KNOW ABOUT BFP (ACPP)

The type FK5G32M variable-speed feed water pump set should be provided for the 135MW-
generating unit with 100% capacity.
Boiler feed pump designation: FK5G32M
Booster pump designation: QG500-80
Hydraulic coupling designation: R17K.2E(VOITH) (Custormer supply)
Driving motor designation: YKOS3700-2(SEMC)
1.2、GENERAL DESCRIPTION
Each pumpset consists of a booster stage pump, directly driven from one end of shaft of an electric
motor, and a boiler feed pump driven from the opposite end of the motor shaft through a variable
speed Hydraulic coupling. The drive is transmitted, in each case, through a spacer type flexible
coupling.
The bearing in the booster pump and boiler feed pump and in the motor are lubricated from the
lubricating oil system incorporated in the Hydraulic coupling.
Each pump,motor and Hydraulic coupling is mounted on its own baseplate, the individual baseplates
being secured to a common concrete foundation block.

1.2.1、Booster Pump
The type QG500-80 booster pump is a horizontal, radial split, single-stage, double- suction, double-
volute pump.The suction and discharge nozzles are set at the top of the pump, thus Liquid enters
the pump at the suction branch. Rotation of the double entry impeller on the pump shaft generates
flow in the liquid which exits at the discharge flange.
The pump comprises a volute casing with integral suction and discharge nozzles and bolted DE and
NDE suction covers. The rotating assembly, comprising principally the shaft and the impeller, is
supported by DE a sleeve journal bearing and NDE a sleeve journal bearing and double-ball
bearing. Each bearing is lubricated from an integral lubricating oil system.
The mechanical sealing is used on the pump's shaft end.

2 Boiler feed pump

The type FK5G32M boiler feed pump has an integrated cartridge with the 5 stage-impeller. The
pump's internals can be withdrawn as a whole without interrupting alignment between the pump and
its in-let and out-let line.
The pump is driven by a Hydraulic coupling, the drive from Hydraulic coupling to the pump is
transmitted through a flexible membrance type coupling.
The pump is sealed at the drive and non-drive ends by labyrinth glands with a flow of cold water
from condensate pump being injected at a controlled pressure into the outboard side of the glands.
The bearing arrangement consists of a double tilting pad thrust and sleeve journal bearing at the
non-drive end and a sleeve journal bearing at the drive end, each bearing being lubricated from the
lubricating oil system associated with the Hydraulic coupling.
TECHNICAL DATA
Booster pump
ITEM UNIT
Type QG500-80
No. of stages 1
Temperature ℃ 166.4
Density kg/m3 900.89
3
Flow rate m /h 521.71
Head m 80.46
NPSH m 4.5
Efficiency % 81
Power absorbed at duty kW 127.07
Speed r/min 2985

Boiler feed pump

ITEM UNIT
Type FK5G32M
No. of stages 5
Temperature ℃ 166.4
Density kg/m3 900.89
Discharge Flow rate m3/h 488.41
Head m 1756.97
NPSH m 30.48
Flow rate (interstage m3/h 33.3
tapping)
Interstage pressure at MPa 7.6
2nd stage
Efficiency % 81.3
Power absorbed at duty kW 2658.17
Speed r/min 4653

Hydraulic Coupling(VOITH)
ITEM UNIT
Type R17K.2E

Input speed r/min 2985

 Output speed r/min 4785

Max. Output power kW 3074

Variable speed range % 25~100

Slip % ≤3

Mechanical loss(full load) kW 136±20

Hydraulic loss(full load) kW 58

Efficiency % 94

Motor（Shanghai Electric Machinery Co,.LTD.）

ITEM UNIT

Type YKOS3700-2TH

Rated power kW 3700

Rated voltage kV 6.6

Rated speed r/min 2982

OPERATION INSTRUCTIONS

PRE-START CHECKS
 1. Ensure that all electrical connections have been correctly made and are functional, and the
electric circuit and motor insulation been examined and are up to the standard.
2. Check that all instruments are connected correctly and that all associated wiring and pipe are
secured.
3. Connect the electrical supply to the instruments and to motor-driven auxiliary lub oil pump at
the Hydraulic coupling.
4. Start the motor-driven auxiliary lub oil pump and check that the oil is circulating freely through
the system by observing the flow through the flow indicators the pump bearings.
5. Open the seal water control valve, check for return water is unimpeded at sight glass and seal
water for normal.
6. If starting the pumpset for the first time after installation or overhaul, disconnect the couplings
between the booster pump and the motor , the boiler feed pump and Hydraulic coupling and
turn the pumps by hand to ensure freedom of rotation.
7. Disconnect the couplings at two ends of the motor,connect the electrical supply to the driving
motor and start it to check that direction of ratation is correct. Isolate the electrical supply to the
driving motor on comletion. Refer to the moto manufacturer’s instructions.
8. Reconnect the flexible couplings and install the coupling guard.
9. Check that the cooling water supply is available to the lbricating oil cooler, the motor air cooler
and the meachanical seals.
10. Restore the electrical supply to the motor.
11. Open the vent valves on the booster pump casing, the ingterconnecting pipe
12. Crack open the inlet isolating valve, and flood the booster pump, boiler feed pump and other
equipment.
13. Close the vent valves when water issues freely from them.
14. Fully open the inlet isolating valves.
15. Open the minimum flow valve, inlet and outlet isolating valve of minimum flow valve.
16. Carry out the pre-start check on the Hydraulic coupling, refer to the manufacturer’s instructions.
17. Set the Hydraulic coupling scoop tube in the ‘MIN’ position.
18. Carry out the pre-start check on the motor, refer to the manufacturer’s instructions.

START-UP
1、 Check that the minimum flow valve is fully open.
2、 Check that the pressure stage pump discharge isolating valve is closed.
3、 Check the lubricating oil pressure.
4、 Check for the pressure downstream the seal water valve is large than the pressure upstream
inlet valve of booster pump 0.05~0.1MPa.
5、 Start the motor.
6、 Open the boiler feed pump discharge isolating valve.
7、 Check that the motor-driven auxiliary lubricating oil pump is automatically switched off as the
pumpset speed increases,
SHUT-DOWN
 1、 Close the pressure stage pump discharge isolating valve, at the same time open the
minimun flow valve.
2、 Stop the motor.
3、 After 30 minutes switch off the auxiliary lubrication oil pump.
MINIMUN FLOW
The minimum flow valve should can full open automatically when the flow less than 132m3/h, and
can close automatically when the flow larger than 280m3/h. The opening/closing signal should be
taken from flow measuring device at outlet of Booster pump.
System should be provided with minimum flow valve which can open within 15sec, if not,trip.

LABYRINTH SEAL SYSTEM

Seal water control valve should be regurated automatically to ensure that the pressure downstream
the valve is always higher than the pressure upstream inlet valve of booster pump 0.05~0.10MPa, at
same time, Seal return water temperature keep 70~80℃.
FAULT FINDING

Symptom Possible Cause Solving Action

(1) Pumpset fails to start
(2) Pumpset performance
low
(3) bearings overheating
(a)Failure of electrical
supply.
(b) Motor fault.
(c) Starter fault.
(d) Seizure in the
pumpset.
(e) Pumpset in ‘Trip’
condition.
(a) motor or electrical
supply fault.
(b) Direction of rotation
incorrect.
(c) Excessive wear in
booster pump or feed
pump internals.
(d) Fault in minimum flow
system.
(e) Pressure stage pump
speed low.
(f) Pump suction
pressure low.
(a)Insufficient or
contaminated lubricating
oil.
(b) Misaligned of pump
and Hydraulic coupling.
(c) bearing worn or
misaligned
(d) Incorrect grade of
Check supply.
Check motor.
Check starter.
Disconnect each element in
turn at the couplings to locate
the seizure. Overhaul as
necessary
Investigate cause. Reset trip.
Check motor and electrical
supply
Check direction of rotation.
Dismantle pump and examine
the internals. Overhaul as
necessary.
Check system
Check setting and operation of
Hydraulic coupling.
Check suction conditions.
check the oil supply
Check alignment
check up the bearing
Check grade of oil
 Symptom Possible Cause
lubricating oil.
(4) Pumpset requires (a) Discharge pressure
excessive power to meet low
duty (b) Friction between
rotating and stationary
pump components.
(c) Excessive internal
clearances in pump
(d) Incorrect installation
of labyrinth glands.
(5) pump overheats or (a) pump running dry.
seizes
(b) Internal friction in
pumps
(c) Insufficient or
incorrect grade of
lubricating oil.
(d) Defects lubricating oil
system
(e) Bearings worn or
misaligned
(f) pumpset misaligned
(6) Excessive noise (a) Rotating assembly
and /or vibration out of balance.
(b) Excessive coupling
misalignment.
(c) bearing worn
(d) Holding down bolts
slack.
(e) Excessive pump
internal clearances
(f) Suction pressure lost
(g) Coupling damaged
(h) Sympathetic vibration
from incorrectly fitted
pipework.
(i) Minimum flow system
fault
Solving Action
Check flow rate
Check clearances
Check clearances
Examine glands
Check that the inlet isolating
valve id open and that strainer
is clean. Check that the
booster pump discharge
pressure is normal.
Check clearances
Check oil supply and grade
Check oil system
EXamine bearings
Check alignment
Indentify element of pumpset
causing fault and check the
dynamic balance of the
rotating assembly.
Check alignment
Examine bearings
Check bolts
Check clearances
Check suction system
Check up the coupling
Check adjacent pipework and
supports.
Check minimum flow system

RUN ON COMPLETE PUMPSET

 Ensure deaerator is filled to working level.
 Check that the suction strainer is clean.
 Check that the suction isolating valve to the booster pump is open.
 Check that the minimum flow valve is fully opened and that the electrical supplies are
available.
 Open all relevant vent valves and flood system. Close vent valve once water has
purged air from system.
 Ensure that the boiler feed pump discharge valve is closed.
 Check that all instrument valves are open and have been vented.
 Ensure that any isolating valves at the inlet and outlet connections from the
deaerator are open.
 Check that the lub oil level in the oil tank is correct.
 Check that the cooling water is available to lub oil.
 Check for the cooling water in labyrinth seal system is normal.
 Ensure that there is a safety clearance certificate.
 Start auxiliary lub oil pump. Check that manifold pressure is correct and that there is
flow from all visual sight glasses.
 Set the Hydraulic coupling scoop tube to minimum speed position.
 Energise motor and run up to minimum speed. Check system for leaks.
 Once the pumpset has reached minimum speed and is in a stable condition a set of
readings from all instruments should be logged. These readings should be taken
approx every 15 minutes for first hour.
 The unit speed should be increased to 80% and a set of readings recorded. The pump
should remain at this speed for approx two hours and log sheets should be filled in
every 15 minutes.
 The unit should then be set to 100% speed for a short time and a set of readings
should be recorded.
 The unit should then be brought back to 80% speed.
 The pumpset is now available to be put onto forward flow.