pumps used in steam power plants

Pumps used in Steam Power Plants

Subhransu Roy Professor of Mechanical Engineering IIT Kharagpur References 1. Black and Veatch, Power Plant Engineering, CBS Publishers, New Delhi, 1998 2. Karassik et al., Pump Handbook, Mc-Graw Hill, 1976

pumps used in steam power plants

1 Introduction 1.1 What is a pump

A pump is a machine that imparts energy into a liquid to lift the liquid to a higher level or to transport the liquid from one place to another. Two basic methods to impart energy to the liquid are (a) volumetric or positive displacement, (b) addition of kinetic energy. Positive displacement of a liquid can be accomplished mechanically by the action of a plunger or screw. Kinetic energy can be added to a liquid by rotating the liquid at high speeds in a device typically known as centrifugal pump.

pumps used in steam power plants

1.2 Positive displacement pump

Positive displacement

Rotary

Reciprocating Plunger Piston Diaphragm

Vane Lobe Gear Screw

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1.3 Centrifugal pump - radial ow

The liquid is forced into a set of rotating vanes. These vanes constitute an impeller which discharges the liquid at its periphery at a higher velocity. This velocity is converted to pressure by means of a volute or by a set of stationery diffusion vanes. The volute increases in area from its initial point until it encompasses the full 360 around the impeller and then ares out to the nal discharge opening. Vertical deep-well centrifugal diffuser pumps are commonly called as vertical turbine pumps.

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1.4 Centrifugal pump - axial or mixed ow

In propeller or other pumps in which axial ow impellers are used, it is not possible to use a volute casing; instead, the impeller is enclosed in a pipe-like casing. Generally diffusion vanes are used following the axial impeller proper to eliminate the radial velocity, but in certain low head units these vanes are omitted. In mixed ow pumps, liquid is discharged into a volute type casing. Pressure is generated by both the lift and the centrifugal force of impellers vanes on the liquid.

pumps used in steam power plants

2 Pump Fundamentals 2.1 Specic speed and impeller conguration for best performance

Ns =

n Q , 3/4 H

n is in RPM, Q is in gpm at BEP, H is head in feet at BEP

D2 >4 D1

D2 = 2 1.5 D1

D2 < 1.5 D1

D2 =1 D1

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2.2 Use of specic speed

characterise the shape and conguration of the impeller denes the ratio of major impeller dimensions suction limitations of the pump pump performance curve (H-Q curve) head per stage in multistage pumps can be calculated

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2.3 Specic speed of power plant centrifugal pumps

Application Boiler feed Condensate Circulating water Typical impeller type radial-vane or Francis-vane Francis-vane Mixed ow

Ns (US units)
1000 - 1800 1500 - 2500 4500 - 7500

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2.4 Typical head vs capacity curve for different pump impeller types

Stable characteristics:
ow

Decrease of head with increase in

Unstable characterics:
ow

Increase of head with increase in

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2.5 Pump terminology pressure terms

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2.6 Pump terminology head terms

Total dynamic discharge head hd

dynamic

= hd

static

+ hv + hf

V2 where, hv = 2g

hdynamic = hstatic + hv + hf for lift; hdynamic = hstatic hv hf for suction head s s s s

total dynamic head TDH

= hdyna hdyna for suction head; TDH = hdyna + hdyna for lift s s d d

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2.7 Similarity analysis afnity laws

Q2 Flow Q1 h2 Head h1
Horsepower hp2 hp1

= = = =

n2 D2 n1 D1 n2 n1 n2 n1 1
2

D2 D1 D2 D1

Efciency

2 1

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2.8 Performance curve variation with impeller diameter

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2.9 Performance curve variation with impeller speed

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2.10 Cavitation
When the pressure in the pump inlet region approaches the vapor pressure of the liquid all pumps have a tendency to cavitate. Cavitation is a two-stage phenomenon consisting of formation of vapour cavities resulting from low pressure and their collapse as they move out of low pressure to high pressure regions. The formation and collapse of the cavities occur in a very short time interval. It is at the point of collapse that damage to the impeller occurs.

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2.11 Net positive suction head

Net positive suction head (NPSH) describes the pump cavitation characteristics. It is the pressure head in excess of the saturation pressure. NPSHA is the NPSH available at the suction of the pump installed in the system.

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2.12 Recommended maximum operating speeds

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2.13 Pump operating point

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2.14 Pump operating point - series operation

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2.15 Pump operating point - parallel operation

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2.16 Pump capacity control

Discharge throttling Speed regulation

most common; inefcient; ok for small pumps

efcient; normally adopted for BFP, condensate pump, CW pump etc. variable frequency motors can be used for speed control

Bypass regulation

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2.17 Minimum recirculation

Impellers are designed to for best performance at or near rated conditions. Operation of pump at low ows not only cause overheating but also noise, hydraulic pulsation, and rapid deterioration of impeller. Recomended minimum ow is 20% to 50% of the ow at BEP. variable speed pumps, such as condensate pumps, should have individual minimum oe recirculation system to prevent operation at speds that produce insuffucuent head to provide ow to the system.

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3 Power Plant Pumps 3.1 CW pump type

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3.2 CW pump design criterion

Design Point Design Q is based on maximum circulating water requirement and number of pumps being provided. The ow rate must be sufcient for 90% cleanliness of the condenser tube when plant is running at full load. If auxiliary cooling water is provided by CW pumps then such cooling water at maximum cooling water temperature is to be provided. The Hydraulic Institute Standards (HIS) require CW pump manufacturers to provide +10% margin in capacity their design. The total design head must have margin of +5% as per HIS. NPSH NPSHR represents the NPSH required to prevent cavitation. NPSHA (i.e. NPSH available) must exceed NPSHR under all operating conditions. Pump manufacturers recommend a 3% safety margin. Submergence Submergence is a measure of the water depth in the pump sump above the pump suction. Submergence must be adequate to meet NPSH requirement at vortexing. The Hydraulic Institute Standards provided detail guidelines for sump design and these should be followed. As a general rule submergence must be at least 1ft for each ft/s velocity at the bell mouth. The velocity at the bell mouth should be kept between 3 to 8 ft/s.

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Submergence may also be set by the sump depth required to meet travelling screen approach velocities. Pump intake sump design The designed should consider model testing for a number of simulated ow conditions within the CW pump intake structure.

n Q it is another parameter used to predict Suction specic speed dened as S = (N P SH)3/4 pump performance. S must equal or exceed SA for the entire range of pump operations.
Rotation speed limitation The Hydraulic Institute Standards specify maximum SA value of 8500. Given SA value of 8500 and NPSHA, the speed n can be calculated. Pump speed may be additionally limited to prevent high erosion rates of the impeller and impeller bowl and to reduce vibration-related problems in vertical wet pit pumps.

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3.3 Typical material of construction for vertical wet pit pump

pump comonent Impeller Shaft Radial bearing Suction bell Column & discharge head Impeller bowl fresh water Bronze Stainless steel Bronze backed cutless rubber Cast iron Carbon steel Cast iron brakish water Stainless steel Stainless steel Bronze backed cutless rubber Stainless steel Stainless steel Stainless steel

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3.4 CW pump construction

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3.5 Condensate pump design criterion

condensate ow at 5% overpressure condition with turbine control valve wide open condensate cycle make-up typically 1% to 3% of the maximum condensate ow soot blowing steam ow, if applicable auxiliary steam ow, if applicable BFP seal water, if applicable 5% margin on the total ow 65 ft/s maximum peripheral velocity for rst stage impeller

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3.6 Condensate pump variable-speed drive

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3.7 Condensate pump construction

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3.8 Boiler feed pump design criterion

Design_point steam turbine throttle ow at VWO and 5% overpressure plus any steam or feed water removed form the ow path betwen boiler feed pump and turbine throttle. a ow margin of 5% is usually kept. A head margin of 5% of total developed head is also kept. Hydraulic consideration The available suction head is one of the most important system parameter for protection of BFP and preservation of stable pump operation at high and low loads and during transient system occurrences. To prevent cavitation in the warm water a NPSH of 130 to 145 ft depending on the elevation of the deaerator storage tank may be kept. BFP should be designed with H-Q characteristics which rises continuously from high to low ow rates without interruptions. The specied requrement for head rise from design ow to shut off id 120% to 130% of the head at design ow. Material casing and discharge head are of forged carbon steel diffusers, stage pieces, shaft, impellers, wearing rings are of 12-14% chromium stainles steel

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3.9 Boiler feed pump layout

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3.10 Boiler feed pump construction

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3.11 Slurry pumps

slurry pumps are designed to minimise the effects of abrasion and moderate corrosion present in most power plant slurries. In most power stations horizontal horizontal centrifugal slurry pumps are common. In a slurry pump wall thickness of wetted parts like casing impeller etc are greater or are equiped with hard metal or rubber liners. They are typically vertically split to alow for replacement of casing and impeller liners. Flow passages are large. There are extra large stufng boxes and replaceable shaft sleeves. The pump casing and impellers are typically made of cast iron and lined with molded rubber. Cast iron alloys containing nickel (4%) and chrome (1.4% to 3.5%), or chrome alone (28%) hardened by heat treatment are used in a variety of slurry pump applications. Slurry pumps run at low spped of 400 to 600RPM.

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3.12 Slurry pump construction

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thank you
for your attention.

any questions?