Sulzer Ag · SIX:SUN
Sulzer — Investor Presentation (March 2013)
49 slides from Sulzer's investor presentation, March 2013
Slide 1: HPT High Speed Boiler Feedwater Pumps
HPT High Speed Boiler Feedwater Pumps Sulzer Pumps The Heart of Your Process
Slide 2: Types of Boiler Feedwater Pumps
Types of Boiler Feedwater Pumps Sulzer Pumps Diffuser Casing Segmental Ring Volute Casing Horizontal Split Diffuser Casing High Speed Barrel Casing HPT Sales Presentation <Copyright © Sulzer Pumps> | slide 2
Slide 3: Volute vs. Diffuser Casings
Volute vs. Diffuser Casings Sulzer Pumps Single Volute Casing Radial loads increase as the liquid flows through the volute and exits through the casing discharge. The result is an unbalanced radial load on the rotating element. FR HPT Sales Presentation <Copyright © Sulzer Pumps> | slide 3
Slide 4: Volute vs. Diffuser Casings
Volute vs. Diffuser Casings Sulzer Pumps A dual volute casing will have Dual Volute Casing an additional passage way 180º from the main volute which will almost balances the generated radial forces. FR ~ 0 HPT Sales Presentation <Copyright © Sulzer Pumps> | slide 4
Slide 5: Volute vs. Diffuser Casings
Volute vs. Diffuser Casings Sulzer Pumps Diffuser Casing A diffuser style casing has multiple discharge passage ways with equal area distributed throughout the circumference resulting in radially balanced rotating element. FR = 0 HPT Sales Presentation <Copyright © Sulzer Pumps> | slide 5
Slide 6: Range Chart
HPT Boiler Feed Pumps Range Chart Sulzer Pumps 4000 3500 H in m 3000 2500 2000 1800 1400 Q in m3/h 1200 300 500 1000 1500 2000 2500 3000 3500 HPT Sales Presentation <Copyright © Sulzer Pumps> | slide 6
Slide 7: Cross Section
HPT Boiler Feed Pumps Cross Section Sulzer Pumps Forged, low alloy Axial thrust steel barrel casing compensation by designed for long balancing piston to term cycling avoid damage during operation transient conditions Special design Hydraulic features which tensioned case eliminate the need cover st
Slide 8: Installation (Removal of Cartridge)
HPT Boiler Feed Pumps Installation (Removal of Cartridge) Sulzer Pumps Advantage Quick and safe cartridge change Step 1 Suspended and supported on rollers at DE Step 2 Supported for re-rigging Step 3 Final installation HPT Sales Presentation <Copyright © Sulzer Pumps> | slide 8
Slide 9: Alternative Arrangements
HPT Boiler Feed Pumps Alternative Arrangements Sulzer Pumps Intermediate Take Off Double Suction Impeller Kicker Stage HPT Sales Presentation <Copyright © Sulzer Pumps> | slide 9
Slide 10: Rotor Design
HPT Boiler Feed Pumps Rotor Design Sulzer Pumps Shrunk on coupling, Shrunk on balance Shrunk on thrust oil press fit, drum, collar, parallel stepped or taper fit oil press fit oil press fit Shrink disk for Impellers are shrunk on, have keys for torque mechanical seal transmission and use split ring
Slide 11: Impeller and Diffuser Design
HPT Boiler Feed Pumps Impeller and Diffuser Design Sulzer Pumps Precision casting Continuous channel Advantages: diffuser Precision castings Thick shrouds • high efficiency • small hydraulic unbalance Thick shrouds • high strength for high head • natural frequency away from resonance thus avoiding s
Slide 12: Static Seals
HPT Boiler Feed Pumps Static Seals Sulzer Pumps Pure Graphite Seal Rings • up to 1000 bar • up to 300 °C Advantages: • low gasket seating load required • fully confined gasket • metal to metal face HPT Sales Presentation <Copyright © Sulzer Pumps> | slide 12
Slide 13: Pressure Retaining Parts
HPT Boiler Feed Pumps Pressure Retaining Parts Sulzer Pumps FE model Analyzed with proven codes: • German vessel code AD, standard • ASME section VIII, Division 1, option • FE for selected cases Advantages: • proven codes provide high reliability • hydro test (1.5 x or 1.3 x pD) of each pressure cas
Slide 14: Tightening of Delivery Cover Studs
HPT Boiler Feed Pumps Tightening of Delivery Cover Studs Sulzer Pumps Hydraulic jacks Air operated hydraulic oil pump Advantages: • accurate tensioning to required pre-load • fast cartridge change HPT Sales Presentation <Copyright © Sulzer Pumps> | slide 14
Slide 15: Case Bolt Tensioning Tool
HPT Boiler Feed Pumps Case Bolt Tensioning Tool Sulzer Pumps Stage 1 Stage 2 Stage 3 Stage 4 Set Up Tighten Stud Bolt Turn Nut Release Tensioning Tool Tensioning Tool HPT Sales Presentation <Copyright © Sulzer Pumps> | slide 15
Slide 16: Mechanical Sealing
HPT Boiler Feed Pumps Mechanical Sealing Sulzer Pumps Shaft seal with single mechanical seal Advantages: Air barrier Mechanical Seal • High pump efficiency • Air barrier and thermo sleeve Cooling jacket insulates hot and cool area thus reduces thermal stratification. Avoids shaft bending due to ther
Slide 17: Mechanical Sealing with Integral Cooler
HPT Boiler Feed Pumps Mechanical Sealing with Integral Cooler Sulzer Pumps Air- filled gaps Cooling water Hot seal water Avoids the heat transfer Decreases the Circulation produced by coming from hydraulic pump temperature in the seal rotating part of the seal parts to the sealing area chamber. driv
Slide 18: Fixed Throttle Bushing
HPT Boiler Feed Pumps Fixed Throttle Bushing Sulzer Pumps Advantages: • simple design Cold condensate • reliable injection • temperature or differential temperature control avoids influx of cold water during Bleed-off for stand still, hence avoiding high suction thermally induced rotor pressures, be
Slide 19: Axial Thrust Development
Axial Thrust Development Sulzer Pumps Opposed Impeller Design Fr Total = 0 Fr 1st Fr xst Pd 1st X X Pd 1st Pd xst X X P d xst Unbalanced pressure distribution on impellers results in a force termed thrust in the direction of suction. Opposed impeller design offsets the unbalanced pressure distri
Slide 20: Axial Thrust Development
Axial Thrust Development Sulzer Pumps Stacked Impeller Design Fr Total = Fr 1st+Fr xst FDrum ~ 85% Fr Total Fr 1st Fr xst FDrum Pd 1st Pd 1st X X Pd xst X X P d xst Ps Unbalanced pressure distribution on impellers results in a force termed thrust in the direction of suction. Stacked impeller des
Slide 21: Axial Thrust Compensation – Balance Drum
Axial Thrust Compensation – Balance Drum Sulzer Pumps Close clearance Balances 85 - 90% of generated pressure breakdown thrust. Residual thrust handled by a thrust bearing. Most reliable design for transient conditions (start up and run down, quick temperature changes, daily starts and stops). P
Slide 22: Axial Thrust Compensation – Balance Disk
Axial Thrust Compensation – Balance Disk Sulzer Pumps Balances 100% of the generated thrust. Axial gap will No thrust bearing required. adjust in response to Rotor floats axially for proper thrust changes operation. Least amount of leakage - higher PSuction PDischarge efficiency. Disk lift
Slide 23: Axial Thrust Compensation According to EPRI Statistics
Product Description Axial Thrust Compensation Sulzer Pumps According to EPRI Statistics 1) : Out of 533 pumps balanced by disks, there were 310 failures (58%). Out of 511 pumps balanced by pistons, there were 27 failures. (5%) Balance disks are not suitable for DSS-operation. (daily start & st
Slide 24: Thrust Compensation Design
Product Description Thrust Compensation Design Sulzer Pumps Driven End Total thrust on impellers without balancing drum + +100% Area of unbalanced thrusts, which depends on differential wearing of impeller wear rings/drum, coupling reactions, impeller/diffuser positions One side thrust bearing capac
Slide 25: Journal and Thrust Bearing Arrangement
HPT Boiler Feed Pumps Journal and Thrust Bearing Arrangement Sulzer Pumps Split bearing housing Non contacting Advantages: oil seal (INPRO) Double acting high Thrust bearing capacity tilting pad thrust low power loss bearing, direct lubricated high safety against overload Journal bearing high
Slide 26: Thrust Bearing Lubrication
Journal and Thrust Bearing Arrangement Sulzer Pumps Thrust Bearing Lubrication A “wedge” of oil builds up between each stationary thrust pad and the rotating collar, and no metal-to-metal contact takes place during normal operation. The white metal lining of the pads are designed to be tolerant of a
Slide 27: Double Acting Tilting Pad Thrust Bearing
Journal and Thrust Bearing Arrangement Sulzer Pumps Double Acting Tilting Pad Thrust Bearing HPT Sales Presentation <Copyright © Sulzer Pumps> | slide 27
Slide 28: Forced Oil Lube Systems
Forced Oil Lube Systems Sulzer Pumps HPT Sales Presentation <Copyright © Sulzer Pumps> | slide 28
Slide 29: Journal or Radial Bearing Lubrication
Journal and Thrust Bearing Arrangement Sulzer Pumps Journal or Radial Bearing Lubrication During normal operation, “wedges” of oil build up between the shaft and the bearing surfaces, providing rotor dynamic stability, know as a hydrodynamic” effect. HPT Sales Presentation <Copyright © Sulzer Pumps>
Slide 30: Sleeve Bearings
Journal and Thrust Bearing Arrangement Sulzer Pumps Sleeve Bearings HPT Sales Presentation <Copyright © Sulzer Pumps> | slide 30
Slide 31: Design of Close Running Clearances
HPT Boiler Feed Pumps Design of Close Running Clearances Sulzer Pumps Design of close running clearances Advantages Optimized labyrinth Optimized labyrinth high efficiency good rotor dynamic behavior Radial grooves Radial grooves increased radial stiffness reduced effect on rotor tilting g
Slide 32: Swirl Breaks
HPT Boiler Feed Pumps Swirl Breaks Sulzer Pumps Swirl Break Advantages: High rotor stability even with worn clearances Drum Liner Prevents pre-rotation of fluid View on A A Impeller Shaft Drum Swirl Brakes HPT Sales Presentation <Copyright © Sulzer Pumps> | slide 32
Slide 33: NPSH Considerations - Cavitation
NPSH Considerations - Cavitation Sulzer Pumps The NPSHA must exceed the pump’s NPSHR or the liquid will vaporize within the pump impeller. This Bubbles (cavities) form Pressure side of vane vaporization of the liquid is called Bubbles collapse cavitation. Cavitation can occur in many areas Cavitatio
Slide 34: NPSH Available – Closed Suction Supply with Head
NPSH Available – Closed Suction Supply with Sulzer Pumps Head NPSH available is a function of the system in which the pump p operates. It is the excess pressure of the liquid over its vapor pressure as it arrives at the pump suction. NPSHA = p + LH – (VP + hf) Where: LH p = pressure in suction vesse
Slide 35: NPSH Required
NPSH Required Sulzer Pumps NPSH Required is physical design property of each pump. It is dependent on the design of the suction casing, impeller, capacities and speeds. In Boiler Feedwater applications the greater the margin between NPSH available to required the better the pump can handle suction t
Slide 36: NPSH Required
NPSH Required Sulzer Pumps NPSH required is measured on the test H stand by reducing the suction pressure 100% 99% and measuring discharge pressure. 97% Incipient values represent the very onslaught of bubble formation with no reduction in head. Q = const. NPSH 0% values represent the beginning of b
Slide 37: NPSH Considerations: Safety Margins
HPT Boiler Feed Pumps NPSH Considerations Sulzer Pumps Approximate Safety Margins for the Determination of NPSH Available (t = 170ºC – 190ºC) 2.4 2.4 NPSH av > SA x NPSH 3% 2.2 2.2 U1 > 65 m/s Safety Margins (SA) 2 bubble length < 4mm 2.0 1.8 1.8 U1 = π(D1)n/60 D1 = Imp Eye Dia. 1.6 1.6 Valid for Hi
Slide 38: NPSH Considerations: Transient Conditions
HPT Boiler Feed Pumps NPSH Considerations Sulzer Pumps If the load reduction > NPSH Common Transient Condition margin and occurs in a time frame which is shorter than the time required for the liquid to Full Load travel to the pump suction Load Reduction Part Load Operation flashing in the piping wi
Slide 39: NPSH Considerations
HPT Boiler Feed Pumps NPSH Considerations Sulzer Pumps Because of the high operating speeds the required NPSH is high and requires either a double suction first stage as a minimum or a separate booster pump. A separate booster pump provides the ability to provide a high margin between available and
Slide 40: Typical Materials
HPT Boiler Feed Pumps Typical Materials Sulzer Pumps Part Material Advantage Barrel casing 10 Cr Mo 9 10, forged high erosion resistance Delivery cover (A182 Gr F22) good thermal transient properties Impeller Diffuser G - X 5 Cr Ni 13 4 high erosion resistance Stage casing (A743, Gr .CA-6MN)
Slide 41: Recommended Instrumentation
HPT Boiler Feed Pumps Recommended Instrumentation Sulzer Pumps Balance water flow Shaft vibration Shaft vibration Bearing Bearing temperature temperature Axial rotor position, possible Guide Keys Bearing housing vibration, Bearing housing vibration, possible possible HPT Sales Presentation <Copyrigh
Slide 42: Recommended Instrumentation: Efficiency Drop
HPT Boiler Feed Pumps Recommended Instrumentation Sulzer Pumps Drop in efficiency Function of increased labyrinth gaps for different specific speed Drop in 0 Efficiency Delta eta % -5 nq 33 -10 nq 26 nq 22 -15 Normal operating range Danger Forbidden range New Worn Worn max Recommended overhaul Opera
Slide 43: Pre-Warming
HPT Boiler Feed Pumps Pre-Warming Sulzer Pumps Most Sulzer Diffuser Style Barrel Pumps do not require warm-up. On the very largest sizes, the warm-up flow back into the discharge surrounds the inner case, making warm-up faster and more uniform. On some of those very largest sizes, additional warm-up
Slide 44: Pre-Warming: Typical Thermal Deformations
HPT Boiler Feed Pumps Pre-Warming Sulzer Pumps Typical Thermal Deformations HPT Sales Presentation <Copyright © Sulzer Pumps> | slide 44
Slide 45: Pre-Warming
HPT Boiler Feed Pumps Pre-Warming Sulzer Pumps Asymmetrical Casing Insulation Sulzer standard casing design provides insulation on the bottom half to retain heat. The top half casing has perforated metal cover but no insulation to let heat escape. The result is a more uniform temperature throughout
Slide 46: Speed Control
HPT Boiler Feed Pumps Speed Control Sulzer Pumps This type of pump is designed to operate at speeds above standard 2 pole motor speeds, typically 6000 rpm. Typical speed control devices are: Geared Fluid Coupling Fixed Speed Coupling Variable Frequency Drives (VFD) Steam Turbine HPT Sales Pr
Slide 47: Typical Layout
HPT Boiler Feed Pumps Typical Layout Sulzer Pumps HPT Sales Presentation <Copyright © Sulzer Pumps> | slide 47
Slide 48: Factory Acceptance Testing
HPT Boiler Feed Pumps Factory Acceptance Testing Sulzer Pumps 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 365,000 Gallon Wet Sump, 30 Feet Deep 50 Ton Crane Capacity N
Slide 49: Maintenance Inspection Frequency
HPT Boiler Feed Pumps Maintenance Inspection Frequency Sulzer Pumps Typical HPT Maintenance Inspection Frequency Operating MEASUREMENTS REPLACEMENTS Time Without Disassembling With Disassembling Mech. Balance Mech. Mech. Balance Wear Hours Years Oil Seal Line Vibrations Alignment Bearings Seal Oil B