5.

5 Things Power Plant Engineers Need to Know

About Pumps

Pumps and pumping systems are used in power plants for primary applications such
as fuel oil handling and for auxiliary systems such as lubrication and cooling (Figure
1). On average, a 300 MW combined cycle power plant will have more than 100
pumps.

When looking for opportunities to improve the performance metrics of a plant, these
pumps and fluid handling systems should be primary targets for evaluation,
optimization and maintenance due to their sheer number and their influence on
overall performance.
However, because pumps and pumping systems are located in so many diverse
applications and locations throughout the plant, their collective impact may be
easily overlooked.
Both centrifugal and positive displacement pumps are utilized in power generation
applications. Of the two, engineers are generally more familiar with centrifugal
pumps, which use an impeller to move fluid through the application process. The
velocity of the rotating impeller imparts energy on the liquid and causes a rise in
pressure (or head) that is proportional to the fluid's velocity.

Positive displacement pumps and, in particular, rotary variants are less common,
but can prove to be more cost effective and offer more efficient fluid handling in
many applications. Instead of creating pressure, positive displacement pumps
simply move liquid. Pressure is generated due to resistance to movement of the
liquid downstream of the pump.

Things to Consider
Whether you are an original equipment manufacturer (OEM), an engineering,
procurement and construction (EPC) firm designing a new system, or a power plant
operator looking to improve the performance and reliability of an existing system,
here are 5.5 things to consider regarding pumps and pumping systems.

1 Liquid
The type and nature of the liquid being handled is a primary consideration when
determining which pump technology to use. When handling viscous liquids such as
heavy crude oil, bunker or residual fuel oils, low sulfur fuels and distillate fuels,
multiple screw pumps a variant of positive displacement pumps provide
remarkably good operating efficiencies as opposed to centrifugal pumps. The high
efficiency performance of multiple screw pumps provides a clear advantage over
centrifugal pumps where liquid viscosity exceeds 100 SSU (20 centistokes).
Progressing cavity pumps are an excellent choice for wastewater and fuel sludge, as
they can handle fluids that are contaminated or contain abrasive materials.

2 Supply
The specific hydraulic characteristics of positive displacement and centrifugal
pumps lead to clear recommendations to keep total cost of ownership (TCO) as low
as possible. When the system pressure is subject to change, a positive displacement
pump is recommended, as it will remain efficient even when operating at varying
pressures. While centrifugal pumps provide good efficiency within a relatively
limited range of heads (pressures), this efficiency deteriorates rapidly if the head is
too low. It suffers even more when the head exceeds the ideal range. Positive
displacement pumps are the most economical choice when liquid viscosity changes,
but flow volume remains constant. The efficiency of centrifugal pumps drops rapidly
when viscosity is outside the optimal range (also known as the Best Efficiency Point,
or BEP), whereas positive displacement pumps are less susceptible to these
fluctuations (Figure 2).

3 Discharge
Whether pressure is constant or not is another key factor in the determination of
which pump technology is better suited to the application. When the system has
varying pressure requirements, centrifugal pumps will be forced to operate outside
of their Best Efficiency Point, increasing the stress and wear on the pump. In these
conditions, positive displacement pumps are the better choice to ensure high
reliability. Today's high performance three screw pumps can operate with system
pressures up to 4500 psi (310 bar) and flows to 3300 gpm (750 m 3/h) with long term
reliability and excellent efficiency. Power levels to 1,000 hp (745 kW) and higher are
available. Two screw pumps are available for flow rates to 18,000 gpm (4000 m 3/h),
pressures to 1450 psi (100 bar) and can handle corrosive or easily stained
materials, again at good efficiencies. Power ranges to 1,500 hp (1,100 kW) are
available on critical applications.

4 Operations
When specifying pumps, consideration should be given to the mode of operation as
well as to the operating conditions; will either change significantly? If flow volume
remains constant, but pressure or delivery head varies, positive displacement
pumps are the right choice due to their fixed displacement design (Figure 3). In
contrast, centrifugal pumps are particularly efficient when operating on water-thin
liquids at fixed operating conditions where it is possible to select the pump based on
exact requirements. Centrifugal pumps will incur noticeably higher costs for spare
parts, maintenance and downtime if viscosity and pressure are not constant. In
either case, costs can be significantly reduced by operating a pump close to its
most efficient range.
3 Centrifugal vs. Rotary Positive Displacement Pump Performance

5 Sizing & Selection

Selecting the right type of pump centrifugal or positive displacement is
important, but it is also critical to ensure that the pump and fluid handling system is
properly sized. Figure 4 is a performance curve typical of multiple screw pumps. It
shows excellent efficiency over a broad range of discharge pressures. When
properly sized, multiple screw pumps also can handle various grades of liquid fuels,
such as distillate or residual oil, using the same pumps and driver. This can provide
a utility with some diversification of available oil supplies. For example, combustion
gas turbines can be started and stopped using light distillate fuel while running on
less costly (and higher heat value) heavy fuels.
4 Rotary Positive Displacement Pump Performance

If each piece of equipment is over-engineered, the power plant will have a system
that is too large, performs at less than optimum efficiency, consumes excessive
energy and adds higher maintenance and service costs. Conversely, a pump that is

undersized may cost less at the outset, but the cost to rework or replace the system
to meet performance expectations will outweigh the initial savings.
The best rule of thumb is to size for worst-case flow and power requirements. In
order to ensure the system is delivering adequate flow especially in applications
where fuel is being delivered to a turbine size the pump for the highest
temperature and lowest viscosity conditions. In contrast, during startup (cold)
conditions, the fluid will have a higher viscosity, resulting in a higher power
requirement. In this case, motor sizing is also important, making sure it can deliver
the required power.
Screw pumps offer excellent suction lift capability, which provides an operation
margin for "upset" conditions, such as during startup when the liquid may be cold
and more viscous or when there is an extended distance to the supply reservoir.
This operation margin allows the use of smaller supply piping, reducing component
costs and a simpler design.
Centrifugal pumps offer good potential for optimization efforts simply because there
are more of them. Centrifugal pumps should be selected for, and normally operated
at, the manufacturer's design rated conditions of head and flow. This is usually at
the best efficiency point, which is where pump impeller vane angles and the size
and shape of the internal liquid flow passages provide the optimum combination of
pressure and flow. As you move away from a centrifugal pump's BEP, the shaft will
deflect and the pump will experience vibration. This causes reduced performance
and accelerated wear.

Maintenance
Power plant operators tasked with improving efficiency and reliability should initiate
a scheduled preventive maintenance program as part of the operational plan.
Pumps used in auxiliary systems for lubrication will, by nature of their clean working
conditions and application, require less preventive maintenance than pumps used
for primary applications such as fuel injection and fuel forwarding.
In both positive displacement and centrifugal pumps, the following components
should be inspected, serviced and replaced when necessary to ensure optimum
efficiency and reliability:
Radial Bearings: if not sealed, these will need periodic lubrication and may

need to be replaced if vibration or excessive heat is being generated

Mechanical Seals: check for leakage and replace if necessary; it should be

noted that a mechanical shaft seal is not a zero leak device

O-rings and Gaskets: check for deterioration and replace if necessary

As a service to their end users, many pump manufacturers provide these parts in
what is sometimes called a "minor kit," allowing the customer to easily identify and
order the parts they need for a scheduled maintenance program on the pump.
In addition to the items mentioned above, centrifugal pumps also require inspection
of the impeller, which can be replaced if worn or damaged. For positive
displacement pumps, virtually every wearing part of the pump screws, gears (in
the case of two-screw pumps), and housing can often be replaced in the form of
what some manufacturers refer to as a "major kit." When repairing a pump with a
major kit, the user essentially has a new pump, at a cost that is somewhat lower
than replacing the entire pump.
When servicing pumps and fluid handling systems, it is recommended to only use
replacement parts manufactured or certified by the pump manufacturer. Knock-offs,
or "pirated parts," may work initially, but are typically not manufactured to the
same standards as OEM parts and could result in early failure, leading to system
downtime, damage to other components or even injury. In most cases, use of nonOEM parts will void any original equipment warranties. Using parts approved by the
manufacturer will result in a longer service life, extended intervals between
maintenance, a more predictable process and an increased system efficiency not
to mention peace of mind.
Pumps and fluid handling systems should be primary targets for evaluation,
optimization and maintenance.
Centrifugal pumps offer good potential for optimization efforts, simply because
there are more of them.
Pumps used in auxiliary systems for lubrication will require less preventive
maintenance.
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Pumps for thermal power plant

Boiler circulating pump

This is the pump peculiar to the forced circulation type boiler. This pump is necessary for
protection of the cooling pipe of the furnace. It circulates water in the cooling pipe of the furnace
when starting the operation and at low load and always maintains the flow in the pipe
approximately at a fixed speed.

Boiler feed water pump

Ring section type

This is the pump for sending high pressure and high temperature fluid to the boiler. The types
vary depending upon the pressure. The single casing type is used for the combined cycle, the
subcritical steam power generation, etc. In the case of the pump of the ring section type,
suction, intermediate and discharge casings are joined tightly with bolts and compose the pump
casing.

Horizontal split type

The casing is split in the upper and lower parts and composes the pump casing. Fabrication and
disassembly is easy but this type is inferior to other types with respect to the capacity of
pressure resistance.

Double casing internal horizontal split type

This is the multi-stage pump having the double casing, the inner casing contained in the outer
casing. Among various boiler feed water pumps, this pump is adopted for high pressure and
high temperature application as in the subcritial steam power generation. The double casing is
also called "barrel type". As in the case of the single casing, there are differences in the way of
splitting the inner casing, and special features are the same.

Double casing internal ring section type

This is the multi-stage pump having the double casing, the inner casing contained in the outer
casing. Among various boiler feed water pumps, this pump is adopted for high pressure and
high temperature application as in the subcritial steam power generation. The double casing is
also called "barrel type". As in the case of the single casing, there are differences in the way of
splitting the inner casing, and special features are the same.

Circulating water pump

Variable pitch vane circulating water pump

This is the pump to send cooling water to the condenser. Depending upon the water intake
source, the vertical type is usually used when taking water directly from sea, and the horizontal
type is commonly used when taking water from the cooling tower. The type having the
controllable movable impeller is called the variable pitch vane type.

Fixed pitch vane circulating water pump

The fixed type impeller as shown to the left is called the fixed pitch vane type.

Condensate pump

This is the pump for pumping condensate from the condenser. This is the important pump that
should be regarded, so to speak, as the starting point of the main cycle of the power plant.