Professional Documents
Culture Documents
L HYDERABAD
.
OPTIMISATION of PUMPS
in
Thermal Power Stations
J. Gopichand
Date : 24.11.2006
CENTRIFUGAL PUMPS :
TYPES OF IMPELLERS
Based on the major direction of flow with reference to the axis of
rotation, Impellers are classified as :
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.
= 30-290
= 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
Efficiency :
It is the measure of the Pump performance.
It is the ratio of WHP to BHP.
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
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
AFFINITY LAWS :
-
and
Q D
H D2
P D3
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
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
Barrel
Cartridge
BOOSTER PUMP
DRY WELL
WET WELL
RECOMMENDED
NOT RECOMMENDED
RECOMMENDED
NOT RECOMMENDED
RECOMMENDED
NOT RECOMMENDED
CLASSIFICATION OF AUXILIARIES
AUXILIARY POWER
Mechanical design
Materials of construction
Performance testing
Layout options
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
Unit
Max. flow
Normal
Flow
Under frq
Turbine
Bypass
40.00
45.00
40.00
40.00
Density of water
kg/m3
992.16
990.20
992.16
992.16
TPH
163.89
155.24
163.89
208.89
TPH
8.19
7.76
8.19
10.44
5%
5%
5%
5%
TPH
172.08
163.00
172.08
219.33
TPH
NA
NA
181.14
NA
TPH
189.29
NA
NA
228.11
TPH
189.29
163.00
181.14
228.11
m3/hr
190.79
164.61
182.57
229.91
Say
m3/hr
191
165
183
230
(Typical)
B. Head calculations
Description
Unit
Max. flow
Normal
Flow
Under
frq
Turbine
Bypass
Kg/cm2
1.23
1.23
1.23
1.23
Kg/cm2
2.20
2.20
2.20
2.20
Kg/cm2
0.40
0.40
0.40
0.40
Kg/cm2
0.20
0.20
0.20
0.20
Kg/cm2
1.50
1.50
1.50
1.50
Kg/cm2
4.36
3.92
4.36
5.89
Kg/cm2
0.60
0.60
0.60
0.60
Kg/cm2
1.00
1.00
1.00
1.00
Kg/cm2
0.80
0.80
0.80
0.80
Kg/cm2
1.00
1.00
1.00
1.00
10
Kg/cm2
1.99
NA
NA
2.31
11
Kg/cm2
15.28
12.85
13.29
17.12
2a
Unit
Max. flow
Normal
Flow
Under frq
Turbine
Bypass
Kg/cm2
14.84
12.37
12.85
16.64
Kg/cm2
NA
NA
1.34
NA
Kg/cm2
14.84
12.37
14.19
16.64
mwc
149.6
124.9
143.0
167.8
mwc
150
125
145
170
m3/hr
191
165
183
230
mwc
150
125
145
170
mwc
188
198
190
170
D. Final parameters
GEN.
Unit
Max. flow
Normal
Flow
105
105
105
105
Density of water
kg/m3
954.74
954.74
954.74
954.74
TPH
43.60
41.20
43.60
43.60
TPH
2.18
0.82
2.18
2.18
TPH
45.78
42.02
45.78
45.78
TPH
NA
NA
2.41
NA
TPH
NA
NA
NA
9.16
TPH
45.78
42.02
TPH
4.58
TPH
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
Unit
Max. flow
Normal
Flow
Under
frequency
TRANSIENT
OPERATION
Kg/cm2 (a)
91.63
NA
NA
NA
Kg/cm2 (a)
NA
81
81
81
Over Pressure ( 3 %)
Kg/cm2
2.75
NA
NA
NA
Kg/cm2
2.06
2.06
2.06
2.06
Kg/cm2
3.00
3.00
3.00
Kg/cm2
1.50
1.50
1.50
1.50
Kg/cm2
1.0
0.69
0.89
1.20
Kg/cm2
0.30
0.21
0.27
0.36
Kg/cm2
1.0
0.69
0.89
1.20
10
Kg/cm2
6.80
6.09
6.55
7.25
11
Kg/cm2
1.43
NA
NA
2.31
12
Kg/cm2(a)
140.67
89.15
89.61
90.32
3.00
Unit
Max. flow
Normal
Flow
Under fr
TRANSIENT
OPERATION
Pressure of De-aerator
Kg/cm2 (a)
1.23
1.23
1.23
1.23
Kg/cm2 (a)
1.38
1.38
1.38
1.38
Kg/cm2
2.61
2.61
2.61
2.61
Kg/cm2
0.2
0.2
0.2
0.2
Kg/cm2
0.20
0.14
0.18
0.24
Kg/cm2
0.40
0.34
0.38
0.44
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
Unit
Max. flow
Normal
Flow
Under
frequency
Transient
Condition
Kg/cm2
102.46
86.88
87.38
88.15
Kg/cm2
NA
NA
9.44
NA
Kg/cm2
102.46
86.88
96.82
88.15
mwc
1073.16
909.14
1014.07
923.25
mwc
1074
910
1015
924
m3/hr
53.00
44.00
50.00
58.00
mwc
150
125
145
170
E. Final parameters
Unit
Max. flow
Normal
Flow
Under
frequency
Transient
condition
32
32
32
32
Density of water
kg/m3
1000
1000
1000
1000
CMH
8750
8750
8750
8750
CMH
4375
4375
4375
4375
CMH
NA
NA
230.26
CMH
NA
NA
NA
875
NA
CMH
4375
4375
4605.26
5250.00
CMH
437.50
NA
NA
NA
CMH
4812.50
4375
4606
5250
CMH
4815
4375
4606
5250
10
Unit
Max. flow
Normal
Flow
MWC
7.00
MWC
4.50
4.50
4.50
4.50
Atmospheric head
MWC
10.30
10.30
10.30
10.30
MWC
21.80
21.80
21.80
21.80
MWC
1.60
1.60
1.60
1.60
MWC
1.10
1.10
1.10
1.10
MWC
3.0
3.0
3.0
3.0
MWC
1.60
1.60
1.60
1.60
MWC
6.00
4.95
5.49
7.13
10
MWC
0.5
0.5
0.5
0.5
11
MWC
0.8
0.8
0.8
0.8
12
MWC
0.5
0.5
0.5
0.5
13
MWC
13.50
10.65
11.19
12.83
14
MWC
5.00
NA
15
MWC
40.30
32.45
7.00
Under
frequency
7.00
NA
32.99
Transient
Condition
7.00
NA
34.63
Unit
Max. flow
Normal
Flow
Under
frequency
Transient
Condition
MWC
2.30
2.30
2.30
2.30
Atmospheric head
MWC
10.30
10.30
10.30
10.30
MWC
12.60
12.60
12.60
12.60
Pr.drop in inline-strainer
MWC
1.00
1.00
1.00
1.00
MWC
11.60
11.60
11.60
11.60
MWC
0.61
0.61
0.61
0.61
MWC
10.99
10.99
10.99
10.99
Unit
Max. flow
Normal
Flow
Under
frequency
Transient
Condition
mwc
28.70
20.85
21.39
23.03
mwc
NA
NA
9.44
NA
mwc
28.70
20.85
23.70
23.03
mwc
29.00
21.00
24.00
24.00
m3/hr
4815
4375
4606
5250
mwc
29.00
21.00
24.00
24.00
3
Net Differential Pump Pr. (1+2)
4
E. Final parameters
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
PERFORMANCE TESTING
Routine tests on all pumps
Mechanical performance to check :
- Vibrations
- Temperatures
- Leakages
PERFORMANCE TESTING
Type tests as optional
NPSH TEST
Conclusion
Optimisation of sizing, selection, mechanical design,
quality/inspection checks and performance testing
results in
Thank You