Boiler Feed Pump Typical Method Statement 3

GENERIC METHOD

STATEMENT

YATESMETER PUMP PERFORMANCE

EVALUATION TESTS FOR

BOILER FEED PUMPS

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~ w w w. Y a t e s m e t e r . c o . u k ~

Title Client Method Statement Boiler Feed Pump

© 2008 Advanced Energy Monitoring Systems ~ TEL#: +44 (0)1404-812294 ~ FAX#: +44 (0)1404-812603 - 2

1 OVERVIEW The purpose of this document is to describe the procedures followed during a typical Yatesmeter Pump Test on a high pressure Boiler feed pump. By measuring the temperature differential produced across a pump, a Yatesmeter determines the efficiency of the unit by exploiting the principles of thermodynamics. This method of measurement is highly accurate and the results can be used to perform pump condition monitoring, flow meter calibration, system optimisation and energy management.

2 CONFIGURATION



EQUIPMENT The AEMS test equipment is fully portable and consists of the following: Yatesmeter Computer Power Monitor (If electric driven) Strobe Temperature Probes Pressure Transducers All equipment is regularly tested to conform to the latest legislation governing the use of Portable Equipment.

3 METHOD OF INSTALLATION

3.1 YATESMETER The Yatesmeter is powered by either a 240Volt power supply or 110Volt supply. Outside of the UK and North America the unit is normally configured to 240VoltsAC.

The Yatesmeter is positioned adjacent to the pump and the temperature and pressure transducers are attached and the sensors connected to the pump as follows:



The temperature probes need to be installed into thermowells in the suction delivery pipework. There are pressure valves in the pump pipework and the suction and delivery pressure transducers will be attached to these via push fit connectors provided as part of the test. It is normal to fit goose necks into the tappings prior to testing these are also supplied as part of the test. All fittings and transducers are rated to the pressures and temperatures required.

3.2 POWER METER During the test procedure it is necessary to monitor the input power to the motor drive this is done by attaching a Power Meter to a 5 Amp secondary circuit fed from the primary voltage through a voltage transformer and through current transformers via an instrument circuit.

The data from the Power Meter is either read in real time into the Yatesmeter via a data lead or logged remotely via a computer and the input power keyed in manually at each test point.

AEMS use the following Powermeters :

True 3 watt meter method

2 watt meter method

1 watt meter method

The power meter connects shown are for a two watt meter method.

R

Y

B

3 PHASE 3 WIRE 110V Phase to Phase

110V

110V

110V

B R

Y

VoltageTransformer

Fuses

Earth

Voltage InputsV V VR Y B

CT Inputs

Current Transformers

S1 S2

P1 P2

S1 S2

P1 P2

R R Y Y B BIN OUT IN INOUT OUT

to load



TEST PROGRAMME Activity Duration Set up equipment and attach transducers 2 hours and power monitoring equipment Calibrate temperature probes 30 mins Run Pump at open valve 30 mins Normal operating point Test Point 1 Change operating condition 30 mins Test Point 2 Change operating condition 30 mins Test Point 3 Change operating condition 30 mins Test Point 4 Change operating condition 30 mins Test Point 5 Change operating condition Test Point 6 30 mins Total Time 5 ½ hours Note

• At least one test point should be taken with the second pump running • All points are subject to operational constraints



PUMP MONITORING

3.3 CALIBRATION The probes and transducers can be attached while the pump is running. Once attached a calibration of the temperature probes is undertaken which necessitates the reversal of the temperature probes, once only from the suction to the delivery pipework i.e. the delivery probe starts off in the suction pipework and is reversed to its final destination in the delivery pipework halfway through the calibration procedure and the suction probe is similarly reversed. The calibration procedure is done at a constant pump speed.

3.4 TEST POINTS The following parameters are taken at each test point: Pump Efficiency Flow Head Power to Motor / Pump Delivery Pressure Suction Pressure Motor Efficiency Velocity Head Absolute Water Temperature Differential Temperature Across Pump Note: The characteristics for the pump would be charged by varying the speed of the pump, or by changing the number of pumps in parallel. (a) Where possible the test is undertaken with the pump running in its system on its

own. Where this is not operationally possible the first point should be with the pump on its own (approx 5 mins) but subsequent points can be taken with a pump or pumps in parallel.



Requirements prior to testing

1. Do the electric motors have variable speed drives.

2. If there are no VSD’s how can the operating state be changed.

3. If we use our own power monitoring equipment would it have to be logged remotely or could we run a data cable between the starter and the pump position (up to 200m length).

4. Can we run a single pump on it’s own.

5. What is the availability of the pumps i.e. is there any restriction on the period or the time of day for the testing.

6. On the high pressure side of the pump does the gate valve used for pressure have a pressure bleed off capability.

Client: Station: Method Statement Sulzer

© 2005 Advanced Energy Monitoring Systems ~ TEL#: +44 (0)1404-812294 ~ FAX#: +44 (0)1404-812603 ~ - 1 -

CASE STUDIES The following case studies are extracts from actual tests on Boiler Feed pumps and boosters. One was undertaken in the UK and the other within a Nuclear facility in The USA.

MAIN PUMPS AND BOOSTER PUMPS 101, 201 AND 302.

PUMP PERFORMANCE The following table lists the pump performance achieved on-site at the maximum flow rate for each pump referred to the rated speed of 5100 rpm.

The data below is displayed in metric units.

Pump No.

Pump Head (m)

Shaft Power (MW)

Pump Efficiency (%)

Pump Flow (m3/hr)

Main 101 1725.06 8.071 83.5 1671.8 Main 201 2124.56 8.088 83.0 1352.2 Main 302 1525.89 8.061 71.6 1618.0

Booster 101 560.80 3.426 76.1 1869.2 Booster 201 534.46 4.627 56.5 1972.7 Booster 302 480.40 6.559 32.1 1763.2

The data below is displayed in US units

Pump No.

Pump Head (ft)

Shaft Power (HP)

Pump Efficiency (%)

Pump Flow (USgpm)

Main 101 5659.63 10818.94 83.5 7361.3 Main 201 6970.34 10841.46 83.0 5954.1 Main 302 5006.18 10804.96 71.6 7124.5

Booster 101 1839.90 4593.16 76.1 8230.9 Booster 201 1753.49 6202.74 56.5 8686.5 Booster 302 1576.12 8792.78 32.1 7763.9



OBSERVATIONS / RECOMMENDATIONS Table 0-1 and Table 0-2 below show a comparison of the manufacturer’s test data with the data taken during the test by AEMS on 22/07/2003 - 24/07/2003. The comparison is carried out at constant head.

Pump No: Pump Head

(ft)

Pump Head (m)

Current Pump

Efficiency

As-new Pump

Efficiency

% Change in Pump

Efficiency 101 Main 5659.65 1725.06 83.5 84.1 -0.7 201 Main 6970.34 2124.56 83.0 85.0 -2.4 302 Main 5006.23 1525.9 71.6 82.5 -13.2

Table 0-1: High certainty results

Pump No: Pump Head

(ft)

Pump Head (m)

Current Pump

Efficiency

As-new Pump

Efficiency

% Change in Pump

Efficiency 101 Booster 1839.90 560.80 76.1 80.2 -5.1 201 Booster 1753.48 534.46 56.5 78.9 -28.4 302 Booster 1576.12 480.40 32.1 76.4 -58.0

Table 0-2: Low certainty results

Pumps 101 Main is in good condition with efficiency shortfall of 0.7%. It can be seen from the pump curve created by AEMS that the pump operates close to BEP. Pump 101 Booster is considered to be in reasonable condition with an efficiency shortfall of 5.1%. However it can be seen from the pump curve that the operating head is higher, at the observed flow rate, than the manufacturers curve. The operating point is to the right of BEP.

Pump 201 Main is in good condition with an efficiency shortfall of 2.4% at constant head. It can also be seen from the pump curve generated by AEMS that the pump operates close to BEP. Pump 201 Booster displays an efficiency shortfall of 28%. This appears very low but can be seen to be operating far to the right of BEP. The head verses flow rate performance is also in excess of the manufacturers curve which is probably due to tighter internal tolerances because of the temperature of the pumped fluid.

Pump 302 Main shows an efficiency shortfall of 13.2% at constant head. There is a reduction in the head / flow rate performance, which is reflected in a reduction in pump efficiency. The differential temperature for pump 302 Booster could not be measured directly. For this reason the certainty in the efficiency determination is low. The calculated value is 32% which should be regarded as an indicator. It is recommended that the pump set 302 should be refurbished and new tappings installed for the booster pumps closer to the pump which will give more objective and accurate test results. The tappings in the delivery pipe work should be before the common header to eliminate any influence from the second booster pump in the set.



4 GENERAL DETAILS

4.1 SYSTEM DESCRIPTION The boiler feed pump system consists 3 pairs of booster and main pumps. The feed pump configuration is numbered as 101, 201 and 302. During the testing AEMS monitored the performance of 101 booster, 101 main, 201 booster, 201 main, 302 booster and 302 main; a total of six pump tests. The pump sets are configured with the booster and main pump operating off a common shaft, driven by a steam turbine.

4.2 PUMP AND MOTOR DETAILS

M AIN PUM PS

PUMP DETAILS Pump Manufacturer: Ingersoll Rand Type: 10x16CA5 Arrangement: Multi stage Duty Head 1999.5 m Duty Flow 1398.9 m3/hr Speed 5100 rpm Serial No: 101 N/A 201 N/A 302 N/A Year of Manufacture: N/A

BOOST ER PUM PS

PUMP DETAILS Pump Manufacturer: Ingersoll Rand Type: 10x16CA Arrangement: Duty Head 621.8 m Duty Flow 1334.2 m3/hr Speed 5100 rpm Serial No: 101 N/A 201 N/A 302 N/A Year of Manufacture: N/A



TABLES OF RESULTS (METRIC): MAIN PUMP 101 AEMS Test Data (22/07/2003 - 24/07/2003)

Suctn Head (m)

Delivery Head (m)

Pump Head (m)

Pump Efficiency

(%)

Volumetric Flow Rate

(m3/hr)

Mass Flow Rate (kg/s)

Shaft Power (MW)

Rotational Speed (rpm)

375.92 1453.06 1077.14 83.5 1321.0 314.97 3.982 4030 548.13 1829.66 1281.53 85.7 1000.8 232.54 3.408 3905 648.67 2175.62 1526.95 87.9 1204.0 276.45 4.703 4374 700.53 2430.73 1730.20 85.4 1368.7 322.46 6.401 4744

AEMS Test Data referred to 5100 rpm Manufacturer’s Test Data

Pump Head (m)

Pump Efficiency

(%)

Shaft Power (MW)

Pump Flow Rate

(m3/hr)

Pump Head (m)

Pump Efficiency

(%)

Shaft Power (MW)

Pump Flow Rate

(m3/hr) 1725.06 83.5 8.071 1671.8 1691.64 84.0 8.724 1589.7 2185.88 85.7 7.591 1307.1 1996.44 85.0 8.721 1362.6 2075.90 87.9 7.456 1403.9 2279.90 81.0 8.709 1135.5 1999.62 85.4 7.953 1471.4 2407.92 72.5 8.221 908.4

2516.12 60.0 7.785 681.3 2590.80 44.0 7.288 454.2 2651.76 24.0 6.838 227.1 2682.24 0.0 - 0.0




Suction Head (m)

Delivery Head (m)

Pump Head (m)

Pump Efficiency

(%)


(m3/hr)


Shaft Power (MW)


557.50 1895.08 1337.57 81.1 920.5 221.68 3.582 3898 591.32 1977.83 1386.51 83.0 1092.3 260.49 4.264 4120


Pump Head (m)

Pump Efficiency

(%)

Shaft Power (MW)

Pump Flow Rate

(m3/hr)

Pump Head (m)

Pump Efficiency

(%)

Shaft Power (MW)

Pump Flow Rate

(m3/hr) 2289.7 81.1 8.022 1204.4 1691.64 84.0 8.724 1589.7 2124.6 83.0 8.088 1352.2 1996.44 85.0 8.721 1362.6

2279.90 81.0 8.709 1135.5 2407.92 72.5 8.221 908.4 2516.12 60.0 7.785 681.3 2590.80 44.0 7.288 454.2 2651.76 24.0 6.838 227.1 2682.24 0.0 - 0.0




Suction Head (m)

Delivery Head (m)

Pump Head (m)

Pump Efficiency

(%)


(m3/hr)


Shaft Power (MW)


381.29 1356.42 975.13 71.6 1293.4 308.68 4.118 4077 562.93 1848.67 1285.74 73.7 1169.8 271.87 4.644 4267 647.97 2102.71 1454.74 77.9 1197.8 274.69 5.028 4475 751.21 2458.90 1707.70 74.8 1403.5 321.37 7.190 4956


Pump Head (m)

Pump Efficiency

(%)

Shaft Power (MW)

Pump Flow Rate

(m3/hr)

Pump Head (m)

Pump Efficiency

(%)

Shaft Power (MW)

Pump Flow Rate

(m3/hr) 1525.89 71.6 8.061 1618.0 1691.64 84.0 8.724 1589.7 1836.74 73.7 7.930 1398.2 1996.44 85.0 8.721 1362.6 1889.47 77.9 7.443 1365.1 2279.90 81.0 8.709 1135.5 1808.37 74.8 7.835 1444.3 2407.92 72.5 8.221 908.4

2516.12 60.0 7.785 681.3 2590.80 44.0 7.288 454.2 2651.76 24.0 6.838 227.1 2682.24 0.0 - 0.0



CASE STUDY 2

TEST PROCEDURE

DESCRIPTION

The temperature probes were inserted into thermowells. One in the suction pipework of the booster pump and the other in the delivery pipework of the high pressure pump. The reversal method was used to determine the precise zero for the temperature probe pair. The pressure in the suction to the booster pump and the delivery of the high pressure pump was measured using pressure transducers which had been calibrated immediately prior to the test. The power supplied to the drive was measured by the Yates Power Meter which was connected in the 2-wattmeter configuration in the switchgear panel, the power data being logged to a computer every minute. The speed of the motor shaft was measured using an optical tachometer. The speed of the high-pressure pump was calculated using the gearbox ratio of 4.021 . Test points for the construction of the pump performance curves were taken by altering the flow through the pump (which adjusted the speed), the following parameters being recorded: a) Differential Temperature across Pumping System b) Absolute Temperature of Water c) Suction Pressure d) Delivery Pressure e) Input Power to Drive f) Motor Speed The Yatesmeter calculates the Pump Head from the suction and delivery pressures, corrected for velocity head and the height difference between the suction and delivery pressure transducers. It then computes the Pump Efficiency from the Differential Temperature across the pump, and further calculates the Flow Rate from the Input Power and the Drive Efficiency. The drive efficiency values have been computed for each input level, based on an estimated drive efficiency of 91%



INSTRUMENTATION LAYOUT

The diagram below shows the position of the instrumentation used on site. The arrows show the flux of information in the system.

Motorand

Driver

BoilerFeedPump

Booster

Powermeter

Computer2

HT YM

Ts(T004)

Td(T002)

PressureLogger 1

(P200)

PressureLogger 3(P204)

Computer1

StationFlowmeter

Tachometer

G/B



MANUFACTURER’S SPECIFICATIONS

PUMP SPECIFICATION

Service Data

Medium handled Boiler feed water demineralized Service temperature 151.5 ºC

Density 0.9155 kg/dm3 Booster Pump

Manufacturer KSB Type YNKN 300/200 Year 1983

Serial No. 2-218-631 415/1 Rate of Flow 607.5 m3/h

Pump inlet pressure 4.88 bar Pump outlet pressure 10.312 bar

Pump power input 110.0 kW Speed 1470 rpm

High Pressure Pump

Manufacturer KSB Type CHTA 50/6 Year 1983

Serial No. 2-218-631 416/1

Flow 607.5 m3/h Min rate of flow 125.0 m3/h Opening point 135.0 m3/h Closing point 175.0 m3/h

Pump inlet pressure 9.8623 bar Pump outlet pressure 228.577 bar

Take off flow 23.6 m3/h Take off pressure 122.24 bar

Pump power input 4608 kW Speed 5920 rpm

Work temperature 151.5 ºC Hours Run: 74,415



MOTOR AND GEARBOX SPECIFICATION

3-phase motor Manufacturer Siemens

Type 1 TM 3640-8DE02 Year 1982

Serial No. D 80 32 208 804 Power rating 6600 /

6600 kW

Voltage (Y connection) 6600 V Current 608 / 677 A

Cos ϕ 0.89 / 0.88 Speed 1489 /

1487 rpm

Frequency 50 Hz Rotor 3400V 1100/1230 A

Insulation Class F Other details IP54 Slipping IPR 44 - air 1.5

m2/s – 2mbar – temperature 42ºC cooling air - inlet water 5331 l/min

VDE0530/72 IEC 34 Gearbox Specification

Manufacturer BSH Type RP 32X Year 1983

Serial No. 501038/6 Power rating 5432 kW

Speed 1470 / 5912

rpm

Ratio 4.021



SITE LAYOUT (NOMINAL VALUES)

MotorBoilerFeedPump

Booster

Flow:607.5 m3/h ( 169 l/s)

Service temperature:150ºC

Pressure:4.88 bar ( 50 m)

Pressure:10.312 bar ( 105 m) to

9.86 bar ( 100 m)

Pressure:228.577 bar ( 2330 m)

Speed:1740 rpm

Speed:5920 rpm

Power:110 kW

Power:4608 kW

G/B

Driver



RESULTS The results are presented firstly in tabular format and then in graphical format. The results are true hydraulic performance and include no allowances for the losses, e.g. bearings, gearbox, or radiation. The manufacturer’s data has been corrected for water temperature and the efficiency calculated from the summation of the heads and shaft powers for each pump.

TABLES OF RESULTS

Test data

Differential Temp. (mK)

Absolute Temp.

(ºC)

Suction Pressure

(MPa)

Delivery Pressure

(MPa)

Total Head (m)

Pump Flow

(m3/h)

Power to Driver (kW)

Pump Speed (rpm)

Pump Efficiency

(%)

2970.6 148.151 0.563 20.895 2240.3 529.1 3825.1 5404 85.85

2957.3 146.912 0.545 20.800 2229.2 623.0 4501.7 5544 85.57

3125.3 147.056 0.547 20.813 2230.4 468.9 3484.1 5295 83.26

3382.3 147.149 0.555 20.960 2234.5 409.6 4089.1 5235 80.03

Data speed corrected to 5920 rpm

Total Head (m)

Pump Flow (m3/h)

Power to Drive (kW)

Pump Speed (rpm)

Pump Efficiency

(%)

2688.4 579.6 5028.1 5920 85.85

2541.0 665.2 5478.3 5920 85.57

2787.3 524.2 4867.4 5920 83.26

2857.2 463.2 4586.3 5920 80.03



CONCLUSIONS / RECOMMENDATIONS. Despite the Boiler Feed Pump having run for 74,415 hours it would appear to be in very good condition showing no signs of wear.

Boiler Feed Pump Typical Method Statement 3

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