Proceedings of the ASME 2014 Power Conference
POWER2014
TRANSIENT ANALYSIS OF A HIGH PRESSURE SEAL INJECTION SYSTEM UNDER
STARTUP CONDITIONS
DeVon A. Washington, PhD
Consumers Energy
Engineering Services Department
Jackson, MI, USA
ABSTRACT
This study examines the transient behavior of a seal
injection system, for four boiler circulating water pumps, in an
effort to optimize seal flush rates under startup conditions.
During startup, seal injection supply water experiences a large
increase in pressure, going from 1.8-26.2 MPa. This large
increase in supply pressure presents a challenge in maintaining
the desired differential pressure across the seals, and hence the
optimum seal flush rate. Overshoot of the control valve
position can result in starving the seals of seal water. Delayed
responses expose the seals to excessively large differential
pressures.
The seal injection system was modeled using PIPENET™
Vision. The model consists of a detailed replica of the seal
injection system pipe network. Initial and boundary conditions
were obtained from plant DCS data and pump OEM
specifications. A baseline model was developed and validated
using actual system response data. Extended models
considered two types of control systems, manual and
differential pressure-control; as well as, control valves with
various flow characteristics: linear and equal percentage.
Additionally, a diffuser breakdown assembly and startup
control valve were also introduced as control components into
the model.
Results show that the implantation of a diffuser breakdown
assembly in series with the primary control valve (modified
linear), in conjunction with automated controls produced a
differential pressure of 436 kPa which was within the OEM
specified range of differential pressures (345-690 kPa). A
startup control valve used in series with the primary control
valve also produced acceptable results (388 kPa). The proper
design and operation of seal injection systems is vital to
extending time between overhauls, thereby reducing
maintenance costs. The use of the aforementioned control
components in series with control valves is common for boiler
feedwater regulation systems during startup; however, this is
the first application known to the authors for pump seal
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July 28-31, 2014, Baltimore, Maryland, USA
POWER2014-32129
LeRoy N. Reiss, PE
Consumers Energy
Engineering Services Department
Jackson, MI, USA
injection systems in fossil plants. The results of the hydraulic
simulation outlined in this study show this application is viable.
Keywords: high pressure seal injection system, seal flush rates,
boiler circulating water pump, startup transients
INTRODUCTION
There are two primary design classifications of boilers: (1)
thermal-circulation, and (2) controlled circulation. In thermal-
circulation boilers, circulation occurs due to differences in
density between slightly subcooled water in the downcomers
and lighter steam-water in the furnace-wall tubes. This type of
design is often referred to as a “natural convection” boiler.
Controlled circulation boilers, also called “forced convection”
boilers, began to emerge in the early 1940s. With this design,
BCWPs are used to provide adequate circulation throughout the
boiler under all operating conditions. Some advantages of the
controlled circulation design include: (1) smaller diameter
furnace-wall tubes with lower metal temperatures, and (2)
faster unit startup times [1].
Generally, BCWPs are vertical constant speed centrifugal
pumps with a single overhung impeller. Although BCWPs
typically generate low head, the subcooled water being pumped
is at full boiler pressure. This requires that the pumps be of
special design to prevent leakage of shaft seal water, which will
flash to steam if exposed to ambient conditions. There are three
categories of pump designs capable of addressing this issue.
The first two designs are variations of glandless or zero-leakage
pumps. The third design, which is the focus of this study,
utilizes a stuffing box in conjunction with an injection seal
system [1].
BACKGROUND
The unit under consideration is located in Michigan and
went into service in 1959. It has an electric power rating of
1 Copyright © 2014 by ASME
 approximately 260 MW. The boiler operating pressure is 16.9 supplied by the BFPs. During startup the feedwater discharged
MPa. from the BFP reaches 26.2 MPa at approximately 450 K. The
pressure of the feedwater used for injection seal water is
BCWP and Injection Seal System regulated such that it is 345-690 kPa above the discharge
As was described previously the BCWPs studied here are pressure of the BCWPs. This ensures that boiler water cannot
vertical constant speed centrifugal pumps, with single overhung back up into the stuffing box.
impellers. Table 1 provides some additional information Figure 1 illustrates the flow path of the injection seal water.
regarding design operating conditions and performance Location F is the injection inlet. Location H is the upper seal
characteristics for the pumps and motors. ring clearance pressure breakdown to leak-off. Location J is
the lower breakdown clearance between the throttling bushing
Table 1 BCWP operating conditions and performance and sleeve, which controls leakage to the pump casing.
characteristics Location E is the leak-off outlet. The leak-off pressure range is
generally 1.2-1.7 MPa. If the leak-off pressure is too low
Operating Conditions flashing may occur, too high the packing maybe damaged.
The floating rings are constructed of hardened martensitic
Drum pressure 17.7 MPa stainless steel. The term floating ring is derived from their
Water temperature 622 K ability to float radially relative to the shaft. The radial
clearance between the rings and shaft is 254-381 µm. This
Pump Characteristics clearance, as well as the distance between the rings regulates
Capacity 31.2 m3/min leak-off [2, 3, 4, 5]. The recommended seal flush rate as a
function of pressure above the BCWP discharge pressure is
Discharge pressure 18.1 MPa given in Fig. 2. The seal flush rate is the sum of leak-off and
leakage to the pump casing. The tight clearances used to
Suction pressure 17.9 MPa
Differential pressure 276 kPa
Motor Specifications
Power 298 kW
Voltage 4160 V
Speed 1770 rpm

The shaft seal system for these pumps are composed of a

stuffing box and pressure breakdown device, in addition to a

Fig. 2 OEM recommended seal flush rates per pump

regulate flow also make the seals vulnerable to suspended

Fig. 1 BCWP injection and leak-off arrangement
combination injection and bleed-off arrangement (Fig. 1). The
pressure breakdown device consists of a set of floating rings
designed to control the temperature, pressure, and rate of
injection seal water leakage. The injection seal water is
particulate in the feedwater.
Typically, injection seal flow is controlled four basic ways:
(1) manually, (2) differential-pressure, (3) differential-
temperature, and (4) constant drain temperature. Manual and
differential-pressure systems are the focus of this study. A
manual system requires that a control valve, which regulates
flow, be manually adjusted every time the pump operating
condition changes. Differential-pressure systems use a
pneumatic control valve and differential pressure transmitter,
which ensures the injection seal supply is maintained at a
predefined differential pressure above the discharge pressure of
the pump.

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 A B

Valve seat erosion O-rings eroded away

Erosion of pressure-balance hole

(upper plug)

C D

Abrasion wear marks

Blockage of seat retainer
(metal shards)

Fig. 3 Damage to various components of the injection seal system pneumatic control valve

By the very nature of its design differential-pressure controls
are prone to feedback instability, but yet instill this is a very
popular control scheme [2].
In addition to control valves, injection seal systems also
include injection piping, isolation valves, and strainers. Pump
OEMs generally recommend 100 mesh strainers be installed.
In older systems, like the one considered here, strainers are
usually located downstream of the control valve. When these
systems were first designed, many of the control valves of the
day were able to pass relatively large particulate without
plugging; therefore, installing strainers downstream of the
control valve was permissible. However, nowadays there is a
wide variety of control valves in the marketplace designed for a
whole host of specific system criteria. Many of these control
valves have torturous flow paths designed to break up the
pressure drop over several stages to prevent cavitation.
Although these designs are very effective at preventing
cavitation they are highly susceptible to pluggage. Abrasion
wear and blockage of various control valve components, due to
particulate in the feedwater, are shown in Figs. 3C and 3D,
respectively.
A concerted effort was made by the rotating equipment
industry to standardize seal types and arrangements which
resulted in API Standard 682, first published in 1994. Before
this time there was minimal coordination between pump and
seal OEMs toward this end [6]. The injection seal system being
investigated here predates API Standard 682 by approximately
4 decades. As various legacy control components are phased
out due to advances in technology, the result is an injection
system with a combination of vintage and modern components.
Seal system configurations are similarly impacted by this issue.
The appropriate configuration for the strainer, pressure and
temperature indicators, and control valve for this type of
injection system is API Plan 32, defined in API Standard 682
[7]. Plan 32 calls for the strainer to be located upstream of the
control valve, as well as the pressure and temperature
indicators. This plan is most often used with a close-clearance
throttling device, where the flushing product is supplied to the
seals by an external source.
Startup Transients
The previous discussion provides a high-level overview of
the pump seals and injection seal systems. Here issues

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 surrounding operating conditions and their impact on various feedwater from the drum to the inlet of BCWPs (276 kPa), and
the head generated by the BCWPs (276 kPa), is approximately
1.6-1.9 MPa. In order to maintain an OEM recommended
pressure of 345-690 kPa above BCWP discharge pressure, the
seal injection supply needs to be maintained between 1.9-2.6
MPa. This cannot be accomplished by the CNDPs; therefore,
the BFPs are started. Figure 6 shows the BFP pressure rise

Fig. 4 Injection seal header

control components will be discussed.
The locations of the primary and bypass control valves,
within the system, are shown in Fig. 4; both valves have custom

Fig. 6 BFP pressure rise time

time. The injection seal supply pressure goes from 1.7-23.9
MPa in approximately 9 seconds, nearly resembling a step
input to the system.
Accurately controlling injection seal pressure during this
transient poses several significant challenges. The stress
imposed on the control valve can be seen in the damage
inflicted to the valve seat and pressure-balance plug in Figs. 3A
and 3B. The corresponding injection seal system differential

Fig. 5 Primary and bypass CV trim characteristics

modified linear trim characteristics (Fig. 5) [8]. However, the
bypass control valve has an unbalanced trim, where the primary
control valve has a pressure-balanced trim. Since the bypass
control valve has an unbalanced trim, it is used to regulate the
pressure differential of the injection supply during base-load
operations. Its position ranges between 20-60% open, which is
well within its rangeability (17:1) [9]. During startups the
primary control valve is used since it has a pressure-balanced
trim, which is better able to maintain a specified position during
transients with extremely high differential pressures.
At startup, injection seal water is initially supplied by the
Fig. 7 Injection seal differential pressure
CNDPs at approximately 1.8 MPa. When the boiler drum
pressure reaches 1-1.4 MPa the BFPs are started and used as pressure during this time is shown in Fig. 7. For nearly 35
the injection seal water source. The result of summing the seconds the differential pressure exceeds the OEM
boiler drum pressure (1-1.4 MPa), head pressure of the recommended 690 kPa, reaching a maximum of 3.7 MPa.

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 The flush rates corresponding to the recommended
differential pressures (Fig. 2) range from approximately 100-
125 L/min. Generally, there are three pumps in service and one
on standby; therefore, the required total injection flow should
the regulated between 416-511 L/min at 345-690 kPa above
BCWP discharge pressure. To achieve this operating point
during startup requires that the primary control valve position
be set at 7-10% open when the valve is in optimal condition,
and 1-5% open when the valve components are worn (Figs. 3A-
D). Positions less than 10% open begin to approach the
clearance flow or the minimum controllable flow of the valve.
The erosion shown in Figs. 3A and 3B are a result of operating
under such conditions and characteristic of cavitation damage.
Here manual mode suggests that an operator is manually
sending an electronic signal to the control valve actuator in
order to set its position. Automatic mode implies that the
control valve position is being determined automatically based
Fig. 8 Model inlet boundary condition
on an input signal from a differential pressure transmitter. In
both cases problems have been encountered during startup. Figures 9 and 10 are the differential pressure and flow rate 1
In manual mode often times the operator will miss the responses of the injection seal system under manual startup
transient altogether and for a short period of time the seals are
subjected to extremely high pressures, as high as full BFP
discharge pressure. API 682 defines three pressures: (1)
maximum static sealing pressure, (2) maximum dynamic
sealing pressure, and (3) maximum allowable working pressure
[7, 10]. Startup conditions which exceed the maximum
dynamic sealing pressure are a major concern. At full BFP
discharge pressure the injection seal supply is 8.3 MPa over the
design operating pressure (Table 1).
In automatic mode the feedback instability inherent to this
type of differential-pressure control scheme causes the control
valve to flutter, and in some instances causes intermittent
interruptions in injection seal supply water. It is suspected that
this intermittent interruption in two cases has resulted in
upward vertical movement of the throttling bushing, and in
another case caused the throttling sleeve and bushing to seize
together locking up the pump. Maintaining the appropriate
clearances and flush rates through the throttling bushing and
sleeve are vital to reliable pump operation [11]. Fig. 9 Baseline injection differential pressure
conditions. Here the control valve was manually operated and
ANALYSIS was not set to a lower position before full BFP pressure was
Based on the operational history of the injection seal reached. The simulated model results of the system response
system, a study was conducted to investigate how the system were within an acceptable range.
may be improved to increase the MTBRs and MTBFs in order Figure 11 depicts the differential-pressure control system.
to reduce O&M costs [12]. It is composed of a transfer function, PI controller, and a
differential pressure sensor. The transfer function models the
Baseline Model dynamics of the control valve [13]. To achieve the observed
A detailed replica of the injection seal system was
developed in PIPENET™ [13]. The pipe network dimensions, d2y dy
boundary conditions, valve characteristics, and system response t2
2
+ 2rt + y = Gx + B (1)
dt dt
were determined from engineering drawings, DCS data, and
OEM design specifications. Figure 8 shows the boundary system behavior the control valve was modeled as a second
condition used for the model inlet. A constant pressure order system, shown in Eq. 1. The PI controller differential
boundary condition of 1.2 MPa was used at the outlet nodes. pressure setpoint was 414 kPa.

1
Injection seal system flow rates are given for all four BCWPs

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 Fig. 10 Baseline injection header flow
Figure 12 is a simulation of the system response of the
bypass control valve under startup conditions. When using the
bypass control valve to regulate pressure in the injection seal
header during startup, operators described oscillations resulting
in audible chatter and vibration. Using simulation data and
valve performance characteristics (Table 2), the calculated
Fig. 12 Bypass CV system response during startup
RESULTS
In order to reduce the excessively high pressures and
flows, as well as mitigate the risk of starving the seals of seal
water, an effort was made to optimize the flush rates. The
results of this effort are presented here for two extended cases.
It is assumed that there are three BCWPs in service and one in
hot standby mode.

Diffuser Breakdown Assembly

This case involves a startup loop that includes three
motorized valves and a diffuser breakdown assembly (Fig. 13).

Fig. 11 Injection seal differential-pressure controls

instability percentage is approximately 4.3% [14].

Table 2 CV open and close times

Control Valve* Close Time (s) Open Time (s)

Primary 7.3 6.7 Fig. 13 Startup loop with diffuser
Bypass 13 12 The motorized valves allow flow to be diverted from the main
* 6.36 cm travel flow path through the diffuser just before the BFPs are started.
The diffuser is designed for a pressure drop of 8.3 MPa at 1136
L/min (Fig. 14). The pressure drop induced by the diffuser
The baseline manual and automatic simulations show during allows the primary control valve to operate within its design
startup the control components are stressed and flow conditions rangeability.
are less than optimal.

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 Examining Figs. 15 and 16 illustrate the dramatic reduction
Fig. 14 Diffuser characteristics
in differential pressure and flow in the injection seal header
when compared to Figs. 9 and 10. The steady state differential
pressure in Fig. 15 is 436 kPa, which is slightly greater than the
Fig. 15 Injection differential pressure with diffuser
original setpoint (414 kPa). The steady state differential
pressure is a reflection of the valve position necessary to ensure
the seals are not inadvertently starved of seal water while
waiting for the BFPs to start, while flow is diverted through the
diffuser. The position of the primary control valve was held
fixed at 50% through the startup transient, and the bypass
control valve was closed. Furthermore, the resulting flow
needs to be sufficient for three BCWPs in operation and a
fourth in hot standby mode. In addition to supplying enough
seal water for four BCWPs, the model results also account for
seal wear. Although not discussed in detail here, two strainers
will be installed in parallel upstream of the startup loop. This
will help reduce potential abrasion wear and blockage of the
diffuser and control valves (Figs. 3C and 3D).
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Fig. 16 Injection header flow with diffuser
Startup Valve
In addition to a diffuser breakdown assembly, the startup
loop was also analyzed using startup control valves with linear
Fig. 17 Valve trim characteristics
and equal percentage trim characteristics (Fig. 17). A linear
trim characteristic results in equal changes in flow coefficient
for a change in travel. Equal percentage trims give an equal
percent change in flow for a given change in travel [9, 15].
Mathematically, an equal percentage trim is described by a first
order differential equation, shown in Eq. 2 [16]. The functional
dy
= ky (2)
dx
form of the solution is exponential.
The modified startup loop configuration is shown in Fig.
18. Its basic structure is the same as the diffuser case except for
7 Copyright © 2014 by ASME
 the replacement of the diffuser with a linear trim startup control
valve.
Fig. 18 Startup loop with startup valve
The results for the linear trim startup valve are given in
Figs. 19 and 20. The startup valve was 45% open. The primary
and bypass control valves were 60% open and 0% open,
respectively. The resulting differential pressure is close to the
diffuser case, 386 kPa. For the stated valve lineup a greater
Fig. 19 Injection differential pressure with startup valve
steady state volumetric flow rate is observed (Fig. 20).
The case for the equal percentage startup valve, not shown
here, required the valve position to be at the upper end of its
rangeability to achieve a comparable steady state differential
pressure and flow rate.
CONCLUSIONS
The use of startup valves is not new. One of the most
extreme applications is the use of boiler feedwater startup
valves. Another similar application is control valves used in
BFP minimum flow recirculation systems. In the latter
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application, in the worst case scenario, pressures range from
full BFP pressure to condenser pressure. For the application
Fig. 20 Injection header flow with startup valve
being considered here the pressure range is not quite as severe.
The extremely high differential pressures experienced in the
injection seal system during startup causes cavitation erosion
and abrasion damage to control valves, as well as making
accurate control a significant challenge. If control valve
position instabilities result in intermittent starvation of seal
water, the pump is also at risk of being severely damaged. The
cost for valve repair is in the thousands of dollars, and pump
overhauls in the tens of thousands. For aging units reducing
O&M cost is paramount [17].
Based on the analysis conducted the implementation of a
startup loop will mitigate the effects of the high differential
pressures experienced during startup. The diffuser breakdown
assembly is effective and allows the primary control valve to
operate within its rangeability. The linear trim startup valve
produces nearly identical results with slightly higher flows.
The equal percentage trim startup valve needs to operate at the
upper end of its rangeability to generate the desired flow
conditions.
From the model results for the equal percentage valve trim,
it was unclear if its installed characteristic behavior would
exceed its design rangeability if included in an actual system.
Furthermore, equal percentage control valves are generally
used to maintain linear behavior in systems when differential
pressure decreases as flow increases [18]. Under startup
conditions the seal injection system experiences increases in
differential pressure and flow, hence the linear trim startup
control valve is best suited for this scenario.
The results presented in Figs. 16 and 20 show seal flush
rates which are greater than that specified by the OEM; this can
be attributed to two primary reasons. First, the model accounts
for seal wear. Secondly, the baseline model was adjusted to
match system response data which reflected the condition and
state of the system at the instant the data was collected.
Although the model slightly over predicts seal flush rates, the
8 Copyright © 2014 by ASME
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