BOILER FEED PUMP

Booster Pump  Model - FA1B75

 Speed – 1495 RPM
 Capacity – 990m3/hr.
 Head – 205 mtr.
 Direction of rotation -
MDBFP set - clockwise
(Viewed from driven end)
TDBFP set – counter clockwise
(Viewed from driven end)

Horizontal, Single Stage, Double

Suction, Axial Split Casing, Radial
Flow.
Double Suction Impeller for
minimum NPSHR.
Shaft sealing by Mechanical Seals.
Boiler feed pump
• Model – FK 4E36
• Discharge capacity – 990 m3/hr.
• Head – 2050 mlc
• Speed - 5465 RPM.
• Operating temp. – 161.6 deg.C
• Installed quantity – 3 nos.
1 no. driven by MOTOR of 10,000 Kw capacity.
2 nos. driven by 16 stage Steam turbine.
• Direction of rotation - counter clockwise (Viewed from driven end)
• Inters tage tap off flow – 55m3/hr.
• Kicker stage flow – 150 m3/hr.
Sectional View of BFP
Constructional Details of BFP
• Boiler Feed Pump is a four + one stage horizontal centrifugal pump of
barrel design casing.
• The pump internals are designed as a cartridge which can be easily
removed for maintenance without disturbing the suction and
discharge pipe work, or the alignment of the pump and the turbo
coupling.
• The rotating assembly is supported by plain white metal lined journal
bearings and axially located by a double titling pad thrust bearing.
• The dynamically balanced rotating assembly consists of the shaft,
impellers, seal sleeves, shaft nuts, balance drum, thrust collar and the
pump half coupling.
• 04 nos. Inter stage tapping after 2nd stage impeller has been made for
attemperation for super heater panel.
• O1 no. tapping from 5th stage (called kicker stage) impeller has been
made for attemperation for reheater panel.
• The pump shaft is sealed at the drive end and non-drive end by
Mechanical Seals
BFP BARREL & CARTRIDGE

DVC GET 2013 7

 BOILER FEED PUMP CARTRIDGE
BFP CARTRIDGE IS A COMPLETE PUMP EXCEPT BARREL (PUMP CASING).

SPARE BFP CARTRIDGE OFFERS THE FOLLOWING ADVANTAGES

IN CASE OF A BREAK DOWN OF RUNNING PUMP, SPARE CARTRIDGE CAN REPLACE IT TOTALLY.

• DOWN TIME FOR CHANGE OVER WILL BE MINIMUM

• SPARE CARTRIDGE RESTORES THE ORIGINAL EFFICIENCY OF THE PUMP

DVC GET 2013 8

Thrust acting on BFP
The pressures generated by the pump exert forces on both its stationary and
rotating parts. The design of these parts balances some of these forces, but
separate means may be required to counterbalance other’s.

RADIAL THRUST – Due to weight of different parts arranged in rotating shaft

assembly.

AXIAL THRUST - On impellers an axial force exists because of differences in

pressure on the front and back of the impeller and the difference in the areas
subject to the pressure. Axial thrust is the sum of these unbalanced forces acting
in an axial direction.
Hydraulic balance arrangement
FK 4E 36 PUMP has an Inline impeller arrangement, all the impellers face
the same direction making the axial thrust of each impeller additive.

Resultant axial thrust = F1 + F2 + F3 + F4 + F5 towards DE

Hydraulic balance arrangement - balance drum
• The pump product passes from the kicker stage of the
(0.20 - 0.24)
pump between the balance drum and the bush, and enters
the balance chamber at a pressure approximately equal to
the suction pressure. Two ports in the discharge cover allow
the product to be piped back to the pump suction side. The
pressure differential across the balance drum is therefore
equal to that across the impellers.

• The cross-sectional area of the balance drum is sized to

give a small residual thrust towards the drive end of the
pump.
 Balancing device leak off flow – 30 m3/hr. (design value)
 If radial clearance betn. Drum & bush increase beyond 0.30 mm,
drum needs to be replaced.
MICHELL DOUBLE THRUST BEARING
Model – OMEGA 08068 NFC HB1
CARRIER SPLIT RINGS /
HALF RETAINING RINGS

Total 4 pads/half retaining ring, so total 8 pads/side

When to replace pads??

 During service of the pump some scoring and wear
on the pads may develop.

 Pads are serviceable up to a wear of 0.125 mm or when dulling

spreads over to more than half of the pad surface area, whichever is
earlier.
 Increasing pump efficiency

Wearing Ring :
• To allow the impeller to rotate freely within the pump casing, a small clearance is
designed to be maintained between the impeller and the pump casing.
• To maximize the efficiency of a centrifugal pump, it is necessary to minimize the
amount of liquid leaking through this clearance from the high pressure or
discharge side of the pump back to the low pressure or suction side.
• Some wear or erosion will occur at the point where the impeller and the pump
casing nearly come into contact. As wear occurs, the clearances become larger
and the rate of leakage increases. Eventually, the leakage could become
unacceptably large and maintenance would be required on the pump.
 Radial clearance - 0.29 - 0.25

To minimize the cost of pump maintenance, Boiler feed

pump is equipped with Wearing rings. These are
replaceable rings that are attached to the impeller or the
pump casing to allow a small running clearance between
the impeller and the pump casing without causing wear of
the actual impeller or pump casing material. These
wearing rings are designed to be replaced periodically
during the life of the pump and prevent the more costly
replacement of the impeller or the casing.
Mechanical seal - make - Eagle Burgmann
• It consists of two highly polished surfaces, one surface
connected to the Shaft – rotating assembly and the other to
the stationary part of the Pump.
SW in SW out • Both the surfaces are of dissimilar materials held in
continuous contact by a spring.
• These wearing surfaces are perpendicular to the axis of Shaft.
Pumping ring • A thin film of working fluid between these faces provides
cooling & lubrication.

• For safe operation of the mechanical seal a circulation circuit is

required, from the seal through a heat exchanger back to the
seal. When the shaft rotates the liquid is circulated by a
pumping ring in the mechanical seal.

• The cooling jacket, which provides a heat soak barrier

between the pump casing and the mechanical seal, is
continuously flushed with cooling water from an external
source.

Jacket cooling
• For Safe operation observing the following seal circuit temperatures, measured at seal outlet :
• warning temperature : 55° C
• shut-off temperature : 65° C
• standstill temperature : 75° C
• A mechanical seal is a dynamic seal that cannot be free of leakage due to physical and
technical reasons. Seal design, manufacture tolerance, operating conditions, running quality of
the machine etc. mainly define the leakage value. As compared to other sealing systems (e.g.
Gland packing's) there is few leakages.
• Small seal leakage is desirable and admissible, because of longer operating life of mechanical
seal. If however, leakage exceeds a value of 8 liters per hour, the seal is damaged . It has to be
replaced.
Cooler for mechanical seal – MECHANICAL SEAL SKID Magnetic filters –
1 working , 1 standby for each end 1 working , 1 standby for each end
CW out CW in

Seal water in Seal water out

Seal water out

Magnetic discs

After cleaning, the

magnetic discs need to be
mounted in such a way that spacers
they attract each others in
pairs but repel adjacent
pairs from which they are
separated by spacers. strainer
Seal water in
Simplex basket filter in BP suction
Filtration rate – 315 micron
Max. allowable pr. Drop –
clean – 0.1 ksc
clogged – 0,15 ksc
Simplex basket filter in BFP suction
Filtration rate – 195 micron
Max. allowable pr. Drop –
clean – 0.1 ksc
clogged – 0.15 ksc
Pumps performance - MDBFP vs TDBFP
MDBFP TDBFP
Reference DESIGN BEP DESIGN BEP
Flow (m3/hr) 990 855 990 855
Head (mlc) 2050 1985 2050 2002
Efficiency 81 80 81 80
Power (kw) 6177 5240 6178 5285
Speed (rpm) 5465 5260 5465 5260

Best Efficiency Point (BEP) is the point at which a pump is least prone to failure and its life
expectancy is greatest i.e the minimum flow a pump should produce in order to operate without
any issues such as high temperature rise, low flow cavitation or low bearing and seal life.
 Major Troubleshooting
SYMPTOMS
Pump performance low
(Pump Discharge pressure low)
Bearings overheating
Mechanical Seal Temperature high
POSSIBLE CAUSE ACTION
Incorrect rotation of pump in case of Check motor electrical connections.
MDBFP
Excessive wear of Dismantle pump and inspect
pump internals components.
Low Speed Check Speed Regulation System.
Strainer Chocked Clean strainer
Defect in lubricating oil system. Check lubricating oil system.
Oil flow to bearing.
Bearings worn of misaligned. Examine bearings.
Misalignment of pump. Check alignment.
Insufficient cooling Water to cooler. Check Heat Exchanger for blockages
and clean.
Mechanical seal damaged Check the rotating and stationary part
of seal
Excessive noise/vibration Misalignment of pump set
Bearing misalignment
Holding down bolts loose
Excessive clearance of pump
internals
Rotating assembly out of balance
Excessive load of interconnecting
pipings acting on pump
Hydraulic flow disturbances
Check alignment
Examine bearing
Tighten holding down bolts
Check clearances overhaul as
necessary
Check dynamic balance
Check hot and cold values of piping
supports and float
Increase flow through pump.
Avoid long running on low flow