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Integrated Solutions Group Feed System Analysis

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Integrated Solutions Group

• Roger DeBlois - Manager, Assessment Engineering • Watson Tomlinson – Pump Improvement Engineer • Rich Holbert – Senior Nuclear Sales Engineer

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Goals and Objectives • Describe some Feed System Analysis techniques and

methods including data collection • Highlight difference between Component Testing and

System Analysis • Discuss some potential obstacles to Feed System

Analysis • Describe a couple of case studies

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Feed System Assessment Goals

• A comprehensive assessment of pumping system using advanced data collection tools and methods coupled with sophisticated modeling techniques

• Increase availability and reliability of key rotating machinery • Identify opportunities to reduce energy usage of major systems

and critical equipment • Diagnose the root cause of an underperforming system and

premature or recurring equipment failures • Develop solutions for chronically problematic equipment using

life cycle cost (LCC) projections

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System Analysis vs. Component Test • Multiple components verses single piece • Operational trending verses performance snapshot • Transient capture verses single point

Parts • Root Cause Analysis • System Cause and Effect • Identification of equipment deficiency • Process efficiency optimization • O&M Cost Avoidance

Methodology

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Analysis

3960*GPM Head SpecificGravity

BHPη × ×=

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Efficiency Calculations, Turbine Driven BFP

To perform this calculation, OEM and test data must be at the same flow. It is assumed that

test and OEM BHP are the same.

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Hydraulic Network Analysis • Process fluids/fittings library

• Head loss curves

• Areas of excessive pressure loss

• Control logic evaluation

• NPSH margins

• Validate with field testing

• Run “what if” analysis

• Confirm designs ≠ capital

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Case Study

Problem • Coal-fired Fossil Power Plant, 650 MW • Unknown performance of Boiler Feed and Condensate Pumps • Historically un-reliable feed pump • Suspected Boiler Feed Pump operating out on its curve beyond BEP.

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Actions • Installed Wireless instrumentation and logged data for several weeks • Inspected used/spare condensate rotor • Rebowl existing condenstate pumps to APKD design with material upgrade

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Monitoring Points (IPS Instrumentation) • Boiler Feed Pump Discharge Pressure, Flow. • Boiler Feed Pump Reheat Spray Flow, Pressure • Boiler Feed Pump Recirculation Flow, Balance Line

Leakoff Flow • Boiler Feed Pump Speed (Tachometer) • Condensate Pumps Suction Flow • Condensate Pumps Suction, Discharge Pressure • Condensate Pump Power

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Power

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Monitoring Points (DCS) • Hotwell Level • Condenser Vacuum • Heater Inlet and Outlet Temperatures • Deaerator Level, Pressure, Temperature (Saturation) • In-kind BFP parameters and Condensate Pump parameters

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Condensate Pump Performance

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Condensate Pump Impellers

• Condensate pump was disassembled for inspection

• Significant erosion was found on each of the series stages (2 -7).

• Operation back on curve

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Condensate Pump Impellers • The damage was almost identical on each stage, and the

example shown is the 4th stage impeller. • Damage to the impeller indicates excessive flow through the

balance holes resulted in erosion around balance holes as well as damage to the vane tips. The excessive recirculation through the balance holes is also a significant contributor to the reduction in pump performance.

• 1st stage impeller showed some cavitation damage on suction side of vanes. Also, visual signs of recirculation due to operation at low flows.

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Boiler Feed Pump

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Boiler Feed Pump Performance

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DCS vs. IPS

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Plant Flow Monitoring Potential Issues • Temperature compensation. Flow meters such as a pitot

arrangement require temperature compensation. • Calibration • Flow orifice wear • Location of installed flow instrumentation in plant system

(straight runs, fully developed flow regime, etc.) • Temporary instrumentation setup and operator experience

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Case Study

Site Information •Generating station produces power and steam for large oil sands refinery. •The unit utilizes:

•(3) De-aeration Units •(5) Flowserve 6x8x11 DVMX 5-stage Boiler Feed Pumps •(8) Boilers

Reason for Assessment •Determine the current conditions of service? • Reduce the total cost of ownership by:

•Increasing the mean time between failure. •Reducing the number of operating pumps to 4 from 5 at full load.

•Determine the flow distribution from De-aeration Units. •Evaluate the flow through the recirculation lines.

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Actions •Installed pressure transducers, flow meters and laser tachometers. •Monitored plant parameters for one week. •Performed operational performance tests on Boiler Feed Pumps and associated recirculation lines. •Monitored vibration at various operational conditions.

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Higher flow target vs. Current Capability

0100200300400500600700800900

1000110012001300140015001600170018001900200021002200230024002500

31G-10A 31G-10B 31G-10C 31G-10D 31G-10E

Flow

(G

PM

)

Required Flow at 9459 GPM Total Flow

Required Discharge Flow Maximum Discharge Flow (GPM)

Current Max output

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Analysis / Conclusions •Created pump curves and plots of several system parameters.

•Performed Net Positive Suction Head analysis. •Performed recirculation line flow analysis including minimum continuous stable flow and onset of recirculation calculations. •Performed a flow distribution analysis on the De-aerator

discharges and created a hydraulic model to help determine the cause of inconsistent flow distributions.

•Verified installed instrumentation readings. •Performed a detailed vibration analysis including harmonic

resonance analysis. •Performed a total feed water flow distribution analysis.

•Made hydraulic re-rate recommendations for all (5) Boiler Feed Pumps to achieve desired goals.

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