Boiler Feed Water Pumps

GBH Enterprises, Ltd.
Engineering Design Guide:

GBHE-MAC-1504
Boiler Feedwater Pumps
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Engineering Design Guide:
Boiler Feedwater Pumps
CONTENTS
SECTION
INTRODUCTION/PURPOSE
SCOPE
SECTION ONE - INTEGRATING.THE PUMP INTO THE SYSTEM
AVAILABILITY CONSIDERATIONS
CHOICE OF NUMBER OF PUMPS
CHOICE OF PUMP TYPE

4.1
4.2
4.3
4.4
DRIVERS
5.1
5.2
5.3
Barske Type
Peripheral Type
Multistage Centrifugal Type
Inlet Booster Pumps
Steam Turbines
Electric Motors
Dual Drivers
DUTY
6.1
6.2
6.3
Differential Head
Capacity
NPSH
MINIMUM FLOW THROUGH PUMP

7.1
7.2
7.3
Limit due to Instability in Head/Flow Characteristic

Minimum Flow Arrangements
Variable Speed Control
TRANSIENT EFFECTS
8.1
8.2
Reverse Flow upon Trip

Flashing
TEMPERATURE GRADIENTS IN CASINGS
10
INLET STRAINERS AND CASING PIPING CONNECTIONS

10.1
10.2
11
Strainers
Casing Piping Arrangements
SEAL COOLING
11.1
11.2
Packed Glands for Category 1 Pumps

Mechanical Seals
SECTION TWO - PUMP CONSTRUCTION FEATURES
12

12.1
12.2
13
Limit Due to First Stage Cavitation Damage

Limit Due to Instability in Head/Flow Characteristic
IMPELLER/DIFFUSER STAGE
13 .1 Local Cavitation
13.2 Labyrinth or Bushing Clearances
13.3 Clearances Affecting Hydraulic Forces
14
ROTOR
14. 1
14.2
14.3
14.4
15
GLAND ARRANGEMENTS
15.1
15.2
15.3
15.4
16
Rotor Dynamics
Rotor Mechanical Balance
Torsional Critical Speeds
Rotor Assembly
Guarding
Soft-Packed Glands
Mechanical Seals for Category 1 Pumps
AXIAL HYDRAULIC THRUST BALANCE METHODS

16. 1 Opposed Impeller Configuration
16.2 Balance Disc
16.3 Balance Piston
17
17.1
17.2
CASING
Casing Type
Casing Connections
18
MATERIALS
19
DRIVER CONSIDERATIONS
BIBLIOGRAPHY
APPENDICES:
A
B
C
D
E
F
G
H
NOTES ON BFW PUMP/DRIVER ARRANGEMENTS

PROPERTIES OF WATER
DEFINITION OF PUMP CATEGORY
TRANSIENT PHENOMENA IN DEAERATORS
NOTES ON PROPRIETARY LEAR-OFF VALVES
NOTES ON CASTINGS FOR HIGH-DUTY IMPELLERS
AREA RATIO METHOD
TECHNICAL COMPARISON SHEETS
FIGURES
1
TYPICAL CROSS-SECTION OF PUMP IN CATEGORY 1
2A
TYPICAL CROSS-SECTION OF PUMP IN CATEGORY 2 SHOWING

AXIALLY SPLIT CASING
2B
TYPICAL CROSS-SECTION OF PUMP IN CATEGORY 2 SHOWING

BARREL CASING WITH RING TYPE CARTRIDGE
TYPICAL CROSS-SECTION OF PUMP IN CATEGORY 3 FOR

POWER STATION APPLICATIONS WITH DRY RUNNING
CAPABILITIES
DOCUMENTS REFERRED TO IN THIS ENGINEERING DESIGN GUIDE
SCOPE
This Engineering Design Guide covers the special requirements of pumps in

Boiler Feedwater service.
SECTION ONE - INTEGRATING THE PUMP INTO THE SYSTEM
AVAILABILITY CONSIDERATIONS
The general reliability classifications are given in Engineering Design Guide

GBHE-MAC-5101. Pump reliability is more difficult to obtain as the pressure of
the system increases. Current practice is to distinguish three categories of the
system by reference to the nominal pressure of the steam boiler drum.
Category
Steam pressure,
bar abs.
1
43
2
43 125
3
160
Category 3 covers a model thermal power station and is beyond the scope of this
Design Guide.
Consult Furnace Section about the consequences of BFW supply failure. For
Category 2, BFW pumps are normally required to have 100% availability in order
to avoid boiler 'dry-out'. Then:
(a)
A standby pump on autostart for immediate readiness is required.
(b)
As a precaution against failure of the electricity supply at least one pump

requires a steam turbine driver with the steam supply taken either from the
boiler or from a secure source. See Appendix A.
Some boilers, particularly those within Category 1, are able to cope with BFW
supply failure and consequently permit the use of electric motors for both main
and standby pumps.
CHOICE OF NUMBER OF PUMPS
Arrangement 1
One 100% duty pump together with one standby pump. Current practice is to
make the standby pump identical to the main pump on grounds of:
(a)
Common spares holding
(b)
Common maintenance and operational methods
(e)
No process interruption upon short-term trip of main pump
(d)
Identical piping arrangement, minimizing design" effort
Arrangement 2
Two running 50% duty pumps with one identical standby pump. This
arrangement may be selected in order to:
(a)
Reduce the NPSH requirement to avoid the need for inlet booster pumps
(b)
Ensure continuity of BFW supplied for process use. This condition is

important when delivery lines are long or heat exchangers are included
which can quickly generate steam upon BFW flow stoppage.
(c)
Increase overall power efficiency when the steaming rate is expected to

be less than 50% of plant rating for long periods, thus allowing operation
with one pump.
(d)
Relax constraints on steam system control.
Special Arrangements
The following arrangements should NOT be used without thorough systems
analysis:
(a)
Two running pumps each rated at 100% duty in order to guarantee BFW
supply continuity at 100% of rated flow.
(b)
'Minimum duty' standby pump sets, either rated at a low pressure and so
requiring rapid boiler depressuring before they can be started, or rated at
a fraction of the main pump capacity.
CHOICE OF PUMP TYPE
4.1
Barske Type
The high-speed one or two stage Barske type pump requires a high NPSH and
may have an unstable Q-H characteristic. Nevertheless, where the steam
demand varies widely, with campaigns of low flow operation, consider the use of
3 or more such pumps in parallel so that the number of running pumps can be
adjusted to meet the BFW demand.
4.2
Peripheral Type
The peripheral type pump is well suited to BFW service for small capacities
because its Q-H characteristic is inherently stable and because BFW is
sufficiently pure and free from suspended solids to make acceptable this pump's
sensitivity to erosion. Specify this type of pump in preference to reciprocating
pumps.
4.3
Multistage Centrifugal Type
Most BFW pumps are of the horizontal shaft multistage centrifugal type. The
choice of the number of stages is not a precise determination. Some guidance is
given in Clause Cl.4 of GBHE-EDG-MAC-1014.
For small pumps where Q.H1/2 < 200 or where the efficiency is not important:
As the number of stages increases the bearing span increases and the rotor
becomes more sensitive to dynamic effects. As a first estimate take the limiting
number of stages as:
Where
k=
34
for stiff rotors, capable of 'dry' running.
and
k=
186 for conventional rotors
A double-entry first stage is the equivalent of 2 single-entry stages for this

calculation.
Where the number of stages thus calculated is less than the number of stages
required to obtain a reasonable efficiency, then consider a vertical shaft pump.
4.4
Inlet Booster Pumps
These may be needed when the NPSH available is insufficient to meet the NPSH
required by the main pump.
The conventional arrangement has the booster directly coupled to a double
ended electric motor which also drives the geared main pump.
DRIVERS
5.1
Steam Turbines
The advantages of using different designs of main and standby turbines are
sufficiently large to outweigh the reasons given in Clause 2 for selecting identical
main and standby pumps.
In normal operation the failure rate of small high efficiency turbines is significantly
higher than that for the conventional small turbine which has only 1 or 2 rows of
impulse blading with large non-critical clearances. Consequently the preferred
driver arrangement is to have main pumps driven by electric motors or high
efficiency turbines and the standby pump driven by a conventional turbine
provided with slowroll and quickstart facilities.
Standby turbines of normal construction are held on slowroll to ensure instant
readiness. For this purpose current practice is to leave the emergency steam
stop valve open and the inlet autostart valve closed but bypassed by a small
restrictor whose orifice size is empirically adjusted to give the required slowroll
speed. The autostart valve actuator is damped to give a valve stroking time of
10 seconds (for a linear valve characteristic) in order to avoid speed overshoot.
Check that the slowroll speed is above the hydrodynamic limit for journal
bearings. Small standby turbines having single wheels with integrally cast blades,
exemplified by t he Terry turbine, need not slowroll.
A standby pump with steam turbine driver imposes a sudden high demand on the
steam supply system upon starting. Such a steam demand can be supplied direct
from the boiler. However, in process plant these turbines are normally supplied
from an intermediate pressure header. Conventional control systems cope better
with reductions than with increases in steam demand; for sensitive systems the
preferred driver for the standby pump is an electric motor. Then, current practice
is to specify Arrangement 2 with each main pump having a turbine driver.
For the emergency condition of electrical supply failure; specify the turbine driver
to be capable of developing rated power when exhausting either to a secure
steam system or to atmosphere via a pressure relief valve.
5.2
Electric Motors
Current practice is to use only induction type motors arranged for direct-on-line
start.
Consult Electrical Section on the advisability of connecting motors to different
unit supply boards in order to reduce upsets due to supply faults.
It is expensive to obtain slowroll operation on an electric motor driven pumpset.
For standby duty, first consider the set as stationary and review the consequent
effects on both pump design and layout. Standby pumps are preferably directdrive. Gears that remain stationary need special consideration; the oil console
should then be provided with an electric motor driven auxiliary oil pump
continuously running to maintain an oil film over the gear teeth.
5.3
Dual Drivers
One pump may be coupled to two drivers, each capable of driving the whole set.
Such an arrangement gives a cost saving for large pumps when the reliability of
the normal driver is much lower than that of the pump. This case arises when the
normal driver is an electric motor connected to an unreliable electric supply
system and the alternative driver is a steam turbine. Now the failure rate of
Category 2 pumps is of the order of 0.5/year, consequently this arrangement is
not justifiable for most sites with access to the CEGB grid, when the supply
failure rate is of the order of 0.1/year.
The dual drive arrangement may be used for power recovery, where the steam
turbine is in continuous operation and the motor can act as an induction
generator exporting surplus energy as electrical power.
DUTY
This is calculated using Engineering Design Guide GBHE-EDG-MAC-1014 with

amendments given in the following notes.
6.1
Differential Head
When calculating the required differential head at rated flow, with throttle control
valves WIDE-OPEN, the delivery vessel pressure is taken as the set pressure of
the boiler drum relief valves. This step does not guarantee that rated water flow
can be then delivered because relief valves require a further increase in pressure
when passing their rated steam flow. The steep pump characteristic can
accommodate this pressure increment (of 5 - 10%) at some marginally lower
flow.
Pumps may require a correction to the simple head calculation; refer to Appendix
B.
6.2
Capacity
Allow for the minimum flow requirement as given in Clause 7.2. Early Category I
installations had duties incorporating an allowance for damaged boiler tubes but
this practice has been discontinued.
6.3
NPSH
When calculating available NPSH note that some boilers have only single
element level control: this demands either a generous NPSH allowance for
acceleration head or a heavily damped throttle control valve, to cope with
transient boiler upsets.
BFW pumps may require unusually large values of NPSH. As speed or capacity
increase, keeping S n constant maintains hydraulic performance but the intensity
of local cavitation increases. There is a limiting value of NPSH for a given
material and impeller construction. For typical castings in 13% Cr steels take
this limit as defined by:
S n (NPSH p)1/4 < 1.2

Where the values are taken at the pump best efficiency point and apply over the
operating range 85 - 105% of the capacity at BEP; S n should be further reduced
if a wider range of operational capacity is required.
Sudden failure of the steam supply to the de-aerator gives a transient reduction
in the available NPSH. If the residence time for the de-aerator is less than 600
seconds, use the method given in Appendix D to calculate the correction;
otherwise apply a correction of 0.1 m.
7.1
Typical pumps have Ns ~ 0.06 for which the minimum flow to avoid instability is
20% of the pump capacity at BEP. As Ns increases, this minimum flow limit also
increases but no generalized quantitative guidance can be given.
Small high-speed Barske pumps require a minimum flow of the order of 60%
BEP flow.
7.2
Minimum Flow Arrangements
Proprietary leak-off valves which combine the functions of a non-return valve and
a bypass valve are currently limited to Category 1 installations.
Current practice to ensure the minimum flow limit is to employ a simple
continuous bypass through a let-down MULTIPLE restrictor back to the inlet
vessel. This continuous bypass bas been used for process purposes. The
capacity of the pump is then increased to supply both the bypass and the
delivery flows.
Large category 2 pumps may merit a dedicated control system to maintain
minimum flow by opening the bypass valve when the delivery flow falls below the
specified minimum flow. Such a system should be of high integrity.
7.3
Variable Speed Control
Such experience as is available is discouraging. The chief considerations are:

(a)
Commercial speed governors for small steam turbines have deadband

zones of about 0.25% when specified to NEMA Class 'D'. For typical pump
and system characteristics, this limits the stable range of control on a
single pump to about 70% of BEP capacity; below this capacity ordinary
throttle valve control is used with the speed held constant.
Arrangements where two pumps run in parallel exacerbate the stability

problem and the only successful method used to date is to run the
turbines at constant speed and rely on throttle valve regulation.
(b)
Fluid couplings provide significant excitation torques at discrete

frequencies and have been identified as the cause of impeller failures.
Variable speed electric motors of the Schrage or commutator type
similarly provide excitation torques.
TRANSIENT EFFECTS
8.1
Reverse Flow upon Trip
Process heat exchangers in the delivery of BFW pumps constitute accumulators

capable of supplying steam which may run the pumps in reverse rotation. Current
practice is to provide a reliable non-return valve in each pump discharge line and
NOT install reverse rotation locks. For' steaming' exchangers the risk is greater
and two non-return valves in series are required at each pump discharge.
8.2
Flashing
Sudden reductions in the speed of turbine driven booster pumps cause steam
flashing in the main pump where booster pumps supply BFW through feedheaters giving water temperatures> 200C at the main pump inlet. The rate of
deliberate speed adjustment should be limited to give a pressure reduction rate
not exceeding 3 bar/min in the feed heater.
.
9
TEMPERATURE GRADIENTS IN CASINGS
Non-return valves leak a small amount. Such leakage can lead to thermal
stratification in the casing and thence to casing distortion. Preventive measures
are:
(a)
The elimination of temperature gradients by slowrolling the standby pump,

to induce a forward flow of feedwater through the pump and bypass return
system, and to guarantee water mixing within the pump.
(b)
The provision of a bypass round the discharge non-return valve in order to

ensure a sufficiently large reverse flow. The required flowrate depends on
pump size and layout but lies in the range 2% to 10% of the pump rated
capacity.
It is ESSENTIAL to maintain adequate thermal insulation around the pump
casing.
A simple hole drilled through the non-return valve element suffers erosion
and generates noise: the recommended arrangement is an external piped
bypass embodying a multiple restrictor which can be empirically adjusted
during commissioning.
This arrangement re-introduces the risk of reverse steam flow from
steaming process heat exchangers; consequently a reverse rotation
detector should be provided to trip shut the discharge block valve.
The distribution of water flows through the stationary pump is
indeterminate unless the natural downward drift of cooled water is
encouraged. Study the detail arrangement of the pump in conjunction with
the manufacturer to identify possible stagnant zones. Extraction of cool
water from such zones may entail the provision of an ancillary pump for
return to the de-aerator. Select a glandless canned motor pump for this
duty to avoid problems of air ingress.
(c)
Temperature gradients can be prevented by positively isolating the pump

to create a truly stagnant water condition. The pump then has to withstand
'cold start' conditions of thermal shock. Both these requirements are
difficult to realize; consequently this scheme should be considered only as
the last resort.
10
INLET STRAINERS AND CASING PIPING CONNECTIONS
10.1
Strainers
Permanent strainers prevent serious damage caused by ingress of welding rod

stubs. Specify an aperture of 1.0 to 1.5 mm in the strainer element. Fine mesh
strainers are NOT recommended because they clog easily and bring pump
operation to a stop.
Pre-commissioning should include acid cleans and wash-through procedures

which adequately remove scale from the -pump inlet system before the pump is
finally connected and started.
.
10.2
Casing Piping Arrangements
Separate inlet, bypass and balance water lines should be provided for each
pump. Manifolding each functional group of lines close to the de-aerator to avoid
multiple vessel branches is permissible, with the following provisos:
(a)
Fault rates more correctly describe the system, not the pump alone,
consequently the expected reliability may not be achieved when main and
standby systems share common elements.
(b)
Pressure drop variations may be excessive; this is particularly true of

balance water lines, which should therefore be generously sized.
(c)
NEVER permit bypass lines to be returned to inlet lines or their manifold.
When reviewing layout arrangements remember that incorrect operation of

valves accounts for a large percentage of cases of damage to BFW pumps.
It is important to avoid accumulation of steam bubbles and to ensure pump
priming: accordingly the rise in the discharge piping adjacent to the pump should
be continuous and exceed a slope of 1 in 40.
The line connecting the booster pump to the main pump inlet should be provided
with a bypass line and orifice restrictor directly returning to the supply vessel in
order to guarantee continuous venting. The flow should not be less than 10% of
the booster pump BEP capacity.
11
SEAL COOLING
11.1
Packed Glands for Category 1 Pumps
The gland enclosure drain should be piped to a safe disposal point where efflux
of flash steam will not obscure operationally important items.
When the pump inlet water temperature exceeds 70C, cool flush water should be
injected through a lantern ring.
The design leakage rate from each gland should be taken as:
.
where
D is the sleeve diameter,
mm
N is the shaft rotational speed,
r/s
Heat exchangers should be rated for 300% of this flow for each gland and shall
cool the flush water to a temperature not exceeding 65C with cooling water or
ambient air temperature at summer values.
The flush should be BFW. Normally the source is a tapping from the main pump
1st or 2nd stage discharge. When the source pressure exceeds 25 bar g, a
pressure limiting system should be provided, for example:
11.2
Mechanical Seals
(a)
For some Category 1 pumps a single mechanical seal may be used,

having a water-cooled seat. Normally, the cooling water for such seats is
run to drain in order to avoid seat distortion due to high or fluctuating
cooling water pressure.
(b)
Specify mechanical seals for Category 2 pumps.

The seal circulates BFW through an external loop which includes a heat
exchanger with cooling water as the cooling medium. This cooler is
mounted above the seal in order to promote thermosyphon action during
pump standstill.
The standby BFW pump is normally required to run for a short period after
failure of the cooling water supply. For an orderly shutdown it is sufficient
to have an overhead reservoir capable of providing the required flow for
about 10 minutes.
SECTION TWO PUMP CONSTRUCTION FEATURES
12
12.1
Limit Due to First Stage Cavitation Damage
The usable capacity range of a pump narrows as S n increases because flow

recirculation in the larger impeller eye results in increased cavitation damage
potential a flows away from the stage best efficiency point.
1/4
When S n (NPSH p) > 0.8 check manufacturer's offer by comparing available

NPSH against curve of 'onset cavitation NPSH' for the recommended minimum
flow point.
12.2
Manufacturers find it difficult to shape the pump characteristics: experience

indicates that all tenders should be thoroughly checked to verify that the stability
requirement has been satisfied.
Note that the classic design methods based on impeller vane angle as the
fundamental parameter do not afford the insight given by the area ratio design
method - see Appendix G.
13
IMPELLER/DIFFUSER STAGE
13.1
Local Cavitation
This occurs when the water velocity is high, typically 60 m/ s relative to the metal
surface. It is not related to the inlet NPSH.
Peripheral and Barske type stages have open impellers which can be fully
machined and which can be used at heads up to 1500 m when manufactured in
18/8 austenitic steels.
Centrifugal pump stages with closed impellers and bladed diffusers of optimum
design for high efficiency are manufactured as castings. Errors occur when using
traditional pattern-making and casting techniques. A convenient classification is
by differential head h across one stage, as follows:
(a)
h < 40 m
No special care needed.
(b)
40 m <. h < 100 m
Good quality commercial castings acceptable against visual examination by the

inspecting engineer for gross defects.
(c)
100 m < h < 250 m

The castings should be subject to inspection for:
(1)
Core shifts. Variations in vane peripheral thickness are unimportant

but shifts altering vane angles should not be accepted.
(2)
Surface finish. All protuberances should be smoothly leveled and

the casting techniques adequate for the production of a surface
finish better than 25 m Ra when viewed against a comparator
tablet for a ground finish.
(d)
250 m < h < 660 m

Material should be 13/4 Cr Ni steel.
Performance adjustment by filing the rear surface of a vane should be
forbidden. After adjustment by machining the vane tips (but not the
shrouds) to smaller diameter, the upper surface of the vane should be
smoothly faired. The trailing edge angle is limited to 0.2 radians.
Impellers should not be balanced by local removal of material from the

disc/shroud surfaces. Such surfaces should run true.
(e)
h > 660 m
Stages above 660 m head need thorough investigation of the design and
manufacturing techniques. Special impeller materials will be required,
exemplified by 17-4 PH stainless steel.
13.2
Labyrinth or Bushing Clearances
Small clearances improve the hydraulic efficiency only as measured during the
works performance test. Such small clearances quickly wear to some equilibrium
value; the consequent rubbing increases the risks of rotor seizure or induced
whirl.
(a) Clearances should not be less than the values given in the following table
based on BS 4500.
(b)
Flexible rotors sag appreciably at rest but approach the nominal geometric
centerline during operation. Eccentric clearance settings are NOT
acceptable; bearing and casing centerlines should coincide.
Bushing wear-rate can be dramatically increased when the pump is run at
much reduced speed, eg during slowroll. Then either:
(1)
the shaft sag should be less than the minimum radial clearance
obtained after allowing the assembly tolerances.
(2)
the minimum speed should exceed the speed at which hydrodynamic forces become effective in supporting the shaft (commonly
~ 30% normal speed).
OR
13.3
Clearances Affecting Hydraulic Forces
Most multistage centrifugal BFW pumps have vaned diffusers. The radial gap
between the impeller vane tips and the diffuser vane leading edges affects the
pressure pulsations at the blade passing frequency, the radial hydraulic forces
and t he broadband noise level.
Let C be the radial gap, R the impeller vane tip radius and E the radial
eccentricity of the shaft centre to the diffuser geometric centre.
Then
C E > 0.02
R
Irregularities in castings may cause variations in the measured gap C. The
inspecting engineer should verify that these measurements fall within the band of
100% to 140% of the least value found for C. Any machining of the leading edges
of the diffuser vanes should be followed by hand finishing to produce the rounded
entry profile.
Pumps with double volutes should be subject to inspection to verify that both the
radius to the tip and the leading edge profile of each volute cutwater is identical.
Then, using the same nomenclature
C - E > 0.04
R
Impellers should have an ODD number of vanes to reduce perturbing torques.
14
ROTOR
14.1
Rotor Dynamics
Multistage centrifugal pumps in Categories 1 and 2 normally have operating

speeds above the first lateral critical speed obtained by assuming the pump run
on air; they rely on the damping provided by the pumped water to suppress
dynamic effects. Unwanted perturbations chiefly arise from operating at part
capacity, producing large low-frequency radial hydraulic forces.
Category I pumps should have rolling element bearings, within the limits set by
Specification GBHE-MAC-18-06A.
Future systems using feed heaters may require the main BFW pump to have a
stiff shaft capable of running dry for short periods.
Current practice is to supply the BFW pump directly from the de-aerator and
permit the use of flexible shaft pumps which cannot withstand running dry. The
pump shaft diameter and bearing span may be varied by pump designers for a
given hydraulic duty, rotor speed and number of stages. Guidance on acceptable
relationships of these parameters is given in Fig 14.1 which is based upon
avoidance of excessive shaft bush wear. Note that such wear has led to shaft
fracture in Zone A.
Category 2 pumps should have the second critical speed of the rotor, as the
natural frequency in air, not less than 130% of the maximum continuous speed.
This frequency is easily measured and is a useful inspection check on
manufacture.
FIG 14.1
HORIZONTAL MULTISTAGE PUMPS WITH RADIAL FACE

MECHANICAL SEALS
NOTES ON FIG 14.1

1
At each impeller location the shaft may be grooved for a retaining ring or
be stepped in diameter. Now the effective diameter should correspond to
the shaft response acting as a beam in bending; for this it is sufficiently
accurate to average all the diameters over the middle third of the span,
ignoring stress concentration factors.
A useful retrospective check is to obtain the restoring force by

measurements on the assembled rotor. The expression
Z X
Z+2
d5
L3
Is then replaced by:
k. w. D
as a close approximation where:

W
.
D
k
14.2
=
=
=
=
weight of rotor (excluding coupling spacer)

measured deflection of rotor at midspan
diameter of shaft/casing bushes
constant ~including g at 9.81 m/s2) of value
8.6 x 10-6
kg
mm
mm
Rotor Mechanical Balance
Each rotor element should be individually balanced before assembly on to the

shaft. Dummy half-keys are necessary to ensure correct balancing. For these
elements the balance quality according to BS 5265 should be better than G6.3
and better than G2.5 for pumps lying in zone B of Fig B3.1 above the 60%
capacity line.
Category 1 pump rotors may have the impellers located by free shaft sleeves
locked by end shaft nuts. Such rotors should NOT be balanced after preassembly but checked as Clause 14.4.
Rotors for horizontal split casing pumps are fully assembled and have each
impeller individually located. The check balance of the assembled rotor should
show a quality better than G6.3. If it does not, the rotor should be disassembled,
each element rebalanced and the shaft checked for straightness.
14.3
Torsional Critical Speeds
The exciting torques is normally small but so is the system damping. No torsional
critical frequency of the pump/driver system, calculated for the rotor running in air
shall be within 20% of the vane pass frequencies. This margin can be reduced to
6% when the critical frequencies have been measured when running in water.
These margins include the normal variation in speed of induction electric motor
drivers and an allowance of 0.6% for variation in to. frequency of the motor
electric supply. The speed regulation performance of steam turbine governors
should be individually assessed.
14.4
Rotor Assembly
Alignment of the hydraulic channels affects to performance. The centerlines of

each impeller exit channel and the diffuser is normally aligned by adjusting the
axial location of individual impellers. However, an over-riding requirement is that
the impeller front shroud surface shall never overlap the surface of the diffuser
channel, despite axial float in the thrust bearing and differential thermal
expansion between rotor and casing.
CATEGORY 1
PUMPS WITH RING SECTION CASINGS
After pre-assembly outside the casing, the rotor should be checked by dial gauge
measurements at stations along the rotor whilst it is supported in V-blocks. This
test verifies that shaft sleeve and impeller mating ends are perpendicular to the
axis. The criterion for rotor straightness is that first mode bends should have a
maximum TIR (total indicator reading) limited to 1:10000 of the span between
bearing midpoints.
CATEGORY 2
PUMPS WITH HORIZONTAL SPLIT CASINGS
The impellers are individually mounted on a stepped shaft so that the bores of
the impellers progressively increase. This provision demands careful numbering
of impellers.
High speed rotors have the impeller bore machining limits adjusted to retain a
transition fit when rotating at the maximum continuous speed. This requires an
interference fit upon assembly.
It is essential that impellers do not swash, i.e. when the rotor is assembled and
supported on 'V'-blocks, a dial indicator bearing axially against the machined
impeller shroud surface should show no variation in reading upon rotor rotation.
CATEGORY 2
PUMPS HAVING BARREL CASINGS WITH RING

SECTION CARTRIDGES
Treat as Category 1 pump with ring section casing but add another criterion for
straightness; viz. that second mode bend should be small, less than 10% of the
first bend, assessed as the mean TIR at the 25% and 75% points along the span.
CATEGORY 2
PUMPS HAVING BARREL CASINGS WITH AXIALLY

SPLIT CARTRIDGES
Treat as pumps having horizontal-split casings.
15
GLAND ARRANGEMENTS
15.1
Guarding
For all pumps specify that:

(a)
Shaft guards at the gland will contain scalding spray leakage.
(b)
The gland enclosure drain size is adequate for gland failure conditions.
15.2
Soft-Packed Glands
Category 1 pumps normally have soft-packed glands to assist rotor damping and
stability. Check that:
(a)
Packing is one of the standard metric sizes of 6, 8, 10, 12.5, 15 mm

square section.
Current material used is Walkers Fortune 417.
Shaft sleeves are provided, of 13% chromium steel preferably BS 970 420
S 45 hardened to 240 - 280 VH and ground to a surface finish better than
0.4 mR a. It is essential that the sleeve surface is concentric with the
shaft: this should be verified at the time when the rotor is inspected for
straightness.
(b)
When the pump inlet water temperature exceeds 70C, cool flush water is
injected through a lantern ring.
15.3
Category 1 pumps may be fitted with mechanical seals having water cooled
seats in order to avoid the need for a cooled BFW flush supply to a packed
gland.
The preferred seal is a Crane Type 502 to material code 468A for operation with
pump inlet water temperatures up to a maximum of 105C.
The sealbox should be 'dead-ended' but check the arrangement for vapor-locked
zones.
Metric seals are required to one of the following series:
For pumps employing a balance disc check that:

(a)
The seal springs are set at their correct compression with the pump
balance disc gap brought to zero by jacking the rotor axially.
(b)
a rotor stop is provided to limit the axial displacement to 1.5 mm.
15.4
Specify Borg Warner Mechanical Seal Type D or DRT to material code 5H4A
(BW) with a seal water heat exchanger to Bulletin 1860-15 with Inconel tubing
(Austenitic stainless steel tubing is NOT acceptable).
Specify the Type DRT seal where the peripheral speed (based on the seal
diameter) exceeds 20 m/s.
The seal circulates BFW through an external loop which includes a separator and
a heat exchanger with CW as the cooling medium. This cooler is mounted above
the seal in order to promote thermosyphon action.
Particles of iron oxide are prevented from reaching the seal faces by a magnetic
particle separator.
16
AXIAL HYDRAULIC THRUST BALANCE METHODS
16.1
Opposed Impeller Configuration
This demands a complicated casing shape; a specific assurance on casting

quality control should be obtained from the foundry nominated by the pump
manufacturer.
A thrust bearing is required to take the residual thrust: to ensure that this thrust is
unidirectional the number of single-entry impellers should preferably be odd.
16.2
Balance Disc
Current practice is to restrict the use of balance discs to Category 1 pumps. The
balancing thrust is automatically adjusted by the change of pressure in cavity 'X'
consequent upon axial movement of the rotor changing gap .
Balance is achieved when the gap is of the order of 60pm, depending on the
clearance in the preceding piston section. Efforts to increase efficiency by
decreasing the leakage flow through a reduction of ~ should be resisted,
otherwise the pump becomes very sensitive to particulate contamination of the
feedwater.
Rubbing occurs during transients. SULFINUZ anti-galling surface treatment has
been used successfully to lengthen disc life but the performance was erratic.
Current practice is to use hardened chromium steels.
The dynamic compliance of the balance disc gives a natural frequency of axial
vibration of the rotor. Interaction may occur with metal diaphragm type shaft
couplings whose spacers have their own intrinsic natural frequency bands of
axial vibration. Such an effect should be specifically assessed for pumps running
above 65 rls.
For truly parallel balance disc faces the restoring force rapidly decreases as the
faces come nearly into contact. This effect is reduced by extending the face relief
nearly to the disc periphery.
It is essential that disc faces are NEVER machined convex to each other.
Because the action of balancing demands freedom of rotor axial displacement,

the first choice of bearing type is either the journal or the cylindrical roller.
16.3
Balance Piston
This is required for Category 2 pumps. A piston does not provide exact balance:
a thrust bearing is required to take the residual thrust. The piston should be
proportioned to ensure that this residual thrust is unidirectional over the normal
operating range.
There is a hydraulic self-centering action, but this is reduced if the piston is
serrated.
Current practice is to ensure that:

(a)
the bush is truly cylindrical. At H > 1250 m the bore should be finished by
a floating stone hone.
(b)
the assembly positioning aligns the bush along the geometric centerline
between bearings.
17
CASING
17 .1 Casing Type
CATEGORY 1
PUMPS
These are invariably of the ring section type having one cell per stage, the whole
being held together by through bolts.
Both rotor and casing are assembled progressively cell by cell; consequently:
(a)
it is important that all parts are match marked
(b)
the fit of the impeller on the shaft should be a light driving fit.
Symmetrical loading by the through bolts is important. This implies that the
extension of each through bolt is measured and brought to the same value.
Torque-spanners are useful only for small pumps where the bolt size is less than
M20. Check that the Manufacturer's Manual includes specific instructions on the
sequence and method of tightening the through bolts.
This type of casing is prone to thermal distortion because the through bolts are
not in contact with the feedwater and the uniformity of bolt temperature depends
on the quality of the lagging application. Consequently this type should be used
only where the pump draws feedwater directly from the de-aerator vessel and the
water temperature is less than 120C.
CATEGORY 2
PUMPS - NOMINAL SYSTEM PRESSURE 43 to 70 BAR
Ring section casings may be used subject to a limit of 7 stages. Such pumps
have been used in double pump arrangements, both pumps being driven by a
double-ended electric motor, but connected in series for BFW flow.
CATEGORY 2
PUMPS - NOMINAL SYSTEM PRESSURE 43 to 100 BAR
The horizontal-split casing type enables the rotor to be assembled as a unit prior
to insertion into the casing.
Volute stages are often used to simplify the casting; it is then important that the
two half-casings match at the split-line. The inspecting engineer should visually
examine the assembled casing to verify that the volute surfaces have been
ground to obtain a smoothly continuous surface over the joint.
Vaned diffuser rings may be inserted to form cells similar to ring section pumps.
Check the method of ensuring simultaneous sealing of each ring to the casing
and of the two casing halves: alloy surface weld deposit maybe needed.
CATEGORY 2 PUMPS - NOMINAL SYSTEM PRESSURE ABOVE 100 BAR

The barrel type casing is required. The cartridge is usually assembled as a ringsection pump but when the limits for rotor dynamics are approached the cartridge
assembly in an axial split arrangement should be considered.
17.2
Casing Connections
(a)
Configuration
Horizontal-split casings have side connections in order to retain the
advantage of removing the upper half casing without disturbing the inlet or
discharge piping.
For ring section and barrel casings, specify top discharge and top or side
inlet connections.
Maintenance of barrel casing pumps is carried out by withdrawing the
pump cartridge, leaving the casing installed. Consequently the high
pressure discharge branch may be butt-welded to the piping.
(b)
Rating
For Category 1 pumps specify that the inlet and discharge connections are
rated for the same pressure.
Category 2 pumps may have the inlet connection rated at the higher value of:
(1)
Nominal 40 bar rating
(2)
120% of the pressure setting on the relief valve fitted between the pump
and the inlet block valve.
(c)
Piping Loads
The connections to ring-section pump casings are broken for maintenance;

consequently the piping should be designed to have NO forces, nor moments,
and be separately supported so that the pump can be removed without disturbing
the pipe system.
Horizontal-split casings are torsionally very weak when the upper half-casing has
been removed; consequently the applied moments should be zero when the
associated piping is cold. Note that this condition occurs not only when all
pumps are shut down but also when companion pump(s) remain in operation.
18
MATERIALS
CATEGORY 2
PUMPS
Current practice is to use the 13% chromium steels because of their good
thermal and mechanical properties and immunity from corrosion by
demineralized feedwater.
Because the feedwater is de-aerated, castings for horizontal-split casings may
have the Chromium content reduced to the lower limit of 5%. High quality
complex castings have become progressively more difficult to obtain.
Consequently for horizontal-split casings, the inspection plan and weld repair
techniques should be agreed with the foundry at the time of placing the purchase
order.
Barrel pump casings may be in carbon steel.
The preferred casting alloy for impellers and diffuser vane rings is 13/4 Cr Ni
steel. Austenitic stainless steels should not be used; in particular they should
NOT be used for shafts.
For rubbing pairs, viz. impeller/casing wear rings and shaft sleeves/bushings, it is
advantageous for the stationary component to have the highest practicable
hardness. Current practice is to specify casing wear rings in PH stainless steel
aged to produce a hardness of 300-340 HV and ground to a surface finish better
than 1.6 m Ra upon visual inspection against a comparator tablet. Impeller wear
rings are vulnerable to disturbance on heavy rubs; consequently the preferred
arrangement for the highest intrinsic reliability is to integrate the wear ring into
the impeller casting. This favors the use of 13/4 Cr Ni alloy heat-treated to obtain
a hardness of 240-280 VH, also ground to a surface finish of 1.6 m Ra. Such a
rubbing pair is reported to be good for speeds up to 60 m/s.
When the rubbing speed is less than 35 m/s, Ni-Resist casing wear rings may be
used.
CATEGORY 1
PUMPS
The important feature is that steam systems in Category 1 normally do not

employ demineralized feedwater and the pump inlet temperature is less than 120
C.
Early practice using bronze impellers and fittings has been discontinued because
of erratic deterioration of bronze components and the high thermal expansion of
this material.
Individual cells of ring section pumps may be in grey cast iron to BS 1452 Grade
14 or 17 but specify the end-sections in carbon steel or nodular cast iron for
design pressures above 16 bar g.
Impellers and diffuser rings may be in grey cast iron to BS 1452 Grade 14 or 17
provided that H < 40 m, except for the first stage which should be in 13/4 CrNi
steel when S n >0.28.
Casing wear rings are normally Ni-resist. For demineralized feedwater follow the
practice for Category 2 pumps.
19
DRIVER CONSIDERATIONS
For Category 2 pumps, check that the torque/speed curve for the motor during
run-up is shaped to give both reasonably uniform acceleration and a total run-up
time of 2-6 seconds. Longer run-up times demand pumps whose rotor
parameters are within Zone C as described in Clause 14.1.
BIBLIOGRAPHY
1
Convention by Inst Mech Eng on Advanced - Class Boiler Feed Pumps

Sept 1970, (Proceedings 1969-70, Vol.184, Part 3N).
Paper 1
A feed pump design concept for 660-MW generating sets, by

J Richardson, BSc., C.Eng., MI Mech.E., and J M Taylor.
Paper 2
The design principles for boiler feed pumps for CEGB.

660-MW units, by F 0 J Otway, MA, C.Eng., MII1ech.E.
When the Central Electricity Generating Board increased the unit
rating of their turbo generators from 500 MW to 660 MW, the
design basis of the boiler feed pumps was completely reviewed.
The prime requirement was that the pumps should be made less
sensitive to mechanical fault and capable of surviving disturbed
suction conditions without failure. At the same time they were to be
capable of rapid replacement. This paper explains the decision
that the pumps should have only two or three stages, with stiff
shafts. Gland security and light-load protection are discussed.
Paper 3
Boiler feed pump design for maximum availability, by R Weldon,

BSc., C.Eng., MI Mech.E
Describes Sulzer design for 660 MW stations.
Paper 4
Advanced-class boiler feed pumps for 660 MW generators, by

TO Leith, BSc., C.Eng., MI Mech.E.,
J R McColl, BSc.C.Eng, MI Mech E, and
M L Ryall, BSc, C.Eng, MI Mech E
Describes Weir design for 660 MW station.
Paper 5
Development of a single-stage boiler feed pump for nuclear power

stations, by A A Gasiunas, Dipl.Ing
The paper discusses the pressure pulses that are generated when
impeller vanes travel past stationary vanes. The influence of
geometrical and hydraulic non-symmetry on radial forces in a
double volute casing is dealt with. Test results of a double suction
model boiler feed pump are presented, including descriptions of
durability runs with paint-coated hydraulic surfaces.
Paper 6
Development of boiler feed pumps in Czechoslovakia, by V Hladis,

B.Sa, and J Kupa
Gives useful description of ring section pumps operating with BFW
at 160C including measurements on through bolt temperature
differences and casing distortion.
Paper 7
The single-stage high-speed nuclear feed pump, by A R Bush, B

Mech.Eng, and J E C Valentin
Feed pumps applied to early large-size light water moderated
nuclear reactors in the United States were modifications of existing
split-casing volute-type pipeline pumps. Reliability was the key
consideration. The final selection was a single-stage solid casing
with an integral diffuser and condensate injection seals. The
manufacturing problems are discussed, together with performance
tests run on the first machines of this type.
Paper 8
Application of the thermodynamic method of measurement for the

determination of the boiler feed pump efficiency in large electrical
power units of Electricite de France, by J S A Guitton, Ingenieur
Ecole Centrale, and H Procaccia, Ingenieur EEIP
Paper 9
Dynamic hybrid bearing characteristics of annular controlled

leakage seals, by H F Black, MSc., C Eng, MI Mech E, and D N
Jenssen, BSc.
The dynamic bearing characteristics of plain seals having
appreciable length-to-diameter ratio are analyzed. Some
experimental results are given and compared with theoretical
predictions. It is shown that length-to diameter ratio has a
considerable effect on seals of appreciable length, e.g. balance
pistons, and that dynamic components of bearing action due to
shaft rotation are comparable with the purely hydrostatic centering
forces.
Paper 10
Radial forces in centrifugal pumps with guide vanes,

by P Hergt, Dipl-Ing., and P Krieger
At partial and overload conditions, radial decentralizing forces act
upon the rotor of a centrifugal pump with diffuser guide vanes if the
impeller is out of centre. The magnitude of these forces increase
with growing eccentricity. At very small flows, these forces become
non-stationary. They rotate at a considerably lower speed than the
rotor speed. The paper discusses the effects and resulting shaft
deflections and vibrations, from measurements On two
experimental test rigs.
Paper 11
Feed pumps for modern steam boiler applications, design,

development, and operation, by P S Neporozhnii and A K Kirsh
Design of Modern Boiler Feed Pumps by H H Anderson
Development of high-pressure boiler feed pumps in Britain during

the last decade by G F Arkless. COny on Steam Plant Ancill1ary
Equipment Proc lnst Mech Eng 1966/7 181 (Pt.3N) 6.
Analysis of cavitation damage in commercial marine condensate

pumps. PE Paashaus ASME - SNAME Meeting New York December
1964.
This paper refers to the "bulging" of impeller shrouds upon "hammering"
when operating on free suction control.
Horenburg, 0: Schaden an Kesselspeisepumpen. Hinweis zur

Schadenverhutung durch Auswertung von Schadenstatisiken. Der
Maschinenschaden 43 (1970), No 4, pp 135/147.
Describes pump damage due to thermal distortion of casings and ingress
of foreign bodies through strainers.
6A
Honold, E : Vergleich von Kesselspeisepumpen fur hohe Enddrucke in

Glieder-und Topfbauweise im Hinblick auf die Entwicklung grober
Kraftwerksblocke, Mitt der VGB (June 1966). No 102, pp 149/152.
6B
Honold, E : Rin kritischer Vergleich von Topfund Gliederpumpe am

Beispiel der Entwicklung der Hochstdruckkesselspeisepumpen in
Deutschland und den USA. KSB Technische Berichte, No 1 (October
1960).
These 2 papers discuss the choice of barrel or ring-section pump casings.
7A
Strub, RA : Abfall des Saugdruckes von Speisewasserpumpen bei

starken Lastschwankungen. Technische Rundschau Sulzer 42 (1960),
No 3, pp 41/44.
7B
Wollschlaeger, K : MaBnalmen zur Verbesserung der zulassigen

Druckabsenkungsgeschwindigkeit bei Kesselspeisepumpen.
Energie 18 (1966), No I, pp 16/18.
7C
Rahlwes, H : Untersuchung zur Klarung Speispumpen bei

Gleitdruckentgasung. No 106, pp 61/67. von Zulaufstorungen an
Mitt VGB (Feb 1967),
7D
Stonner, A : Ein Beitrag zur Schadenverhutung an

Hochdruckkesselspeisepumpen. Energie 18 (1966), p 360.
These 4 papers discuss flashing within pump casings and inlet lines.
Paper 7D describes effects of leaking stop valves on standby pumps.
Leakage and Hybrid Bearing Properties of Serrated Seals in

Centrifugal Pumps. H F Black & E A Cochrane, Sixth International
Conferennce on Fluid Sealing 1973, 65, pp 61 - 69.
W Schumacher
Wear and Galling of Nitrogen-Strengthened Stainless Steels
Report in Machine Design August 1983 on paper presented at Wear of
Materials 1983 Conference, Reston, V.a. Apr 1983. Indicates that nitrogen
addition improves strength and hardness of stainless steels but does not
improve wear resistance.
Increasing nickel content decreases the wear resistance. Best material
NITRONIC 60.
APPENDIX A
NOTES ON BFW PUMP/DRIVER ARRANGEMENTS
I
HISTORICAL PRACTICE FOR POWER STATIONS
In the UK early power stations had both main and standby pumps driven by
steam turbines. The 1920's saw the introduction of the arrangement with the
main pump driven by an electric motor and the standby pump by a steam turbine.
This has remained the preferred practice for petro-chemical plants.
The steam turbine driven high-speed main pump, with a 50% capacity
starting/standby pump having electric motor drive, appeared about 1955. A
variation of this arrangement used a main pump driven through a hydraulic
coupling and gearbox from the turbo alternator set.
EXTRACT FROM ANSI/ASME BPV - VII, 1977 EDITION
C5.401
Feedwater should be available at the boiler at flow rates

and pressures which are adequate to take care of any emergency.
C5.403
A spare feedwater pump or injector, in addition to the feedwater

equipment required by PG-61.I, Section I, is preferable. Where
feedwater pumps are electrically driven and there is no fully
independent auxiliary source of electric supply, there shall be
maintained, ready for service, steam-driven feed pumps or injectors
of sufficient capacity to safeguard stoker-fired boilers in case of
failure of electric power. This recommendation also applies to
boilers fired by other methods if furnaces contain large amounts of
refractory or are arranged to accumulate slag in the bottom.
C6.803
Normal Operation
A connection should be provided between the pump discharge line
and a point on the suction system, preferably the deaerator, as a
means of preventing overheating of the pump when it is required to
operate at shut-off pressure or extremely low rates of delivery. This
line, which is commonly known as the recirculating connection,
should be connected into the discharge line between the pump and
the check valve.
The recirculating line should be connected back into the suction

system at some point where the heat added by the pump will be
dissipated before the water can re-enter the pump suction. This line
should be provided with a stop valve and an orifice of such size as
to permit recirculation at the minimum flow rate stipulated by the
manufacturer of the pump.
The stop valve should be locked or sealed in the wide-open
position whenever the pump is in operation or ready for operation.
All valves in hydraulic-balancing drum-leak-off lines should be
locked or sealed in the wide-open position whenever the pump is
ready for or in operation.
EXTRACT FROM PG-61 (GENERAL REQUIREMENTS FEEDWATER

SUPPLY)
61.1
Except as provided for in PG-61.2 and PG-61.4, boilers having more than
500 sq.ft. (47 m2) of water heating surface shall have at least two means
of feeding water. Except as provided for in PG-61.3, PG-61.4 and PG61.5, each source of feeding shall be capable of supplying water to the
boiler at a pressure of 3% higher than the highest setting of any safety
valve on the boiler. For boilers that are fired with solid fuel not in
suspension, and for boilers whose setting or heat source can continue to
supply sufficient heat to cause damage to the boiler if the feed supply is
interrupted, one such means of feeding shall be steam operated.
61.2
Except as provided for in PG-61, a boiler fired by gaseous, liquid or solid

fuel in suspension may be equipped with a single means of feeding water
provided means are furnished for the shutting off of its heat input prior to
the water level reaching the lowest permissible level established by PG60.
61.5
A forced-flow steam generator with no fixed steam and water line shall be
provided with a source of feeding capable of supplying water to the boiler
at a pressure not less than the expected maximum sustained pressure at
the boiler inlet, as determined by the boiler manufacturer, corresponding
to operation at maximum designed steaming capacity with maximum
allowable working pressure at the superheater outlet.
EXTRACT FROM GERMAN CODE
The main points of the German statutory code for feedwater installations as
published in the Bundesanzeiger (Federal German Official Gazette), Vol.4,
No.19, 29 January 1952 are as follows.
(1)
Every steam-raising plant must be equipped with at least two feedwater

systems.
(2)
If only two feedwater pumps are installed, each must be capable of

supplying:
(a)
1.6 times the maximum continuous output of all boilers fed by the
system when the boilers are not equipped with automatic feedwater
control or the total steam output of the boiler plant does not exceed
30 t/h.
(b)
1.25 times the maximum continuous output of all boilers fed by a

common feedwater system if the boilers are equipped with
automatic feedwater control and the total steam output of the plants
exceeds 30 t/h.
(c)
1.25 times the maximum continuous output of all boilers fed by the
system where the pumps are driven direct from the prime mover.
The total quantity of feedwater required is the sum of the quantities
required for the maximum continuous output of all boilers fed by the
system. According to German Standard Specification DIN 2901, the
maximum continuous output is 25% above the normal and 'boilers
fed by the system' include not' only those in regular use but also
stand-by boilers, unless they have been certified as permanently
out of service. The factor of 1.25 includes a 5% allowance for
blowdown losses. If the blowdown losses etc. are greater than
those corresponding to this figure the factor must be increased
accordingly.
(3)
If more than two feedwater pumps are installed and a pump or power
failure causes the pump having the maximum capacity to cut out, the
remaining pumps operating in parallel must be capable of delivering at
least 25% more feedwater than is required by the boilers.
(4)
The feed pumps must be capable of delivering the required amount of

feedwater against a pressure 10% higher than the rated (permissible)
maximum steam pressure in the boiler with the safety valves blowing off
plus the resistance (pressure losses between the feed pump and the
boiler).
Each pump must be so arranged that in the event of a sudden stoppage of
the pump no reversal of flow is possible.
(5)
At least two independent sources of power must 'be available to drive the
feedwater pumps. It is however permissible in the case of steam-driven
pumps to supply them from a common steam system. Only one actual
supply 11 ne to the prime mover is required irrespective of whether the
drive is by steam or electricity.
The feed pumps must be so connected to the source of power (whether purely
electric or dual steam and electric) that, in the event of failure of one of the
sources, the pumps which can still be retained in service are capable of
supplying 1.25 times the required feedwater quantity when operating in parallel.
Feed pumps which have cut out because of some failure or other but which can
be switched to an alternative power supply are included in those regarded as
available for service.
The table gives various arrangements which are permissible with steam and
electric drivers or combinations of both.
S = Steam driven
E = Motor driven
Output of the individual pumps in % of the maximum continuous load
APPENDIX B
PROPERTIES OF WATER
B.1
DATA SOURCE
'STEAM TABLES IN SI UNITS'
Published by CEGB, Sudbury House, London, ECIA, 7AU
B.2
CALCULATION OF RATED DIFFERENTIAL HEAD H

The density of water depends on both pressure and temperature.
Now the temperature rise T through each stage of a pump is
given by:
The density change due to this temperature rise, together with the change
due to the compressibility of water, is then used to calculate the differential
head across the stage. Integrating these stage heads over the whole
pump and referring the head to the inlet conditions gives the approximate
relation:
APPENDIX C
DEFINITION OF PUMP CATEGORY
The development of BFW pumps has been matched to advances in the size and
steam conditions of power stations. Stages in this historical development have
been distinguished by features conveniently grouped by reference to the nominal
pressure of the steam system.
Note that the pump casing pressure rating is higher than this nominal pressure.
These categories group together construction elements of current horizontal
multistage centrifugal pumps whose duties are akin to the duties of former power
station pumps at their appropriate stage of development.
FIGURE 1 - TYPICAL CROSS-SECTION OF PUMP IN CATEGORY 1
FIGURE 2A -
TYPICAL GROSS-SECTION OF PUMP IN CATEGORY 2

SHOWING AXIALLY SPLIT CASING
FIGURE 2B - TYPICAL CROSS-SECTION OF PUMP IN CATEGORY 2

SHOWING BARREL CASING WITH RING TYPE CARTRIDGE
FIGURE 3 - TYPICAL CROSS-SECTION OF PUMP IN CATEGORY 3 FOR

POWER STATION APPLICATIONS WITH DRY RUNNING CAPABILITIES
APPENDIX D
TRANSIENT PHENOMENA IN DE AERATORS
Experience in power station pumps has shown that a main turbine trip can cause
the boiler feedwater pump to stop delivery.
The instant that the turbine trips, both the bleed heating of the demin water and
the steam supply to the de-aerator are interrupted, leading to a drop in the
pressure in the deaerator. This drop may be so great that the water in the line to
the boiler feed water pump starts boiling.
Nomenclature
H
M
Q
Enthalpy kJ/Kg
Mass Kg
Flow Kg/sec
Suffixes
c
i
o
s
d
h
p
cold well
water into deaerator
water out of deaerator
steam into deaerator
deaerator
heater
pump inlet
For normal running conditions a heat balance gives:
When Qs - 0 the cool entry water Q i is heated the steam in the vapor space of
the vessel. This tends to reduce the pressure in the vapor space and cause the
hot water already in the deaerator to flash.
The pressure decays as the bulk water temperature reduces. Eventually
equilibrium is regained at the temperature of the inlet water. Meantime a transient
condition exists where the water entering the pump is hotter than the water at the
deaerator water surface. Thus the available NPSH at the pump inlet is
temporarily reduced.
Two further phenomena complicate the real behavior:

1
The contents of the deaerator are not perfectly mixed - this causes
the loss of NPSH to be underestimated.
The flash steam creates a band of bubble/water mixture extending

down from the free surface by an amount depending on the severity
of the transient. Note that this does not alter the effective head: the
bubbles change both the apparent density am the surface level of
the mixture in the vessel. However, if bubbles are formed in the
inlet line, unstable two-phase flow can occur with complete failure
to pump forward.
If the flow through the pump is maintained, Q0 is constant.

When the steam to the deaerator is turned off, Qs - 0 at time t = 0
Then:
where H is the enthalpy in the deaerator at time t
Similarly if both steam an:! feed heating are stopped at the same time the
enthalpy in the deaerator becomes:
The maximum loss in NPSH can be estimated from:
The enthalpy at the pump at time t is that which had occurred in the deaerator at
a time:
The difference between the two enthalpies so obtained can be used to calculate
the drop in NPSH provided that no vapor bubbles form in the pump inlet line.
On systems with a large transient decay it is necessary to optimize the available

head during transient conditions by examining the inlet pipe to the pump
Decreasing the diameter increases the velocity in the pipe and so increases the
friction losses. On the other hand the water volume in the inlet pipe itself is
reduced and as the transient decay is directly proportional to the inventory the
transient loss is reduced.
To optimize a system it is best to tabulate the friction loss and the transient loss
for various pipe diameters. For the available NPSH to be a maximum during
transients the velocity will be between 2 - 5 m/secs, the higher value applying to
systems sensitive to transients.
Reference: 'Analysis of Feedwater Pump Suction Pressure Decay under
`Instant Turbine Load Rejection' - by G S Liao and P Leung
(Journal of Engineering for Power, April 1972)
EXAMPLES
To show the magnitude of the effect, two examples have been worked out. One
applies to a power station with a small de aerator capacity, where steam heating
to the deaerator and feed heat is lost at the same time. The second one applies
to a deaerator of the type used on a typical chemical plant.
EXAMPLE
I - POWER STATION
Conditions:
Capacity:
(a) Deaerator
- 180 seconds
(b) feed section
- 60 seconds
(c) pump inlet lines
- 10 seconds
Temperatures and total heat s:
On loss of all heating steam, the deaerator pressure will decay as follows
(using Formula 5):
TABLE I
This shows that the total loss in available NPSH is 9.7 m am occurs about 70
seconds after the steam has turned off.
This compares to the value of 10 meters estimated by using Formula 7.
EXAMPLE
A fault only affects the steam heat to the deaerator. It does not affect the feed
heat. The enthalpy in the de aerator will change slowly and the transient head
loss is negligible.
APPENDIX E
NOTES ON PROPRIETARY LEAK-OFF VALVES
This type of valve combines the functions of a non-return valve and a minimum
flow bypass valve. Typical arrangements of the Schroeder and Yarway leak off
valves are shown in Figures E.l and E.2 respectively.
The method of operation is ON-OFF. On low flow, the non-return valve element
activates the kickback valve, allowing bypass flow of the desired rate.
The kickback valve is not closed until the flow through the non-return valve
element increases considerably.
Important features are as follows:(a) Such valves are subject to considerable internal wear, and typically have a
life expectancy of 1000 hours on continuous kickback duty.
(b) No alternative materials are commercially available for high pressure
duties. Manufacturers allow for high pressure drops by increasing the
number of let down stages within the kickback valve. The internals can be
replaced without disturbing the main body of the valve from the pipework.
(c) High noise levels are generated by leak off valves when on continuous
kickback duty.
Current practice is to employ these valves only for Category 1 installations.
For Category 2 installations, adequate 'demand reliability' assessments are not
available; consequently current practice is to use a permanent bypass or a
modulated bypass valve.
FIGURE E1 -
SPECIAL COMPENSATING BY-PASS CHECK VALVE

(DIAGRAM) SCHROEDER
FIGURE E2 -
SPECIAL COMPENSATING BY-PASS CHECK VALVE

(DIAGRAM) YAAWAY
APPENDIX F
NOTES ON CASTINGS FOR HIGH-DUTY IMPELLERS
In order to obtain satisfactory castings it is essential to discuss the quality
requirements with the foundry. The following notes are intended for use in
drafting the specification for a particular pump in conjunction with the pump
manufacturer.
NOTES:
1
Material Specification
High duty impellers are normally cast in 13/4 Cr Ni steel, typically ASTM A
487 CA6 NM.
.
2
Dimensional Tolerances and Surface Finish
2.1
Surfaces Left As-cast
Tolerances important for the pump Q-H characteristic (from the area ratio theory)
are:
- axial widths b to be within + 3% of design value
- vane widths t to be within + 12% of design value
The surface finish should be better than 25 m Ra and the waviness better than 1
mm in 50 Mm.
2.2
Setting-up locations for machining
(a)
Swash
The front surface of each intervane passage shall lie within + 0.01 b of the
plane B which passes through the mean position of these surfaces and is
perpendicular to the rotation axis.
(b)
Concentricity
The datum shall be the circle A through the transition from front shroud to
vane root.
The asymmetrical deviation of the surface from the datum circle shall not
exceed 0.1% of the circle diameter.
2.3
Uniformity relations
(a)
Vane spacing
The peripheral spacing of the vanes shall be determined by measuring the
chord length between vane trailing edges after proof machining the
impeller outer diameter. All values shall lie between + 1.5% of the mean of
the values.
(b)
Vane fillets
The fillet radius shall be 40% to 60% of vane width t, subject to a limit of
40% of passage width b.
(c)
Inlet surface concentricity

If S n > 0.55 the inner surface C shall be fully machined to give a surface
finish better than 3.2 m Ra . The resulting boundary between machined
and as-cast surfaces shall be smoothly faired by hand finishing.
(d)
Balance
Notwithstanding that individual tolerances have been satisfied, the
distribution of variations shall be determined by check-balancing the
impeller after preliminary machining. The balance quality shall not be
worse than G.20 grade of BS 5265 before material removal for balancing.
2.4
Machining allowance and finish
(a)
Preliminary machining shall leave all dimensions oversize by 1 to 4 mm

and give a surface finish not worse than 16/ m Ra in order to obtain
satisfactory balance and dye penetrant tests.
(b)
Any final machining shall give a surface finish better than 3.2 m Ra on
wetted surfaces.
Quality Control Points
3.1
Test samples shall be cut both tangentially and radially from material
added to the hub ring and shall be identified by an Inspector's stamp.
3.2
All surf aces shall be subject to a dye-penetrant crack detection check

immediately before final machining.
3.3
Shot blasting is not accepted.
3.4
Weld repairs to castings shall precede final heat-treatment.
3.5
Certification shall be to DIN 50049/3.1B.
SPECIAL PRECISION CASTINGS BY THE LOST-WAX PROCESS
Dimensional tolerance
- +0.5% to -0.5%
Surface Finish
- 3.2 mR a
Finished Weight
- 10 kg
Ruling Section
- 5 - 500 mm
1.0 to 50 mm wall thickness
Material:
Air cast
Air cast
Air cast
- ANC.6A
- PE.IO
- ANC.3B
APPENDIX G
AREA RATIO METHOD
Anderson conceived the parameter of the area ratio Y to relate the flow
conditions at the pump impeller outlet to those at the casing volute throat, where:
Worster showed that the Q-H-E performance characteristics of a centrifugal

pump are chiefly determined by Y and not by the impeller blade angle.
Following Thorne, the impeller outlet area is defined as:
Where
Z is the number of impeller vanes

b is the impeller passage width at the periphery
The throat area A t is the sum of the two corresponding areas for a double volute
or the sum of the outlet areas between diffuser vanes defined as for the impeller.
Intrinsic assumptions are that:
(a)
High efficiency pumps are being sought for clean liquids of low viscosity,
so that vane incidence angles and shapes are properly matched to the
flow conditions.
(b)
Impellers have the optimum number of vanes, given approximately by 15.

where is the vane angle to the tangent, in radians.
(c)
Impeller inlet dimensions are not distorted to obtain the exceptionally low
NPSH capability corresponding to pump operation at suction specific
speed (S n) values above 0.4.
Commercial and manufacturing considerations result in low specific

speed pumps having large area ratios, where
However, when pumps having a stable Q-H characteristic or a non-overloading

E-Q characteristic are required, then smaller values of Yare needed where:
The efficiency does not vary strongly with Y but there is an advantage for values
of Y near unity.
REFERENCES
I
Centrifugal Pumps - An alternative theory H H Anderson. Proc.l.Mech.E

1947 vol 157
The interaction of impeller and volute in determining the performance of a

centrifugal pump. R C Worster. BHRA Report RR.679. 1960
Design by the Area Ratio Method E W Thorne. BPMA Sixth Tech Conf.
Paper C2 1979
DOCUMENTS REFERRED TO IN THIS ENGINEERING DEPARTMENT

DESIGN GUIDE
This Engineering Design Guide makes reference to the following documents.
AMERICAN SOCIETY FOR TESTING AND MATERIALS
ASTM A 487
Steel Castings Suitable for Pressure Service (referred to in

Appendix F Note I).
DEUTSCHES INSTITUT FUR NORMUNG

DIN 50049
Materials Testing (referred to in Appendix F Note 3.5).
BRITISH STANDARDS
BS 970
Specification for Wrought Steels for Mechanical

Engineering Purposes (referred to in Clause 15.2).
BS 1452
Specification for Grey Cast Iron (referred to in Clause 18).
BS 3468
Austenitic Cast Iron (referred to in Clause 15.3).
BS 4500
ISO Limits and Fits (referred to in Clause 13.2).
BS 5265
Mechanical Balancing of Rotating Bodies (referred to in

Clause 14.2 and Appendix F Note 2.3).
GBHE ENGINEERING SPECIFICATION

GBHE-MAC-18-06A
Bearing Arrangements for Machines (referred

to in Clause 14.1).
ENGINEERING DESIGN GUIDES

GBHE-MAC-1014 Integration of Special Purpose Centrifugal Pumps into
a Process (referred to in Clauses 4.3 and 6).
GBHE-MAC-5101 Reliability Analysis - the Weibull Method (referred to
In Clause 2).

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Engineering Design Guide:

Boiler Feedwater Pumps

Information contained in this publication or as otherwise supplied to Users is

Engineering Design Guide:

Boiler Feedwater Pumps

SECTION ONE - INTEGRATING.THE PUMP INTO THE SYSTEM

CHOICE OF NUMBER OF PUMPS

CHOICE OF PUMP TYPE

MINIMUM FLOW THROUGH PUMP

Limit due to Instability in Head/Flow Characteristic

Reverse Flow upon Trip

TEMPERATURE GRADIENTS IN CASINGS

INLET STRAINERS AND CASING PIPING CONNECTIONS

Packed Glands for Category 1 Pumps

SECTION TWO - PUMP CONSTRUCTION FEATURES

MINIMUM FLOW THROUGH PUMP

Limit Due to First Stage Cavitation Damage

AXIAL HYDRAULIC THRUST BALANCE METHODS

NOTES ON BFW PUMP/DRIVER ARRANGEMENTS

TYPICAL CROSS-SECTION OF PUMP IN CATEGORY 1

TYPICAL CROSS-SECTION OF PUMP IN CATEGORY 2 SHOWING

TYPICAL CROSS-SECTION OF PUMP IN CATEGORY 2 SHOWING

TYPICAL CROSS-SECTION OF PUMP IN CATEGORY 3 FOR

DOCUMENTS REFERRED TO IN THIS ENGINEERING DESIGN GUIDE

This Engineering Design Guide covers the special requirements of pumps in

The general reliability classifications are given in Engineering Design Guide

A standby pump on autostart for immediate readiness is required.

As a precaution against failure of the electricity supply at least one pump

CHOICE OF NUMBER OF PUMPS

Common spares holding

Common maintenance and operational methods

No process interruption upon short-term trip of main pump

Identical piping arrangement, minimizing design" effort

Ensure continuity of BFW supplied for process use. This condition is

Increase overall power efficiency when the steaming rate is expected to

Relax constraints on steam system control.

CHOICE OF PUMP TYPE

Multistage Centrifugal Type

for stiff rotors, capable of 'dry' running.

186 for conventional rotors

A double-entry first stage is the equivalent of 2 single-entry stages for this

Inlet Booster Pumps

This is calculated using Engineering Design Guide GBHE-EDG-MAC-1014 with

S n (NPSH p)1/4 < 1.2

MINIMUM FLOW THROUGH PUMP

Limit Due to Instability in Head/Flow Characteristic

Minimum Flow Arrangements

Variable Speed Control

Such experience as is available is discouraging. The chief considerations are:

Commercial speed governors for small steam turbines have deadband

Arrangements where two pumps run in parallel exacerbate the stability

Fluid couplings provide significant excitation torques at discrete

Reverse Flow upon Trip

Process heat exchangers in the delivery of BFW pumps constitute accumulators

TEMPERATURE GRADIENTS IN CASINGS

The elimination of temperature gradients by slowrolling the standby pump,

The provision of a bypass round the discharge non-return valve in order to

Temperature gradients can be prevented by positively isolating the pump

INLET STRAINERS AND CASING PIPING CONNECTIONS