HPT Multistage Barrel Casing

Boiler Feed Pump

Sulzer Pumps – Striving to Serve You Better

Sulzer Pumps combines more

than 135 years of experience in
pump development and manufac-
turing with a deep commitment to
fully understand the needs of our
customers.

Our detailed process and applica-

tion knowledge has allowed us
to develop innovative pumping
solutions for our focus segments
including tailor-made systems. Our
active research and development
supports the customer-oriented
approach.

Sulzer Pumps has sales and

service facilities in major markets

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of the world to provide fast and
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HPT – Efficient and Reliable

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HPT radially split barrel-casing The pump’s efficiency is a result Although the HPT is a well-estab-
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pumps are specifically designed of its advanced hydraulic design lished design, with many years of
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for boiler feed applications in and so does not rely on the use reliable operation, it has been con-
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thermal power stations. These of close internal clearances. This tinually updated to take advantage
pumps are optimized to provide is also the case for the rotor- of technological developments.
high availability and high efficiency dynamic design, which ensures These include developments in
operation over an extended period low vibration by providing a high precision casting, sealing technol-
of time, reducing operation and degree of damping throughout ogy and materials as well as the
maintenance costs. Their robust the life of the pump, even with the application of FE analysis and
construction and tolerance of clearances worn to their maximum state-of-the-art manufacturing
changing conditions makes them values. techniques.
particularly suitable for cyclic
operation.

Drawing of original 1905 Sulzer boiler feed pump with a

balance disc. Sulzer has the original patent for disc/coun-
ter-disc balancing systems.
Design Features Optimized Thermal Design
• Horizontal, multi-stage barrel • The pump is designed to oper-
casing based on EPRI contract ate under cyclic conditions, with-
developments out the need for pre-warming
• Maximum safety due to double • The design minimizes thermal
casing design distortion to avoid the reduction
• Full cartridge pullout design for of internal clearances
rapid changeover • High strength materials are
• Inspection and overhaul without selected to accept thermal
disconnection of main pipe work stresses
• Single or double entry first stage • Graphite stationary seals ensure Computerized analysis to optimize
impeller available secure sealing under all tran- temperature distribution under
• Axial thrust compensated by sient conditions various conditions
balance piston
• Design features to eliminate the
need for pre-warming on most
applications

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Shaft Seal Option

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Cooling jacket decreases Bleed-off for high suction

temperature in seal chamber pressures, without bleed-off
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for low suction pressures

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Cold condensate injection Air barrier avoids Mechanical seal

heat transfer from
hydraulic pump parts Thermosleeve Cold condensate
to sealing area with air gap injection

• •
• ••
• •

• •
•
Drain Hot (~180°C) Cool (~60°C) Drain

With Floating Rings Single Mechanical Seal Fixed Throttle Bushing

• Moderate leakage • Minimal leakage • Simple and reliable design
• Low energy consumption • Less sensitive to dirt and
flashing
HPT Design Features and Options

• Barrel design incorporates many design features resulting Top or bottom facing nozzles welded or
from Sulzer/EPRI research contract flanged; can be positioned to suit the
• Maximum safety due to double casing design planned installation layout
• Pipework connections remain undisturbed during disassembly
• Barrel casing design provides maximum rigidity and accepts
high pipe loads

Full cartridge pull out for rapid changeover •

• Axial thrust compensation by balancing piston

to avoid damage during transient conditions
• Long operating life regardless of the operating
mode
•
Design features to eliminate the need

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for prewarming in most installations

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Fully rated double acting
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tilting pad thrust bearing
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• •
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Removal of bolts, coupling hub, piston and thrust

collar by means of a common hydraulic pump •
to simplify maintenance and reduce cartridge
replacement time

• Design of close running clearances Centerline

• Optimized labyrinth—high efficiency and good rotor- mounting
dynamic behavior
• Radial grooves—increased radial stiffness, reduced
effect on rotor tilting and good rotor dynamic behav-
ior • Precision casting in chrome nickel steel
• Swirl break at balancing piston to maintain rotor • Optimization of hydraulic profiles
stability even when internal clearances are worn • Kicker stage available
 Optional intermediate
take-off possible • Integral impeller wear rings for longer life di-
mensioned to allow re-machining several times
• Double suction first stage available

Pure graphite stationary seal rings used

• • Bearing housing fixed to pump cartridge through 360°

• Bearing provides high stiffness and damping to minimize
shaft movement
• Anti-whirl journal bearings

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• Forged, low alloy steel barrel casing as stand-
ard; designed for long term cycling operation
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and to resist erosion-corrosion without the need
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for overlays
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• High strength material to accept thermal shock

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• Other materials possible to suit customer re-

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Sliding pads to maintain align-

ment during thermal movements
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Optional Double Suction Optional Kicker Stage

Kicker stage flow •

Kicker stage forged design

for flow < 50 m3/h •
Kicker stage cast design •
for flow >= 50 m3/h
Shaft forged in chrome nickel Balance drum leakage •
steel flow
• Low L/D ratio
• Stable operation without Main discharge flow •
critical speed problems
• Reduced vibration levels
HPT Features

Integral Cartridge Design Step 1

Advantages • Suspended and

supported on rollers
• The cartridge is completely assem- at DE
bled outside the barrel case
• Prior to installation of the cartridge,
the mechanical seals are set, the
rotor is radially and axially adjusted
and the axial thrust bearing clear-
ance is set
• Quick cartridge changes for in-
creased productivity
• Cartridge support for increased Step 2
safety
• Cartridge includes the shaft, • Suspended
for re-rigging
coupling hub, static and dynamic
hydraulic parts, shaft seals, radial
bearings and thrust bearing, bal-
ancing system, suction and deliv-
ery cover
•

Step 3 Final Installation

Rotor Design
Rotor

Advantages Shrunk on thrust Shrunk on balance Shrunk on coupling,

• Shrunk on parts allow for high rotor collar, oil press fit drum, oil press fit oil press fit, parallel
stepped or taper fit
balancing quality
• Shrunk on parts avoid fretting cor- •
•
rosion and minimize stress concen-
trations • •
• Shrunk on parts avoid loose parts
on shaft during operation and Impellers are shrunk on, have keys for
result in lower vibration torque transmission and use split ring
for thrust loading
Diffuser and Impeller Design
Thick impeller shrouds
Continuous
Advantages channel diffuser Precision castings
Precision castings
• High efficiency •
• Small hydraulic unbalance • •
Thick impeller shrouds
• High strength for high head
• Natural frequency away from
resonance, thus avoiding shroud
breakage
Continuous channel diffuser
Diffuser Impeller
• High efficiency

Tightening System for

Delivery Cover Studs
Hydraulic jacks •
Advantages
• Accurate tensioning to required
pre-load
• Fast cartridge change Air operated
hydraulic oil pump •

Stage 1 Stage 2 Stage 3 Stage 4 Case Bolt

Tensioning
Tool

Set up Tensioning Tool Tension Stud Bolt Turn Nut Release

Tensioning Tool

Pressure Retaining Parts

Advantages
• Hydro test (1.5 x or 1.3 x pD) of
each pressure casing provides
high safety

Analyzed with proven codes for

high reliability:
• German vessel code AD, standard FE Model
• ASME section VIII, Division 1, Diffuser
optional
• FE for selected cases
Testing

Sulzer Leeds, UK
Test Facility
• 10 MW electric motor at full
speed
• Electric capacity to 16 MW
• Speed increasing gearbox with
multiple ratios
• 30 MW gas turbine drive
• 365000 gallon wet sump,
30 ft deep
• 50 ton crane capacity
• NPSH testing
• Hot or cold testing

Materials

Part DIN material ASTM material Advantage

Barrel casing 10 Cr Mo 9 10, forged A 182 Gr F22 • High erosion resistance
Delivery cover 10 Cr Mo 9 10, forged A 182 Gr F22 • Good thermal transient properties
Impeller G-X 5 Cr Ni 13 4 A 743 Gr CA-6MN • High erosion resistance
Diffuser G-X 5 Cr Ni 13 4 A 743 Gr CA-6MN • Good cavitation resistance
Stage casing G 17 Cr Mo 9 10 G-X 5 Cr Ni 13 4
Suction casing A 217 Gr WC 9 A 743 Gr CA-6NM
Shaft X 4 Cr Ni 13 4 A 182 Gr F6MN • High strength
• High fatigue resistance
Balance drum X 20 Cr Ni 17 2 A 276 Type 431 • At least 50 HB hardness difference
Stationary wear parts X 20 Cr Ni 17 2 A 276 Type 431 • High erosion resistance
Stud 36 Ni Cr Mo 16 • High strength
Static seals Pure graphite • Good pressure / thermal resilience
Performance Range
Flow (USGPM)
1700 2200 2600 3000 4000 5300 7000 9000 11000 13400 15500
Head (m) Head (ft)
13000
4000
Frame 1s
3600 11800
Frame 3
Frame 2
3200 Frame C
10500
300 300 Frame 1
-33 300 - 33
0/2 -33 0/3
2900 6 0/2 3
9
9200
175 6s
-28 6s
2500 0/2 6s
8 200
150 -32
-25 0/2
0/2
6
6s 8 7700
2300
5s 5s
6s 5s
6s
6500
2000
5s
5s 4s 6000
4s
4s
1600 5s
5200

4500
1300

4000

1000 3200
300 400 500 600 700 800 900 1000 1200 1400 1600 1800 2000 2500 3000 3500
3
Flow (m /h)

Note: The range chart and the data table show the normal operating range. However, for special cases,
the HPT can be adapted in design to cover duties outside of this range.

Operating Data

HPT Pump
Pump sizes From 150-260 to 400-482
Units Metric units U.S. units
3
Capacities up to 4000 m /h up to 17613 US gpm
Heads up to 4200 m up to 13778 ft
Horsepower up to 27800 kW up to 37280 hp
Temperatures up to 220°C up to 430°F
Speeds up to 7300 rpm
References

Lippendorf—the most modern lignite- of 2,420 t/h (supercritical), 267 bar (8932 Lippendorf, Germany
fired power plant in the world, located in ft) and 554° C (1029° F). The electrical HPT 400-482 / 6 stage
central Germany’s Saxony region. The efficiency is 42.6%, which is at present 3468 m3/h (15259 US gpm)
new plant is a 2 x 920 MW lignite-fired the world’s highest efficiency for a lignite- @ 3909 m (12821 ft)
power plant (2 x 875 MW net electrical fired plant. Much of the design efforts of 36661 KW (49160 hp) @ 4721 rpm
power output), commissioned in 1999. the Lippendorf plant have been concen-
Lippendorf delivers 230 MW of district trated on reducing environmental impact
heating to the city of Leipzig. The once- in accordance with new European Union
through type boilers have a steam output directives.

Boxberg, Germany Pulau Seraya Power Station, Singapore Almeria II Power Station, Spain
HPT 350-440 / 5 Stage HPT 150-260/1d / 5 Stage HPT 300-330 / 5 Stage
3353 m3/h (14753 US gpm) 441 m3/h (1941 US gpm) 1202 m3/h (5291 US gpm)
@4035 m (13234 ft) @ 2154 m3/h (7067 ft) @ 2333 m (7654 ft)
36258 KW (48620 hp) @ 5797 rpm 2890 kW (3875 hp) @ 6364 rpm 7900 kW (10600 hp) @ 6200 rpm

West Thurrock, UK Shajiao “C” Power Station, China Schwarze Pumpe, Germany
HPT 230-305 / 3 Stage HPT 300-330 / 4 Stage HPT 350-440 / 5 stage
876 m3/h (3859 US gpm) 1327 m3/h (5843 US gpm) 3165 m3/h (13926 US gpm)
@ 1953 m (6408 ft) @ 2369 m (7771 ft) @ 4100 m (13448 ft)
4671 kW (6265 hp) @ 7200 rpm 9172 kW (12300 hp) @ 6358 rpm 35833 KW (48050 hp) @ 5795 rpm
Your Global Partner

Worldwide Test Facilities Customer Support Reference installations and retro-

Sulzer operates over 20 test Services fits:
facilities world-wide, suitable for Global businesses require local • Janschwalde Power Station,
horizontal or vertical, open pit, services. Sulzer Pumps is com- Germany (12 units)
high flow rate/high-energy and mitted to providing local support • Mosenergo Power, Russia (19
multiphase testing. We have the through our worldwide network of units)
ability to perform tests at 50 and over 50 service facilities. • Novocherkasskaja Power, Rus-
60Hz and, depending on the site, sia (9 units)
are able to operate using diesel Retrofit of Existing Barrel • BHEL, India (12 units)
engines, gas engines and gas Type Boiler Feed Pumps • Dunamenti Power, Hungary (6
turbines in addition to convention- Applying our unique experience units)
al electric motors. A specialty of and expertise, we are able to • Ratcliffe, United Kingdom (2
Sulzer is the ability to fully string deliver consistently high quality, units)
test large high-energy pumps to value-added support. In addition
prove the pump package as a to supplying parts and service for Using root-cause failure analysis,
whole to our customers. Sulzer equipment, our in-house system investigation and materi-
re-engineering specialists can als assessment, retrofit special-
This ability is particularly impor- modernize and retrofit existing ists modify installations to meet
tant for critical offshore applica- boiler feed pumps with the follow- new duty conditions or to improve
tions where on-site correction is ing capabilities and benefits: operating efficiency. Beyond
both expensive and time consum- • Repair and re-machining of optimizing performance, retrofit-
ing. existing pump barrel casings ting existing installations results
• Integration of a new Sulzer de- in increased component life and
Our gas turbine test stand allows signed internal cartridge reduced energy consumption. We
full load string testing of pumps • Increasing pump efficiencies provide a full range of services
or compressors without having to • Main piping, foundation and for pumps and other associated
build the sets at third party sites. pump drive remain unchanged equipment with local customer
We are the only pump manufac- • Pumps compatible with existing service available 24 hours a day,
turer in the world able to under- oil supply system 7 days a week, backed by our
take in-house tests of machines service group support teams.
generating over 30 MW.
Check our worldwide offices at
www.sulzerpumps.com

E00616 en 3.2006 (XXXX), Copyright © Sulzer Pumps

This brochure is a general presentation. It does not provide any warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our
products. Directions for use and safety will be given separately. All information herein is subject to change without notice.