BOILER FEED PUMP

CHAPTER 1
INTRODUCTION

A Boiler Feed Pump(BFP) is a specific type of pump used to pump water into steam
boiler. The water may be freshly supplied or retuning condensation of steam produced by the
boiler. These pumps are normally high pressure units that use suction from a condensate
return system and can be of centrifugal pump type or positive displacement type or Horizontal
barrel type multi- stage pump. Also, in some cases , BFP is located in the feed water cycle and
pumps the demineralised feed water from deaerator to economiser inlet header. To force water
into the boiler, the pump must generate sufficient pressure to overcome the steam pressure
developed by the boiler. This is usually accomplished through the use of centrifugal pump.
[1]

In a thermal power plant, the BFP is one of the critical auxiliary machines that are
equivalent to the heart of the plant. In Thermal power generation, high pressure stream is used
to drive a turbine, which in turn rotates the generator directly connected to the turbine to
generate power . The steam is produce by feeding hot Water to the boiler from the BFP. This
means that an unexpected stop of the BFP completely stops power generation and therefore
the BFP requires a very high level of reliability. The power consumption of BFP has been
accounted for about 5% of power generation capacity in the large generating units.[3]
The water capacity of a boiler is only great enough to supply steam to the prime
mover for a period of a few minutes when operating at full load. This fact outlines the
extreme importance of an uninterrupted water supply to the, boiler. This is why, when
selecting boiler feed pumps, its performance record, installation and operation must be
considered prior to any commitment in order to insure this uninterrupted flow of water to the
boiler. [2]

1.2 General arrangement of BFP

Booster Pump

To Ensure a Net Positive Suction Head (NPSH) for Main Feed Pump Saves a Costly Main
Pump due to any damage from Cavitation. Typically a single-stage, centrifugal pump.

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Recirculation :
To maintain the Continuous flow of feed water when the valve to Economizer is Closed.

Suction Strainers
To Protect Booster pump and main pump against Catastrophic failure due to entry of coarse
Particles.

Hydraulic Coupling
Used to Transmit power from motor to pump as per the Load requirement.

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CHAPTER 2
Literature Survey

Author Keywords
Description
Name
Thermal power plant manual,
Specific BFP Model, Typical
Specifications,
Neyveli Lignite Corporation Constructional Details of
Boiler feed Pump Report
Limited BFP, Common Failures of
BFP, Troubles (Suction,
Mechanical,Hydraulic)

Operational manual, BFP

NTPC discription, BFP Booster Boiler feed pump manual
Pump, Technical data.
This paper explains how
BFPs have been upsized and Feed water pump,High
Shigeru YOSHIKAWA made compatible to higher pressure, efficiency, super
pressures;main specifications critical thermal power etc.
of BFPs; structures and
materials of typical BFP
P. M. V. Subbarao BFP, BFP Capacity, NPSH,
Driving Modes of
drives for Pumps
BFP,Cavitation and NPSH

BFP Review, Types Of BFP,

Purushottam R.Mukkundi BFP Review, Types
Design Criteria.

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CHAPTER 3
BFP Design Criteria (Typical)
3.1 Design Point:
The design capacity of boiler feed water pump is specified by design capacity and
head. The design capacity is based on plant’s maximum steam flow requirements. For a large
capacity power station, this would be the steam turbine throttle flow at valves‐wide‐open and
5% over pressure, plus steam or feed water removed from and not returned to the flow path
between boiler feed pump suction and turbine throttle. For example steam supplied to process
industries like sugar, textile etc.
3.2 Design Capacity:
The following are contributing factors generally considered in the determination of
boiler feed pump design capacity.
• Turbine throttle steam flow.
• Steam cycle make‐up flow.
• Seam blowing steam flow, if applicable.
• Auxiliary steam flow, if applicable.
• Reheat steam de‐superheating flow, if applicable.
• Any other steam / feed water requirement (ex. For Process application)

3.3 Design Head :

The total developed head for boiler feed pump is calculated by determining the
difference between the boiler feed pump discharge head and suction head as shown in table
below.
Boiler Feed Pump Total Suction Head Determination

Item
Deaerator pressure
Max. Static head between deaerator
and BFP impeller centre line
Friction loss between deaerator and
BFP suction line
Comments
Based on deaerator operating pressure @
max. turbine HBD (Heat Balance
Diagrams) conditions.
Based on low low water levelin storage tank
of deaerator.
This includes pipe friction loss, suction
filter 50% clogged condition (‐ve value)

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Total Suction Head Sum of above items

Based on turbine throttle pressure at

Turbine throttle pressure
maximum turbine heat balance conditions

Based on maximum turbine heat balance

conditions. Typically, main steam line
Main steam line friction loss
economically sized to render a 100‐200 psi
pressure drop

Determined by the steam generator

manufacturer. Generally limited by the
Super heater friction loss
plant designer to an economically feasible
value by specification

Determined by the steam generator

Economizer friction loss
manufacturer and limited by specification

Static head between steam

drum water level a Based on steam
Based on steam generator configuration
generator configuration and
economizer water inlet

Static head between the economizer

Based on location of the economizer inlet elevation
water inlet and the center line of the
and the boiler feed pump Elevation
boiler feed pump impeller
Generally limited by feed water heater design and
High‐pressure feed water heater
specifications to 50 psi or
pressure drop
less depending on the number of feed water heaters
Total discharge head Sum of the above items
Total developed head Total discharge head minus total suction head
Typically 5% of the subtotal of total developed
Design margin
head above
Design total developed head Sum of the above items

CHAPTER 4

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4. BOILER FEED PUMP (FK 6D 30TYPE)

The FK 6D 30 type boiler feed pump is a six stage horizontal centrifugal pump of the
barrel casing design. The pump internals are designed as cartridge which can be easily
removed for maintenance without disturbing the suction and discharge piping work or the
alignment of the pump and the turbo coupling The pump shaft is sealed at the drive end and
non-drive end by mechanical seals, each seal being flushed by water in a closed circuit and
which is circulated by the action of the seal rotating ring. This flushing water is cooled by
passing through a seal cooler, one per pump which is circulated with demineralized cooling
water. The rotating assembly is supported by plain white metal lined journal bearings and
axially located by a Glacier double tilting pad thrust bearing.

4.1 TECHNICAL SPECIFICATIONS (TYPICAL)

Pump type : FK6D30
No of stage :6
Direction of rotation viewed : Anti-clockwise On drive end
Liquid pumped : Boiler Feed Water
Sp.wt.at suction temp.,(kg/m3) : 905.0
Suction temperature(OC) :162.5
Differential head(m) : 2222

Design flow rate (m3/hr) : 420

Minimum recirculation flow (m3/hr) : 100

Efficiency (%) : 81
Speed rev/min : 5300
Power (kw) : 2840

4.2 PUMP CASING:

The pump casing consists of a forgot steel barrel with welded suction, discharge
branches, inter stage Lapping and mounting feet. The drive end of the casing is closed by a
suction guide which is entered from the non-drive end of casing and is located by a spigot
against the inner face of the casing. A mild steel gasket is located between the suction guides
spigot and the casing inner face to prevent the leakage between the barrel casing and suction

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annulus. An O ring with backup ring is also fitted in a groove in the periphery of the suction
to prevent leakage. Leakage between the suction annulus and the drive end of the pump
casing is prevented by an O ring and gasket located on an insert ring which is secondary to
the pump casing by a ring of studs and nuts. The non-drive end of the casing is closed by a
discharge cover is secured to a casing by a ring of studs, washers and nuts, sealing being
effected by an O ring located in a machine recess in the pump casing. On each side of the
casing, on its horizontal Centre line, are two feet which are secured to the base plate pedestals
by spacer pieces, washers and holding down bolts, thus allowing for expansion. Transverse
keys in the drive end pump feet ad longitudinal keys under the casing transfer moments and
thrust to the base plate, while allowing the casing freedom to expand. Provision is made on
the pump casing for a drain connection and temperature probes.

Boiler Feed Pump Assembled

4.3 DISCHARGE COVER:

The discharge cover closes the non-drive end of the pump casing and also forms the
balance chamber which, in turn, is closed by the non-drive end water jacket and
mechanical seal housing. The discharge cover as a close fit in the casing bore and is held in
place by a ring of studs and units. A spring disc is located between the last stage diffuser
and the discharge cover balance drum bush to provide the force required to hold the ring
section assembly in place against the drive end of the barrel before start-up. Once running,

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the discharge pressure assists the spring disc in holding the ring sections in place. The last
stage diffuser is free to slide over the balance drum bush which is shrunk into the discharge
cover bore to minimize the flow of liquid to the balance chamber.
Two holes are drilled radially through the periphery of the discharge cover to provide
outlet connections through which the liquid from the balance chamber is returned to the
pump suction piping and two similarly drilled holes are also provided in the discharge
cover for cooling water connections to the water jacket. The non-drive end bearing housing
is attached to a bearing bracket secured to the outer face of the discharge cover by studs,
nuts and dowel pins.
To assist in removing the cover, two tapped holes are provided on the flange for the
use of starting screw and a tapped hole is provided on top of the cover for an eye-bolt.

Discharge Cover
4.4 SUCTION GUIDE:
The suction guide closes the drive end of the pump casing and forms the suction
annulus. As a section of the pump cartridge, the suction guide is not secured to the pump
casing but is held against an internal shoulder in the casing by the ring section assembly,
the discharge cover and the spring disc. Like the discharge cover, the suction guide is
closed by the drive end water jacket and mechanical seal housing.
Two tapped holes are provided in the suction guide for cooling water connections
to the water jacket. The drive end bearing housing is attached to a bearing bracket secured
to the outer face of the suction guide by studs, nuts, and dowel pins.

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Suction Guide
4.5 RING SECTION ASSEMBLY:
The ring section assembly consists of ring section which located one to another by
spigots and are secured to each other by socket head screws in counter-bored holes, sealing
being effected by metal to metal joint faces and O rings with backup rings located in
grooves in the ring section spigots.
Diffusers are dowel and spigot located to the ring section and to the suction guide, and
the last stage diffuser is secured to the last stage ring section with socket head screws in
counter-bored holes, the screws being locked in position by locking strips. Packing rings
are shrunk in to the bores of the ring section and diffuser and are secured by the pumped
liquid between the stages.

Ring Sections

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4.6 ROTATING ASSEMBLY:

The dynamically balanced rotating assembly consists of the shaft, impeller,
abutment rings, keys, and the rotating parts of the mechanical seal, shaft nuts, balance
drum, thrust collar and the pump half coupling. The shaft is chromium plated at each end
where it is supported by the journal bearings, and its diameter increases in increments from
the non-drive end towards the drive end to facilitate the fitting and removal of the
impellers.
The impellers are of the single entry shrouded inlet type and are keyed and shrunk
onto the shaft, the keys, one per impeller, being alternately fitted on diametrically opposite
sides of the shaft to maintain the rotational balance. The hub of the each impeller butts
against a split abutment ring fitted in a groove in the shaft. The split ring is retained by an
extension on the impeller hub.

Rotating Assembly

Diffuse Impeller

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The balanced drum is keyed and shrunk onto the shaft and held in place against the
shaft location shoulder by the balance drum nut and lock-washer. The inner end of the
balance drum is recessed and the bore of the recess is a close fit over the last stage impeller
hub. The faces of the balance drum incorporate a connection for oil injection to assist to
removal of the drum and tapped holes are provided for withdrawal purpose.
The rotation parts of the mechanical seals are fitted to the shaft where it passes
through the seal housings. The seal sleeves are keyed to the shaft and are clamped in
position by seal sleeve nuts and lock nuts. The thrust collar is keyed to the non-drive end of
the shaft and is secured against a shoulder on the shaft by the thrust collar nut locked by a
lock-washer. The pump half coupling is located on the tapered end of the shaft by the keys
and it is secured by a coupling nut locked by a grub screw.

Balancing Drum
4.7 MECHANICAL SEALS:
The mechanical seals fitted at each end of the pump and each seal comprises a seal
body assembly secured to a seal housing which contains the rotating components of the
seal. Each seal consists of a rotating tungsten carbide seat, mounted in a carrier, running
against a stationary carbon face. Contact between the face and seat is maintained by the
hydraulic pressure during running by the spring pressure on the start-up. Any other
possible leakage paths, within the seal unit, are sealed with "O" rings and the stationary
components are prevented from rotating by keys or anti-rotation pins.
The seal is designed to re-circulate the pumped product through a seal cooler, to
maintain an acceptable temperature in the region of the seal face.

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Mechanical Seal
4.8 JOURNAL AND THRUST BEARING:
The rotation assembly is supported at each end of the shaft by a white metal lined
journal bearing and the residual thrust is carried by a tilling pad double thrust bearing
mounted at the non-drive end of the pump. The journal bearing shells are mild steel, white
metal lined, thin wall type and are split on the horizontal plate through the shaft axis. Each
bearings is secured in a bearing housing and prevented from rotating by lugs locating in
recesses in the housing.
The thrust bearing is fitted in the non-drive end bearing housing and has eight digit
white metals lined tilting pads held in a split carrier ring positioned on each side of the
thrust collar. The carrier ring are prevented from rotating with the shaft by the dowel pins
in the each ring which engage in slots in the bearing housing top half. The thrust pads are
retained on the carrier rings by special pads stops screwed into the rings.
A split floating oil sealing ring is located in a groove in the thrust bearing housing
to restrict the escape of lubricating oil from the thrust bearing chamber. To ensure that the
thrust bearing remains flooded, an orifice is filled at the oil outlet.
Machined spacers are fitted behind the carrier rings to affect the axial position
setting of the rotation assembly on the original built. The bearings are supplied with the
lubricating oil from the forced lubrication oil system.

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4.9 BEARING HOUSINGS:

The bearing housings in the form of cylindrical castings split on the horizontal shaft
axis. The drive end bearing housing is secured to the bearing housing brackets by bolts,
nuts and washers and is radially located by dowel pins fitted in the flange of the housing
brackets. The journal bearing is located by lugs in recesses in the bearing housing, and held
by the top half bearing housing, which is secured to the bottom half by studs and the nuts
are located by dowel pins. Oil guards fitted in the groove at each end of the bearing
housing are dowel located and serve to prevent oil escaping from the housing.
An air breath is screwed to the tapped hole in the top half bearing housing are tapped
hole is provided for a temperature gauge. Connections for an oil inlet and an oil outlet are
provided in the bottom half bearing housing. The non-drive end bearing housing, which
contains both the journal and the thrust bearings, is secured to the bearing housing bracket
by studs and nuts. The top and bottoms halves of the bearing housings are secured together
by stud and nuts and located on dowel pins. Leakage of lubricant oil from the non-drive
end bearing housings prevented by the oil guard in the inboard side of the housing and by a
bearing housing end cover with O ring, secured to the outboard side of the housing by
socket head screws.

Bearing Housing

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4.10 FLEXIBLE COUPLING:

The flexible coupling between the hydraulic coupling and the pump shafts consists
of two hubs flexibly connected through laminated stainless steel elements to a tubular
spacer. The element assemblies are secured to the flanges of the spacer and the hubs by
bolts and Nyloc nuts. The flanges of the hubs are drilled to clear the overload washers
fitted to the bolts which secure the flexible element to the spacer. Similarly the flanges of
the spacer are drilled to clear the overload washers fitted to the bolts which secure the
flexible elements to the hubs. The coupling is thus above to accommodate a certain amount
of misalignment between the turbo coupling and pump shafts, to which the hubs are fitted.

4.11 HYDRAULIC BALANCE:

The rotating assembly is subject to varying forces due to the differential pressure
force acting on the impellers. The pump has therefore been designed so that the shaft is
kept it tension by the location of a balance drum at the non-drive end, and is hydraulically
balanced so that only a small residual thrust remains, which is carried by the thrust bearing.
The main components of the hydraulic balancing arrangement are the balance
chamber in the discharge cover, the balance drum which is secured to the shaft and the
balance drum bush fitted in the bore of the discharge cover. The thrust caused by the
discharge pressure acting on the area outside each impeller wear ring on the inlet side of
the impeller is balanced by the same pressure acting on an equal area on the outlet side of
each impeller. The thrust caused by the suction pressure acting on the area inside the wear
ring on the inlet side of each impeller is overcome by the much greater thrust caused by the
discharge pressure acting on an equivalent area on the outlet side of each impeller. The
resultant thrust force, due to the different pressures acting on these equal areas, tends to
move the rotating assembly towards the drive end of the pump.
The thrust force will vary with the load on the pump but the hydraulic balance
arrangement will reduce its effect, enabling the residual thrust to be taken by the tilting pad
thrust bearing. This bearing has a double face so that the surges in opposite directions
which occur during the start-up period and during transient conditions will be
accommodated.

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CHAPTER 5

Boiler Feed water Pump Balancing Line

Due to pressure difference across the pump there is always thrust on the rotor
toward suction side of pump due to fluid. Therefore, there balancing system is required.
5.1 Balancing drum
Balancing drum is cylindrical portion installed on the rotor of the pump generally at
the discharge end side. Small gap in mm is maintained axially between casing or dummy
piston which is stationary part attached with pump casing .One side of balancing drum,
pressure=discharge pressure while another side of balancing drum, the pressure =suction
pressure slightly greater than suction pr. which is maintained by a balancing line connected
to suction line of pump. Therefore, due to pressure difference across balancing drum there is
thrust which will opposite to the thrust created by fluid

The operation of the simple balancing disk is illustrated in Figure above. The disk is
fixed to and rotates with the shaft. It is separated by a small axial clearance from the
balancing disk head, or balancing sleeve, which is fixed to the casing. The leakage through
this clearance flows into the balancing chamber and from there either to the pump suction or
to the vessel from which the pump takes its suction. The back of the balancing disk is subject
to the balancing chamber back pressure, whereas the disk face experiences a range of
pressures. These vary from discharge pressure at its smallest diameter to back pressure at its
periphery. The inner and outer disk diameters are chosen so that the difference between the
total force acting on the disk face and that acting on its back will balance the impeller axial
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thrust.
If the axial thrust of the impellers should exceed the thrust acting on the disk during
operation, the latter is moved toward the disk head, reducing the axial clearance between the
disk and the disk head. The amount of leakage through the clearance is reduced so that the
friction losses in the leakage return line are also reduced, lowering the back pressure in the
balancing chamber. This lowering of pressure automatically increases the pressure difference
acting on the disk and moves it away from the disk head, increasing the clearance. Now the
pressure builds up in the balancing chamber, and the disk is again moved toward the disk
head until an equilibrium is reached.
To assure proper balancing in disk operation, the change in back pressure in the
balancing chamber must be of an appreciable magnitude. Thus, with the balancing disk wide
open with respect to the disk head, the back pressure must be substantially higher than the
suction pressure to give a resultant force that restores the normal disk position. This can be
accomplished by introducing a restricting orifice in the leakage return line that increases back
pressure when leakage past the disk increases beyond normal. The disadvantage of this
arrangement is that the pressure on the seal chamber is variable, a condition that may be
injurious to the life of the seal and therefore should avoided.

CHAPTER 6
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Cavitation & NPSH

 As the liquid flows onto the impeller of the pump it is accelerated and initially its
pressure falls (Bernoulli).

 The pressure subsequently increases as the fluid leaves the impeller and as the kinetic
energy is recovered in the volute chamber.

 If the pressure of the liquid falls below the vapour pressure, Pv, the liquid boils,
generating vapour bubbles or cavities-cavitation.

 The bubbles are swept into higher pressure regions by the liquid flow, where they
collapse creating pressure waves and cause mechanical damage to solid surfaces.

 Moreover, pump discharge head is reduced at flow rates above the cavitation point.

 Operation under these conditions is not desirable and damages the equipment.

NPSH (Net Positive Suction Head).

 Net Positive Suction Head Required, NPSHr

 Pumps can pump only liquids, not vapours.

 Rise in temperature and fall in pressure induces vaporization

 NPSH as a measure to prevent liquid vaporization

 Net Positive Suction Head (NPSH) is the total head at the suction flange of the pump
less the vapour pressure converted to fluid column height of the liquid.
 To avoid cavitation, pressure of fluid at any point should be greater than saturated
pressure at all locations.
 Net positive suction head available (NPSHA)
NPSHA = P(at suction) – Psat
 Net positive suction head required (NPSHR) is the minimum NPSH necessary to
avoid cavitation.

 ∴ NPSHA ≥ NPSHR ( to avoid the cavitation)

CHAPTER 7
COMMON FAILURES OF BOILER FEED PUMPS:
1. Pump does not deliver liquid

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2. Insufficient capacity delivered.

3. Insufficient pressure developed
4. Pump loses prime after starting.
5. Pump requires excessive power.
6. Pump vibrates or is noisy at all flows.
7. Pump vibrates or is noisy at low flows.
8. Pump vibrates or is noisy at high flows.
9. Shaft oscillates axially.
10. Impeller vanes are eroded on visible side.
11. Impeller vanes are eroded on invisible side
12. Impeller vanes are eroded at discharge near center
13. Impeller vanes are eroded at discharge near shrouds or at shroud/vane fillets
14. Impeller shrouds bowed out or fractured
15. Pump overheats and seizes.
16. Internal parts are corroded prematurely
17. Internal clearances wear too rapidly.
18. Axially split casing is cut through wire drawing.
19. Internal stationary joints are cut through wire drawing.
20. Packed box sleeve scored
21. Packed box leaks excessively or packing has short life.
22. Mechanical seal leaks excessively.
23. Mechanical seal: damaged faces sleeve bellows.
24. Bearing have short life.
25. Coupling fails.

CHAPTER 8
Typical Materials

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Conclusion.
• With the increase of unit capacity, capacity of feed water pump correspondingly will
increase.
• The driving mode of boiler feed pump is mainly affected by thermal economy of system.
• To Ensure NPSH for Main Feed Pump usually Booster Pump is used which Saves a
Costly Main Pump due to any damage from Cavitation.