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B.H.E.

L HYDERABAD
.

OPTIMISATION of PUMPS
in
Thermal Power Stations

J. Gopichand
Date : 24.11.2006

AGM(PED), BHEL, Hyd.

Pump is a device which converts mechanical


energy into pressure energy due to which the
fluid moves from one point to another.
(A)

CENTRIFUGAL PUMPS :

Energy is generated through the centrifugal


force of the vortex.
(B)

POSITIVE DISPLACEMENT PUMPS :


Energy is generated by the direct displacement
of the fluid.

TYPES OF CENTRIFUGAL PUMPS


Based on type of casing, Centrifugal Pumps are classified as :

VOLUTE CASING PUMP

DIFFUSER VANE PUMP

TYPES OF IMPELLERS
Based on the major direction of flow with reference to the axis of
rotation, Impellers are classified as :

RADIAL FLOW IMPELLER

AXIAL FLOW IMPELLER

MIXED FLOW IMPELLER

TYPES
OF
IMPELLERS
TYPES OF IMPELLERS
Based on the flow into the suction edges of the vanes, Impellers are
classified as :

SINGLE-SUCTION IMPELLER

DOUBLE-SUCTION IMPELLER

TYPES OF IMPELLERS
Based on the mechanical design, Impellers are classified as :

OPEN IMPELLER

SEMI-CLOSED IMPELLER

CLOSED IMPELLER

TYPES
OF
CASINGS
TYPES
OFPump
CASINGS
Based on the Casing
splitting type,
Casings are classified as :

AXIALLY-SPLIT CASING

RADIALLY-SPLIT CASING

SPECIFIC SPEED :
It is the speed of a geometrically similar Pump which
delivers one unit of Capacity against one unit of total
Head.
It is generally used for comparison between various types
of Centrifugal Pumps.
It is expressed as
NS = ( N Q ) / H3/4
where N is the Speed of the Pump, rpm.

It determines the type of Impeller.


Its value varies from 30 to 1000 for Centrifugal Pumps.

Radial Flow Impeller

= 30-290

Mixed Flow Impeller

Axial Flow Impeller

= 440-1000

290-440

PUMP CHARACTERISTICS :
It is the relationship between Capacity, Head, Power and
Efficiency.
The graphs, showing the inter-relationship between
Capacity, Head, Power and Efficiency, are called Pump
Characteristic Curves.
Capacity :
It is the quantity of fluid flowing through the Pump for a
given time of
period.
It is expressed in m3/hr.
It is measured by weight method, volumetric method,
orifice plate or by weirs.
Head :
It is the measure of energy to move the fluid from one
point to another.
It is expressed in metres of liquid column.

Power :
The horse power produced by the liquid is called as
Water Horse
Power (WHP) or Liquid Horse Power
which is expressed as
WHP = ( Q H) / 75
where Q = m3/sec , H = mlc & = kg/m3

The power required to drive the pump is called as


Brake Horse
Power (BHP) which is expressed as
BHP = ( Q H) / 75
where is the efficiency of Pump.

Efficiency :
It is the measure of the Pump performance.
It is the ratio of WHP to BHP.

CHARACTERISTIC CURVE OF A PUMP


H E A D ( m lc )

1800

5 2 .5 H z

1600

50 Hz

1400
1200

4 7 .5 H z

P O W E R (k W )

1000
2000
1500
1000
500
90

70
60
50

20

40

15

30

10

20

10

0
0

30

60

90 120 150 180 210 240 270 300 330 360 390 420 450

S U C T IO N F L O W (c u b . m . / h r.)

N P S H R ( m lc )

E F F IC IE N C Y (% )

80

NET POSITIVE SUCTION HEAD (NPSH) :


Available (NPSHA) :
NPSHA is the total Suction Head of liquid (absolute),
determined at the first stage Impeller datum, less the
absolute vapour pressure of the liquid at a specified
Capacity.
NPSHA = hsa - hvp
where

hsa = Total Suction Head (abs) = hatm + hs

hatm = Suction Pressure


hs

= Static Water level at reference datum

hvp = Absolute Vapour Pressure of liquid at


pumping
Temperature
NPSH is the parameter used to evaluate the suction
conditions of
the system.

Required (NPSHR) :
It is a parameter of the selected Pump.
It is the amount of Suction Head, over Vapour
Pressure, required
to prevent more than 3% loss in
total Head from the first stage of
the Pump at a
specified Capacity.
It is an important parameter in the pumping system to
ensure that
the NPSHA (which is determined by the
system) is at least equal to the NPSHR by the
Pump
(which is a function of Impeller design &
Pump Speed).
It is required to ensure adequate margin between
NPSHA & NPSHR.
It is therefore essential that the Pump manufacturer is
given
adequate information on NPSHA, operating
Flow range,
transient conditions, etc., so that the
best Pump selection can be put forward.

N PSH

COMPARISION BETWEEN NPSHA & NPSHR :

AFFINITY LAWS :
-

All Centrifugal Pumps follow the Affinity Laws which are


given below :
Q N
H N2
P N3

and

Q D
H D2
P D3

where N is the Speed of the Pump (rpm) &


D is the Diameter of the Impeller

SYSTEM HEAD :
It is the total head of a system against which a pump
must operate.
For a given capacity, it is expressed as
System Head = Total Static Head from supplying level
to discharge level + Discharge Pressure - Suction
Pressure - Friction losses - entrance and exit losses

OPERATING CONDITIONS :

PARALLEL OPERATION :
PUM P A
C O M B IN E D

PUM P B

SYSTEM HEAD

Pump is a device which converts Mechanical energy into Pressure


energy due to which the fluid moves from one point to another.

Major pumps in a power


station :

BOILER FEED PUMPS


BOILER FEED BOOSTER PUMPS
CONDENSATE EXTRACTION PUMPS
CIRCULATING WATER PUMPS
AUX COOLING WATER PUMPS

Typical arrangement of Pumps in a thermal power station

Function of Pumps
in a thermal power station
BFPs are used to feed water from deaerator feed storage tank to
the boiler
Booster pumps are provided ahead of BFPs to ensure adequate
NPSH to BFP for its cavitation free performance
CEPs are used to transfer condensate from condenser hotwell
to deaerator
CWPs are used to circulate cooling water through condenser for
condensing steam and ACWPs to supply cooling water to
various auxiliary coolers

BOILER FEED PUMP

BFP BARREL & CARTRIDGE

Barrel

Cartridge

BOILER FEED PUMP

Boiler Feed BOOSTER PUMP

BOOSTER PUMP

BOILER FEED PUMP TRAIN

CONDENSATE EXTRACTION PUMP

CIRCULATING WATER PUMP

CIRCULATING WATER PUMPS

DRY WELL

WET WELL

DESIGN OPTIONS FOR CWPs

Wet well / Dry well


Pull out / Non pull out
Single / Double foundation
With / Without thrust block at discharge elbow
With / Without non reversible ratchet
With/ Without shaft inclosing tube

SUMP MODEL STUDIES

Improper sump design results in :

Vortex formation, swirl and poor flow distribution


Loss of hydraulic performance
Noise and vibration
Accelerated wear of components
Mechanical failures

Multiple CW Pumps installations

Sump Dimensions - Plan view

Multiple CW Pumps installations

Sump Dimensions- Elevation view

Sump Dimensions versus Flow

Multiple CW Pumps installations

RECOMMENDED

NOT RECOMMENDED

Multiple CW Pumps installations

RECOMMENDED

NOT RECOMMENDED

Multiple CW Pumps installations

RECOMMENDED

NOT RECOMMENDED

CLASSIFICATION OF AUXILIARIES

Turbine Auxiliaries (~30% of total power consumption)


CEP, BFP and TG integral auxiliaries like vacuum pump, GSC
exhauster, oil purifier, oil vapour exhauster etc.
Power consumption for TG Auxiliaries for 500 MW shall be
~4% of total power consumption with TD BFPs in operation

Boiler Auxiliaries (~30% of total power consumption)


Mills, ESP, ID / FD / PA fans and LT drives
Boiler Circulating Water Pumps for 500 MW unit

CLASSIFICATION OF AUXILIARIES (contd..)


Plant auxiliaries (~ 40% of aux. power )

CW, ACW, DMCW & Plant Water System


DM plant & pre-treatment plant
HP/ LP dosing & chlorination plant
Hydrogen generation plant
Coal and Ash handling plant
Compressed air system
Air conditioning & ventilation system
Fuel oil system / Electric tracing
Electrical system: GT, UAT, ST losses & lighting load

AUXILIARY POWER

Auxiliary power consumption along with heat


rate are the two important technical
parameters used by the power utilities to
assess the performance of power plants

AUXILIARY POWER (contd..)

Auxiliary power consumption can be defined as the


difference between gross electric power generated at
generator terminals and net exportable power to grid

Power plant itself consumes nearly 8 10% of energy


generated

Optimisation Areas in Pumps

Sizing and design margins

Mechanical design

Materials of construction

Quality / Inspection checks

Performance testing

OPTIMISATION OF AUXILIARY POWER

Aux. power can be brought down by proper sizing of


pumps, selection of technology and equipments

The following factors having impact on auxiliary power


consumption need to be considered during design
stage of the project:

Optimisation of sizing & design margins

Proper selection of equipments

Layout options

Optimisation of sizing & design margins

Design margins are provided on equipment / systems


to cater for ageing, wear & tear, uncertainties etc
Conservative designs with large margins ( e.g. on flow
and head of pumps) and specifying suitability for
abnormal operating conditions result in lower efficiency
and higher auxiliary power consumption
Proper standby philosophy based on efficiency of
operation, availability & reliability, like
1x100% Working + 1x100% Standby or
1x100% Working + 1x30% Startup or
2x50% Working + 1x50% Standby
etc.

OPTIMUM DESIGN MARGINS


COMPARISON OF 500 MW CEP PARAMETERS
Parameters

CEP
Vindhyachal Simhadri
Stage-II *

Design Parameters
Capacity (M 3/Hr)
Head (MLC)
Power at Pump Input (KW)
Efficiency (%)

835
350
971
81

800
275
731
81

617
840
79.5

615
628
80

Parameters at 100% Load


Capacity (M 3/Hr)
Power at Pump Input (KW)
Efficiency (%)

* FOR VINDHYACHAL CEP PARAMETERS WERE WORKED OUT BY NTPC

CEP SIZING CRITERIA (Typical)


A. Flow calculations
Description

Unit

Max. flow

Normal
Flow

Under frq

Turbine
Bypass

Temperature of the condensate

40.00

45.00

40.00

40.00

Density of water

kg/m3

992.16

990.20

992.16

992.16

Condensate flow (HRSG with 0% BD)

TPH

163.89

155.24

163.89

208.89

HRSG blow down (3% Con , 2% Int)

TPH

8.19

7.76

8.19

10.44

5%

5%

5%

5%

Total flow ( 3+4)

TPH

172.08

163.00

172.08

219.33

Flow with margin due to low


frequency

TPH

NA

NA

181.14

NA

Flow with 10% margin . Only 4% in


turbine bypass

TPH

189.29

NA

NA

228.11

Required flow from each pump

TPH

189.29

163.00

181.14

228.11

Required flow from each pump

m3/hr

190.79

164.61

182.57

229.91

Say

m3/hr

191

165

183

230

CEP SIZING CRITERIA

(Typical)

B. Head calculations
Description

Unit

Max. flow

Normal
Flow

Under
frq

Turbine
Bypass

Deaerator operating pressure

Kg/cm2

1.23

1.23

1.23

1.23

Static head up to Deaerator nozzle(22 mts


above ground)

Kg/cm2

2.20

2.20

2.20

2.20

Static head from ground level to eye of


impeller(4 mts)

Kg/cm2

0.40

0.40

0.40

0.40

Pressure drop in Deaerator spray nozzles

Kg/cm2

0.20

0.20

0.20

0.20

Pressure drop in flow control valve

Kg/cm2

1.50

1.50

1.50

1.50

Pressure drop in CPH

Kg/cm2

4.36

3.92

4.36

5.89

Pressure drop in Flow nozzles (2 nos)

Kg/cm2

0.60

0.60

0.60

0.60

Pressure drop in piping

Kg/cm2

1.00

1.00

1.00

1.00

Pressure drop in Gland steam condenser

Kg/cm2

0.80

0.80

0.80

0.80

Pressure drop in SJAE

Kg/cm2

1.00

1.00

1.00

1.00

10

Margin on variable pressure drop {21% of


(sum of 3 to 9 above) or min 1.0 kg/cm 2}

Kg/cm2

1.99

NA

NA

2.31

11

Total required discharge pressure.

Kg/cm2

15.28

12.85

13.29

17.12

2a

CEP SIZING CRITERIA (Typical)


C. Differential Head calculations
Description

Unit

Max. flow

Normal
Flow

Under frq

Turbine
Bypass

Net Differential head to be developed by


pump (B11-C6)

Kg/cm2

14.84

12.37

12.85

16.64

Margin due to change in frequency i.e


applying factor {(50/47.5)2-1}

Kg/cm2

NA

NA

1.34

NA

Required differential pressure

Kg/cm2

14.84

12.37

14.19

16.64

Required differential pressure

mwc

149.6

124.9

143.0

167.8

Say (rounding up to next 5mwc)

mwc

150

125

145

170

Capacity of each pump

m3/hr

191

165

183

230

Pump differential head required

mwc

150

125

145

170

Head developed as per curve

mwc

188

198

190

170

D. Final parameters

CEP/ BFP Sizing during turbine bypass condition


BOILER

GEN.

BFP SIZING CRITERIA (Typical)


A. Flow calculations
Description

Unit

Max. flow

Normal
Flow

Temperature of the feed water

105

105

105

105

Density of water

kg/m3

954.74

954.74

954.74

954.74

HRSG capacity ( with super heater


spray built in)

TPH

43.60

41.20

43.60

43.60

HRSG blow down (3% Con , 2%


Intermittent)

TPH

2.18

0.82

2.18

2.18

Total feed water flow


requirement(3+4)

TPH

45.78

42.02

45.78

45.78

Flow with margin due to low


frequency

TPH

NA

NA

2.41

NA

Feed water flow with 20% margin


during transient operation

TPH

NA

NA

NA

9.16

Capacity of each Pump

TPH

45.78

42.02

10% design margin on flow


(allowance for ageing)

TPH

4.58

Required flow from each pump

TPH

SELECTED CAPACITY IN CMH

m3/hr

10

Under
frequency

Transient
Condition

48.19

54.04

NA

NA

NA

50.36

42.02

48.19

54.94

53.00

44.00

50.00

58.00

BFP SIZING CRITERIA (Typical)


B. Discharge Head calculations
Description

Unit

Max. flow

Normal
Flow

Under
frequency

TRANSIENT
OPERATION

Highest safety valve set pressure

Kg/cm2 (a)

91.63

NA

NA

NA

Drum Operating Pressure

Kg/cm2 (a)

NA

81

81

81

Over Pressure ( 3 %)

Kg/cm2

2.75

NA

NA

NA

Static pr. due to drum height (21.6 m)


{height) x sp.gravity/10 }

Kg/cm2

2.06

2.06

2.06

2.06

Pr. Drop in Economizer

Kg/cm2

3.00

3.00

3.00

Pr. Drop in feed control station

Kg/cm2

1.50

1.50

1.50

1.50

Pr. Drop in discharge piping including


fittings, valves, etc.

Kg/cm2

1.0

0.69

0.89

1.20

Pr. Drop in flow element

Kg/cm2

0.30

0.21

0.27

0.36

Pr. Drop in ARC valve at discharge

Kg/cm2

1.0

0.69

0.89

1.20

10

Total variable pressure drop (5+6+7+8+9)

Kg/cm2

6.80

6.09

6.55

7.25

11

Margin on variable pr. drop (21%)


(min. 1 kg/cm2)

Kg/cm2

1.43

NA

NA

2.31

12

Pressure at discharge of Pump


(1 + 2 + 3 + 4 + 10 + 11)

Kg/cm2(a)

140.67

89.15

89.61

90.32

3.00

BFP SIZING CRITERIA (Typical)


C. Suction Head calculations
Description

Unit

Max. flow

Normal
Flow

Under fr

TRANSIENT
OPERATION

Pressure of De-aerator

Kg/cm2 (a)

1.23

1.23

1.23

1.23

Pr. due to Height of the De-aerator LWLL


from BFP suction nozzle

Kg/cm2 (a)

1.38

1.38

1.38

1.38

Total of above (1+2)

Kg/cm2

2.61

2.61

2.61

2.61

Pr.drop in suction strainer-50% clogged


(normal pr. drop approx. 0.1 Kg/cm 2)

Kg/cm2

0.2

0.2

0.2

0.2

Pr. drop in suction piping, inclusive of


fittings, valves, etc

Kg/cm2

0.20

0.14

0.18

0.24

Pr. loss on suction side of BFP (4+5)

Kg/cm2

0.40

0.34

0.38

0.44

Available pr. on pump section side (3 6)

Kg/cm2

2.21

2.27

2.23

2.17

Available NPSH (7 1)

Kg/cm2

0.98

1.04

1.00

0.94

mwc

10.26

10.92

10.50

9085

Kg/cm2

5.13

8.42

8.00

7.35

Considering margin between NPSHA &


NPSHR as minm. 2.5 m, the NPSHR of
the pumps shall be limited to max. ( 50
% for rated flow)

BFP SIZING CRITERIA (Typical)


D. Differential Head calculations
Description

Unit

Max. flow

Normal
Flow

Under
frequency

Transient
Condition

Net Differential head to be developed by


pump

Kg/cm2

102.46

86.88

87.38

88.15

Margin due to change in frequency i.e.


applying factor {(50/47.5)2-1}

Kg/cm2

NA

NA

9.44

NA

Required differential pressure

Kg/cm2

102.46

86.88

96.82

88.15

Required differential pressure

mwc

1073.16

909.14

1014.07

923.25

Final selected differential pressure

mwc

1074

910

1015

924

Capacity of each pump

m3/hr

53.00

44.00

50.00

58.00

Pump differential head required

mwc

150

125

145

170

E. Final parameters

CWP SIZING CRITERIA (Typical)


A. Flow calculations
Description

Unit

Max. flow

Normal
Flow

Under
frequency

Transient
condition

Temperature of the feed water

32

32

32

32

Density of water

kg/m3

1000

1000

1000

1000

Maximum water demand

CMH

8750

8750

8750

8750

Capacity shared by each pump (50%)

CMH

4375

4375

4375

4375

Margin in flow due to low frequency


on feed water flow

CMH

NA

NA

230.26

Feed water flow with 20% margin

CMH

NA

NA

NA

875

NA

during transient operation


7

Capacity of each Pump

CMH

4375

4375

4605.26

5250.00

10% design margin on flow


(allowance for ageing)

CMH

437.50

NA

NA

NA

Thus, capacity of each pump with


margin

CMH

4812.50

4375

4606

5250

Selected capacity of each pump

CMH

4815

4375

4606

5250

10

CWP SIZING CRITERIA (Typical)


B. Discharge Head calculations
Description

Unit

Max. flow

Normal
Flow

Cooling tower spray nozzle elevation


from ground level including pr. drop in
spray nozzle

MWC

7.00

Pump impeller / bell mouth level below


pump-base plate level

MWC

4.50

4.50

4.50

4.50

Atmospheric head

MWC

10.30

10.30

10.30

10.30

Total static head (1+2+3)

MWC

21.80

21.80

21.80

21.80

Pr. Drop in discharge piping including


fittings, valves, etc.

MWC

1.60

1.60

1.60

1.60

Pump Internal losses

MWC

1.10

1.10

1.10

1.10

Pr. Drop in discharge piping including


fittings, valves, etc.

MWC

3.0

3.0

3.0

3.0

Pr. Drop in flow element

MWC

1.60

1.60

1.60

1.60

Pressure drop in Condenser

MWC

6.00

4.95

5.49

7.13

10

Pressure drop in rubber expansion joint

MWC

0.5

0.5

0.5

0.5

11

Pressure drop in nozzle

MWC

0.8

0.8

0.8

0.8

12

Pressure drop in return line

MWC

0.5

0.5

0.5

0.5

13

Total variable pressure


drop(5+6+7+8+9+10+11+12)

MWC

13.50

10.65

11.19

12.83

14

Margin on variable pr. drop


(21% subject to min. 5 mwc)

MWC

5.00

NA

15

Bowl discharge head of Pump (4


+13+14)

MWC

40.30

32.45

7.00

Under
frequency
7.00

NA
32.99

Transient
Condition
7.00

NA
34.63

CWP SIZING CRITERIA (Typical)


C. Suction Head calculations
Description

Unit

Max. flow

Normal
Flow

Under
frequency

Transient
Condition

Pump bell mouth / impeller level below


sump min. water level

MWC

2.30

2.30

2.30

2.30

Atmospheric head

MWC

10.30

10.30

10.30

10.30

Total of above (1+2)

MWC

12.60

12.60

12.60

12.60

Pr.drop in inline-strainer

MWC

1.00

1.00

1.00

1.00

Available pr. on pump suction side (3-4)

MWC

11.60

11.60

11.60

11.60

Vapour pressure head of water at 32C

MWC

0.61

0.61

0.61

0.61

Available NPSH (5-6)

MWC

10.99

10.99

10.99

10.99

CWP SIZING CRITERIA (Typical)


D. Differential Head calculations
Description

Unit

Max. flow

Normal
Flow

Under
frequency

Transient
Condition

Differential Bowl Head of pump

mwc

28.70

20.85

21.39

23.03

Margin due to change in frequency i.e.


applying factor {(50/47.5)2 -1}

mwc

NA

NA

9.44

NA

mwc

28.70

20.85

23.70

23.03

mwc

29.00

21.00

24.00

24.00

Capacity of each pump

m3/hr

4815

4375

4606

5250

Pump differential head required

mwc

29.00

21.00

24.00

24.00

3
Net Differential Pump Pr. (1+2)
4

Selected Differential Bowl Head of pump

E. Final parameters

PROPER SELECTION OF EQUIPMENT

Pumps are selected based on Parameters :


- pump flow rate
- total dynamic head
- operating temperature
- suction pressure / NPSH available
Developments in design & technology have made
available reliable & efficient products & systems aimed
to reduce auxiliary power consumption
The best efficiency shall preferably be between design
and normal point. Design capacity shall be within 80110% of the best efficiency capacity
Pumps shall have stable Q-H characteristics
Continuous head rise to shut off of atleast 10%
preferred for parallel operation

VARIABLE SPEED DRIVES

Boiler Feed Pumps (BFPs), Forced Draft (FD) fans and ID


Fans are large consumers
Constant speed drives use throttling elements incurring
energy losses in the system
Variable speed drives are being increasingly used due to
several advantages they have over the conventional fixed
speed drives
Use of hydraulic coupling reduces the losses to some
extent as efficiency of coupling itself is very low at lower
speed
VFD enables operation over a wide range of load at high
efficiency with low energy consumption at lower speeds

Optimisation of Mechanical Design

Mechanical design parameters like the design


pressure of pump casings etc. are specified
corresponding to the most severe possible scenario
such as ;
- over frequency of operation at 51.5 Hz
- highest operating speed of the pump
- shut off head at zero flow

The above criteria results in higher values for design


pressures thereby increasing the pump component
costs. In actual site operation, eventuality of pump
subjected to all the above severe operating
conditions simultaneously is remote.

Optimisation of Materials of construction

Bronze
Cast iron
Cast steel
400 series Stainless steel
300 series Stainless steel etc.
Selection criteria for materials :
corrosion resistance
abrasive wear resistance
cavitation resistance
casting & machining properties
endurance limit
notch sensitivity
galling characteristics
cost

Optimisation of Quality / Inspection checks

Too much ambitious quality checks like LPI, MPI, UT


and Radiography for 100% quantity & 100% area
would add to cost of product as well as increased
cycle time in view of the CHPs involved

Too much ambitious special/type tests like NPSH test


on all the contracted pumps would add to cost of
product as well as increased cycle time in view of the
CHPs involved
Routine test is ok

PERFORMANCE TESTING
Routine tests on all pumps
Mechanical performance to check :
- Vibrations
- Temperatures
- Leakages

Hydraulic performance to check :


- Flow Vs Head Characteristic
- Flow Vs Power Characteristic
- Flow Vs Efficiency Characteristic

PERFORMANCE TESTING
Type tests as optional
NPSH TEST

Special tests on Boiler feed pumps :


HOT WATER PERFORMANCE TEST
COMBINED STRING TEST
AXIAL THRUST MEASUREMENTS
PRESSURE PULSATION TEST
DRY RUN TEST
THERMAL SHOCK TEST
VISUAL CAVITATION TEST

Conclusion
Optimisation of sizing, selection, mechanical design,
quality/inspection checks and performance testing
results in

lower auxiliary power


lower cost &
lower cycle time

Hence utmost attention is to be given for the


optimisation of the above

Thank You

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