11

Paper 2
THE DESIGN PRINCIPLES FOR BOILER FEED
PUMPS FOR C.E.G.B. 660-MW UNITS
F. 0. J. Otway*

When the Central Electricity Generating Board increased the unit rating of their turbo-generators from 500
MW to 660 MW, the design basis of the boiler feed pumps was completely reviewed. The prime requirement
was that the pumps should be made less sensitive to mechanical fault and capable of surviving disturbed
suction conditions without failure. At the same time they were to be capable of rapid replacement. This paper
explains the reasoning from these requirements that led to the decisions that the pumps should have only
two or three stages with stiff shafts. The selection of suction stage pumps for use with the main pressure
stages is considered. Gland security and light-load protection are discussed.

INTRODUCTION
THEHISTORY of the development of the boiler feed pump
in recent years has been very adequately described by
Anderson (1)tand Arkless (2). The second of these papers
covers development of boiler feed pumps at the power
stations of the Central Electricity Generating Board
(C.E.G.B.) up to the installation of 500-MW units.
Although these feed pumps are generally proving very
satisfactory in service, a number of possible short-
comings were foreseen, particularly their vulnerability
to loss of, or disturbance to, the suction. The possible
effects on unit availability have been concealed by the
installation of expensive stand-by plant. Accordingly,
when the boiler feed pumps for 660-MW units were being
considered, the principles of the design were reviewed
and it was decided to make a number of fundamental
changes to the designs to ensure less sensitivity to mech-
anical fault; in doing this it was accepted that these changes
would be accompanied by a small reduction in efficiency.
F E A T U R E S OF EXISTING D E S I G N S
The development that took place during the 500-MW unit
programme is shown in Figs 2.1 and 2.2. The first shows
a main boiler feed pump as installed at West Burton power
station at the beginning of the programme, and the second
The M S . of this paper was received at the Institution on 29th
January I970 and accepted f o r publication on 19th February 1970.
* Head of Pumps and Blower Group, Turbo-Generator Design
Branch, Central Electricity Generating Board, Walden House,
24 Cathedral Place, London, EC4.
t References are given in Appendix 2.1.
Proc lnstn Mech Engrs 1969-70
a main boiler feed pump at Cottam towards the end of the
programme.
The main features of the West Burton pumps (Fig. 2.1)
are as follows:
(1) A long flexible shaft with six stages, having a static
deflection of about 0.028 in.
(2) The residual thrust from the impellers is taken
by a conventional balance disc having an associated
restriction bush to give automatic balance.
( 3 ) The bearings are mounted on separate pedestals.
These pedestals have to be removed before the main
pump internals can be removed.
(4) The main bolted casing joint is subject to full dis-
charge pressure. In this case a seal is provided by the
Ruston-Grayloc joint. The size of the body is such that
a substantial time, of the order of a week, is required to
change a cartridge.
(5) The glands are of the labyrinth type with leak-in
and leak-out connections.
From considerations of these features (1)-(3) and (5)
it is clear that loss of water or reduction in n.p.s.h., even
momentarily, is likely to result in metallic contact, leading
to seizure. Should this occur, feature (4) shows that a
substantial outage will be required to put in a replace-
ment pump cartridge.
When the Cottam pump (Fig. 2.2) is examined, it will
be seen that feature (2) has been eliminated with the
impeller thrust balanced by a balance drum, comparable
with the types used in steam turbines and centrifugal
blowers. Since this does not give an exact balance, a
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12 F. 0. J. OTWAY

Fig. 2.1. Section of main 100 per cent duty boiler feed pump at West Burton power station

Fig. 2.2. Section of main 100 per cent duty boiler feed pump at Cottam power station

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 THE DESIGN PRINCIPLES FOR BOILER FEED PUMPS FOR C.E.G.B. 660-MW UNITS
conventional thrust bearing of the Michell type has been
added to take the residual thrust. Feature (3)has also been
changed, with the journal bearing housings being mounted
on brackets off the pump casing. Some alteration has been
made in feature (1); the number of stages has been reduced
to 4, giving some increase in shaft stiffness and a reduction
in static deflection. The other features remain although
the outermost glands in this case are of the floating-ring
type. While these are more tolerant of misalignment, they
are more vulnerable to loss of water. The situation is
therefore basically the same as for the West Burton
pumps.
As the head generated per stage is greater for the
Cottam pump, the height of the de-aerator is not sufficient
to give the required n.p.s.h. to cover transients, so a
separate low-speed suction stage pump has been added.
This is driven through a reduction gear from the extension
of the main pump shaft.
REQUIREMENTS OF THE NEW DESIGNS
T o overcome the shortcomings, as described above, the
following requirements were set for the new designs to be
used on 660-MW units. The 100 per cent duty pumps have
a discharge pressure of about 3000 lbffin2and handle flows
around 8000 gal/min.
(1) The shafts were to be substantially stiffened. This
was to be accomplished by reducing the number of stages
preferably to only two and certainly to not more than
three. It was also intended that the glands should be of the
hydrodynamic type (referred to below under ‘Gland
design and security’). The aim was to make the total shaft
length less than half of those on 500-MW boiler feed
pumps with a static deflection of only 0.002 in to 0-003 in.
(2) The balance valve was to be replaced by a balance
drum and a Michell thrust bearing to take residual thrusts.
(3) The internal clearances were to be considerably
increased. This feature, together with the two previous
ones, should ensure that the pump will be capable of
running dry without damage (referred to below under
“‘Dry running ” requirements’).
(4) The joints were to be of well proven pressure-held
types.
(5) The entire pumps were to be so designed that in the
event of breakdown or damage it would be possible to
remove all working parts from the outer casing or the
complete pump and replace them with a factory-assembled
element or pump from the store. The target change-over
time was 8 hours.
With these requirements it was considered that the new
designs of pumps would show a marked improvement in
reliability and lead to savings and major simplification in
installation. It was accepted that there would be a small
reduction in pump overall efficiency, but it was considered
that improvement in reliability was more important than
the maximum possible efficiency.
The high rotational speeds that are a consequence of
the first requirement result in relatively small diameter
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13
Table 2.1. Manufacturers of and stations for n e w
designs of feed pump
~
Manufacturer Station Station for
prototype
Sulzer Bros (London) Ltd Dungeness ‘B’ Tilbury ‘B’
G. and J. Weir Ltd Drax Ferrybridge ‘C‘
The Harland Engineering
Co. Ltd Hinkley Point ‘By Eggborough
impellers. These again mean small casing inner diameters
and hence less thick casings to withstand the hoop stresses.
I n turn, this means lower thermal stresses during tran-
sients so that the more compact pumps should be more
reliable.
Although it was not laid down as a basic requirement, the
pumps all have their bearings, both thrust and journal, in
housings supported off the pump body or internal cart-
ridge. This makes the pumps more immune to the effects
of pipework loads and should eliminate any troubles
resulting from shaft misalignment in the glands on this
account.
Since these requirements meant a radical departure
from the then current practice, it was considered essential
that thorough proving tests should be made of prototypes
of these new designs and these should be installed in power
stations to give substantial running experience in advance
of the main orders. I n addition, contracts for a consider-
able amount of associated development work were
arranged with the manufacturers selected to manufacture
these pumps. These new designs of pumps were ordered
from three manufacturers. Table 2.1 shows the power
stations for the main orders and also where the prototypes
are installed.
The prototypes at Ferrybridge ‘C’ and Eggborough,
which have 500-MW units, correspond with the 100 per
cent duty pumps at Drax and Hinkley Point ‘Byand have
many components interchangeable with them. Tilbury ‘B’
only has 350-MW units; the prototype there corresponds
in size with the 50 per cent duty pumps at Dungeness ‘By.
This paper does not go into the details of the designs by
which the C.E.G.B.’s requirements were met, since the
individual features are described in papers to this con-
vention by members of each company concerned (3)-(5).
The decision to adopt these new designs was taken at the
beginning of 1966 and the orders for the prototypes were
placed during that year. The first prototype was installed
before the end of 1967 and the last at the beginning of 1969.
GLAND DESIGN AND SECURITY
As mentioned under ‘Requirements of the new designs’,
the original intention was that the glands should be of the
hydrodynamic type, the principle of which is illustrated
in Fig. 2.3. Effectively, these function as centrifugal
impellers, and the intention was that the head generated
should be sufficient to retain the water in the glands with a
water-steam and air interface near the inner diameter of
the hydrodynamic gland. However, development of this
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14 F. 0.J. OTWAY

cover for temporary loss of condensate. I n the second,

special gland water pumps are used, using condensate
from a suitable source. In neither way is it claimed that
the gland water supplies are 100 per cent secure but, as
stated above, short-time interruption of gland water is
acceptable.
Since the leakages through labyrinth glands are
relatively high, it is desirable to reduce the leakage flow
when a pump is standing. Therefore standing seals were
specified to come into operation when a pump comes to
rest.
These arrangements of seals are considered satisfactory
for the present, but long-term developments may result in
a change. Two possibilities are under consideration. One
is the design of a continuously flashing gland, which would
reduce the mass flow for given clearances. The second is

Fig. 2.3. Hydrodynamic gland

4-
r;i
the use of mechanical seals, either of the simple face-seal
type or the hydrostatic variety. By the use of suitable
coolers and careful mechanical design it is considered that
water can be retained at the seal faces even during dis-
turbed suction conditions, so complying with the ‘dry
running’ requirements.
‘ D R Y R U N N I N G ’ REQUIREMENTS
The requirements that boiler feed pumps should be
capable of surviving loss of water is a new one for this type
of pump. Although the C.E.G.B. have specified that the
type did not proceed as rapidly or as satisfactorilyas hoped. pumps shall be capable of surviving being run dry, they are
While the principle of operation was established, a more concerned that they should be capable of surviving
number of difficultiesstill remained, including an inability very badly disturbed suction conditions with the n.p.s.h.
to give satisfactory sealing at reduced speed. Accordingly, reduced substantially below that normally required, as
the decision was taken that the glands should be of the may occur during a sudden substantial load rejection. The
labyrinth type with fixed bushes having leak-in and leak- only way that it is envisaged that a pump could run dry in
out connections. These are similar to those on the pumps service is if the suction isolating valve were to be shut,
at West Burton, previously described. Consideration was accidentally or deliberately. However, a pump that has
given to the use of floating ring glands; although the leak- shown that it is capable of surviving being run substan-
age flows will be smaller with this type when new, they are tially dry-apart from such water as may enter through the
vulnerable to loss of water supply and were rejected glands-should be able to withstand the worst disturb-
because they would not comply with the Board’s dry ances that may be expected in suction conditions. Accord-
running requirements (referred to in the next section). ingly, the current C.E.G.B. specifications require that:
With the stiff shaft design the glands should be capable ‘The pumps shall be capable of “dry running”; by this it
of surviving temporary loss of injection water. This will shall be understood that they shall be capable of accepting
tend to result in flashing taking place in the outermost without damage :
bushes of the glands. If such operation is prolonged, there
is the risk of water being carried over into the bearing oil
(1) Transient reductions in suction pressure well
below those required for freedom from cavitation and
supply, although this should be avoided in the later pumps
since the C.E.G.B. currently specifies that ‘Space for free shall accept without distress the re-establishment of
normal suction conditions following the transient with
circulation of air shall be provided between the glands and
bearing housings to reduce risk of carry over of water or no necessity for a pump shutdown.
(2) Complete loss of water due to incidents such as
steam to the bearings.’
This was not an original requirement. For the present, the inadvertent complete closure of the suction valve.
therefore, a substantially secure supply of gland injection I n such an extreme case it is recognized that the pump
water is required. I n the stations under consideration this should be shut down and only restarted after it has been
is being supplied in two ways. I n the first, feed water is reprimed by the approved method-the pumps must,
tapped from the discharge of the suction stage pumps and however, be capable of being shut down in a controlled
passed through a cooler, where it is cooled by condensate. manner and brought to rest safely.’
The capacity of the pipework downstream of the coolers is A number of these pumps have been subjected to ‘dry
designed to have a residence time of about 5 minutes to running’ tests during their works tests, sometimes at
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 THE DESIGN PRINCIPLES FOR BOILER FEED PUMPS FOR C.E.G.B. 660-MW UNITS
reduced speed. The author has been present during two
such tests when the pumps were run for 4-10 minutes after
the suction valve had been closed with effectively zero
discharge pressure; they were then shut down, primed,
and restarted, and continued to run perfectly satisfactorily.
SUCTION STAGE P U M P S
With the very high heads per stage generated in these
two- and three-stage pumps, it is even less possible to
provide sufficient n.p.s.h. for the main pressure stages
than for the four-stage Cottam pumps previously de-
scribed. Where separate low-speed suction stage pumps
have previously been provided on turbine-driven boiler
feed pumps at C.E.G.B. stations, they have been driven
through a reduction gearbox from the end of the main feed
pump remote from the turbine. T o have repeated this
arrangement on the 660-MW designs would have pre-
judiced the rapid change-over requirements since the
gearbox and probably the suction stage pump would have
had first to be removed. I n view of this, separate motor-
driven suction stage pumps are used. At the time that the
first of these new designs of feed pumps were ordered, the
glandless type of pump was being developed for use as a
lift pump in direct contact heater installations following
successful use on boiler circulating pump duty (6). Three
50 per cent duty suction stage pumps per unit were
specified for each unit. This type of pump promised
elimination of gland problems and freedom from routine
maintenance as its main attractions.
In principle there could always be operational difficulties
-as distinct from hazards-under some circumstances
with separately driven suction stage pumps. However, the
change-over to electronic governing of turbines has meant
that the suction stage pump with its gearbox can be more
readily arranged at the opposite end of the driving turbine
from the pressure stages. Furthermore, with the develop-
ments in gland design and in mechanical seals, glanded
suction stage pumps should not require much main-
tenance, and there will also be a substantial reduction in
first cost owing to the lower cost of the glanded suction
stage pumps and the simpler pipework arrangement.
Accordingly, on the later 660-MW units, shaft-driven
suction stage pumps are bcing specified with the suction
stage pump arranged at the other end of the driving unit
from the pressure stages. This arrangement has been used
on earlier motor-driven pumps. The same dry running
and rapid change-over requirements apply as for the
main pressure stage pumps.
For the present, separate suction stage pumps are
necessary. Feed pump installations would be simplified
significantly if they could again be dispensed with. There
is no possibility of the de-aerators being installed at a great
enough height for this. Therefore the one possibility of
their elimination is the development of axial flow inducer
stages capable of operation at much higher suction specific
speeds than centrifugal stages. This combination of axial
flow inducer stages with centrifugal stages in the same
casing is being examined by the C.E.G.B. in conjunction
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15
with the manufacturers. T o avoid lengthening the distance
between bearing centres with the introduction of an axial
flow inducer stage, at least one of the journal bearings
would be water lubricated, so eliminating the axial length
of a gland. Water-lubricated journal bearing development
has proceeded far enough for use but it is still an open
question whether satisfactory development of inducers for
the very high peripheral speeds in these pumps will be
achieved.
LIGHT-LOAD PROTECTION
With earlier designs of boiler feed pumps it has been
necessary to maintain a minimum flow through the pumps
to prevent the heat generated in the pumps raising the
water to such a temperature that evaporation occurs
when metal-to-metal contact will take place either at the
balance disc or the wearing rings; this will inevitably result
in seizure. The minimum flow is usually between 15 and
20 per cent and is achieved by leak-off equipment operat-
ing when the flow falls to a set minimum value.
Currently, the C.E.G.B. is specifying electric actuator-
operated parallel slide valves for this duty. The decision
was taken a number of years ago when difficulties were
being experienced with reliable operation of the hydraulic-
ally operated mushroom-type valves then in use; modifi-
cations to the control of these have resulted in a substantial
improvement in reliability in recent years, but a change
back is not considered desirable at present.
While the available evidence points to the parallel
slide-valve type proving satisfactory, electric actuation
means that the valves have lost their ‘fail safe’ features.
I n view of this, the valves are currently duplicated on each
feed pump. At one station, pneumatic operation of the
parallel slide valve is in use. Should this show advantages
over electric operation, a change may be implemented.
With the change from a conventional balance disc to a
balance drum for thrust balancing and with the C.E.G.B.’s
‘dry running’ requirement, thermal considerations suggest
that a reduction in leak-off quantity is permissible. At the
same time there is the intention to reduce stand-by
capacity so that the motor-driven pumps become just
starting pumps, which should mean that they only run for
a short time. Consequently, maximum efficiency is not of
paramount importance and it is reasonable to consider
continuous leak-off arrangements. Conveniently, this
could be done by increasing the balance drum flow on such
pumps. This would be a satisfactory arrangement if the
balance drum leakage is returned to the de-aerator but less
satisfactory if it is returned to the pump suction, which
gives a more satisfactory thrust balance when a balance
drum is used.
However, while such an arrangement would be accept-
able from consideration of thermal safety of the pump,
another factor has appeared that suggests that caution is
needed before a general reduction in leak-off quantity is
accepted on these new designs, or any other designs, of
boiler feed pump. This is the phenomenon of rotating stall.
While this phenomenon has been known to exist in
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16
centrifugal compressors for at least a quarter of a century
-Cheshire (7) referred to it in 1945-it is only recently
that it has been observed in centrifugal boiler feed pumps.
I n at least one case (8) rotating stall has been thought to be
a cause of significant pressure fluctuations in and vibration
of the pipework adjoining a feed pump. Additionally, it
has been observed in a feed pump for the C.E.G.B. under
works test and has been suspected as a possible cause of
pipework vibration in one of their power stations.
At present the conditions under which rotating stall
occurs in boiler feed pumps are not fully understood, but
the remedy is simple, namely to increase the minimum
flow through the pump. Accordingly, substantial reduc-
tions in leak-off flow should not be considered until the
phenomenon of rotating stall and other flow instabilities in
high-head pumps operating at low flows are more fully
understood. In a number of cases increases may be
necessary.
CAPACITY A N D DRIVES OF FEED P U M P S
AND F U T U R E DEVELOPMENT§
I n the C.E.G.B. stations with 500-MW units one 100 per
cent boiler feed pump driven by a bled steam turbine and
two 50 per cent pumps driven by electric motors through
gearboxes are provided per unit.
I n the stations with 660-MW units one 100 per cent
turbine-driven feed pump will be provided per unit, but
its turbine will now be fed with live steam as well as bled
steam. This permits it to be brought on at a much lower
load than the purely bled steam turbines, for which
insufficient bled steam is available until a load approaching
50 per cent is reached. With this and the considerable
design effort that has been put into making these new
pumps less susceptible to damage, coupled with the quick
change-over that can be achieved in the event of failure,
a reduction in installed stand-by is considered to be
economically justified.
Accordingly, only one 50 per cent motor-driven pump
per unit will be installed at these stations, although two of
the earlier ones will have two 50 per cent pumps per unit
since they had been ordered before a firm decision had
been taken. Although all the prototype pumps had been
run at the time of going to press, there had not been
sufficient experience to fully support this decision. None
the less, it is still considered correct.
At each station one spare cartridge or, in the case of the
Harland design (3), one spare pump, will be kept in the
stores for each size of pump. This change should lead to
significant reduction in station construction costs without
more than a very small loss of availability.
The starting pump duty is determined by the boiler feed
demand when raising pressure and temperature to the
values at which steam may be admitted to the turbine.
For the once-through boilers of the A.G.R. stations
the minimum flow is high enough to justify the use of
the already developed 50 per cent duty pumps, but
for the oil-fired drum-type boilers of the 660-MW units
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F. 0. J. OTWAY
at the Isle of Grain only one 15 per cent starting pump
per unit is specified.
In all cases, both on 500- and 660-MW units, speed
variation on the motor-driven pumps at C.E.G.B. power
stations is provided by the use of slip-ring induction
motors. On a number of occasions consideration has been
given to the alternative use of squirrel cage motors and
fluid couplings. Although the reliability of fluid couplings
is not in doubt, it has not been possible to make out an
economic case for a change, bearing in mind that the
starting current for a squirrel cage motor is approximately
double that of a slip-ring motor and so will necessitate
auxiliary electrical gear of higher rating. The slip-ring
motors have performed very satisfactorily. They also have
the advantage that start-up time is less, so reducing the
likelihood of having to trip a unit on sudden loss of the
main turbine-driven pump.
Looking ahead, when larger units will be constructed,
the next jump may be expected to be to 1200-1300-MW
units. For these it would seem sensible to retain the
existing starting pump designs, which would effectively
become 25 per cent pumps. One per unit should be
sufficient. Such a decision would mean that no further
development would be required on the slip-ring motors or
gearboxes. The main pumps would continue to be rated
at 100 per cent. No problems are foreseen in the designs
of them or their driving turbines.
A number of boiler feed pump designers foresee the use
of single-stage pumps, possibly integrated with their
driving turbines. This may be the long-term development;
if so, it should be allowed to develop naturally. Consider-
able advantages should accrue from the two- and three-
stage designs now being installed by the C.E.G.B. The
gain from subsequent developments will be smaller. I n the
author’s opinion there is no advantage in getting down to
a single pressure stage if rhis results in the suction stage
pump needing to be a multi-stage design. In addition, the
integral pump turbine will only be worth while if:
(1) Oil lubrication can be completely eliminated. This
depends on satisfactory development of water-lubricated
thrust bearings of substantial load capacity.
(2) The rapid change-over facilitity and essential
features of the ‘dry running’ concept are not prejudiced.
TESTING O F BOILER FEED P U M P S
With the increase in power consumption of boiler feed
pumps as unit size has increased, pump manufacturers
may no longer be able to carry out full-load works tests on
100 per cent duty boiler feed pumps. Since the feed water
flow requires to be measured very accurately for the turbo-
generator acceptance tests, the C.E.G.B. decided a few
years ago that the guarantees on 100 per cent duty boiler
feed pumps supplied to them should also be based on
site acceptance tests, with the guarantees on the 50 per cent
duty motor-driven pumps continuing to be based on works
tests results.
It is intended that the main feed pump site acceptance
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 THE DESIGN PRINCIPLES FOR BOILER FEED PUMPS FOR C.E.G.B. 660-MW UNITS 17

tests will be carried out at the same time as the acceptance I n addition, the author gratefully acknowledges the
test on the associated turbo-generator. The power trans- kind permission given to reproduce the following illus-
mitted from the driving turbine will be measured by a trations: Mather and Platt Ltd for Fig. 2.1; G. and J.
torquemeter-normally of the optical type; this will Weir Ltd for Fig. 2.2.
eliminate any doubt about the transmitted power between
the turbine and feed pump which needs to be known for A P P E N D I X 2.1
the turbine acceptance tests. A site test code has been REFERENCES
prepared for these tests (9), but at the time of going to (I) ANDERSON, H. H. ‘Design of modern boiler feed pumps’,
press no site test on a boiler feed pump has been carried Proc. Instn mech. Engrs 1961 175, 12.
out. (2) ARKLESS, G. F. ‘Development of high-pressure boiler feed
pumps in Britain during the last decade’, Cum. on Steam
CONCLUDING REMARKS Plant Ancillary Equipment, Proc. Instn mech. Engrs 196667
181 (Pt 3N), 6.
This paper has outlined the reasoning that led the (3) RICHARDSON, J. and TAYLOR, J. M. ‘A feed pump design
C.E.G.B. to specify high-speed boiler feed pumps with concept for 660-MW generating sets’, Paper 1 of this
stiff shafts and other novel features for use with their 660- Convention.
MW units. The first prototype pumps with these new (4) LEITH, T. O., MCCOLL,J. R. and RYALL,M. L. ‘Advance
features are installed and preliminary indications are that class boiler feed pumps for 660-MW generators’, Paper 4
they will prove successful. of this Convention.
With the greater reliability expected from these designs, ( 5 ) WELDON,R. ‘Boiler feed pump design for maximum avail-
ability’, Paper 3 of this Convention.
less stand-by capacity should be required, and this ought (6) BARKER,B. and BLACKMORE, R. H. ‘Glandless pumps in
to lead to overall economies in the costs of boiler feed pump C.E.G.B. power stations’, Symp. on Glandless Pumps for
installation and operation in the long term. Power Plant, Proc. Instn mech. Engrs 1969-70 184 (Pt 3K), 1.
(7) CHESHIRE, L. J. ‘Centrifugal compressors for aircraft gas
turbines’, Proc. Instn mech. Engrs, W.E.I. No. I 2 1945.
ACKNOWLEDGEMENTS (8) DUSSOIJRD, J. L. ‘An investigation of pulsations in the boiler
The author wishes to thank the Central Electricity feed system of a central power station’,?. bas. Engng, Trans.
Am. SOC.mech. Engrs 1968,607.
Generating Board for permission to publish this paper,
(9) C.E.G.B./B.E.A.M.A. TURBINE ACCEPTANCETESTCOM-
Grateful acknowledgement is made to his colleagues for MITTEE ‘Site performance testing of boiler feed pumps’,
suggestions that they have made. C.E.G.B. Site Test Code N o . I 1969, Issue 2.

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