SR. NO. CONTENT PAGE NO.

Acknowledgement

Abstract

Contents

List of figures

List of tables

1. Introduction

1.1 Introduction

1.2 Problem statement

1.3 Objectives

1.4 Future scope

2. Literature review

3. System description

3.1 Working of Centrifugal pump

3.2 Pump Selection

3.3 Boiler feed pump

3.4 Modelling of parts

3.5 Application of feed pumps in thermal power station

4. Conclusion

5. References

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ABSTRACT
Pump is energy absorbing rotodynamic machinery transporting fluid from one place to
another, being key parameter and heart of any industrial process plant as well as thermal
and nuclear power plant, also used for dewatering and irrigation purpose. Boiler feed water
pump feeds condensed return water against high steam pressure produces by the boiler.
BFP normally are centrifugal type pump containing a wide number of operating
parameters, operator requirement makes this system to work within parameter functioning
by the manufacturer on high efficiency regimes.
As pump is centrifugal type pump, water enters axially through impeller eye and exit
radially. Generally electric motor is used as a prime mover to run the pump. In the present
study we design and analysis of boiler feed pump having a flow of 138 m3/hr under a head
of 632 m at 3550 RPM and operating temperature range is 200 15 degree Celsius has
been taken up.in these design judgmental task is to set up an high head with in four stages.
The various pump parameter obtained from design is developed using 3D modeling
software Pro-E, and analysis is carried out by using Ansys, CFD software module.

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1.INTRODUCTION

1.1 Introduction
Pumps are energy-consuming devices being used in many industrial applications
and in particular in dewatering, handling water & other fluids and in agricultural, the
efficiency improvement of pumps has significant meaning to energy conservation. The
entire project work focus is deal with the performance & efficiency of pump which directly
save power. In this project we design a multi-stage centrifugal pump which complies to
various aspects require to US boiler feed water pump market.
Feed pumps are an essential subsystem of boilers used in industrial process plants
and called as boiler feed pump (BFP). Normally, BFP is high pressure unit that takes
suction from condensate return system and can be of the centrifugal type pump. In
centrifugal pump, water enters axially through the impeller eyes and exits radially.
Generally, electric motor is used as prime mover to run the feed pump. To force water into
boiler, the pump must generate sufficient pressure to overcome steam pressure developed
by boiler.
The usual design is based upon a certain desired head and capacity at which the
pump is operated most of time. In design of centrifugal pump, the parts to be designed are:
shaft, impeller, vane, casing, and selection of bearing. To design these parts different
methodologies can be obtained through literature survey. From the given conditions, the
specific speed is obtained. According to required head, the flow rate and from specific
speed, pump of double volute, doubles suction and single stage type is selected. The
minimum shaft diameter can be obtained by using maximum shear stress theory. Impeller
and vane are designed according to methodology provided by Church. To design the vane
empirical relations are used. API standard is used to design the volute and for bearing
selection.

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1.2 Problem statement:
To develop higher head with high efficiency by decreasing the number of stages
that is currently used. The present Boiler Feed Pump range has got limitation on head
developed per stage resulting to a greater number of stages. This is a trigger point for this
development.
At a growing technology & awareness user requires compact size of pump & its
assembly (especially in developed countries). Parts interchangeability pump require to
meet the various standard.

1.3 Objectives:
 Reducing the number of stages by increasing head per stage by improving
performance of pump.
 Existing BB4 range expansion to cover requirement of BFW pump.
 Generating the hydraulics which can comply with various standards (country
specific).
 Design of Compact size pump complying with requirement.
 Pump suitability for 60 Hz@3550 rpm

1.4 Future scope:

The future scope of the project is that the current technique used for the protection
of the boiler in the power plant can be evolved to protect the entire power plant as a whole.
This may include the main assets of the power plant such as the turbine, generator etc. This
advancement can be achieved if separate signals are sensed from each part of the power
plant and are accordingly checked and the power plant is safeguarded from the failures
automatically.

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2. LITERATURE REVIEW

1. Hu Si-ke etal 2011 was discovered According to the characteristics of utility-type

generator set in variable load sliding-pressure operation, the paper comprehensively
analyzes the features of feed-water system, in which variable-speed main feed-water
and power frequency booster-pump connect first in series and then in parallel. It puts
emphasis on fitting characteristics equation of feed-water pump under different
operations, determining characteristics of feed-water pipeline under sliding-pressure
operation, corresponding resistance coefficient, and finally deducing the equation of
lift, efficiency and rotating speed when different loads and different sliding pressures
are adapted only by main feed-water pump variable

2. Hu Si-ke etal 2011 was discovered According to the characteristics of utility-type

generator set in variable load sliding-pressure operation, the paper comprehensively
analyzes the features of feed-water system, in which variable-speed main feed-water
and power frequency booster-pump connect first in series and then in parallel. It puts
emphasis on fitting characteristics equation of feed-water pump under different
operations, determining characteristics of feed-water pipeline under sliding-pressure
operation, corresponding resistance coefficient, and finally deducing the equation of
lift, efficiency and rotating speed when different loads and different sliding pressures
are adapted only by main feed-water pump variable speed adjusting. It takes one power
plant 600MW supercritical unit for example to compare the energy consumption of
different operation modes, and thus puts forward a more suitable operation mode under
different loads, providing theoretical basis for the practical application of project.

3. M H Rashid etal 2012 was found according to the report addresses the real-time
condition monitoring of technical state and automatic diagnosis of auxiliary equipment
for bearings supports vibration, for example, control of the feed-pump operating modes
of thermal power stations. The causes that lead to premature birth and development of
defects in rolling bearings are identified and the development of activities ensuring safe

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 and continuous operation of the auxiliary equipment of thermal power stations is
carried out. Collection and analysis of vibration parameters of pumping units during
their operation at the operating modes of the technological process are realized by
means of real-time technical condition monitoring. Spectral analysis of vibration
parameters of one of the pumps showed the presence of frequency components, which
mark violations in the operating practices of the pump, the imbalance development and,
as a consequence, the development of defects in the bearings by long-term operation
of the unit. Timely warning of the personnel on the operation of the unit with the
"INTOLERABLE" technical state and automatic warning issuance of the need to
change the technological process allowed to recover the estimated pump operation
mode in due time and prevent further development of defects in equipment.

4. V N Kostyukov etal 2013 was found according to for all accelerators and many research
and industries, excellent vacuum conditions are required and the highest possible
pumping rates are necessary. For most applications the standard ion sputtering pump
(ISP) meets these requirements and is optimal for financial point of view also. The
physical principle of the ISP is well known and many companies manufacture variety
of ISP. Most of them use dipole magnetic field produced by permanent magnet and
electric dipole field between the electrodes in which tenuous plasma is created because
of interaction of between the relatively fast electrons slow residual gas atoms.
Performance of an ISP depends basically on the electron cloud density in between the
titanium electrodes but in the available present configurations no consideration has
been given to electron confinement which needs a mirror magnetic field. If this is
incorporated it will make a robust ISP surely; furthermore, the requirement of constant
feeding of high voltage to electrodes for supplying sufficient number of electrons will
be reduced too. A study has been performed Comparing the current performance of
BFP with the text data. The present performance is found to be good. The pump
efficiency is maximum at rated output of 400T/hr. the requirement of feed water is
mostly at the rate of 350T/hr per feed pump and a total of 700T/hr.

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3. SYSTEM DESCRIPTION

3.1 Working of Centrifugal pump

The provision of sufficient pumping capacity to meet flow requirements under all
operational circumstances. It is normal practice to include a flow margin to accommodate
additional demand by the turbine above its design rating during transient flow disturbances.
A margin on pump generated head is also appropriate to cover for deterioration resulting
from internal wear during periods between overhaul. In the interests of keeping pump set
sizes and powers to a reasonable minimum, consistent with maintaining the pump best
efficiency close to the duty point operation, these margins have been optimized as 5% on
flow and 3% on generated head.
Constraints should be considered
• The need to ensure that failure of a single pump set does not impair the start-up of the
main unit or affect output capability. Standby capacity equivalent to the largest duty
pump set is indicated with a rapid start-up capability, sufficient to prevent the loss of
boiler drum level and consequent unit trip.

• The need to ensure that the plant is able to operate satisfactorily during and after a
large load rejection by the turbine-generator unit. This requires that the drives for the
duty pumps and their power supplies must be suitable for this operating condition.
Alternatively, a suitable rapid start/standby pump set is necessary.

• The need to provide adequate NPSH margins, taking into account that the pumps are
supplied from a direct contact heater (de-aerator), which can be subject to pressure
decay following a reduction in turbine load.

• There should be at least two pump sets capable of starting the unit. If a turbine drive
is to fulfill this function, then a steam supply independent of the main boiler (i.e., an
auxiliary boiler) is required.

• If two or more pumps are required to operate in parallel, then the pump sets should be
able to accommodate runout duties following loss of an operating pump.

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Fig. 1 Boiler feed pump working

PUMP Types of pumps

A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by
mechanical action. Pumps can be classified into three major groups according to the
method they use to move the fluid: direct lift, displacement, and gravity pumps.

Fig. 2 pumps classifications

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Pump services in Main Steam Cycle
1. Turbo generator and auxiliaries

• Screen wash-water pumps

• Cooling tower make-up pumps

2. Steam generator equipment

• Condensate pumps

• Condensate booster ums

• Boiler-feed pumps

• Boiler-feed booster pumps

• Heater drain pumps (low and high pressure)

Pump is a machinery or device for raising, compressing or transferring fluid. It moves

fluids or sometimes slurries, by mechanical action. It operates by some mechanism and
consumes energy to perform mechanical work by moving the fluid. It operates via many
energy sources, including manual operation, electricity, engines, or wind power.
They come in many sizes, from microscopic for use in medical applications to large
industrial pumps. Mechanical pumps serve in a wide range of applications such as pumping
water from wells, aquarium filtering, pond filtering and aeration, in the car industry for
water cooling and fuel injection etc.
Pumps operate by some mechanism and consume energy to perform mechanical work by
moving the fluid. Pumps operate via many energy sources, including manual operation,
electricity, engines, or wind power, come in many sizes, from microscopic for use in
medical applications to large industrial pumps.
Mechanical pumps serve in a wide range of applications such as pumping water from wells,
aquarium filtering, pond filtering and aeration, in the car industry for watercooling and fuel
injection, in the energy industry for pumping oil and natural gas or for operating cooling
towers. In the medical industry, pumps are used for biochemical processes in developing
and manufacturing medicine, and as artificial replacements for body parts, in particular the
artificial heart and penile prosthesis.

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Single stage pump – When in a casing only one impeller is revolving then it is called single
stage pump.
Double/multi-stage pump – When in a casing two or more than two impellers are
revolving then it is called double/multi-stage pump.

Pumps are mainly classified in two broad classes:

Displacement
The liquid or gas is displaced from the suction to the discharge by the
mechanical variations of the volume of chambers. They can be subdivided in
two classes:

a. Reciprocating pump
In this a plunger or piston is mechanically reciprocated in a liquid cylinder.
a. Rotary pumps
In this the liquid is forced through the pump cylinder or casing by means of screw
or gears.

Centrifugal
Flow through the pump is induced by the centrifugal force imparted to the
liquid by the rotation of an impeller or impellers

3.2 Pump Selection

From the information supplied in the data sheet, a pump can normally be selected
from the pump manufacturer’s sales book. These are normally divided into sections, each
representing a particular construction. Performance maps show the range of capacity and
head available, while individual performance curves show efficiency and NPSHR. If the
pump requirements fall within the performances shown in the sales book, the process of
selection is relatively simple. When the re- quired pumping conditions, however, are
outside the existing range of performance, selection is no longer simple and becomes the
responsibility of the pump designer.

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Definition of Pump Specific Speed and Suction Specific Speed
Pump specific speed (Ns) as it is applied to centrifugal pumps is defined in U.S.
units as:

Specific speed is always calculated at the best efficiency point (BEP) with
maximum impeller diameter and single stage only. As specific speed can be calculated in
any consistent units, it is useful to convert the calculated number to some other System of
units. See Table The suction specific speed (Nss) is calculated by the same formula as
pump specific speed (Ns) but uses NPSHR values i n feet in place of head (H) in feet. To
calculate pump specific speed (Ns) use full capacity (GPM) for either single- or double
suction pumps. To calculate suction specific speed (Nss) use one half of capacity (GPM)
for double suction pumps.

Table Specific Speed Conversion

It is well known that specific speed is a reference number that describes the hydraulic
features of a pump, whether radial, semi-axial (Francis type), or propeller type.

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3.3 Boiler feed pump
Boiler feed pumps are also referred to as feed pumps (see Reactor pump) and
designed as multistage radial flow pumps, they serve to feed a steam generator such as a
boiler or a nuclear reactor with a quantity of feed water corresponding to the quantity of
steam emitted. Today, all boiler feed pumps are centrifugal pumps.

Fig. 3 centrifugal boiler feed pump

A Centrifugal pump is a mechanical device for moving air or other gases or fluid.
They use the kinetic energy of the impellers or the rotating blade to increase the pressure
of the air/gas/liquid stream which in turn moves them against the resistance caused by
ducts, dampers and other components. Centrifugal fans accelerate air radically, changing
the direction (typically by 90°) of the airflow. They are sturdy, quiet, reliable, and capable
of operating over a wide range of conditions.
Centrifugal pump are constant displacement devices or constant volume devices,
meaning that, at a constant fan speed, a centrifugal fan will pump a constant volume of air
or water rather than a constant mass. This means that the velocity in a system is fixed even
though mass flow rate through the fan is not.

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 Centrifugal pumps which belong to wider group of fluid machines called turbo
machines are the most common type of pump used to move liquids through a piping
system. The fluid enters the pump impeller along or near to the rotating axis and is
accelerated by the impeller, flowing radially outward or axially into a diffuser or volute
chamber, from where it exits into the downstream piping system. Centrifugal pumps are
typically used for large discharge through smaller heads.
Computational fluid dynamics (CFD) analysis is being increasingly applied in the
design of centrifugal pumps. With the aid of the CFD approach, the complex internal flows
in water pump impellers, which are not fully understood yet, can be well predicted, to speed
up the pump design procedure. Thus, CFD is any important tool for pump designers. The
use of CFD tools in turbo machinery industry is quite common today. Recent advances in
computing power, together with powerful graphics and interactive 3D manipulation of
models have made the process of creating a CFD model and analyzing results much less
labor intensive, reducing time and, hence, cost. Advanced solvers contain algorithms which
enable robust solutions of the flow field in a reasonable time.

3.5 Modelling of parts

CATIA is a mechanical design automation software is a feature-based, parametric
solid modelling design tool which advantage of the easy to learn windows graphical user
interface. We can create fully associate 3-D solid models with or without while utilizing
automatic or user defined relations to capture design intent etc.
A. The Dimensions of Pump Rotor Shaft
 Dimension of shaft is a follow:
 Overall length is 1052 mm, diameter is 65 mm.

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Fig. 4 3D Model of pump rotor shaft

The material properties of steel

The material is ASTM 434 TP 4140, which is having all these characteristics.

TABLE I Material Properties

Material ASTM 434
Young’s modulus 2.1e5MPa
Poisson’s ratio 0.3

Density 7850 Kg/m3

Yield strength 250 MPa
Tensile strength 550 MPa

B. Dimension of Rotor
Gross Weight of Impeller m =7 Kg
Total Weight in Newton = 7 x 9.81
W =68.67 N
Maximum diameter of impeller = 293 mm

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Minimum diameter of impeller = 255 mm
Number of blades of impeller = 6
Angle of blade = 12 0C
Impeller exit width = 12 mm

Fig. 5 Modelling of impeller

C. 3D Modeling of Inlet and Outlet Casing.

Fig. 6 ‘3D’ Views of Inlet Casing

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Pressure-containing parts are generally made thicker than required for handling a
noncorrosive liquid so that full pumping capability will be maintained even after the loss
of some material to the corrosive medium.

D. 3D modeling of Guide vane

Fig. 7 ‘3D’ Views of guide vane

Guide vane is designed to give path to the liquid which is coming out from impeller
and discharges liquid to inter-stage casing.
Internal diameter =65mm
Number of exit port = 8

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E. Assembly of Pump

Fig. 8 ‘3D’ Views of Assembly of pump

Table Comparison of Old and New Model

Parameters Existing pump New prototype pump

Flow (Usgpm) 440.20 610.90
Pump head(feet) 1320.13 2074.81
Pump efficiency (%) 66.5 68.0

Scale Factor Base 1.050

Pump input (Kw) 164.75 351.41
Specific Gravity 1.000 1
Pump speed (rpm) 2980 3550
Stages Required 7 4
Motor rating 220 450
NPSHr (feet) 15 23
Specific Speed (Ns) 800 800

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3.5 Application of feed pumps in thermal power station:

1. Boiler Feed Pump is used for pumping the hot feed water from feed water tank to boiler
drum through high- pressure heaters and economizer.

2. Condenser extraction pump for pumping condensate from condenser hot well to the feed
water tank through low-pressure heaters, main ejectors gland steam coolers, vent
condenser and Dearator.

3. Cooling water pumps for circulating cooling water from cooling water fore bay to the
condenser tubes for condensing the steam and then to cooling tower.

4. Starting oil pump for governing of turbine during startup of the turbine.

5. Emergency oil pump for the lubrication of turbine bearings during emergencies.

6. Gear pump for the lubrication of boiler feed pump bearings.

7. Main oil pump for governing of turbine, supply of lubricating oil and sealing oil for
hydrogen sealing in generator.

8. Reciprocating pumps are used for dozing chemical viz hydrogen, phosphate to the boiler.

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4. CONCLUSION

As deflection and stress of model is within the range Thus, the design of the model is
safe after running pump at 3550 rpm and with enlarged scaled factor 1.05. Result obtained
in the final test of the pump is satisfactorily with increase in efficiency by 1.5% to
reference. Using the modern state of art composite material weight of the impeller and
shaft will reduce considerably it optimizes the operation of pump effectively.

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5. REFERENCES

1. Ankur Geete, khandwawala, A.I (2013) ‘Thermodynamic analysis of 120MW

thermal power plant with combined effect of constant inlet pressure (124.61bar)
and different inlet temperature case studies,Thermal Engineering,Vol.1,pp.17-25.
2. Benjamin Greening, Adisa Azapagic (2013) ‘Domestic solar thermal water
heating: A sustainable option for the UK’, Renewable Energy, Vol.63, pp.23-36
3. Burkhard Sanner,Constantine Karytsas,Dimitrios Mendrinos,Ladislaus Ryback
(2003)’Current status of ground source heat pumps and underground thermal
energy storage in Europe’,Geothermics,Vol.32,pp.579-588.
4. Cuizhen Zhanga, Mo Yang,Mei Lua,Jiaxian Zhub and Wendong Xua
(2012)’Thermal economic analysis on LiBr refrigeration-heat pump system applied
in CCHP system’’ Physics Procedia, Vol.33,pp.672-677.
5. Hu Si-ke, Gao Hui-fen,Jia Xue-jing (2012)’ Regulating Characteristics Analysis of
Boiler Feed-water Pump when 600MW Unit Sliding-pressure Operating’,Energy
procedia,Vol.17,pp.1153-1160
6. Hu Si-ke, Wang Li-ping (2012)’A Comprehencive Analysis of Boiler Feed-Water
Pump when 600MW Unit Sliding-pressure Operating’, Energy procedia thermal
system Transformation’, Energy Procedia, Vol.17, pp.11691176
7. Marcello Aprilea, Rossano Scocciaa and Mario Mottaa (2012)’Modeelling and
control optimization of a solar desiccant and evaporative cooling system using an
electrical heat pump’, heat pump system’. Energy Procedia, Vol.30, pp.562-570
8. Ralf Dotta, Andreas Genkingera and Thomas Afjeia (2012) ‘system evaluation of
combined solar &heat pump system’, Energy Procedia, Vol.30, pp.562-570

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