Boiler Feed Pumps in Utility Power Stations. Generate Power Reliably and Economically

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1 Boiler Feed Pumps in Utility Power Stations Generate Power Reliably and Economically

2 We will make sure 2

3 KSB Your Pump and Valve Specialist Worldwide you achieve the maximum yield Through targeted investments in research, technology and new materials development, we continually improve our products. Aided by our pioneering technologies, modern utility power stations realize improved plant efficiency and reliability. Our innovative products and top-quality services have played a major role in every progress made in the industry over the past 130 years. 3

4 Two KSB solutions keep your plant running full steam No matter which product you choose: KSB s high-pressure ring-section pumps and barrel casing pumps are equally cost-effective pump types. Wherever in the world our specialist engineers start up a boiler feed pump in a power station, quality, safety, reliability and economy of operation take first priority. The optimum hydraulic design will save you money Having a diverse hydraulic coverage, KSB s boiler feed pumps can be perfectly matched to your plant conditions. This helps you optimize plant performance. Your benefits: High level of availability Long service life Low maintenance requirements Cost-effective operation These advantages add up to a sizeable reduction of the life cycle costs. 4

5 Maintenance requirements are kept to a minimum You can be assured low servicing costs and plant downtime with the service-friendly design of the KSB boiler feed pumps. With our quick assembly designs, the complete cartridge of a barrel casing pump, including the main wear parts, balancing system parts, bearings and seals, can be replaced without dismantling the casing or disturbing the motor and feed water piping. 5

6 1A 1B 1C 2 3A 4 3B How you will benefit from our HG pump technology 1 Operating reliability A The safe start-up and shutdown of the pump is ensured by a pivoted segmental thrust bearing which reliably absorbs the residual axial thrust. B The pump casing contour is carefully adjusted to the deflection line of the rotor, thus allowing the pump to be started and stopped without causing component wear and at the same time, achieving a high pump efficiency and availability. C KSB s double drum design optimally balances the axial forces across a broad operating range. This provides the user with the highest degree of dependability, even in the event of a momentary imbalance resulting from transient operating conditions. 2 Tapping By providing one or more tapping nozzles on the stage casings of the pumps, a low-pressure partial flow of feed water may be tapped for use elsewhere in the station. 3 Ease of service and maintenance A Stage casing gaskets and O-rings are eliminated because the forged stage casings have metal-to-metal sealing surfaces. B Balancing system parts, bearings and mechanical seals can be replaced without disassembly of the pump body. 4 Long service life The hydraulically optimized inlet helps to keep NPSH values low and the inlet flow uniform to the eye of the suction impeller. This prevents cavitation damage to pump components. 5 Low capital expenditure A low NPSHR suction impeller in the pump s first stage is standard. As an option, we also build pumps with a double-entry inlet. In many applications, this design will save the user the cost of a booster pump. 6

7 Q [U.S. gpm] Q [Imp gpm] B H [m] H [ft] HGD HGC 2 HGC 3 HGC 4 HGC 5 HGC Q [l/s] Q [m 3 /h] Performance data HGC HGD Capacity up to Q [U.S.gpm] Head up to H [ft] Temperature T [ F] Pump inlet pressure p s [psig] Pump discharge pressure p d [psig] Speed n [rpm] Materials HGC HGD Suction casing Discharge casing Stage casing Impellers/diffusers Casing wear rings Shaft sleeves Shaft Carbon steel (plated) Quenched and tempered steel Carbon steel (plated) 7

8 1A 2A 3A 1C 3B 3C 4 1B How you will benefit from our CHT pump technology 1 Operating reliability A The safe start-up and shutdown of the pump is ensured by a pivoted segmental thrust bearing which reliably absorbs the residual axial thrust. B The pump casing contour is carefully adjusted to the deflection line of the rotor, thus allowing the pump to be started and stopped without causing component wear and at the same time achieving a high pump efficiency and availability. C KSB s double drum design optimally balances the axial forces across a broad operating range. This provides the user with the highest degree of dependability, even in the event of a momentary imbalance resulting from transient operating conditions. D By having the bearing brackets directly connected to the barrel, hydraulic axial forces are translated to the barrel. This prevents these active forces from entering the inner assembly by way of the cartridge to the inner seal between the cartridge and the barrel. 2 Long service life B A The axial forces are transmitted to the bearing housing via a thrust ring. This ensures uniform, concentric thrust bearing loading and prevents uneven wear. Hydraulically optimized geometries ensure concentric inlet flow to the first stage. Combined with a suction impeller or a double-entry inlet, this is a failsafe method to prevent cavitation damage. 3 Ease of service and maintenance A Balancing system parts, bearings and mechanical seals can be replaced without disassembly of the pump body. B Stage casing gaskets and O-rings are eliminated because the forged stage casings have metal-to-metal sealing surfaces. C The pump cartridge can be replaced without removing the barrel. 4 Lower costs Cellular surface wear rings reduce the leakage flow within the pump stages and thus improve efficiency. This results in a sizeable reduction in your energy costs. 8

9 Q [U.S. gpm] Q [Imp gpm] B 3A 4000 H [m] H [ft] CHTD CHTC 3 CHTC 4 CHTC 5 CHTC Q [l/s] Q [m 3 /h] D Performance data CHTC CHTD Capacity up to Q [U.S.gpm] Head up to H [ft] Temperature T [ F] Pump inlet pressure p s [psig] Pump discharge pressure p d [psig] Speed n [rpm] Materials CHTC CHTD Barrel casing Stage casing Impellers/diffusers Casing wear rings Shaft sleeves Shaft Carbon steel (plated) Quenched and tempered steel Carbon steel (plated) 9

10 You will save money with KSB s innovative technology Year after year, we invest more than 20 million on R&D to improve the economics and reliability of our pumps, valves and systems. Technical innovations and new design details are integrated into our products to help you improve your overall plant performance. An example of our innovative technology is our cellular surface wear ring design. Pumps fitted with cellular surface wear rings tend to run smoother and longer, allowing you to reduce your power costs and plant emissions - saving you money. KSB cellular surface wear ring Originally developed for the fuel pumps of the Space Shuttle, cellular surface wear rings reduce the internal hydraulic flow losses to a minimum. Your benefits Lower operating costs as a result of higher efficiency Long service life Higher level of operating reliability Save money through the use of cellular surface wear rings made by KSB: Capacity Q [U.S.gpm] Head H [ft] Drive rating in original condition P K [kw] Efficiency gain η 1 [%] Efficiency in original condition η 0 80 [%] Operating time per annum t 8000 [h] Price of electricity k 0.05 [ / kwh] Annual savings: Energy E 360 [MWh] Costs K [ ] 10

11 Double-entry inlet The hydraulically optimized inlet and the standard suction impeller ensure low NPSH values. Your benefits Increased operating reliability Cavitation damage in the first stage is eliminated. Longer service life Smoother operation results in longer life of bearings and mechanical seals. Reduced capital expenditure The need for a booster pump can be eliminated by utilizing our double-entry inlet option. NPSH Standard impeller Suction impeller Double-entry inlet Capacity 11

12 Research and development The acute minds at KSB constantly search for new solutions for fluid transfer, looking for new ways to optimize our pumps, valves, drives and systems. Our achievements in the fields of materials technology, hydraulic design, including the development of intelligent process integration systems and remote diagnosis equipment render our products fit for the future, available today. Advisory service As early as the planning phase, our highly qualified, experienced KSB pump and valve experts will provide you with exactly the type of guidance and advice you need. This gives your project the solid base on which to develop safe and sound technical solutions. You name your requirem 12

13 Processing One-stop engineering shop for all your specification needs. When designing the pump units and systems to fill your requirements, we can utilize our extensive database of successful delivered projects. Having a supplier with this depth of experience saves you time and money. Service We respond quickly to your every need 24 hours a day, 7 days a week. With more than 90 KSB service centers worldwide ready to serve you, there is sure to be one near you. Our intelligent remote diagnosis systems allow teleservice matched to your requirements. we will take care of the details ent Pumps, valves, pipework, drives, instrumentation We strongly believe in all-inclusive catering to our customers needs, from the first advisory meeting, through project management, engineering and working out specifications for pumps and pump units, to successful commissioning and service. Why not take advantage of our innovative strength and experience? Visit us at where you will find more information about our products and services for energy applications. 13

14 Sines, Portugal Heilbronn, Germany Afsin-Elbistan, Turkey Rovaniemi, Finland Vado Ligure, Italy Son Reus, Mallorca, Spain KSB knows what it means to be responsible As one of the leading manufacturers and suppliers of pumps, valves and systems with more than 12,000 employees all over the world and an annual sales volume of well over 1 billion we are well aware of our responsibilities. One of KSB s 1,000 service engineers is bound to be close at hand, ready to ensure that your pumps, valves and systems will give the reliable service you expect. Always ready to fulfill your 14

15 Hub River, Pakistan Perm, Ukraine Tainan Kuan Tian, Taiwan Niederaussem, Germany Rosignano, Italy Från Brista, Sweden needs at a place near you. 15

16 KSB. Your Pump and Valve Specialist Worldwide Bitte neues Motiv liefern Competence and experience Contact us today. Energy Competence Center Tel.: +49 (62 33) Fax: +49 (62 33) Around-theclock service KSB sales organization near you: Intelligent allin-one solutions On-site advice /10 09/02 bdf Subject to technical modification without notice. KSB Aktiengesellschaft Johann-Klein-Straße Frankenthal (Deutschland)