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BOILER FEED PUMP

INTRODUCTION:
It sucks water from Deaerator storage tank at 22.5 mtrs. And feed it to the
economizer inlet either through HPHs or bypassing HPHs one or both.
The pump internals are designed as cartridge which can be easily removed for
maintenance without disturbing the suction and discharge piping work or the
alignments of the pump and the hydraulic coupling.
As BFP is handling the feed water of 160 degree C, so net positive suction head
requirement of BFP must be maintained.
To meet NPSH , BFP suction pressure is being increased by
1. Placing Dearerator at higher elevation.
2. Pressurizing Deaerator with pegging steam.
3. Using Booster pump.
CONTRUCTION:
The Boiler feed Pump consists of the following main components:
Pump casing
Discharge cover
Suction guide
Ring section assembly
Rotating assembly
Mechanical seal
Journal & Thrust bearing
Hydraulic balance
Coupling
TECHNICAL SPECIFICATION:
01 Make & Type
02 Direction of rotation viewed from
drive end
03 Rated flow
04 Shut off Head
05 Impeller type
06 Min. recirculation flow
07 Feed water temperature
08 Suction strainer
09 No. of stages
10 Suction bore diameter(mm)
11 Discharge bore diameter(mm)
12 Speed(rpm)
13 Power absorbed(kw)
14 NPSH required

M/S BHEL & FK6D 30(Barrel Casing)


Anti-Clock-wise
305 TPH
1620 mlc
Radial flow, Single suction
80 m3/hr
165.5 degree C
SS Simplex basket, 315 microns mesh size
6
200
150
4220
1332 KW
15 mlc

15
16
17
18
19
20
21

BFP leak off flow at rated speed


No. of pump bearing
Type of balancing system
Coupling type
BFP motor rating
Motor RPM
Booster pump type

22
23
24
25
26

NPSH required at Booster pump


Rated speed (RPM) of Booster pump
Power input at rated flow (305m3/hrs)
Direction of rotation(from Motor side)
Type of lubrication

14 m3/hrs
2 journal + 1 Thrust bearing
Balance drum
Flexible
2100 KW
1485(6.6 KV)
Single stage, FA1B56 double volute type with
horizontal split casing and double suction
impeller.
3.4 mlc
1485
115KW(Booster pump)
Anti-clockwise(Booster pump)
Oil lubrication

VOITH variable Speed Coupling:


The Main Component of this type o coupling are:
1. Input Shaft
2. Gear and Pinion
3. Primary shaft
4. hydro Coupling primary wheel
5. Hydro coupling secondary wheel
6. Scoop tube
7. Working Oil/Lube oil pump with spar and bevel gear
8. Auxiliary Lube Oil pump assembly.

Input shaft o Hydraulic coupling is coupled with motor shaft & power
transmitted to the gear through this shaft.
Here Gear and Pinion has 142 and 39 nos. of teeth respectively. So, GEAR
RATIO is 142/39.
From the pinion power transmitted to hydro coupling primary wheel through
a shaft called primary shaft.
Then power/torque transmitted to secondary wheel by pump & turbine action
of primary and secondary wheel respectively.
A scoop arrangement control the speed of the secondary wheel by controlling
quantity of working oil in the coupling chamber between primary and
secondary wheel.

OIL CICUIT:
The same Oil is used as working and Lube oil. Working oil pump (centrifugal) and
main lube oil pump (gear) is combine to form a pump set driven by the input shaft of
geared variable speed turbo coupling.
The electric motor driven Auxiliary lube oil pump (AOP) lubricate the unit during
start up, shut down and incase of interference.

WORKING OIL CIRCUIT:


Pump-------------- through the Oil circulation valve-------- Coupling working
chamber---------Scoop chamber (due to centrifugal force, forms a oil ring & scoop tube
position determines the thickness of oil ring in the scoop chamber and thus also the filling in
working chamber) ----------- The scoop tube scoop up the warmed up working oil in
working chamber-------------------- Working oil cooler (where oil cooled down)
------------ Oil circulation valve.
Close Circuit completed.
***The oil circulation valve controls the working oil flow rate dependent on the
accumulated power losses. Any excessive oil in the circuit is returned through the pressure
relief valve into the tank.
*** If the close circuit is interrupted and the geared variable speed turbo coupling oil
temperature rises to 160 Degree C, the FUSIBLE PLUG blow due to a temporary thermal
overloading of oil circuit i.e. due to cooler failure or overloading of coupling, the control
behavior o the coupling changes slightly.
LUBE OIL CIRCUIT:
Main Lube oil pump-------------- Non return valve------------ Pressure relief
valve--------- Lube oil cooler----------------- Duplex filter--------------- Bearing points,
pressure switches and gear wheel.
The lube oil pressure set is approx 2.5 kg/cm2.
To ensure the bearing is coated with an oil film during start up, shut down, failure,
they are supplied with oil by auxiliary oil pump before the drive motor is switched
on and after it is switched off.
Auxiliary oil pump------------ Non return valve--------- Lube oil circuit.
Lube oil for external unit (e.g. Drive machine, driven machine or connecting
coupling) are supplied from the same lube oil circuit and returned to the oil sump.
SCOOP TUBE CONTROL:
The scoop tube which regulates the amount of oil in the coupling is controlled by the
actuator turning the cam disc, positioning the scoop tube accordingly.
STEP UP SPEED CONTROL: The scoop tube moves away from the oil ring in the
coupling, the amount of oil scooped up decreases, the pressure in the circulating
control valve drops, the pressure relief valve closes, the quantity delivered by the
working oil pump is also used to fill the working chamber.

BFP START UP PERMISSIVE


SN

START PERMISSIVE

CONDITION

Motor Winding Temp. not high.

2
3

Journal Brg. Temp. not high & Thrust Brg.


Temp. not high.
Suction valve open

Journal = 90 deg.
Thrust = 100 deg.
Limit Switch.

Lube oil header pressure OK

0.8 kg/cm2 for 5 sec.

BFP # A is not tripped.

Breaker is in service.

BFP # A is OFF.

BFP condition stand by.

Two BFP not running.

10

No low switch acted.

11

Deaerator level normal: (2450mm)


High: 2700mm
High-High:2950mm
Lock out relay reset.

12

Breaker not in test.

MCC

13

Switch Gear is not TRIPPED.

MCC

14

Scoop position minimum.(25%)

MCC

BFP # A selected or FCV


open & Dis. Valve close.

MCC

BFP TRIPPING LOGIC & VALUE


SN

Protection Type

Set Point
Alarm
Tripping

Breaker in Test.

MCC

Motor Winding Temp. very


High.
BFP brg. Temp. very high.
(Journal+Thrust +H/C +
motor)
Diff. temp. very high &
Suction flow LOW.

120 deg.

126 deg

90 deg.

101 deg.

3
4

Condition

Diff. temp.> 15
deg for 2 sec. &
suction flow 100
TPH.

Working Oil temp. very high. 110 deg

130.5 deg.

BFP suction pressure very


low.
Lube Oil pressure very low
& BFP ON.

17
kg/cm2
0.8
kg/cm2

15.5 kg/cm2
0.5 kg/cm2

Suction < 16
kg/cm2
Lube Oil press.<
0.5 kg/cm2 for 7
sec.

550mm

2/3 logic.

7
8

Suction valve not open.

Deaerator level very low.

1935mm

10

BFP vib. Very high.

11

Switch Gear tripped.

11mm/sec 18.5mm/sec(delay
time: 5 sec.)
MCC

CASE : After Major S/D


PREPARATION FOR STARTUP:

All permits are returned from all service agencies.


Check that the compressed air and electrical supplies are available for the
instruments leak off equipment and valves.
Check that the booster pump and the feed pump drain valves are shut.
Check that the recirculation valve and its isolating valves are open.
Check that all the instruments tapping points and isolating valves are open and
that all drain equalizing valves are shut.
Open the feed pump drive end and non drive end mechanical seal cooler
circulation water inlet and outlet isolating valves.
Check that the pump discharge valve and its bypass is close and power on .
Crack open the pump suction side isolating valve.
Open the booster stage air vent valve and vent any trapped air or gasses from the
pump casing.
Shut the booster pump air vent valve when water issues freely from it.
Vent the feed pump mechanical seals cooler and the oil coolers.
Fully open the pump suction isolation valve.
Ensure that the clarified cooling water and the Auxiliary cooling water are
available for the pump set.
Prepare the hydraulic coupling and lube oil system for starting.
Check that the auxiliary cooling water from the booster pump mechanical seals is
flowing freely through the flow indicators
Check that the auxiliary cooling water from the feed pump mechanical seal
coolers is flowing freely through the flow indicators.

START UP:
Ensure that the hydraulic coupling auxiliary lube oil pump is running.
1. Lube oil pressure at minimum of 2.5 bars and no leakage from any joint .
2. Check that the lube oil is flowing freely through the following flow
indicators.
Booster pumps DE and NDE bearing drain flow.
Booster pump side and hydraulic coupling side motor bearing
drain flow.
Feed pump DE and NDE bearing drain flow.
Check that the deaerator is filled to normal working level > 2450 mmwc .
All protections are in service
Start the boiler feed pump driving motor. Note the Current on recirculation flow
/Suction flow /Pump
speed / Pump Discharge pr / All brg vib and Temp.
Run the pump for at least two hrs and keep close watch on all parameters
Note: Simultaneously with the starting of the boiler feed pump open cooling water
valve to supply water to drive
motor air coolers.

RUNNING CONDITION:
When the pump set is running normally the recirculation valve ensures a minimum flow
of 100 tph through the pump set. A scoop tube on the hydraulic coupling is controlled by
a pneumatic actuator to automatically vary the speed of the BFP according to the load
requirement, from a different pressure transmitter across the feed regulating valve
The auxiliary lube oil pump should be stopped.

ROUTINE CHECKS:

Check that the driving motor ammeter reading is normal.


Check that all pressure and temperature readings are normal.
Check that the lube oil is flowing through the following indicators
1. Booster pump DE and NDE bearing drain flow.
2. Booster pump side and hydraulic coupling side drive motor bearing drain flow.
3. Feed pump DE and NDE bearing drain flow.
Check that the clarified cooling water from the booster pump mechanical seal is
flowing freely through the flow indicators.
Check for any undue noise or vibration.
Check for joints and valve glands for leakage.
Check the security o all fastenings paying particular attention to the holding down
bolts.

STANDBY CONDITION:
When the pump set is required or standby duty, it should be prepared as follows.
1. Set the selector switch to auto condition.
2. Open the discharge valve.
3. Start the auxiliary lube oil pump.
Note: The scoop of the standby pump set will follow the scoop tube of running pump
set.

TRIP CONDITION:
The operating feed pump set will trip when any of the following condition exists.
1. Deaerator level low low.
2. Lube oil pressure in common header low.
3. Differential temperature rise between the discharge and suction of the feed pump,
above the preset value.
4. Hydraulic coupling temperature high.
SHUTDOWN:
Stop the driving motor and position the circuit breaker in OFF position
Shut the discharge valve

Close the cooling water valve to the driving motor air cooler and water cooler of the
hydraulic coupling.

AUTO START UP SEQUENCE:


Step 1

AOP start & Lube oil Header press > 0.8 kg/cm2.

Step 2

BFP # A O/L valve close command issue and check the close feedback.

Step 4

BFP # A O/L valve IBV close command issued and checks the close
feedback.
BFP recirculations Valve open command issued and checks the open
feedback.
BFP Scoop is in min. condition, (25%)
BFP A start command and discharge pressure OK(150 kg/cm2)

Step 5

BFP A discharge valve IBV open command issued.

Step 6

BFP A discharge valve open command

Step 7

BFP A scoop AUTO enable (presently by passed ,for first time operation)

Step 8

BFP discharge valve IBV close command issued.

Step 3

SHUT DOWN SEQUENCE


Step 1

BFP-A stop command


BFP-A AOP start command ( For 15 minutes protection on )

Step 2

BFP-A recirculation valve open command.


BFP-A discharge valve IBV close command.
BFP-A discharge valve close command.
SHUT DOWN sequence complete

Step 3

FAULTS:
SYMPTOMS
Pump fails to start

POSSIBLE CAUSES
Drive motor fails to start
Power supply fails
Seizure of pump set
Deaerator level low low
Pump set tripped

SYMPTOMS
Performance low

SYMPTOMS
Bearing overheating

SYMPTOMS
Mechanical seals
overheating

POSSIBLE CAUSES
Drive motor fault
Wrong rotation
Hydraulic couple scoop
tube actuator faulty
Booster pump faulty
Recirculation valve faulty
Excessive wear of pump
internals

POSSIBLE CAUSES
Lube oil defect
Bearing worn out or
misaligned
Pump misaligned

POSSIBLE CAUSES
Insufficient cooling water
Mechanical seal faulty

ACTIONS
Check motor
Check supply
Decouple and locate
seizure. Overhaul if
necessary.
Check deaerator
Investigate cause. Arrest
trip.

ACTIONS
Check motor
Check motor connections
Check operations of scoop
tube actuator.
Check booster pump
Check booster valve
Dismantle pump and
inspect

ACTIONS
Check lube oil
Examine bearings
Check bearings

ACTIONS
Check cooling water to
mechanical seals
Check the seals.

SYMPTOMS

POSSIBLE CAUSES

ACTIONS

Excessive noise or
vibration

Misalignment of pump set


Bearing misalignment
Holding down bolts loose
Excessive clearance of
pump internals
Rotating assembly out of

Check alignment
Examine bearing
Tighten holding down bolts
Check clearance and
overhaul
Check dynamic balance

balance