Boiler Feed Pump Hydraulic Coupling

PAVAN K. SHARMA
Addl. MANAGER (OPERATION)
 Boiler Feed Pump

¾ Motor Speed -1493 rpm

¾ Gear ratio -165/41
¾ Primary speed -6008 rpm
¾ Full load slip -3 %
¾ Max. O/P speed of geared variable speed coupling -5829 rpm
¾ Regulating range -5780 to 1200 rpm
¾ Pumps- 1) Working oil pump (Centrifugal)
2) Lub oil pump (Gear Pump)
Both driven from I/P shaft of geared variable speed coupling.
3) Aux. oil pump (Electrical Motor driven)
¾ Lub Oil pressure (Normal) -2.5 bar, at 1.5 bar-alarm & at 1.2-AOP starts.
¾ Control oil pressure -3.5 BAR & alarm -2.2 bar.
¾ Working oil pump pressure -1.6 to 2.1 bar
¾ Working oil upstream of control valve -1.0 to 1.8 bar
¾ Working oil flow rate -1068 Litre/min.
Geared variable speed turbo coupling:

The variable speed turbo coupling and step up gear are

incorporated in a common housing, while the lower section serves as an
oil tank.
Flexible connecting couplings are applied for power transmission
from the motor to the geared variable speed turbo coupling and from there
to industrial machine. The speed is increased between I/P and primary
shaft by means of a gear stage(165/41). Torque is transmitted hydro
dynamically from the primary wheel to the secondary wheel by working oil.
The torque generated by the driving machine is provided to
accelerate the fluid in primary wheel (Pump Impeller) This is delayed in the
secondary wheel (Turbine Wheel) to produce an equal torque. The fluid
can only circulate by a pressure drop between the primary and secondary
wheel. This requires that the secondary wheel speed is lower than that of
the primary wheel. Thus a slip is required for power transmission.
 M
AOP
LUB OIL
I/P SHAFT PRV-24
B1 B2
LOP

WOP 32 PRV-31

B8/9
B5 B6 B7 B10

WORKING OIL
49
B3/4
48
43
46
CONTROL OIL
47
45

44
 The coupling size is selected so that the full power can be
transmitted with a low slip, the “full load slip” (at max. filling). The O/P
speed can be regulated infinitely by changing the oil filling in the
working chamber between the primary and secondary wheel. This is
accomplished by positioning the scoop tube accordingly which will
determine the oil filling of the working chamber.
The power loss caused by slip will heat up the working oil. The
heat is then dissipated in the working oil cooler.
Oil circuits:
The same oil is used as working and lub oil. The working oil
pump and main lub oil pump are combined to form a pump set and are
driven by the I/P shaft of the geared variable speed turbo coupling.

The electric motor driven AOP lubricates the unit at start up,
during rundown and in case of interferences.
 M
AOP
LUB OIL
I/P SHAFT PRV-24
B1 B2
LOP

WOP 32 PRV-31

B8/9
B5 B6 B7 B10

WORKING OIL
49
B3/4
48
43
46
CONTROL OIL
47
45

44
Working oil circuit:
The working oil circuit consists of a closed circuit superposed by an
open circuit so that the filling can be changed.

In the Closed circuit, the oil which flows into the coupling via the
circulating control valve(32) for power transmission and heat dissipation, is
removed by the displaceable scoop tube. Under the action of dynamic
pressure the oil flows through the scoop tube housing, working oil cooler
and circulating control valve(32) back into the coupling.

The Open circuit is made up of the working oil pump, throttle and
pressure relief valve. The coupling is filled by oil flowing from the open to
the closed circuit. Excess oil supplied by the working oil pump flows
through the pressure relief valve back into the sump. The same applies
when the coupling filling is reduced.
 M
AOP
LUB OIL
I/P SHAFT PRV-24
B1 B2
LOP

WOP 32 PRV-31

B8/9
B5 B6 B7 B10

WORKING OIL
49
B3/4
48
43
46
CONTROL OIL
47
45

44
 The connecting line with orifice plate between lube and working oil
circuit is provided for faster filling of working oil circuit during start up. The
operating pressure of working oil is set on the pressure relief valve.

If the closed circuit interrupted and the geared variable speed turbo
coupling oil temperature rises to 160 deg cent the fusible plug blow. Bores
in the fusible plugs are thereby released and the coupling drains.
 M
AOP
LUB OIL
I/P SHAFT PRV-24
B1 B2
LOP

WOP 32 PRV-31

B8/9
B5 B6 B7 B10

WORKING OIL
49
B3/4
48
43
46
CONTROL OIL
47
45

44
Lub oil and control oil circuit:
The main lub oil pump pumps oil out of the sump through the non
return valve, pressure relief valve(24), lub oil cooler, and reversible double
filter to the bearing points, pressure switches and gear wheels.
Oil for hydraulic scoop tube control is branched off upstream of the
adjustable orifice plate(22). The control oil pressure is approximately 3.5
to 4.0 bar.
The lub oil pressure is set about 2.5 bar. Control oil pressure and lub
oil pressure are set on the pressure relief valve(24) and on the adjustable
orifice plate(22) as a function of each other.
To ensure the bearings are coated with oil during coupling start up,
rundown and failure they are supplied with oil by the aux. oil pump before
the drive motor is switched on and after it is switched off.
The aux. lub oil pump which is driven by the electric motor draws lub
oil out of the sump and pump it back through a non return valve into the
lub oil circuit.
 M
AOP
LUB OIL
I/P SHAFT PRV-24
B1 B2
LOP

WOP 32 PRV-31

B8/9
B5 B6 B7 B10

WORKING OIL
49
B3/4
48
43
46
CONTROL OIL
47
45

44
External Oil supply:
Lub oil for external units is taken from the coupling’s lub oil circuit
and returned to the oil sump. Pilot bored orifice plates are fitted at the lub
oil outlets of geared variable speed turbo coupling to the motor and to the
driven machine.

Control:
The output speed is controlled by an actuator adjusting the scoop
tube and thus the filling in the geared variable speed coupling. The cam
disc serves for linearization the angle of adjustment of actuator as a
function of the controlled variable speed.
Scoop Tube Positioning:
The scoop tube which regulates the amount of oil in the coupling is
controlled by turning the cam disc by means of actuator. The control
valve(46) is actuated by roller which is held by spring pressure against the
cam disc.
If the cam disc is moved in the direction of “full output speed” the
control valve(46) opens the pressure oil flow into the chamber(49) of the
double acting positioning cylinder. The scoop tube which is connected to
piston(48) is moved in the direction “full O/P speed” and the degree of
filling in the coupling is increased. Simultaneously the control valve(46) is
returned to its starting position by a spring load roller which presses
against the slope of the scoop tube and shuts off the oil feed as soon as
the scoop tube position preset by the actuator is reached.
When cam disc is turned in direction “min O/P speed “ control valve
opens the oil flow into the chamber(47) and the scoop tube is moved in
the direction “min O/P speed”.
 M
AOP
LUB OIL
I/P SHAFT PRV-24
B1 B2
LOP

WOP 32 PRV-31

B8/9
B5 B6 B7 B10

WORKING OIL
49
B3/4
48
43
46
CONTROL OIL
47
45

44
Oil throughput control:
The duty of circulating control valve(32) is to supply the coupling with
enough working oil to compensate for the losses. A cam disc controls the
circulating control valve as a function of the scoop tube position.

Rapid positioning of scoop tube:

Using this arrangement the scoop tube is moved from any position
towards “zero O/P speed” and back in the direction “full O/P speed” more
rapidly than is possible with the actuator. Normal coupling emptying and
filling time with up to 75 mm2/s oil viscosity are around 5 to 10 sec. Rapid
regulation is used for example in the following cases.

1) Quick run up of drive motor and driven m/c by rapid draining of the geared
variable speed turbo coupling:
The two solenoid valve(43 &45) are energized for rapid run up of main
motor under no load. The energized solenoid valve(43) lets pressure oil
flow into the chamber(47) of the scoop tube positioning cylinder
irrespective of the position of control valve(46). At the same time solenoid
valve(45) stops the supply of oil….
 M
AOP
LUB OIL
I/P SHAFT PRV-24
B1 B2
LOP

WOP 32 PRV-31

B8/9
B5 B6 B7 B10

WORKING OIL
49
B3/4
48
43
46
CONTROL OIL
47
45

44
 …and allows the oil in the chamber(49) to flow unhindered into the oil sump.
The scoop tube moves in the position 0% filling.
After run up of drive motor (With approximately 95% normal speed) the
solenoid valve are de energized and the scoop tube moves at once to the
position fixed by the actuator. The coupling fills within the specified time the
driven machine runs up to the corresponding speed.

2) Quick run down of drive motor and driven machine by rapid draining of
geared variable speed coupling:
The two solenoid valve(43 & 45) are energized for rapid draining of the
coupling. The scoop tube moves in the position of 0% filling as per
description in section-1. The coupling drains and power transmission from
drive motor to driven machine is interrupted.
 M
AOP
LUB OIL
I/P SHAFT PRV-24
B1 B2
LOP

WOP 32 PRV-31

B8/9
B5 B6 B7 B10

WORKING OIL
49
B3/4
48
43
46
CONTROL OIL
47
45

44
Thank You