-9. 8e
aware IhaI i NR3 is added Io lower Ihe PR value, Ihe
NR3 will also Iear down Ihe bronze.
lLLD PUMP S1Ak1-UP
When Ihe pumps are being sIarIed, you have Io Iake
Ihe ollowing Iwo Ihings inIo consideraIion.
l Ihe pump is equipped wiIh a requency converIer, iI
is imporIanI IhaI Ihe pump sIarIs aI such high speed
IhaI iI delivers a higher pressure Ihan Ihe one in Ihe
boiler. l noI, iI will be like running againsI closed val-
ves unIil iI overcomes IhaI pressure. 1his can resulI in
a burned shaI seal.
l Ihe ramp up Iime is seI Io 0 sec., Ihe waIer column
in Ihe inleI o Ihe pump has been shown Io having
been Iorn aparI and some sorI o vacuum pockeIs
have been creaIed. When IhaI pockeI collapses again
or Ihe waIer column caIches up, iI creaIes some sorI
o waIer hammer wiIh a very high pressure. 1his
phenomenon happens very asI and pressure peaks
above 120 bar have been ound. 1his pressure peak
can desIroy all sensors in Ihe inleI o Ihe pump and aI
Ihe same Iime liI Ihe chamber sIack in Ihe pump so
explosively IhaI Ihe moIor bearings can be damaged.
23
24
LNGlNLLklNG MANUAL NE%8E& 9#$ &"\"#7
E,>?- 1*+ -0F0*G
8eore sizing your pumps, Ihe ollowing Ihree acIors
need Io be considered:
P1]0.1.04*
l Ihe waIer in Ihe deaeraIor or Ihe condensaIe Iank
has a high IemperaIure, iI is dihculI Io pump wiI-
houI causing Ihe pump Io caviIaIe. 1he higher Ihe
IemperaIure, Ihe more likely caviIaIion is Io occur.
1his is because you have Io pull" in Ihe waIer in Ihe
hrsI impeller and as a resulI Ihe pressure will all a
liIIle and Ihe waIer will sIarI Io evaporaIe. When Ihe
pressure is rising Ihrough Ihe impeller and Ihe small
sIeam bobbles are sIarIing Io implode and become
waIer again, Ihis is called caviIaIion.
8ecause o Ihis problem, Ihe deaeraIor condensaIe
Iank is oIen placed several meIres above Ihe pump
inleI Io ensure as high an inleI pressure as possible.
1he pump can be made wiIh a special hrsI sIage de-
sign IhaI reduces Ihe pump's NPSR value. See more
under sizing o pumps.
&B1C. -512 4/ 81G[$/0]5
lor eed pumps pumping rom a vacuum Iank, Ihe-
re is a risk o air inhlIraIion Io Ihe pump Ihrough
Ihe shaI seal. 1his phenomenon occurs when Iwo
eed pumps are running in parallel as duIy sIandby
pumps. Rere, Ihere is a risk IhaI Ihe sIandby pump
may leI air Ihrough Ihe shaI seal due Io Ihe va-
cuum in Ihe deaeraIor condensaIe Iank. 1his pro-
blem can be addressed by insIalling pumps wiIh
a double shaI seal arrangemenI wiIh barrier wa-
Ier or a Mag-Drive pump. kead more abouI our
cusIom-builI pumps in Ihe Grundos caIalogue.
&0F0*G
ln Ihe LU, Ihe LN 12952-7 norm has Io be used when
sizing pumps. Rowever, please check Ihe acIor re-
quiremenIs in your local counIry.
lLOW SAlL1 lAC1Ok ACCOkDlNG
1O LN 12952-7
1he eed pump capaciIy shall correspond aI leasI Io
1.25 Iimes Ihe allowable sIeam ouIpuI o all sIeam
boilers. lor saeIy reasons, 1.15 Iimes o maximum
conIinuous raIing is enough. lor availabiliIy and di-
erence in service condiIions a greaIer margin may be
necessary.
Where boiler waIers are consIanIly blown down in
volumes exceeding 5 % o Ihe allowable sIeam ouI-
puI, Ihe eed pump capaciIy shall be increased by Ihe
corresponding percenIage e.g., i Ihe blow down is
8 % o Ihe allowable sIeam ouIpuI, Ihe eed pump
capaciIy shall be increased by 8 %.
PkLSSUkL SAlL1 lAC1Ok ACCOkDlNG
1O LN 12952-7
1he eed pump shall be capable o supplying Ihe
sIeam boiler wiIh boIh Ihe eed waIer quanIiIy aI
maximum allowable pressure as specihed above and
Ihe eed waIer quanIiIy corresponding Io Ihe allowa-
ble sIeam ouIpuI 1.1 Iimes Ihe allowable working
pressure.
ln some counIries you are allowed Io reduce Ihe 10 %
i Ihe securiIy valve is o a cerIain size. Please check
Ihe local rules and regulaIions.
8esides Ihe rules and regulaIions above, you cannoI
|usI read Ihe ow and pressure on Ihe nameplaIe o
Ihe boiler and use Ihis daIa Io size Ihe pump. 1his is
because o Ihe high IemperaIure on Ihe waIer and
hereby Ihe lower densiIy o Ihe pumped waIer. See
Ihe example below.
25
26
35 1V1/5 .B1. ?,>?- 0* K4025/ 1??20=1.04*- 1/5
*4. 1 ?1/. 4C .B5 E/5--,/5 5Y,0?>5*. +0/5=.0]5
^@NHLN6P RE6$T 1==4/+0*G .4 G,0+520*5 DNDD;
LXAMPLL Ol lLOW AND RLAD CALCULA1lON
1he ollowing inormaIion is Iaken rom Ihe boiler
nameplaIe in hg. 22.
- Q8oiler = 20 Ionshour
- P8oiler max = 12.5 bar
- P8oiler operaIing = 10 bar
- 1emp. = 175 C
As you can see rom Ihe illusIraIion above, Ihe 175C
menIioned on Ihe nameplaIe is Ihe IemperaIure
on Ihe sIeam in Ihe ouIleI rom Ihe boiler. 1his inor-
maIion however is o no use as Ihe pump never re-
gisIers iI. AB5* -0F0*G O4, >,-. 12V1O- ,-5 .B5
.5>?5/1.,/5 0* .B5 +515/1.4/;
lrom Ihe vapour Iable we have ollowing daIa on
waIer wiIh a .5>?; 4C DMI_P;
DensiIy (rho)= 955.2 kgm3
vapour pressure = 1.1668 bar
lirsI we musI calculaIe Ihe daIa rom Ihe nameplaIe
Io m3h and mvs IhaI can be used in Ihe sizing.
Steam
20 ton/hour
175C
Boiler
Burner
Deaerator
Feed pump
Condensate
5

m
Q
8oiler =

Q
8oiler
=
20
.
10
3
= 20.9m
3
h
955.2
h
8oiler =

p
8oiler
=
12.5
.
10
5
= 133.4mvs

.
g 955.2
.
9.81
h
OperaIing =

p
8oiler
=
10
.
10
5
= 106.7mvs

.
g 955.2
.
9.81
lig. 22
LNGlNLLklNG MANUAL NE%8E& 9#$ &"\"#7

27
When we Ihen apply Ihe saeIy acIors rom LN
12952-7, we geI Ihe ow and head as specihed below.
Q
Pump max = 1.25 x
Q
8oiler =1.25 x 20.9 = H<;D >
L
NB
Q
Pump conIinuous = 1.15 x
Q
boiler = 1.15 x 20,9 = HI;M >
L
NB
h
Pump = 1.1 x
h
boiler = 1.1 x 133.4 = DI<;@ >J-
All values are now calculaIed so we can sIarI Io
choose Ihe pump. Please noIice IhaI Ihe pumps do
noI have Io handle boIh Ihe ow and pressure aI Ihe
same Iime. lI should be carried ouI as shown below
and in hg 23.
&0.,1.04* D;` llow 26.1 m
3
h aI 133.4 mvs
&0.,1.04* H;` Read 146.7 mvs aI 20.9 m
3
h
lrom Ihese siIuaIions we choose Ihe ollowing pump
because Ihe pump is capable o doing boIh siIuaIions.
Now we have a pump IhaI can do Ihe |ob, buI beore
ordering we have calculaIe Ihe NPSR value.
1o avoid pump caviIaIion,
NPSR
sysIem
- NPSR
pump
NPSR
sysIem
= h
b
- h

- h
v
h
geo
- h
s
NPSR
sysIem
= ls Ihe pressure available aI Ihe inleI o
Ihe pump.
h
b
= AImospheric pressure aI Ihe pump siIe.
h

= lricIion loss in Ihe sucIion pipe.

h
v
= vapour pressure o Ihe liquid.
h
geo
= vapour pressure o Ihe liquid.
h
s
= SaeIy acIor. Normally varies beIween 0.5
and 1 m.
lig. 23
Q = 20.9 m/h
H = 147 m
100%
H
(m)
P
(kW)
NPSH
(m)
200
180
160
140
120
100
80
60
40
20
16
12
8
4
0
0
8
6
4
2
0
0 5 10 15 20 25 Q(m/h)
P2 = 13.6 kW
P1 = 16 kW
P1
P2
NPSH = 3.83 m
Eta pump = 68.9%
Eta pump+motor = 58.9%
Q = 26.1 m/h
H = 133 m
n = 100% / 50 Hz
CRE 20-14
28
6a1>?25` : WiIh Ihe value rom earlier and Ihe Iank
placed 5 m above Ihe pumps, Ihe ollowing ormula
is ound:
As wriIIen earlier iI is Ihe densiIy o 104C waIer we
are using as Ihis is whaI Ihe pump regisIers.
8uI when we Iake anoIher look aI Ihe ormula we will
see IhaI Ihe hb and Ihe hv oseI each oIher. 1his is
because Ihe waIer in Ihe deaeraIor always is kepI aI
Ihe boiling poinI.
1his phenomenon will always occur in a boiler sysIem
and because o IhaI we can reduce Ihe ormula Io Ihe
ollowing.
NPSR
sysIem
= h

- h
geo
- h
s
So now we have a NPSR
sysIem
on 2 mvs, and Ihe Iwo
selecIed pumps have NPSR values way above IhaI.
8ecause o Ihis we will now look aI Ihe low NPSR ver-
sions o Ihe pumps, see hg 24.
h
sysIem
=

p

- h

-

p
- h
geo
- h
s

=

.
g
.
g
1.25
.
10
5
- 2 -

1.25
.
10
5
+ 5 - 1

= 2.0mvs
955.2
.
9.81 955.2
.
9.81
LNGlNLLklNG MANUAL N E%8E& 9#$ &"\"#7
lig. 24
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28
5
10
15
20
0
2
4
6
8
Q[m/h]
NPSH
[m]
H
[m]
QH 2900 rpm
1
QH 2900 rpm
1n
LOW NPSH
NPSH
29
As we can see on Ihe curve, Ihis pump can bee used in
a low NPSR version.
We have now ound a pump IhaI can handle Ihe |ob,
hg. 25. l we Iry Io puI in Ihe acIual duIy poinI iI looks
alrighI, buI i we compare iI wiIh a pump wiIh 2 less
impellers iI is looking even beIIer, hg. 26. 8uI please
noIice IhaI i we choose Ihe pump wiIh 12 impellers,
iI musI run over synchronous Io reach Ihe duIy poinI
according Io Ihe LN norm. Which one you choose is
up Io you.
lig. 25
lig. 26
100%
85%
H
(m)
P
(kW)
NPSH
(m)
200
180
160
140
120
100
80
60
40
20
16
12
8
4
0
0
8
6
4
2
0
0 5 10 15 20 25 Q(m/h)
P2 = 8.55 kW
P1 = 10 kW
P1
P2
NPSH = 2.13 m
Eta pump = 71.3%
Eta pump+motor = 60.9%
Q = 20.9 m/h
H = 107 m
n = 85% / 42 Hz
CRE 20-14
100%
90%
H
(m)
P2
(kW)
NPSH
(m)
eta
(%)
160
140
120
100
80
60
40
20
12
8
4
0
20
10
30
40
50
60
70
80
0
0
6
4
2
0
0 5 10 15 20 25 Q(m/h)
P2 = 8.41 kW
NPSH = 1.93 m
Eta pump = 72.5%
CR 20-12
Q = 20.9 m/h
H = 107 m
n = 90%
"EN duty point
Q = 26.1 m/h
H = 133 m
30
LNGlNLLklNG MANUAL N J9EQ%( '93:6
J1?4,/ .1K25
vapour pressure and densiIy o waIer aI dierenI IemperaIures
1his Iable shows Ihe
vapour pressure p |bar]
and Ihe densiIy |kg
m
3
] o waIer aI dierenI
IemperaIures I |
o
C].
Likewise, Ihe Iable shows
Ihe corresponding
absoluIe IemperaIure 1
|K].
vapour pressure p and densiIy o waIer aI dierenI IemperaIures
I|C] 1|K] P|bar] |kgm
3
] I|C] 1|K] P|bar] |kgm
3
] I|C] 1|K] P|bar] |kgm
3
]
0 273.15 0.00611 0999.8 138 411.15 3.414 927.6
1 274.15 0.00657 0999.9 61 334.15 0.2086 982.6 140 413.15 3.614 925.8
2 275.15 0.00706 0999.9 62 335.15 0.2184 982.1 145 418.15 4.155 921.4
3 276.15 0.00758 0999.9 63 336.15 0.2286 981.6 150 423.15 4.760 916.8
4 277.15 0.00813 1000.0 64 337.15 0.2391 981.1
5 278.15 0.00872 1000.0 65 338.15 0.2501 980.5 155 428.15 5.433 912.1
6 279.15 0.00935 1000.0 66 339.15 0.2615 979.9 160 433.15 6.181 907.3
7 280.15 0.01001 999.9 67 340.15 0.2733 979.3 165 438.15 7.008 902.4
8 281.15 0.01072 999.9 68 341.15 0.2856 978.8 170 443.15 7.920 897.3
9 282.15 0.01147 999.8 69 342.15 0.2984 978.2 175 448.15 8.924 892.1
10 283.15 0.01227 999.7 70 343.15 0.3116 977.7
180 453.15 10.027 886.9
11 284.15 0.01312 999.7 71 344.15 0.3253 977.0 185 458.15 11.233 881.5
12 285.15 0.01401 999.6 72 345.15 0.3396 976.5 190 463.15 12.551 876.0
13 286.15 0.01497 999.4 73 346.15 0.3543 976.0 195 468.15 13.987 870.4
14 287.15 0.01597 999.3 74 347.15 0.3696 975.3 200 473.15 15.50 864.7
15 288.15 0.01704 999.2 75 348.15 0.3855 974.8
16 289.15 0.01817 999.0 76 349.15 0.4019 974.1 205 478.15 17.243 858.8
17 290.15 0.01936 998.8 77 350.15 0.4189 973.5 210 483.15 19.077 852.8
18 291.15 0.02062 998.7 78 351.15 0.4365 972.9 215 488.15 21.060 846.7
19 292.15 0.02196 998.5 79 352.15 0.4547 972.3 220 493.15 23.198 840.3
20 293.15 0.02337 998.3 80 353.15 0.4736 971.6 225 498.15 25.501 833.9


21 294.15 0.02485 998.1 81 354.15 0.4931 971.0 230 503.15 27.976 827.3
22 295.15 0.02642 997.8 82 355.15 0.5133 970.4 235 508.15 30.632 820.5
23 296.15 0.02808 997.6 83 356.15 0.5342 969.7 240 513.15 33.478 813.6
24 297.15 0.02982 997.4 84 357.15 0.5557 969.1 245 518.15 36.523 806.5
25 298.15 0.03166 997.1 85 358.15 0.5780 968.4 250 523.15 39.776 799.2
26 299.15 0.03360 996.8 86 359.15 0.6011 967.8 255 528.15 43.246 791.6
27 300.15 0.03564 996.6 87 360.15 0.6249 967.1
28 301.15 0.03778 996.3 88 361.15 0.6495 966.5 260 533.15 46.943 783.9
29 302.15 0.04004 996.0 89 362.15 0.6749 965.8 265 538.15 50.877 775.9
30 303.15 0.04241 995.7 90 363.15 0.7011 965.2 270 543.15 55.058 767.8
275 548.15 59.496 759.3
31 304.15 0.04491 995.4 91 364.15 0.7281 964.4 280 553.15 64.202 750.5
32 305.15 0.04753 995.1 92 365.15 0.7561 963.8
33 306.15 0.05029 994.7 93 366.15 0.7849 963.0 285 558.15 69.186 741.5
34 307.15 0.05318 994.4 94 367.15 0.8146 962.4 290 563.15 74.461 732.1
35 308.15 0.05622 994.0 95 368.15 0.8453 961.6 295 568.15 80.037 722.3
36 309.15 0.05940 993.7 96 369.15 0.8769 961.0 300 573.15 85.927 712.2
37 310.15 0.06274 993.3 97 370.15 0.9094 960.2 305 578.15 92.144 701.7
38 311.15 0.06624 993.0 98 371.15 0.9430 959.6 310 583.15 98.700 690.6
39 312.15 0.06991 992.7 99 372.15 0.9776 958.6
40 313.15 0.07375 992.3 100 373.15 1.0133 958.1 315 588.15 105.61 679.1
320 593.15 112.89 666.9
41 314.15 0.07777 991.9 102 375.15 1.0878 956.7 325 598.15 120.56 654.1
42 315.15 0.08198 991.5 104 377.15 1.1668 955.2 330 603.15 128.63 640.4
43 316.15 0.08639 991.1 106 379.15 1.2504 953.7 340 613.15 146.05 610.2
44 317.15 0.09100 990.7 108 381.15 1.3390 952.2
45 318.15 0.09582 990.2 110 383.15 1.4327 950.7 350 623.15 165.35 574.3
46 319.15 0.10086 989.8 360 633.15 186.75 527.5
47 320.15 0.10612 989.4 112 385.15 1.5316 949.1
48 321.15 0.11162 988.9 114 387.15 1.6362 947.6 370 643.15 210.54 451.8
49 322.15 0.11736 988.4 116 389.15 1.7465 946.0 374.15 647.30 221.2 315.4
50 323.15 0.12335 988.0 118 391.15 1.8628 944.5
120 393.15 1.9854 942.9
51 324.15 0.12961 987.6
52 325.15 0.13613 987.1 122 395.15 2.1145 941.2
53 326.15 0.14293 986.6 124 397.15 2.2504 939.6
54 327.15 0.15002 986.2 126 399.15 2.3933 937.9
55 328.15 0.15741 985.7 128 401.15 2.5435 936.2
56 329.15 0.16511 985.2 130 403.15 2.7013 934.6
57 330.15 0.17313 984.6
58 331.15 0.18147 984.2 132 405.15 2.8670 932.8
59 332.15 0.19016 983.7 134 407.15 3.041 931.1
60 333.15 0.19920 983.2 136 409.15 3.223 929.4
LNGlNLLklNG MANUAL N 76#6(9:
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Poul Due !ensens ve| 7
DK-8850 8|erringbro
www.grundos.com
8eing responsible is our oundaIion
1hinking ahead makes iI possible
lnnovaIion is Ihe essence
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