GOVERNMENT OF INDIA

INDIRA GANDHI CENTRE FOR ATOMIC RESEARCH

. KALPAKKAM - 603 102
THIS DOCUMENT IS THE PROPERTY OF INDIRA GANDHI CENTRE FOR ATOMIC RESEARCH.
THIS SHALL NOT BE REPRODUCED OR COMMUNICATED WITHOUT OWNER'S PERMISSION.

STEAM WATER SYSTEM

TITLE: STUDY ON POWER PLANT PUMPS AND THEIR APPLICATIONS IN FBRs

No. Date Approved

POWER PLANT CONTROL DIVISION FAST BREEDER REACTOR 1 &2

STEAM WATER SYSTEM

FBR 1&21 40000 DN 1 1004

NAMES SIGNATURE DATE REV jA j I I
PREPARED Vivek Singh ~.~C"~
.J.. - 11 9-10-11 Distribution: Dir. RDG
AD,NSAG
AD,NSDG
Head, PPCD
Head, SHTD
Head, SWCS
Head, PLAS

CHECKED L. Satish Kumar ~~ Dq'IoltlUp ~

Tanmay Vasal ~~\I;;h.J 'J., v·)7

I~ --r 4 ,to' C1
APPROVED N. Theivarajan •......
::z:::::.--

SUMMARY

Power plants employ three major centrifugal pumps in the power cycle - boiler feed pump, condensate
extraction pumps and condenser cooling water pump. The design and selection of the type of these
pumps depends on the requirements of capacity and head to be developed for the specific applications.
The present note covers a brief description of the basic design features of centrifugal pumps in general
and major power cycle pumps, in particular, along with their application considerations and selection.
 STUDY ON POWER PLANT PUMPS AND THEIR APPLICATIONS IN FBRs

1.0 INTRODUCTION
The power plant application use different types of pumps from reciprocating to
centrifugal. Centrifugal pumps are the most common types of pumps dealing with transfer of
large volumes of low viscous, clean liquids. The power cycle operates nearly at constant
pressure and temperature while flow is adjusted commensurate with the target power levels.
Power plant applications are suitable for centrifugal pumps where flow is controlled by
selecting no. of pumps in operation, throttling or by using variable speed drives. Positive
displacement pumps can handle high viscosity fluid at relatively low flows. These pumps are
ideally suited for chemical dosing application allowing accurate metering. The major pumps
used in the main steam water cycle, namely Boiler feed pump, Condensate extraction pump
and Condenser cooling water pump are centrifugal pumps, which are subject of this study.
Working principle and theory are same for all the centrifugal pumps but power plant
application are different in some aspects. The difference lies in type, capacity, power
consumption and size. Thus a study of the design and construction aspect of different types of
pumps used in power plant becomes important to enable proper selection of pumps suitable
for the applications.

2.0 BASIC FEATURES OF CENTRIFUGAL PUMPS

A centrifugal pump is composed of a casing, a bearing housing, the pump shaft and an
impeller. The liquid to be pumped flows through the suction nozzle to the impeller. The
impeller mounted on the shaft is driven via a coupling by a motor. The impeller transfers the
energy necessary to transport the fluid and accelerates it in the circumferential direction. This
causes the static pressure to increase in accordance with kinetics. The fluid exiting the
impeller is decelerated in the volute and the diffuser to utilize the greatest part of the kinetic
energy at the impeller outlet for increasing the static pressure. The diffuser forms the
discharge nozzle. Impeller and casing are separated by a narrow annular seal through which
some leakage flows back from the impeller outlet to the inlet. A second annular seal on the
rear shroud serves the purpose of counter balancing the axial forces acting on the impeller
front and rear shrouds. The leakage through this seal flows back into the suction chamber
through ―axial thrust balance holes‖ which are drilled into the rear shroud. The impeller can
be described by the hub, the rear shroud, the blades transferring energy to the fluid and the
front shroud. Fig.1 shows the section and the plan view of an impeller. The leading face of

PFBR/40000/DN/1004/R-A Page 1 of 32
the blade of the rotating impeller experiences the highest pressure for a given radius. It is
called pressure surface or pressure side. The opposite blade surface with the lower pressure
accordingly is the suction surface or suction side.

Fig. 1: Section and plan view of a radial impeller, LE: Leading edge, TE: Trailing edge

3.0 CLASSIFICATION OF CENTRIFUGAL PUMPS

According to the performance and application requirements different type of pumps
are available which can be classified on the basis of specific speeds. Fig. 2 along with Table 1
shows the variation in shape of the impeller shroud with the specific speed. Specific speed
and suction specific speed are very useful parameters for centrifugal pump design and
application.
A detailed study of specific speed leads to the necessary design parameters for all
types of pumps.
Pump specific speed (Ns) as it is applied to centrifugal pumps is defined as:
N ∗ Q0.5
Ns =
H 0.75
Where,
N is in RPM
Q is in m3 /s
H is in meters.
Specific speed is always calculated at the best efficiency point (BEP) with maximum
impeller diameter and single stage only. The specific speed can be calculated in any
consistent units. The suction specific speed (Nss) is calculated by the same formula as pump
specific speed (Ns), but uses Net Positive Suction Head Required (NPSHR) values in meter
in place of head (H). To calculate pump specific speed (Ns) full capacity (m3 /s) is used for
single suction pumps and half of capacity (m3 /s) is used for double-suction pumps.

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 The specific speed is a reference number that describes the hydraulic features of a
pump, whether radial, semi-axial, or propeller type. The term, although widely used, is
usually considered only as a characteristic number without any associated concrete reference
or picture. This is partly due to its definition as the speed (RPM) of a geometrically similar
pump which will deliver one m3 /s against one meter of head.

Fig. 2: Impeller types

Table 1: Specific speed and impeller types
Impeller Type Ns Metric
Radial Flow 500 - 1,700
Francis Vane 1,700 - 4,000
Mixed Flow 4,000 - 9,000
Axial Flow > 9,000
Metric units – speed in rpm, flow in m3/s, head in m
3.1 Radial flow – Pumps of this type are characterised by low flow high head, with single
inlet impellers and have specific speed between 500-1700 metric unit. This type is commonly
referred to as a centrifugal pump. In centrifugal pumps the liquid enters the impeller at the
hub and flows radially to the periphery, exiting perpendicular to the rotating shaft.
3.2 Mixed flow - This type of pump has a single inlet impeller where the flow enters
axially and discharges in a mixed axial and radial direction. Pumps of this type usually have a
specific speed from approximately 4,000 to 9,000 metric unit.
3.3 Axial flow - Pumps of this type are characterised by high flow low head. A pump of
this type has a single inlet impeller with the flow entering axially and discharging nearly
axially and usually have a specific speed above > 9,000 metric unit.

4.0 PUMP CHARACTERISTICS

The performance of a centrifugal pump can be shown graphically on a characteristic
curve.
The performance data of a centrifugal pump are described by:

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• The flow rate Q which is normally defined as the volume flow through the discharge nozzle
• The specific work Y or the head H = Y/g
• The shaft power at the pump coupling P
• The mechanical efficiency η of pump
The above terms are related as
ρgHQ
P=
ɳ
• The net positive suction head NPSH at the pump inlet, or the net positive suction energy
NPSE = g×NPSH.
• In addition to these data, the speed n of the pump rotor is indispensable.
When the flow rate of a pump varies, the head, the power consumption and the
efficiency change too. Plotting these quantities against the flow rate we obtain the ―pump
characteristics‖ (Fig. 3). At a certain flow rate the pump efficiency has a maximum value
called the ―best efficiency point‖ (BEP). The pump is designed for this BEP which is
characterized by Qopt, Hopt, Popt and ηopt at a given speed and pumps should be operated at this
point for high efficiency.

Fig. 3: Typical pump characteristics

Any pump application is characterized by the flow rate Qopt, the head Hopt and the
rotor speed N.
5.0 SERIES AND PARALLEL ARRANGEMENT OF PUMPS
5.1 PUMPS IN SERIES
When two (or more) pumps are arranged in serial their resulting pump performance
curve is obtained by adding their heads at the same flow rate as indicated in Fig.4. In power
cycle series arrangement is used for boiler feed main and booster pumps to develop high
required head.

FBR 1&2/40000/DN/1004/R-A Page 4 of 32

 Fig. 4: Pumps in series
Centrifugal pumps in series are used to overcome larger system head loss than what
one pump can handle alone.
 For two identical pumps in series the head will be twice the head of a single pump at
the same flow rate - as indicated with point 2.
With a constant flowrate the combined head moves from 1 to 2 - but in practice the
combined head and flow rate moves along the system curve to point 3.
 point 3 is where the system operates with both pumps running
 point 1 is where the system operates with one pump running
 the head for each pump equals half the head at point 3
 the flow for each pump equals the flow at point 3

5.2 PUMPS IN PARALLEL

When two or more pumps are arranged in parallel their resulting performance curve is
obtained by adding the pumps flow rates at the same head as indicated in the Fig.5. In power
plant parallel arrangement is used in all major pumps wherever the capacity is split.

Fig. 5: Pumps in Parallel

Centrifugal pumps in parallel are used to supply larger volume of flows than what one
pump can handle alone.
 for two identical pumps in parallel with the head kept constant - the flow rate doubles
compared to a single pump as indicated with point 2, but the combined head and
volume flow moves along the system curve as indicated from 1 to 3.

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  point 3 is where the system operates with both pumps running
 point 1 is where the system operates with one pump running
If one of the pumps in parallel or series stops, the operation point moves along the
system resistance curve from point 3 to point 1 - the head and flow rate are decreased.
For two pumps with matching performance curves running in parallel
 the head for each pump equals the head at point 3
 the flow for each pump equals half the flow at point 3

6.0 FLOW REGULATION OPTIONS

The flow requirement of the power plant varies with power level and during transient
operations like startup and shutdown. The flow in the power plants is regulated using
different flow regulation techniques depending on the pump power consumption and capital
cost, as described below:

6.1 CONSTANT-SPEED PUMPS WITH THROTTLE VALVE CONTROL.

This arrangement consists of pumps connected directly to constant-speed motors.
Flow control is accomplished by control valves located downstream of the pump. The system
resistance curve shown on this Fig. 6 represents the sum of the deaerator pressure, static head,
and pressure losses due to the piping, valves, and equipment. The design head that the pump
must develop at the design flow rate is the sum of the system resistance and the pressure drop
through the control valve at the design flow rate (Fig. 6a). Those arrangements that use
variable-speed pump drives for flow control do not require control valves. The design head
for a variable-speed pump is less than the design head for a constant-speed pump by the
amount of pressure loss across the control valve.

Fig. 6: a) constant speed pump, b)variable speed pump

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The constant-speed pumping arrangement is relatively simple in design, easy to control, and
highly reliable. The capital investments to install this arrangement are less than the cost of a
variable-speed pump arrangement, but the energy and demand costs are higher.

6.2 VARIABLE-SPEED DRIVES.

The effect of varying the pump speed on the pump head curve is shown in Fig. 6b
where two pump head curves for the same pump at two different speeds are shown. As the
speed of the pump is reduced, the pump head curve shifts to a lower position, but the shape of
the curve remains the same as the shape of the curve at the design speed. The system
resistance curve is also shown. This is the same resistance curve as shown in Fig. 6a. The
design point for the variable-speed pumping arrangement does not include the additional
friction head margin required by a control valve since control valves are not required. An
advantage of the variable-speed arrangement is shown in Fig. 6b. If Point 1 is the desired
flow rate, the pump speed is reduced to speed nI such that the head and flow rate of the pump
match the system resistance. No excess head is developed and no energy is dissipated by a
throttle valve. Variable-speed pumps can be driven by variable speed motors, by constant-
speed motors through variable speed couplings, or by variable frequency drive arrangements.
The energy is saved, particularly at lower loads, by adopting variable speed drives, thereby
increasing the overall efficiency of the plant. The variable-speed pumping arrangement
generally has higher capital costs, but has lower operation cost.

7.0 MAJOR POWER CYCLE PUMPS

Pumps are the critical elements of the power cycle, which add mechanical energy to
the cycle. The power plant application demand continuous operation for prolonged duration.
The pump design and application must ensure trouble free operation for all possible
variations in the operating conditions during different operating stages such as start-up,
steady state operation and shutdown. Pumps being large rotating equipments demand
occasional maintenance and repairs. Thus reliability, availability and maintainability of the
pumps become important objectives in their design, selection and configuration.
The general features of the centrifugal pumps are dealt with in the previous section.
The design and construction features, flow regulation requirements, pump types, selection
and configurations are detailed in this section for the following major power plant pumps:
1. Boiler feed pumps
2. Condensate extraction pumps

FBR 1&2/40000/DN/1004/R-A Page 7 of 32

 3. Condenser cooling water pumps

7.1 BOILER FEED PUMPS:

Boiler feed pumps are high head, high capacity pumps. The boiler feed system of a
typical power plant includes a deaerator at some elevation above the suction of the boiler feed
pump to provide a reservoir of heated, deaerated condensate to the boiler feed pump at
available suction head for the pump. A booster boiler feed pump may be included to provide
suction head to the main boiler feed pump. The booster pump may be motor-driven or driven
by the main boiler feed pump driver through an extended shaft off the driver (usually a steam
turbine) through reduction gearing. A single-suction first-stage impeller is usually used in the
main boiler feed pump in this system. The discharge of the boiler feed pump includes pump
recirculation instrumentation, valves, and piping back to the deaerator storage tank.
Downstream, several stages of regenerative feedwater heating is used.
Although direct-contact heaters would have thermodynamic advantages, a separate
pump would be required after each such heater. The use of a group of closed heaters permits
a single boiler feed pump to discharge through these heaters and into the boiler. The power
plants are based on a compromise system: one direct-contact heater is used for feedwater
deaeration, whereas several additional heaters of the closed type are located upstream as well
as downstream of the direct-contact heater and of the boiler-feed pump. Such a cycle is
termed an open cycle and the same is followed in PFBR. In FBTR the initial cycle followed
was open cycle having all the heaters as direct contact heater with pumps in between every
open heat exchanger. Later all heaters, except deaerator were converted to closed shell and
tube heaters in view of wild level fluctuations encountered in them during plant transients.
FBR 1&2, as well as FBTR-2, is also envisaged to have open cycle with deaerator as the only
direct contact heater. In closed cycle all the heaters are of closed type and the major variation
is in the place of deaeration which is accomplished in the condenser hot well.

7.1.1 DESIGN CONSIDERATIONS AND DESIGN POINT

In typical power plant applications the boiler feed pumps have specific speed in the
range of 1000 to 1800 metric units and radial vane area or francis vane area as impeller
profile. Each BFP (3 X 50%) of PFBR has design flow rate of 1235m3/hr and discharge head
of 2030 mlc. The head is developed in four stage horizontal barrel type pump. The required
NPSH is 59 mlc and it consumes 7.93 MW at this operation point. For FBR 1&2 total

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feedwater flow requirement is expected to be 2600m3/hr. The head requirement is expected to
be nearly same as in PFBR.

7.1.1.1 HYDRAULIC CONSIDERATIONS

A number of hydraulic considerations influence the life and performance of the boiler
feed pump. The available suction head is the most important system parameter in relation to
protection of the boiler feed pump itself and the preservation of stable pump operation at high
and low loads and during transient system occurrences. Inadequate suction head can permit
localized vaporization of the water when accelerated through the impeller. Cavitation can
lead to pump instability and structural damage and should be avoided in high-head, high-
speed applications such as boiler feed service. The net positive suction head (NPSH)
represents the net suction head at the pump suction, over and above the vapour pressure of
the feedwater. If the pump takes its suction from a deaerating heater, the feedwater in the
storage space is under a pressure equivalent to the vapour pressure corresponding to its
temperature. Therefore the NPSH is equal to the static submergence between the water level
in the storage space and the pump centre line less the frictional losses in the intervening
piping. The required NPSH is independent of operating temperature but, this temperature
must be taken into account when establishing the recommended submergence from the
deaerator to the boiler-feed pump. A margin of safety must be added to the theoretical
required NPSH to protect the boiler-feed pumps against the transient conditions that follow a
sudden reduction in load for the main turbo-generator.
Pump manufacturers typically specify the net positive suction head required (NPSHR)
for their pump based on the value observed in pump tests corresponding to a 3% reduction in
first-stage developed head. The NPSHR is specified in this manner because of the inability of
the pump manufacturer to determine at exactly what point the initial head reduction begins.
The specified NPSHR at 3% head reduction is, therefore, not an adequate design basis since
the pump will experience some cavitation under these conditions. Consequently, a boiler feed
pump should be selected to ensure ample margin between the pump NPSHR and the NPSHA
of the system. This margin should be specified not only to include extra NPSH to protect the
pump during foreseeable transient occurrences, but also to provide the NPSH margin between
the 3% and the 0% head reduction points. Industry experience has shown that a margin of at
least 50% above the manufacturers' stated 3% head reduction point is usually adequate.
Additional margin above and beyond this value is justified by the additional reliability
provided as indicated in the EPRI Survey of Feed Pump Outages (1978), in which a margin

FBR 1&2/40000/DN/1004/R-A Page 9 of 32

of 80% is recommended. Insufficient margin, on the other hand, may produce intense
cavitation and accelerated impeller wear. In every case, the pump manufacturer should be
consulted for appropriate NPSH margins.
Another hydraulic phenomenon that is important in boiler feed pump design is suction
recirculation. As the flow through the impeller is decreased, a point is reached where vortices
form in the suction eye of the impeller. These vortices are unstable and result in pressure
pulsations at the pump discharge. The net results of this phenomenon are pump instability,
noisy operation, and vibration of both the pump and the suction piping. The chances of boiler
feed pump suction recirculation are much less with a booster boiler feed pump or with
double-suction pumps. Boiler feed pumps have low specific speeds (1,000 to 1,800) and
therefore define impeller passages that are essentially radial. In general, lower values of Ns
imply more stable pumps with smoother, more uniform head capacity curves. For reliable
partial load operation and stable operation of matched pumps in parallel, the specific speed
for a boiler feed pump should be 1,600 or less. Boiler feed pumps should be designed with a
head capacity characteristic which rises continuously from high to low flows without
interruption. The specified requirement for head rise from design flow to shutoff is
recommended to be not less than 120% and not more than 130% of the head at design flow.
The continuously rising characteristic curve to shutoff guarantees that the boiler feed pump
will be able to operate in parallel from minimum flow to runout with equal load sharing,
without excessive vibration, hunting, pressure pulsations, or cavitation.

7.1.1.2 DESIGN POINT

The design point for boiler feed pumps is specified by the design capacity and head.
The design capacity is based on the plant's maximum steam flow requirements. For a large
power station, this would be the steam turbine flow at valves-wide-open and 5% over-
pressure, plus any steam or feedwater removed from and not returned to the flow path
between the boiler feed pump suction and the turbine throttle. This point often does not match
the true operating point. Reasons for this include: uncertainties related to the system
characteristic curve, properties of the fluid handled differing from those used for initial
calculation, manufacturing tolerance, system-dependent control of the centrifugal pump,
uncertainties related to the calculations and characteristic curves selection chart of series-
produced pumps. The following are contributing factors in the determination of the boiler
feed pump design capacity:
• Turbine throttle steam flow typically at valves-wide-open and 5% overpressure conditions;

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• Steam cycle makeup flow, typically 1% of the turbine throttle flow;
• Spray in HPT bypass valve and
• Reheat steam desuperheater flow, if applicable.
The total developed head for the boiler feed pump is calculated as the turbine throttle
pressure minus the losses in the steam piping, steam generator and feed water piping. A head
margin of 5% of the total developed head is taken. The required discharge pressure will
generally vary from 115 to 125% of the SG outlet pressure. The net pressure to be generated
by the boiler-feed pump is the difference between the required discharge pressure and the
available suction pressure.
In the range of specific speeds normally encountered in multistage centrifugal boiler-
feed pumps, the rise of head from the point of best efficiency to shutoff will vary from 10 to
25%. Furthermore, the shape of the head-capacity curve for these pumps is such that the drop
in head is very slow at low capacities and accelerates as the capacity is increased. If the pump
is operated at constant speed, the difference in pressure between the pump head-capacity
curve and the system-head curve must be throttled by the feedwater regulator. Thus the
higher the rise of head toward shutoff, the more pressure must be throttled off which goes
unutilised. Also, the higher the rise, the greater the pressure to which the discharge piping and
the closed heaters will be subjected. However, too low a rise to shutoff or too flat a curve is
not conducive to stable control because a small change in pressure corresponds to a relatively
great change in capacity, and a design that gives a very low rise to shutoff may result in an
unstable head-capacity curve, difficult to use for parallel operation. When several boiler-feed
pumps are to be operated in parallel, they must have stable curves and equal shutoff heads.
Otherwise, the total flow will be divided unevenly and one of the pumps may actually be
backed off the line after a change in required capacity occurs at light flows. The head flow
characteristic for 1200 to 1500 NS pumps typically has a constantly rising curve slope. The
characteristic curve for a pump with a NS of 1600 to 2100 often will exhibit a depression
(change to a very low, or negative slope) at reduced flow rates as can be seen in Fig. 7. If a
high specific-speed pump is operated at reduced flow rates, there is risk of entering a
performance curve region that will result in flow instability and surge and high vibration.
This operating condition is potentially damaging to the boiler feed pump. Attention to
impeller and diffuser areas is critical to prevent this condition from occurring. Under filled
impellers and high area ratios between the impeller and the diffuser or volute will tend to
flatten the performance curve and can result in a depressing effect on the slope of the
performance curve.

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 Fig. 7: Higher specific speed pump’s characteristics

7.1.2 PUMP TYPE AND CONSTRUCTION

BFP is horizontal pump having multistages to develop the required pressure at the
steam generator outlet. Because of the high discharge pressure, the pumps are required to
have high RPM leading to high NPSHr. This NPSHr is met with the help of booster pumps.
Relevant options for the types of pumps as applicable in power plant applications are
discussed here.
The boiler feed pumps are mainly divided into two types based on the type of casing and
rotor arrangement.

7.1.2.1 TYPES OF CASING

Based on the type of casing the boiler feed pumps are divided into two types:
 Multistage barrel pull-out pumps (Fig. 8),
 Ring-section pumps (Fig. 9),
These two types only differ in the construction of their pressure-retaining enclosure,
which influences the manufacturing costs and ease of installation. There are no differences
with regard to operating reliability and robustness in abnormal operating conditions. The
dimensions of the rotating parts and flow passages can be designed identically.

Fig. 8: Multistage barrel pull-out pumps

FBR 1&2/40000/DN/1004/R-A Page 12 of 32

 Fig. 9: Ring-section pumps

7.1.2.1.1 BARREL CASING

 The casings of barrel pull-out pumps and barrel casing pumps are usually made of
unalloyed or low-alloyed ductile forged steel. Deposit welding is used on all surfaces
in contact with the feed water to coat them with corrosion and erosion resistant
material.
 In order to weld the pump into the piping, an adapter must be provided if the materials
of the nozzles to be connected are from different material groups.
 Barrel cover is fastened by means of large non-torqued studs. Sealing is provided by a
profile joint which is pressurised purely by the prevailing pressure (of up to several
100 bar) without any external forces acting on it.
 In the case of barrel pull-out pumps, the inside of the barrel is divided into three
pressure zones so that a partial flow at the required intermediate pressure can be led
off directly to the outside.
7.1.2.1.2 RING-SECTION PUMPS
 The casings of ring-section pumps are preferably made of forged chrome or carbon
steel plated with austenitic material.
 The sealing element between the individual stage casings seals off by metal-to-metal
contact, the individual casings being clamped together axially by tie bolts between the
suction and discharge casings.
 In the case of ring-section pumps, a partial flow at an intermediate pressure can easily
be tapped through a tapping nozzle in one of the stage casings.
Thermal shocks causing various thermal expansions mainly lead to additional loads
on the tie bolts and sealing surfaces of the stage casings.

FBR 1&2/40000/DN/1004/R-A Page 13 of 32

 Two aspects of deciding between a ring-section and a barrel pull-out pump are
described below:
 The smaller the mass flow rate and the higher the pressure, the higher the material and
manufacturing costs of barrel pull-out pumps. This does not apply to the same extent
to ring-section pumps.
 Barrel pull-out pumps have some advantages over ring-section pumps when it comes
to repairing a pump installed in the system. If a rotor has to be replaced, the barrel can
remain installed in the piping. This is significant with regard to the availability of a
power station unit, if no full pump back-up is available or if pump replacement is very
time-consuming.

7.1.2.2 TYPES OF AXIAL BALANCING

A key factor in pump selection for demanding boiler feed service is rotor hydraulic
axial balance. Two types of rotor construction need to be considered:
 In-line (tandem) impellers (Fig. 10)
 Opposed (back-to-back) impellers (Fig. 11)

Fig. 10: In-line (tandem) impellers

Fig. 11: Opposed (back-to-back) impellers

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 With in-line impellers, the hydraulic axial thrust of the impellers is usually countered
by a balancing device—either a balance disk or a balance drum—or sometimes a
combination of both.
The advantages of a balance disk design include reduced internal recirculation (better
volumetric efficiency) and the disk’s ability to compensate for wear and the amount of thrust
that requires balancing. The disk is referred to as a self-compensating balancing device and
may be used to exclude an axial thrust bearing in certain designs, reducing initial cost and
simplifying rotor construction and assembly. The balance drum does not compensate for
changes in thrust and typically exhibits more internal recirculation losses than a balance disk.
The advantage of the balance drum compared to the balance disk is in the openness of
its running clearance. For systems in which severe upsets may occur or in which foreign
material is continuously present, balance drums (with their larger running clearances) may
prove less sensitive (less susceptible to damage) than balance disks.
If, however, a more complex, parallel-coupled back-to-back impeller arrangement is
chosen the axial thrust experienced is less as it is balanced by the opposite back impeller,
only the normal axial thrust per stage occurs. Both pump types must be equipped with thrust
bearings of appropriate strength.
PFBR has barrel casing type horizontal pump with balance drum for axial balancing.

7.1.3 FLOW REGULATION AND PUMP DRIVES

The flow demand to steam generator can be varied by adopting flow regulation
techniques described under section 6. With increase in the required head and flow rate, due to
increase of the capacity of the power station the power input to pump has also gone high.
This calls for adopting variable speed drives for these pumps as the benefits of power savings
associated with large power pumps are high.
The majority of boiler-feed pumps in small steam plants are driven by electric motors.
It was the practice to install steam-turbine driven standby pumps as a protection against the
interruption of electric power, but this practice has disappeared in large size steam stations. In
medium and large sized plants, a combination of electrically driven and turbo driven pumps
are used. Electrical drive is used during start up and turbo driven during normal operation.
Large power plants with capacity in excess of 200 MW have trended away from electric
motor drives, including those equipped with hydraulic couplings, fluid, and variable
frequency drives, to steam turbines for following reasons:
1. Steam turbines are more efficient and inherently rugged.

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2. Driver speed can be matched ideally to the pump optimum speed
3. A steam turbine provides variable-speed operation and better flow compliance to varying
plant load and flow demands without an additional component, such as a hydraulic coupling
4. The use of an independent steam turbine increases plant capability by eliminating the
auxiliary power required for boiler feeding and the elimination of the boiler-feed pump
motors may permit a reduction in the station auxiliary power.
5. Proper utilization of the exhaust steam in the feedwater heaters can improve cycle
efficiency in case of back pressure turbines.
In conventional power stations above 500 MW full loads feed pumps are driven by
steam turbines. In most cases condensing turbines running at 5000 to 6000 rpm are used.
Electric motors usually drive part load feed pumps, both in fossil-fuelled and in nuclear
power stations. Speed control of electrically driven feed pumps is affected by either fluid
coupling or by electrical closed-loop control systems by means of thyristors up to a drive
rating of approximately 18 MW.
Four possible options of installing boiler feed pump drives are shown in Fig. 12. The
low-speed booster pump is usually driven by the free shaft end of the turbine via a step-down
gear or directly by the free end of the electric motor.
Variable Speed
Fixed Low
Fluid Drive
speed Motor
coupling with
Step -up gears motor
High RPM Main
Low RPM Booster
pump
pump

a) Low Speed Motor with Variable Speed Fluid Coupling and Speed Increase Gears
Variable Speed Fixed Low
Planetary Gear speed Motor
Fluid Drive motor
Coupling

Low RPM Booster

High RPM Main pump
pump

b) Low Speed Motor with Variable Speed Planetary Gear Fluid Drive Coupling
Step-up
gears Low Speed
VSD motor
Low RPM Booster
pump
High RPM Main
pump

c) Low Speed VSD Motor with Step-up Gears

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 High speed VSD Step -down
motor gears

High RPM Main

Low RPM Booster
pump
pump

d) High Speed VSD Motor with Step-down Gears

Fig. 12: Boiler feed pump drives
In PFBR low speed (1500rpm) motor with variable speed fluid coupling and speed
increase gear for the main pump and direct coupling for booster pump (configuration (a)
above) is used.

7.1.4 PUMP SELECTION AND CONFIGURATION

The boiler-feed pumps are designed for 100% capacity with additional margin to
cover boiler swings and the eventual reduction in effective capacity from wear. This margin
varies from as much as 20% in small plants of less than 100 MW like FBTR to as little as 5%
in the larger capacity power plants as in PFBR. The design margin in the case of FBR 1&2
will also be 5%. The total required capacity must be either handled by a single pump or
subdivided between several duplicate pumps operating in parallel. Power stations tend to use
2 X 100% capacity pumps up to a rating 200 MW and 3 X 50% capacity electrical driven
pumps up for intermediate capacity plants. For 500MW and higher capacity plants 3 X 50%
capacity pumps are generally used, out of which one is electrical driven and two are turbo
driven pumps. This provides optimum reliability and availability. The motor driven pump is
used primarily for plant startup activities, but can also be used to supplement the reliability
and availability of the boiler feed system by operating in parallel with the main boiler pump
at reduced plant loads or even at design load, depending on the capacity and head available
from the starup boiler feed pump. Fast Breeder Test Reactor has 2 X 100% BFP. In PFBR 3
X 50% BFP are installed of which one is motor driven and two are turbo driven pumps. The
FBTR-2 is envisaged to have 3 X 50% capacity motor driven pumps considering high
availability and operational flexibility. For FBR 1&2, 2 X 50% turbo driven pumps are
recommended for normal operation in view of their high efficiency and ruggedness. For
standby and startup duty 2X25% motor driven pumps are proposed considering operational
flexibility and high efficiency under part load operations.
In the evolution of thermal power plants, as steam pressures rose from 200 to 310 bar the
total head that was required to be developed by the pump rose from around 1220 m to as high

FBR 1&2/40000/DN/1004/R-A Page 17 of 32

as 3660 m. The only means available to achieve these high heads using 3600 rpm 2-pole
motor at 50 Hz was to increase impeller diameter and the number of stages. The pumps were
required to have longer shafts to accommodate the larger number of stages threatening the
long uninterrupted life between overhauls. The solution was to reduce the shaft span by
reducing the number of stages. In the 1970s, stage pressures rose from ~245 m/stage to ~915
m/stage and higher. The higher head requirements were achieved by increasing the speed of
rotation instead of increasing impeller diameter or stage number. As a result, boiler feed
pumps in large power stations generally operate at high rpm from 5000 to 9000 requiring
high NPSHr, The increased sizes of modern boiler-feed pumps coupled with the practice of
operating these pumps at speeds considerably higher than 3600 rpm have led to NPSH
requirements as high as 46 to 76 m. In most cases, it is not practical to install the direct-
contact heaters from which the feed pumps take their suction high enough to meet such
requirements. In such cases, it has become the practice to use boiler-feed booster pumps
operating at lower speeds, such as 1750 rpm, to provide a greater available NPSH to the
boiler-feed pumps than can be made available from only static elevation differences. Such
booster pumps are generally of the single-stage, double-suction design.
FBTR has a steam pressure of 125 bars accomplished by one multi stage BFP of KSB
make, no booster pump is installed. PFBR has a steam pressure of 170 bars. PFBR has multi-
stage barrel casing type horizontal pump with balance drum for axial balancing. The NPSHr
for main pump is met by a booster pump. The same type of pump and arrangement is
envisaged for FBR 1&2.

7.2 CONDENSATE EXTRACTION PUMPS

Condensate extraction pumps are medium head and medium to high capacity pumps.
In typical power plant applications the impeller profile of condensate extraction pumps is of
francis vain area type and specific speed in the range of 1500 to 2500 metric units.
Condensate pumps take their suction from the condenser hot well and discharge either
to the deaerator in open feedwater systems or to the suction of the boiler-feed pumps in
closed systems. These pumps, therefore, operate with a very low pressure at their suction.
The available NPSH is obtained by the submergence between the water level in the condenser
hot well and the centerline of the condensate pump first-stage impeller. It is desirable to
locate the condenser hot well as low as possible and avoid the use of a condensate pump pit.
Frictional losses on the suction side are kept to a minimum. The piping connection from the
hot well to the pump is as direct as possible of ample size and with minimum number of

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fittings. Because of the low available NPSH, condensate pumps operate at relatively low
speeds, ranging from 1750 rpm in the low range of capacities to 880 rpm. It is customary to
provide a liberal excess capacity margin above the full-load steam condensing flow to take
care of the heater drains that may be dumped into the condenser hot well if the heater drain
pumps are taken out of service for any reason.

7.2.1 DESIGN CONSIDERATION AND DESIGN POINT

In typical power plant applications the condensate extraction pumps have specific
speed in the range of 1500 to 2500 metric units and mixed flow vane area as impeller profile.
CFP of PFBR has BEP(79.5%) at flow rate of 920m3/hr and discharge head of 265 mlc. The
head is developed in six stage vertical canister type pump. The required NPSH is 3.4 mlc and
it consumes 0.83 MW at this operation point. For FBR 1&2 water flow requirement is
expected to be 1800 m3/hr. The head requirement is expected to be nearly same as in PFBR.

7.2.1.1 DESIGN POINT

The capacity of the condensate pump is determined by the maximum steam mass flow
rate of the steam turbine and the head to be developed by the pump is composed of following
heads:
 Head difference between the water levels in Deaerator water storage tank and
condenser
 Difference of static pressure heads in Deaerator water storage tank and
condenser
 Head losses of the flow in the pipeline, including installed valves (e. g. gate
valve, swing check valve) and system components (e. g. suction strainer,
condensate preheater).
The design of the condensate pump is governed by the vapour pressure of the water
on the suction side (for pure water at 35 °C approximately 56.2 mbar) and by the low inlet
head resulting from the position of the condenser within the structure. The inlet head is
calculated by subtracting the flow losses in the inlet line from the head between the standard
water level in the condenser and the level of the impeller of the first stage.
To achieve an optimum operating behaviour and prevent cavitation damage the
available NPSH of the system must be greater or equal to the required NPSH at the impeller
of the first stage. This applies to the entire operating range.

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 Measures to increase the system-side inlet head include the following:
 Minimising the flow losses in the inlet line; e. g. by means of larger nominal pipe
diameters
 Vertical arrangement, e. g. dry installation which reduces the height of the first-stage
impeller above the installation floor and increases the difference in geodetic head.
Vertical arrangement as a "can-type pump", in which the geodetic head difference is
increased by lowering the suction stage into an inlet "can" arranged below the installation
floor. The inlet and discharge lines are arranged above the installation floor.

7.2.1.2 FIRST-STAGE IMPELLER DESIGN.

Proper design of the condensate pump first-stage impeller is a critical consideration
for reliability in a condensate pump to eliminate cavitation problems. Foremost in the design
of a condensate pump is the pump suction specific speed required (S). The Hydraulic Institute
suggests that for normal pump design S varies from 6,000 to 12,000, and allows higher
suction or specific speeds for special pump designs. For condensate pump service, the suction
specific speed allowance of 12,000 (based on total pump flow) has been found acceptable.
Another important parameter established for good condensate pump design is the limitation
of the peripheral velocity of the outer tip of the first-stage impeller inlet vanes to 20 m/s.
Most condensate pumps operate without cavitation if they meet these two separate but related
criteria. With the suction specific speed and peripheral velocity limitations, the NPSH, and in
turn, the condensate pump and suction "can" lengths can be established. Typically, both are
established at the maximum pump flow operating at run-out conditions. Most conservatively,
the NPSH required to prevent any reduction in the pump first-stage head at pump run-out
operation is used to determine the length of the condensate pump.

7.2.1.3 CONDENSATE PUMP HEAD PER STAGE.

The head produced by an impeller is an important condensate pump parameter.
Condensate pumps that produce high head per stage are more likely to have problems or
actual damage resulting from higher vibrations, cavitation, and erosion because of higher
energy input to the condensate. Modern condensate pumps have inputs as high as 600 to 700
horse power per stage, which translates to approximately 111.25 to 121.92 m of head per
stage in a typical installation. A good conservative head per stage allowance is 30.48 to
68.58m.

FBR 1&2/40000/DN/1004/R-A Page 20 of 32

7.2.2 PUMP TYPE AND CONSTRUCTION
Both horizontal and vertical condensate pumps are used. Depending on the total head
required, horizontal pumps may be either single-stage or multistage. Plants constructed in the
1950s and before utilized horizontally split multistage pumps mounted at the lowest plant
level, near the bottom of the condenser. The condensate flow increased in later years, with
use of vertical can-type multistage pumps.
Fig. 13 shows a single-suction, single-stage pump with an axially split casing used for
heads up to about 30 m. It is designed to have discharge pressure on the stuffing box. The
suction opening in the lower half of the casing keeps the suction line at floor level. An
oversize vent at the highest point of the suction chamber permits the escape of all entrained
vapours, which will be vented back to the condenser and removed by the air removal system.

Fig. 13: Single-stage horizontal condensate pump with axially split casing
Multistage pumps are used for higher heads. A two-stage pump is shown in Fig. 14,
with the impellers facing in opposite directions for axial balance. By turning the impeller
suctions toward the center, both boxes are kept under positive pressure to prevent leakage of
air into the pump. For higher heads and larger capacities, a three-stage pump, as in Fig 15,
may be used. The first-stage impeller is of the double-suction type and is located centrally in
the pump. The remaining impellers are of the single-suction type and are also arranged so
both stuffing boxes are under pressure. Two liberal vents connecting with the suction volute
on each side of the first-stage double-suction impeller permit the escape of vapour. Current
plant construction utilizes vertical can-type condensate pumps as in Fig. 16. The chief
advantage of these pumps is that ample submergence can be provided without the necessity
of building a dry pit. The first stage of this pump is located at the bottom of the pumping
element, and the available NPSH is the distance between the water level in the hot well and
the centerline of the first-stage impeller. Condensate pumps are located very close to the

FBR 1&2/40000/DN/1004/R-A Page 21 of 32

condenser hot well, and the suction piping is short so that the frictional losses in this piping
are not significant. However, strainers are occasionally installed in this piping, which require
attention for the extra frictional losses through them and their frequent cleaning.

Fig. 14: Two-stage horizontal condensate pump with axially split casing

Fig. 15: Three-stage horizontal condensate pump with axially split casing

Fig. 16: Vertical condensate extraction pump

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The increasing use of full-flow CPU, increases the discharge pressures required from the
condensate pumps, resulting in the need to split condensate pumping into two parts. The
condensate pumps proper thus develop only a small portion of the total head required. The
balance of the required head is provided by separate condensate booster pumps, which have
generally been of the conventional horizontal, axially split casing type. As larger plants were
constructed, the vertical can-type multistage condensate pump became the standard.

7.2.3 FLOW REGULATION AND PUMP DRIVES

When a condensate pump operates in a closed cycle ahead of the boiler-feed pump,
the two pumps can be considered as a combined unit as their head-capacity curve is
concerned. Variation in flow is accomplished either by throttling the boiler-feed pump
discharge or by varying the speed of the boiler-feed pump. In an open feedwater system,
several means can be used to vary the condensate pump capacity with the load, as below:
1. The condensate pump head-capacity curve can be changed by varying the pump speed.
2. The system-head curve can be changed by throttling the pump discharge by means of a
level control.
3. The pump can operate at the intersection of its head-capacity curve and the normal
system-head curve. The net discharge is controlled by bypassing all excess condensate
back to the condenser hot well.
4. Methods 2 and 3 can be combined so the discharge is throttled back to a predetermined
minimum, but if the load, and consequently the flow of condensate to the hot well, is
reduced below this minimum, the excess condensate handled by the pump is bypassed
back to the hot well.
The feedback for the controls used in methods 1, 3, and 4 is taken from the deaerator level.
 Condensate flow requirements from the condenser hot well with the unit operation at
maximum turbine heat balance conditions; typically 5% overpress
ure conditions with the turbine control valves wide open (VWO);
 Condensate cycle makeup flow, typically 1% to 3 % of the maximum condensate
flow;
A flow margin of 5% of the total flow determined above is typical to provide latitude for
future increase in the flow requirements due to any of the contributing factors. A head margin
of 5% of the total developed head is taken for design.

FBR 1&2/40000/DN/1004/R-A Page 23 of 32

 Constant-speed and variable-speed condensate pumps are the two types of flow
control typically used in modern power station. A variable speed drive for CEP can result in
power savings, however only fixed speed AC motor driven pumps are selected, as in
conventional power plants, as these are smaller rating pumps as compared to BFP and
condensate flows are controlled by throttling the deaerator level control valves with 2X100%
duty.

7.2.4 PUMP SELECTION AND CONFIGURATION

The number and size of condensate pumps can be:
a) Two half-capacity pumps,
b) Three half-capacity pumps, or
c) Two full-capacity pumps.
Option a and b are for power plants of higher capacity while option c is for power
plants of lower capacity. Capital costs and annual operating costs associated with each
pumping arrangement listed above are the key deciding factor but the reliability of the
pumping system should be considered when selecting the number of condensate pumps for
the power station.
The configuration of CEP in fast reactors is not different from conventional power
plants. Two full-capacity pump configurations is sometimes used in low capacity plants.
However three half-capacity pump configurations is preferred over other options, in view of
the following advantages:
(a) Operational flexibility and higher efficiency under part load conditions.
(b) Redundancy in case of a single pump failure.
(c) Lower maintenance requirements due to pumps operating near their best efficiency
point even at part loads.
For PFBR option b i.e. 3x50% pump configuration is used. The same is proposed for
FBR 1&2.
The two important condensate pump selection factors are the number of condensate
pumps required and the type of pump flow control to be used.
The selection of a condensate pump is highly influenced by the configuration type of
cooling and overall space availability of the power station. Water cooled condensers are
required to be located at lowest possible location to reduce pumping cost of cooling water
pumps. The available NPSH for CEP is generally extremely low, on the order of 0.6 to 1.2 m.

FBR 1&2/40000/DN/1004/R-A Page 24 of 32

Hence vertical-can condensate pumps are used which can be installed below ground
providing higher values of submergence.

7.3 CONDENSER CIRCULATING WATER PUMPS

Condenser circulating water pumps are high-capacity low-head pumps that provide
the cooling water flow for the circulating water system. CCWPs provide large quantity of
water to condense steam in the steam surface condensers. Because of their large size and
continuous operation, circulating water pumps must be carefully selected for economical and
reliable operation over the lifetime of the plant.

7.3.1 DESIGN CONSIDERATION AND DESIGN POINT

CCWPs have high specific speed in the range of 4500 to 7500 in typical power plant
application with mixed flow area as impeller profile. CCWP of PFBR has BEP(87.1%) at
flow rate of 13.8 m3/s and developed head of 23.5. The head is developed in single stage
horizontal concrete volute pump. The required NPSH is 10.4mlc and it consumes 3.736 MW
at this operation point. For FBR 1&2 sea water flow requirement is expected to be 15m3/s.
The head requirement is expected to be same as in PFBR.

7.3.1.1 DESIGN POINT

The design point for circulating water pumps is specified by the design flow rate
(capacity) and total developed head (TDH). Design capacity per pump is determined based on
the design circulating water flow rate and the number of pumps.
Submergence is a measure of the water depth in the pump above the pump suction.
Submergence is defined in Fig. 16 for each type of circulating water pump. Submergence
must be adequate to meet NPSH requirements and to prevent vortexing.

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 Fig. 16: Submergence of the three types of pump
7.3.2 PUMP TYPE AND CONSTRUCTION
Circulating water pumps are typically selected from one of three pump designs:
vertical wet pit, horizontal dry pit, and vertical dry pit pumps. These pump types are shown in
Fig. 17.

Fig. 17: Vertical wet pit, horizontal dry pit, and vertical dry pit pumps
For once-through circulating water systems (systems without cooling towers) , vertical wet
pit pumps are most commonly used, followed by horizontal dry pit pumps and vertical dry pit
pumps, in that order.

FBR 1&2/40000/DN/1004/R-A Page 26 of 32

 Fig. 18: Vertical wet pit circulating water pump (non-pull-out)

Fig. 19: Vertical wet pit circulating water pump (pull-out)

7.3.2.1 VERTICAL WET PIT PUMPS

Vertical wet pit pumps, are typically of the mixed flow, single-stage, single-suction
type for circulating water service. Axial flow pumps are occasionally used for very low-head
applications. Vertical wet pit pumps use a vertical, internally lubricated shaft to drive the
pump impeller. The pump is partially submersed in a wet pit with the motor mounted directly
over the pump above the water level. Location of the motor directly above the pump column

FBR 1&2/40000/DN/1004/R-A Page 27 of 32

minimizes horizontal space requirements. Vertical wet pit pumps may be of pull-out or non-
pull-out design as shown in Figs. 18 and 19 respectively. Pull-out design allows the rotating
elements and critical non rotating components such as the impeller shroud and pump
bowl/diffuser/volute to be quickly removed without removing the column or disconnecting
the pump discharge. Non-pull-out design has a 20% to 25% lower capital cost; however,
pump disassembly is more difficult and requires a longer pump outage. Another design
variable for vertical wet pit pumps is the location of the discharge relative to the base plate.
An above floor or above ground discharge indicates that the pump discharge is above the
base plate, whereas a below-floor or belowground discharge refers to the opposite. The below
floor discharge is more difficult to disconnect since access to the discharge is usually limited.
Because disconnecting the discharge is required for disassembly of non-pull-out pumps,
below-floor discharge combined with non-pull-out design may create maintainability
problems. In applications where large variations in water level exist, short column vertical
wet pit pumps can be used to avoid the use of pumps with long column lengths. Short column
vertical wet pit pumps, place the pump discharge and motor in a dry pit below the high water
level. Seals are placed around the pump base plate and discharge pipe to prevent water
leakage into the dry pit. The resulting pump has fewer bearings and is less susceptible to
vibration. However, failure of the seals could flood the dry pit and damage the motor.

7.3.2.2 HORIZONTAL DRY PIT PUMP.

For circulating water service, horizontal dry pit pumps are typically split-case, single-
stage, double-suction type with either centrifugal or mixed flow design. Horizontal dry pit
pumps, as shown in Fig. 17, use a horizontal shaft with external bearings on each side of the
pump casing. The pump is located in a dry pit below the water level with suction taken
through horizontally mounted suction piping that connects to the sump. The pump motor is
adjacent to the pump on the floor of the dry pit. Where horizontal space is limited, horizontal
dry pit pumps can be installed in a vertical position with the motor above the pump. This
arrangement, however, is unusual and requires redesign of the bearings.

7.3.2.3 VERTICAL DRY PIT PUMPS.

Vertical dry pit pumps, as shown in Fig. 17, are of the mixed flow, single-stage,
single-suction type. Vertical dry pit pumps use a vertical shaft with bearings external to the
pump casing. The pump is located in a dry pit below the water level, with suction taken from
a suction tunnel located below the pump. The pump motor is above the pump, thus

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minimizing horizontal space requirements. As shown in Fig. 17, turning vanes are used with
vertical dry pit pumps to improve flow uniformity into the suction bell. The turning vanes are
typically made of fabricated steel embedded in the concrete walls of the suction tunnel. A
draft tube suction can be used as an alternate to turning vanes. Vertical dry pit pumps
normally have a lower design point efficiency than either vertical wet pit or horizontal dry pit
pumps.

7.3.2.4 CONCRETE VOLUTE PUMP

Concrete volute pumps are vertical volute pumps whose casing is made of concrete
instead of steel. Concrete volute pumps are designed for high flow applications, resulting in
fewer pumps. The pump is predominantly produced in concrete, eliminating potential
corrosion problems often experienced in corrosive environments (especially in hot sea water).
Concrete volute pumps have several advantages over the conventional tubular casing
pump. The main advantages are to be found in construction, total cost, handling, installation
and maintenance:
 Lower specific speed results in a slower running speed and shorter submerged
setting depth. Both the above factors will significantly reduce the depth of civil
dig and overall land area excavation required for the intake and pump house
structures.
 The lower specific speed (volute design) pump offers a lower rise to closed valve
head, resulting in reduced system pressure rating.
 Pump construction is concurrent with intake and pumphouse structures, ensuring
correctness of mechanical and civil interfaces the combination of the concrete
volute pumps’ slower running speed, minimal wear and exceptional reliability
eliminates the need for stand-by units.
Type Vertical Metallic Casing Pump Concrete Volute Pump
Wet-Pit Dry-Pit

Casing Corrosion (chemical & No corrosion

electrolytic)
External fouling No erosion
Vibrations, cracks No fouling No vibrations

Inspecting / Difficult to maintain Minimum maintenance

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 Maintenance Long duration and costly Simple and easy
interventions
Heavy loads No heavy loads
Requires general overhaul at Inspection without
intervals of 2 to 3 years. dismantling
General overhaul at
intervals of 5 to 7 years.

Contact with Full metallic casing is in contact Only metallic part in contact
water with water with water is impeller

Intake Sump or pit Special Hydraulic design

Chance of vortices No vortices
Sand/ Silt deposit No deposit
Irregular flow pattern Stream lined flow pattern

Bearing Submerged bearing bushes. Out of water, no wear

Less reliability
Difficult and expensive to
maintain
Shaft In water, subjected to irregular
stress and problems. Possibility of
vibrations and cracks
Duplex stainless steel( shaft and
impeller both)
Minimum 10 years life
Simplified maintenance
Easy temperature check
Dry, no water contact
No corrosion, long life
No vibrations
Only impeller is to be
manufactured with Duplex
stainless steel

Availability Availability approaching

100% is achieved on all
installations. Low wear
leads to negligible spares
usage

FBR 1&2/40000/DN/1004/R-A Page 30 of 32

7.3.3 PUMP SELECTION AND CONFIGURATION
In view of the advantages mentioned in previous section, concrete volute pumps are
more reliable and preferred for large seawater flow applications. As the seawater flow
requirement for FBR 1&2 is more than 6m3/s, concrete volute pumps are envisaged as in
PFBR. Since concrete volute pumps are highly reliable (typical reliability = 99.95%) no
standby pump is required and a 2 X 50% configuration is envisaged, as in PFBR. For twin
unit FBR 1&2 the seawater intake and outfall structures and the seawater pump house will be
common. The CCWP shall be independent for the individual units, however a cross tie
arrangement is envisaged between the pumps of two units.

6. CONCLUSION
The design and construction of major power plants centrifugal pumps, namely boiler
feed pump, condensate extraction pumps and condenser cooling water pump differs in type,
capacity, power consumption and size in accordance with their specific application
requirements. Boiler feed pumps are high head, high capacity pumps. The main BFPs are
horizontal, multistage barrel type variable speed pumps running at high rpm and are preceded
by a low speed single stage booster pumps to meet their NPSHr. The feed water system for
FBR 1&2 is proposed to have 2X50% capacity turbo driven boiler feed pumps for better
reliability and efficiency. The system would also include 2X25% motor-driven variable speed
boiler feed pumps with hydraulic couplings, used for plant start-up and stand-by duty,
supplementing the reliability and availability of the system for operation at reduced plant
loads or even at design load.
Condensate extraction pumps operate with a very low pressure at their suction. The
available NPSH is obtained by the submergence between the water level in the condenser hot
well and the centreline of the condensate pump first-stage impeller. As NPSH is extremely
low, vertical-can type pumps, operating at relatively low speeds, are used which can be
installed below ground providing higher values of submergence. 3X50% pump configuration
with constant speed induction motor drives are proposed for FBR 1&2, similar to PFBR.
Condenser cooling water pumps are very high capacity and low head pumps, making
them large sized pumps, running at low rpm. For FBR 1&2 concrete volute pumps in 2X50%
configuration are envisaged, as in PFBR, in view of their high reliability (typical reliability =
99.95%) and no standby pump is required. All the above pumps with their stated
configurations are envisaged independent for the individual units of FBR1&2. For twin unit
FBR 1&2 the seawater intake and outfall structures and the seawater pump house will be

FBR 1&2/40000/DN/1004/R-A Page 31 of 32

shared. However, in case of CCWP, a cross tie arrangement is envisaged between the pumps
of two units to further enhance system availability.

REFERENCES
[1] Gülich Johann Friedrich, ―Centrifugal Pumps‖, second edition, 2010, Springer.
[2] Lobanoff Val S. and R. Robert Ross ―Centrifugal Pumps Design & Application‖,
Second edition, 1992, Gulf publishing company, Houston, TX.
[3] Karassik I. .J, et al., ―Pump Handbook‖ third edition, 2008 McGRAW-HILL‖.
[4] Boiler Feed Pump Drive Selection and Configuration, CBR/43200/DN/1000/R-A,
2016.
[5] Power Plant Engineering, Black and Veatch, Springer, 1996.

FBR 1&2/40000/DN/1004/R-A Page 32 of 32