TESTING OF THE BOOSTER FEED PUMP

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Y WE USE BOOSTER FEED PUMP

In power plant we use feed water pump of having very high pressure and must make net postive suction head It is used to prevent cavitation. For a 80 MW power plant,The BFP requires 10 KGf/sq.cm suction pressure for which u have to place your DM tank & deaerator at 100 mtr. which will be more cost for the form to build the structure & erect the piping. To save cost without compromising on suction pressure for BFP, we require Booster feed pump.

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FEED PUMP
PUMP:- Pump is a device which converts mechanical energy into pressure energy classifications of pumps:1.Centrifugal pumps 2.Reciprocating pumps Centrifugal pumps:- Energy is generated through the centrifugal force of the vortex Reciprocating pumps:- Energy is generated by the direct displacement of the fluid

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Generally in power plants we use centrifugal pumps as its performance is better than positive displacement pumps

Generally in power plants we use centrifugal pumps as its performance is better than positive displacement pumps TYPES OF CENTRIFUGAL PUMPS Centrifugal pumps are classified based on two categories 1. Based on type of casting 2. Based on number of impellers
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BASED ON TYPE OF CASING

VOLUTE CASING PUMP:- Kinetic energy of fluid is converted into pressure energy by volute casing itself DIFFUSER VANE PUMP:- kinetic energy of fluis is converted into pressure energy by a set of vanes

BASED ON NUMBER OF IMPELLERS

SINGLE STAGE PUMP:- The head is developed by single stage impeller MULTI STAGE PUMP:- The head is developed by multi stage impeller

MAJOR COMPONENTS OF PUMPS:

Suction guide Pump casing Diffuser Ring section assembly Wearing ring Rotating assembly Discharge cover

Stuff boxing Mechanical seal Seal housing Bearings Bearing house Couplings Base plate Impeller

SELECTION OF PUMPS
Flow rate Total head Type of fluid Temperature Suction head available Application system, duty, operation Vibrations Power

PUMP CHARECTARISTICS
It is the relationship between capacity, head, power, efficiency. Capacity:It is a quantity of fluid flow through the pump at a given time. It is measured by orifice plate. It is expressed in m3/ hr. Head: It is measure of energy to move fluid from one point to another point. It is expressed in metre. Power: The power required to drive pump is called break horse power. BHP= QH/75 Efficiency: It is the measure of the pump performance It is the ratio of BHP/ (QH/75).

Affinity laws: All the centrifugal pumps follow the affinity laws which are given below QN QD H N2 & HD P N3 P D3 Where N is speed of the pump, rpm D is the diameter of the impeller. Specific speed: It is the speed of geometrically similar pumps which deliver one unit of capacity against one unit of 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 speed of the pump in rpm It determines the type of impeller Its values varies from 30-1000 for centrifugal pumps Radial flow impeller = 30-290 Mixed flow impeller= 290-440 Axial flow impeller= 440-1000

TYPES OF FEED PUMPS USED IN PLANT

In power station we are using 4 types of feed pumps. They are: 1. 2. 2. 3. Boiler feed pump (BFP) Feed booster pump (FBP) Condensate extraction pump (CEP) Cooling water pump (CWP)

FEED BOOSTER PUMP(FBP)

DESIGN FEATURES OF FBP: Horizontal,Single Stage,Double Suction,Axial Split Casing,Radial Flow. Double Suction Impeller for minimum NPSHR. Shaft sealing by mechanical seals Compatible materials for stationary and rotating parts

IMPELLER: -It is a semi open type,mixed flow,dynamically balanced -It doesnt have any hydraulic thrust balance holes -It is made up of stainless steel BY USING DOUBLE SUCTION IMPELLER: -Theoretically its in hydraulic balance with the presurre on oneside equal to and counter balancing the pressure on the other side BY USING OPPOSED IMPELLER: -It involves mounting of one-half of the impeller facing in one direction and the other half is facing in opposite direction.

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TYPES OF BOOSTER PUMPS

Now we are going to discuss two types of booster feed pumps in detail(testing) Feed booster pump(FBP)210 MW Feed booster pump(FBP)600 MW

TEST PROCEDURE OF FEED BOOSTER PUMP(4 X 600MW)

BOOSTER PUMP TYPE: FA1B75
1.0.0 SCOPE OF TEST: 1.1.0 The following tests are proposed at our test plant on FBP Type FA1B75 as per ANSI / HI 1.6 - 2000. 1. Performance test with cold water for 12 pumps 2. NPSH test on one of the above 12 pumps at cold water.

2.0.0 MEASUREMENTS: 2.1.0 FLOW: The pump discharge will be measured by Magnetic Flow meter / Transmitter, located at suction pipe line with an accuracy of 0.5 % instruments. 2.2.0 HEAD: The head developed by the pump will be measured by means of pressure Transmitter with an accuracy of 0.5% FSD. The pressure Transmitter will be calibrated for every test. 2.3.0 POWER: The electrical power for drive motor will be measured by means of Power transmitters with 0.5 % accuracy instruments. 2.4.0 SPEED: Speed measurements will be carried out by non-contact type digital speed indicator with an accuracy of 1 rpm.

2.5.0 TEMPERATURE: Temperature measurement will be carried out by RTD (0 200 C) with an accuracy of 0.5 %. 2.6.0 VIBRATION: Vibration measurement will be carried out by vibration monitor with + 5% accuracy instrument. 2.7.0 NOISE LEVEL: Noise level measurement will be carried out by noise level meter with 1 dBA accuracy meter. 2.8.0 All the instruments used for testing will be calibrated as per Annexure

3.0.0 TEST ARRANGEMENTS :

3.1.0 Test arrangement for shop testing of FBP will be as per the schematic drawing in Annexure - II. The pump under test will be driven by test plant 850 kW, 6600V drive motor. Pump suction and discharge will be connected to the test loop. The lube oil to pump bearings will be supplied by the test plant lube oil system.

4.0.0 PERFORMANCE TEST:

4.1.0 HYDRAULIC PERFORMANCE TEST: -Performance test with cold water will be conducted at Design condition for all pumps at about 1495rpm speed using test plant drive motor for establishing Flow Vs Head, Flow Vs Power & Flow Vs Efficiency characteristics. - The test will be conducted over the following percentage range of design flows (i.e.110%, 100%, 90%, 80%, 65%, 50%, 25% and 0%). For each load point simultaneous readings of all the parameters will be noted down. Computation of test results for specified speed will be done as per Annexure III.

- From the test results a graph is drawn for Flow Vs Head, Flow Vs Power & Flow Vs Efficiency. -Performance testing will be conducted for a period of 1 hour keeping minimum of 5 minutes of gap between each reading. 4.2.0 MECHANICAL PERFORMANCE TEST: -Vibrations will be noted down at all the load points in velocity mode (RMS) in H-V-A directions of NDE bearing housing and H-V direction of DE bearing housing of the pump. - The maximum allowable vibration level during shop testwill be 11.2 mm/sec (RMS). Acceptable standard is ISO 10816-3, Group 3 and Zone c/d -Noise level will be measured at all the measuring points. Noise level will bemeasured by keeping the noise level meter at 1 meter distance and at 1.5 meter elevation, at 2 locations DE and NDE side pump

7.0.0 GUARANTEE PARAMETERS 7.1.0 The contractual acceptance tolerance are in accordance with ANSI / HI 1.6 2000 for MDBP are : Sl. parameter design ANSI/ HI 2000 tolerance No details condition 1.6 Alt - I Alt II 01 Discharge Flow (Q in m3/hr) 1240 --0to+10% 02. Head developed (H in mlc) 192 -0to+3% --03. Pump efficiency (%) 82.2 -0to+-% -0to+-% 04. Pump speed (rpm) 1495 ----05. Pump Input Power (kW) 713 -----06. NPSH(R) at 3% Head drop (m ab) 5.9 -----

s. no 1 2

parameter symbol Temperatu t re specific weigth of water pump test speed flow rate qt wt

unit oc gr/cc

value 49.133 .09883

3 4 5 6

Nt Qt

rpm m^3/h kg/cm^2 kg/cm^2

1476.8 987.15 22.139 22.139

Discharge pd' pressure Discharge pd pressure after error

7 8

suction pressure suction pressur after error pump head Motor input power Motor efficiency motor o/p power pump efficiency

ps' ps

kg/cm^2 kg/cm^2

4.1133 4.1233

9 10

Ht pe

m/c kw

212.124 656.68

11 12 13

nm pt np

--kw -----

664.58 665.58 81.5

PERFORMANCE TEST REPORT

PUMP SPECIFIED CONDITIONS
Flow rate head speed power efficiency water temptrature specific weight N.p.sh m^3/h mlc rpm kw % deg c gr/cc m ab 990 205 1445 614 81.4 161.7 0.9055 4.5

TEST MOTOR DETAILS

TYPE SI.NO POWER VOLTAGE CURRENT SPEED AWM ILA 7632-4 470688T-401-11-01 850KW 6600 volts 93.6 amps 1484 rpm

PUMP MECHANICAL PERFORMANCE DATA:

VIBRATION READING DRIVE END(HORIZONTAL) DRIVE END(VERTICAL) NON DRIVE END(HORIZ) NON DRIVE END(VERTI) NON DRIVE END(AXIAL) MM/SEC(RMS) M M/SEC(RMS) MM/SEC(RMS) MM/SEC(RMS) MM/SEC(RMS) 4.02 2.02 2.74 4.41 1.36

BEARING OIL TEMPERATURE(at the end of test)

DRIVE END NON DRIVE END DEG C DEG C 53.31 49.44

NOTE:- ALL THE READINGS ARE TAKEN FROM COMPUTER WITH THE HELP OF DAC. AND SOME OTHER READING ARE TAKEN FROM LOG SHEETS, GRAPH SHEET WIHCH ARE STANDARDLY AVAILABLE

Thank You

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