EH. June 1978 Byron Jackson Pump Division soap (WARNER BORG-WARNER CORPORATION Section 1-105 Page 1-1105-1 HIGH PRESSURE DOUBLE CASE « TYPE HDB & HSB FEED PUMPS GENERAL DESCRIPTION ‘The Byron Jackson double case construction features a simple cylindrical forged steet outer barrel and cover, with one cit- cular joint, enclosing a longitudinally split cast chrome inner volute case, The pump consists of four basic sub-assemblios; the outer barrel and cover, the Inner volute, the rotating ele- ‘ment, and the bearings. Most Byron Jackson double case pumps are type HDB with a {double suction first stage impeller which reduces inlet veloc~ ities and permits safe operation at lower net positive suction head, This may eliminate the necessity for a separate booster pump. ‘The type HSB pump with a single suction, first stage impetior is available for some sizes of low capacity pumps and some applications where ample NPSH is provided ‘The Byron Jackson design is extremely suitable for high pres~ ‘suro service under the most severe conditions and can be ‘operated with varying loads and with stops and starts every day without any limitation and without any extra wear whatsoover. From the following detailed description, it can be seen why. this design meets with the most stringent requirements for reliability In the power station field FEATURES OF THE DOUBLE CASE DESIGN Only the very simplo barrel and the discharge cover, made of forged stoel, are exposed to tho tll discharge pressure, mak- Ing the pump safely designed for any pressure. Only one full pressure sealing to atmosphere (barrel-to-cover) and ono full pressure sealing to suction (volute-to-barrel) aro used, with fully confined gasketed joints. ‘Tho space bolwoon the outer barrel and inner voluto caso fe filed with the liquid pumped at full discharge pressure. This compresses the volute case halves together and provides Toading on the confined volute-to-barrel gasket sealing off the barrel discharge section from the suction section Tho main suction and discharge nozzles, which are welded to the Darrel, can be located either at top oF at bottom, to suit the customer's best main piping layout. The main piping can be welded directly to the pump nozzles of flanged as desired. ‘The pump internals can be removed from tho barrol in @ mini- mum of time without breaking the main piping connections ‘and without interfering with the driver postion EXCLUSIVE FEATURES OF THE BYRON JACKSON DOUBLE CASE DESIGN ‘The Byron Jackson inner volute case construction consists of two halves bolted together along the horizontal split and has many advantages aver other designs which use individual radially spit diffuser cases for every stage. The Byron Jackson Unique double volute ease design offers the following desir- able features: 1. Both volute case halves are identical and, in fact, are cast from the same pattern. This results In a completely symmetrical design, which uniformly lstributes neat throughout tho pump inner case during tomporature transient conditions, permitting cold pump start up. 2. The double volute design provides for machining the natural deflection of the rotating element into the bottom Volute case half, with the recult that all running clear ances remain concenteo, singo the shatt operates in ts Geflected position. This refinement cannot be practically etfectod with the diffuser design with its multiplicity of ‘concent fits 3, The rotating element can be fully assembled and dyna- ically balanced as a completo unit. Prior to installation Into the pump barrel, the fully assembled rotating ele ‘mont is morely lowered into the lower half volute case {and the top halt case is bolted on. By placing the rotat- ing element, including all rotating and stationary wear parts, into the bottom volute case half, al! running clear- ‘ances can be checked with a feeler gage. 4. In case of an emergency situation, a rotating element ‘can be quickly removed from its volute case and a new spare one installed. Stocking of a spare inner volute is, ‘optional since it Is not considered a wearing part. Many Customers stock a spare rotating element only. In order to expedite disassembly and assembly time with a diffuser design, the customer must purchase a com- plete assombled rotating element with all the difuser ‘cases installed, since fled assembly of rotating element {and diffuser cases Is a time consuming procedure 5, The Byron Jackson design has opposed grouping of Impellers, which result in & pump whose axial hydraulic thrust is inherently balanced over its fll operating range without resorting to the use of a close clearance high pressure drop balancing device. Because there is. no ‘eed for a balancing drum or disc, here is 42) No reduction in pump efficiency, since our efficiency Je true nozzle-to-nozzle efficiency. ') No limitation in operating range as there is for pumps: with balancing devices. & Byron Jackson pump ean safely operate on turning gear. €) No expensive external bleed back piping to a feed water system Generator, ar low pressure point, along with accompanying flow measurement devices and safety equipment. Note that heat energy BTU's lost with a balancing device bleed back flow must be Considered in a pump evaluation. No indicating device on the pump shatt and pump to ‘monitor rotor position eritical to balance device close ‘axial clearances. In the Byron Jackson design, the ump rotating element position i fixed. ‘ 6. Tho maximum pressure broakdlowns across running eleat= ances within the Byron Jackson design aro 50% of the ump differential pressure at the center bushing and at tho balance stage piece, where the pressure to the out- board stulfingdox is reduced to suction pressure. The running clearance lengths ate proportioned for equa pressure drop per unit of length eo that as normal woar ‘occurs, there is no resulting axial unbalance. Pumps, using @ balancing device, have full pump differential prosture breakdown over a relatively short running claar- ance and, hence. subject to extra wear with resulting unbalance, 7. Realizing the tremendous direct and indirect damage to boiler feed installations caused by pump seizure, the [Byron Jackson double ease boiler feed pump ullizes a unique configuration that permits larger intemal clear- lances, while actualy Increasing pump efficiency. This feature, in addition to * The sag boring of the Inner volute to conform to the natural shaft deflection, ‘© The dynamic balancing of the completely assembled roiating efemont, ‘© The axial balance achieved by back-to-back impeller arrangement, which eliminates problems common to Sensitive hydraulic devices, Makes the Byron Jackson pump virtually selzeprootSection 1-105 Byron Jackson Pump Division BORG WARNER BORG-WARNER CORPORATION Page 1-1108-2 EH, June 1978 HIGH PRESSURE * DOUBLE CASE + TYPE HDB & HSB FEED PUMPS. ENGINEERED COMPONENTS DETAILED ni DESCRIPTION . Inner Volute Case. A. Outer Barrel and Cover The outer barrel and cover are of forged low carbon steel, with only one circular high pressure sealing joint, with a fully retained Flexitalic gasket, which can be Feadlly designed for any desired pressure, This one joint Is held tight by heavy ASTM A193 Grade 7 studs and ASTM A104 Class 2H heavy hexagon nuts ‘The outer barrel is supported by two feet on each side along the horizontal centerline and bolted to support Pedestals. To provide for longitudinal expansion on ‘smaller pumps, the barrel is doweled at the two feet next to the coupling end, while the two feet next to the cover have elongated holes which allow the batrel to expand ‘away from the coupling, On largor pumps, Byron Jackson has a unique design to accomodate thermal expansion and to restrain piping induced forces and mounts. This design permits com- plete adjustment at any time. ‘A connection at tho Bottom af the barrel leads to a drain valve, and may be Interconnected to function as a warm- ing line inlet. No drain valves. are Tumished by Byron ‘Jackson with units whose cischarge nozzles are on the bottom of tho barrel, These units should bo drained by using connections provided in the customers piping ‘The volute-to-bartol fit and the cover-to-barrel fit are overlaid with type 308 stainless steel to prevent any ero sion at these locations, The barrel and cover are hydro statically ested {o a minimum af one and one halt times the pump shutoff discharge prossuro calculated at pump rated speed and temperature. B. Discharge and Suction Connections. Discharge and suction connections can be located on the top or the bottom of the barrel, They ean be made to fit the customer's specitications for any type flanged for welded connections and are normally forged ASTM [A105 stool, welded to the outer barrel. Both shaft seale are under suction pressure. This is ‘accomplished atthe discharge cover end by means of a throttle bushing (balance stago pioce) which reduces Internal intermodiate stage pressure to suction pressure, then through a bleed off retuin to the suction sido of tho pump. ‘The shalt soal designs are selected to best handle the customer's specific requirements and preferences. Shaft sealing can be accomplished by ‘© conventional packed stutfingbox with type John Crane No, 101M or equal packing, with water quenching through split cowl type glands. Packing applications are limited in use in view of shaft peripheral spec. ‘suction pressure and temperature. ‘© mechanical seals, preferably a= manufactured by Borg-Warner, especially devolopod for boller toed service, © throttle bushing with cold condensate injection for rellable service, minimum maintenance, and remark- ably low wear. Byron Jackson engineers review the Customer's pre boiler feedwater system parameters to make the best selection of a specific ype of throttle bushing system. Variations are numerous but they all fall under threo basic concepts: Controlled Pressure, Temperature Controlled, and Intermediate Outlet Con. trolled Pressure types. ‘The innor volute case is @ double volute design, cast of chrome steel, longitudinally spilt in two identical halves. All volute water passages between stages are integral With each volute casting. The horizontal spit parting faces are processed to provide @ perfect seal without a ‘gasket, The inner caso Is subjact to compressive stresses, nly, and is designed with metal sections consistent with the ‘service encountered, Only light bolting along the ‘pit is required, which greatly facilitates dismanting. ‘The double volute design, wth water outlets 180 degrees. apart, assures radial balance of the pump for all capacl- ties, ang equal temperature distribution in the outer barrel. all eroscover passages are hydrostatically tested af the required pressure to assure tightness of the inner ase. Al fits ‘are accurately machined for perfect alignment. ‘A unique Byron Jackson feature Is incorporated in the inner volute ease design because of the fact that the folating element of any horizontal pump has a shaft Ueflection, the amount Being a function of shaft length, ameter, and weight of the rotating parts. If this shaft ollection exceeds the radial clearances, metalic con- tact exists at standstil, When rotating, @ wedge action ‘of the pumped liquid at the running fits lift the element Clear. However, the fits do not centralize and result in ‘closer clearances at the lower running fils. Byron Jackson eliminates this problem by boring the inner Volute case to correspond to shaft sag. This results in properly centralizing all case wear ring and interstage piece fits, aiving uniform circumferential clearances, and materially increasing pump life and reliability ‘The rotating element consists of the shaft, impellers, rotating and stationary wearing parts. A complete rotat- ing eloment on a Byron Jackson pump can be removed or assembled a a unit. This can be accomplished in the field Yor inspection of paris subject to wear, checking of ‘learancss,, and straightness of the complete rotating ‘clement. This Is extremely important as proper align- ment of running parts, bearings, and shaft seals Is ‘essential to the long life of the pump, Pump Shaft ‘This shalt ig mado from a vertically heat treated 11.5% to 19% chrome. steel forging, turned, and ground all ver. Itie ecarfed at the clction eye of each impeller to afford maximum streamlining and minimum peripheral ‘oye velocity of the pumped liquid, To facilitate removal fand assembly of tho Impellers, the shaft is machined in (0,008 inch steps from the center toward each end of the shat Impetiers. ‘The impollors are enclosed type cast in chrome steel and finlshed all over. They are carefully staically and ‘dynamically balanced. They are carefully designed and manufactures to provide a high degree of hydraulic efficiency. Design and. workmanship are combined to ‘maintain this high efficiency over a wide range of the hhead-capacily curve, ‘The impellers are designed to produce a stable continu- ‘ously rising curve trom maximum output to zero capaci ‘A heac-capacity curve with a hooked characteristic at {aw flow is not acceptable for boiler feed service. aHigh-Pressure Double-Case Boiler Feed Pumps Cold Pump Start-up. Two-piece horizontally split inner-volute construction offers advan- tages of cold start-up... concentrie running ‘clearances (which can be checked with feeler gauge). Rotating element is dynamically bal- anced as an assembly before installation. Choice of Shaft Seals. Throttle bushings with cold-condensate injection in exclusive Byron Jackson design feature reliable service, min- imum maintenance and remarkably low wear. Also available — conventional packing for lower service requirements . .. and mechan- ical seals developed especially for boiler teed service. Less Downtime. For maximum reliability, re~ duced maintenance and lowest noise level double-acting pivot-shoe thrust bearing and selt-aligning, lubricated, babbitt-lined radial bearings are standard. Optional Booster Impeller. Provides high- pressure spray water for steam attemperation. Optional Attemperator Tap. Pump stage can be tapped to provide water spray for hot reheat steam line temperature control. Low NPSH. First-stage double-suction impel- Ter ensures low NPSH requirements, (Also available in Type HSB single-suction first- stage impeller) Designed for High Pressure. Only forged- steol barrel and discharge cover are exposed to {ull discharge pressure. Welded suction and discharge nozzles can be located at top or bottom for best main piping layout. Inherent Axial Balance for High Reliability. Because of opposed impeller grouping, axial hydraulic thrust is inherently balanced over full operating range without use of close- clearance balancing device. Therefore, no external bleedback piping to a low-pressure point in the system Is required.Byron Jackson constantly maintains qualified pro- urement, sound fabrication, precise machinin stringent inspection, extensive testing, and com: Prehensive quality ‘control measures at every phase of pump design and manufacture. Byron Jackson double case manufacturing facilities are located in Etten-Leur, The Netherlands; Los An- geles, California; Mexico City, Mexico; Tokyo, Japan; Toronto, Canada: and Victoria, Australia Shown at right is nozzle-to-barrel welding by quali- fied welder to approved procedures with weld integrity proven by strict NOT. ‘There are over 1600 Byron Jackson double case boiler feed pumps operating worldwide with over 60% of those operating in the United States. The earliest Byron Jackson double case boiler feed Pump was installed in 1939 and ig still operating today. Today's generation of Byron Jackson dou- ble case pumps in commercial operation in fossil fueled power plants have ratings up to 16100 GPM (3660 M2/Hr.), up to 4700 psi (330 Ko/CM) dis- charge, up to 7150 RPM, and up to 30,000 HP (22370 KW). As generating power plants continue to increase in size and output, Byron Jackson will continue to maintain a high degree of reliability in meeting the challenge of critical performance requirements, ‘Shown at right is Oklahoma Gas & Electric Com- any Seminole Unit 2 8500 HP, 5500 RPM, 50% capacity boiler feed pump ing With our comprehensive program of nondestruc- tive testing, hydrostatic testing, and performance testing, we know exactly how much pressure, tem- perature, and vibration Byron Jackson pumps can take and how they react to severe temperature transients, loss of suction, and loss of shaft seal injection, Pump rotor dynamics, vibration, pres- sure pulsations, among the pump hydraulic char- teristics, are carefully measured, recorded, and analyzed in our specialized test laboratories. Shown at left is Byron Jackson's newest hot loop test facility in Etten-Leur which joins those similar facilities at the Los Angeles and Toronto plants. Shown on cover is Niagara Mohawk Power Com- any's Oswego Unit 5 28600 HP, 5300 RPM, 100% capacity boiler feed pump.BULLETIN 1-1105 J Tw HIGH PRESSURE DOUBLE CASE oe TYPE HDB & HSB = FEED PUMPS Byron Jackson Pump Division