SGWC PUMPS IN

500MW UNITS

RAJIREDDY K
SR.ENGR(O)
 Circulation in Boiler
The steam generator has to produce steam at highest purity, and
at high pressure and temperature required for the turbine. Water
must flow through the heat absorption surface of the boiler in
order that it be evaporated into steam Natural circulation is the
ability of water to circulate continuously, with gravity and changes
in temperature being the only driving force known as "thermal
head“.

The ratio of the weight of water to the weight of steam in the

mixture leaving the heat absorption surfaces is called
Circulation Ratio.

Cold feedwater is introduced into the steam drum where, because the density of the
cold water is greater, it descends in the 'downcomer' towards the lower bottom ring
header, displacing the warmer water up into the front tubes.
Continued heating creates steam bubbles in the front tubes, which are naturally
separated from the hot water in the steam drum, and are taken off.
 Natural Circulation & Forced
Circulation
Natural Circulation
 The downcomer contain relatively
cold water, whereas the riser tube
contain steam water
mixture ,whose density is
comparitively less .this density
difference is the driving force ,for
the mixture. (thermo-siphon
principle)
 Circulation takes place at such a
high rate that the driving force
and frictional resisitance in water Natural Circulation Forced Circulation
wall are balanced.

Forced Circulation
 Beyond 180 Kg/cm2 of pressure, circulation is to be assisted with
mechanical pumps, to overcome frictional losses. To regulate the flow
through various tubes, orifice plates are used. This system is applicable in
the high sub-critical regions (say 200 Kg/cm2).
 Why controlled circulation is
•
required?
AS THE PRESSURE INCREASES,THE
DIFFERENCE IN DENSITY BETWEEN
WATER AND STEAM REDUCES .
• THUS THE HYDROSTATIC HEAD
AVAILABLE WILL NOT BE ABLE TO
OVERCOME THE FRICTIONAL
RESISITANCE FOR A FLOW
CORRESPONDING TO THE
MINIMUM REQUIREMENT OF
COOLING OF WATER WALL TUBES.
• NATURAL CIRCULATION IS LIMITED
TO 175KSC

Diff in Density
 SGWC Pump
• The circulator consists of a single stage
centrifugal pump and a wet stator induction
motor which are mounted within a common
pressure vessel.
• The vessel consists of three main parts,
• A pump casing
• Motor housing
• Motor cover
• The motor is suspended beneath the pump
casing and is filled with boiler water to full
system pressure.
 PUMP SPECIFICATIONS
• Type: Single suction- double discharge
• Design pressure: 208ksc
• Design temp: 366 deg C
• Normal operating duty
• Suction pressure: 194.16ksc
• Pumping temp: 362 deg C
• Sp. gravity at pump suction at pumping temp: 0.5993
• Quantity pumped: 47990 L/min
• Differential head: 32.55m
• Differential pressure: 1.948ksc
 SGWC Pump

Cut a way illustration of the

circulator
 SGWC Pump
• No seal exists between the pump and motor, but provision is made to
thermally isolate the pump from the motor in the following respect:
• Thermal conduction. - thermal neck to minimize heat conduction from
pump at above 340 deg C to the motor whose temp is limited to about 54
deg C
• Hot water diffusion. To minimize diffusion of boiler water, a narrow
annulus surrounds the rotor shaft, between the hot and cold regions. A
baffle ring restricts solids entering the annulus.
• Motor cooling. The motor cavity is maintained at a low temp by a heat
exchanger in a closed loop water circulation system, thus extracting the
heat conducted from the pump.
• In addition, this water circulates through the stator and bearings
extracting the heat generated in the windings and also provide bearing
lubrication. An internal filter is incorporated in the circulating system.
• In emergency conditions, if low pressure coolant to the heat exchanger
fails, or is inadequate to cope with heat flow from the pump case, a cold
purge can be applied to the bottom of the motor to limit the temp rise.
 MOTOR SPECIFICATIONS
• Make: Hayward Tyler
• Type : Wet stator – squirrel cage induction motor
• Output: 336kW
• Motor case design temp: 343 deg C
» HOT DUTY COLD DUTY
• Motor efficiency : 86.8% 88.7%
• kW input: 209.6 342.3
• Power factor : 0.72 0.81
• Overall efficiency : 72.9% 74.5%
• Full load current: 25.4A 37 A
• Full load speed: 1450 rpm
• Supply voltage: 6.6kV
• Motor starting current: 190A
 Motor
• The motor is a squirrel cage, wet stator, induction motor, the stator
wound with a special water-tight insulated cable.
• The phase joints and lead connections are also moulded in an insulated
material. The motor is joined to the pump casing by a pressure tight
flange.
• The motor shell contains all the moving parts, except for the impeller.
Below the impeller is situated an integral heat baffle which reduces the
heat flow, a combination of convection and conduction, down the unit. A
baffle wear ring-cum-sleeve above the baffle forms a labyrinth with the
underside of the impeller to limit sediment penetration into the motor.
Should foreign matter manage to pass the labyrinth device into the motor
enclosure, it is strained out by a filter located at the base of the cover-end
bearing housing.
 MOTOR

• Within the pump cavity rotates a key driven, fully

shrouded, mixed flow type impeller, mounted on
the end of the extended motor shaft. Renewable
wear rings are fitted to both the impeller and
pump case. The impeller wear ring is the harder
components to prevent galling
 Aux. Cooling Circuit
• The motor is provided with its own auxiliary
closed circuit, which besides cooling the motor
lubricates the bearing.
• The water is continuously circulated through the
bearings, motor windings and an external heat
exchanger (cooler), by an auxiliary impeller at the
thrust bearing end of the motor shaft.
• When the motor is stationary, thermo-siphon
circulation takes place to remove conducted heat
from pump end of the motor.
Aux. Cooling Circuit
 Bearings
• Two Journal bearings, at pump end and motor cover end.
• One thrust bearing, situated below the motor cover end
journal bearing and takes the full hydraulic thrush of the
pump.
• The thrust disc is also designed to operate as an auxiliary
impeller to circulate the internal water content of the
motor.
• Reverse thrust bearing, the weight of the rotating
component and thrust imposed at start up / shut down are
taken by the reverse thrust bearing. It’s a stationary
component on which the thrust disc/auxiliary impeller
operates.
 Internal Filter
A stainless steel woven wire strainer, fitted at the
base of the reverse thrust seat housing, filters the
liquid in the motor before it is circulated through the
bearings after passing through the heat exchanger
(cooler).
The filter should be cleaned at normal maintenance
periods, removing any accumulation of foreign matter
in the motor cover.
 Terminal gland
• The electrical supply to the motor is taken through special high pressure,
single lead cable, terminal glands, of the high temperature, safety type.
• The seal is effected by a terminal gland moulding, together with o-rings
located between an insulating sleeve and an inner casing, and between
the inner casing and the motor case. The addition of a cone shaped collar
within the terminal moulding, plus the design of the inner casing,
prevents any possibility of a gland blowout at high temperatures.
• However, if the motor is subjected to sustained overheating, a slight
leakage may occur into the terminal box, this is protected by the terminal
box being pressure tight.
Terminal gland
 Heat Exchanger
• A heat exchanger (cooler) must be fitted to dissipate
the heat generated by the motor winding and heat
conducted from the pump.
• Brackets are provided on the motor case to mount
the heat exchanger.
• High pressure inlet and outlet connections are
situated at the top and bottom of the motor case
respectively for connection to high pressure heat
exchanger/motor case stub pipes.
 Instrumentation
• Thermometer(Local)– to measure motor temp
• Temp switches(Two)
– one for alarm on cavity temp hi
– another one for tripping the motor on cavity temp
hi-hi
• Thermocouples(Three)
– One for UCB display of cavity temp
– Two more for measuring skin temp of pump
casing and suction manifold resp to calculate DT.
 Instrumentation
• DP transmitters (Two) - To measure dp across
the pump used for initiating dp low alarm,
boiler trip and runback operation

• Flow meter- provided in ECW return line from

heat exchanger, used as permissive.
• OPERATION
 ECW Supply For SGWC Pumps overflow
Emergency CW
Tank (72 m)
To 55m furnace
drain access door
LHS/RHS cooling

Fill and Purge cooler FILL&PURGE WATER IN

FILL&PURGE WATER OUT

SGWC
A
FS SGWC B SGWC C

To 10.2m furnace
access door
LHS/RHS cooling
ECW
supply/return
boiler LHS ECW
supply/return
boiler RHS
SGWC booster
pumps
ECW supply header – boiler side

ECW return header – boiler side

 Fill source from CEP
SGWC Pumps Motor Cavity Fill And Purge discharge
Fill source from Boiler
System STRAINER fill pump

Purge source from BFP

discharge
Fill and Purge cooler ECW IN

ECW OUT
TO PUMP A TO PUMP C

INTER TIE
STRAINER TO/FROM
casing PUMPS A & C
vent

drain

casing drain

SGWC
PP – B FS
MOTOR

ECW OUT
ECW IN
drain
INITIAL FILLING AND VENTING OF THE
PUMP
• Prior to starting a pump make sure it was properly filled and
vented in accordance with procedures. Bearing failure will
occur immediately if pump is run dry.
• It is extremely important that the motor cavity remains filled
with liquid at all times.
• IT IS ESSENTIAL THAT FILL AND PURGE LINES ARE FLUSHED TO
ATMOSPHERE BEFORE ADMITTING WATER INTO MOTOR
CAVITY . EFFLUENT SHOULD BE CHECKED WITH A FILTER TEST
TO ASSURE CLEANLINESS.
 Fill source from CEP
LINE FLUSHING BEFORE MOTOR CAVITY discharge
Fill source from Boiler
FILLING STRAINER fill pump

Purge source from BFP

discharge
Fill and Purge cooler ECW IN

ECW OUT
TO PUMP A TO PUMP C

INTER TIE
STRAINER TO/FROM
casing PUMPS A & C
vent

drain

casing drain

SGWC
PP – B
MOTOR

drain
 Fill source from CEP
FLOW SETTING BEFORE MOTOR CAVITY discharge
Fill source from Boiler
FILLING STRAINER fill pump

Purge source from BFP

discharge
Fill and Purge cooler ECW IN

ECW OUT
TO PUMP A TO PUMP C

INTER TIE
Throttle this STRAINER TO/FROM
casing PUMPS A & C
valve to set 1.5 vent
LPM flow in the
strainer drain
drain

casing drain

SGWC
PP – B
MOTOR

drain
 Fill source from CEP
MOTOR CAVITY FILLING discharge
Fill source from Boiler
STRAINER fill pump

Purge source from BFP

discharge
Fill and Purge cooler ECW IN

ECW OUT
TO PUMP A TO PUMP C

INTER TIE
STRAINER TO/FROM
casing PUMPS A & C
vent

drain

casing drain

SGWC
PP – B
MOTOR

drain
 OPERATION
• Pre Start Checks
– Ensure that the circulator is completely vented.
– Ensure that the low pressure cooling water valves are open and the cooling
water flow rate is adequate.
– Ensure that the high pressure cold water purge at 20°c maximum temperature is
connected but isolated.
– Make sure the temperature differential between the suction manifold and
pump casing does not exceed 100°F.
– Using a 1000V megger, check that the insulation resistance to ground of the
motor leads is above5megohms when measured at the terminal stems with the
unit full of water below approximately 20°c, if possible, or a t normal local
ambient temperature.
– Test the operation of all instrumentation and alarms.
– Ensure inter tie valves are open for standby pump warm-up
– Ensure that sufficient N.P.S.H. is available for the pump to run without
cavitation.
– Ensure that the stems of the discharge valves are open.
 OPERATION
• The unit circulation system is designed to operate at full load with two
pumps in service. The third pump can be kept in service for increased
operating flexibility.
• With one boiler circulating pump in service continuous operation at 60%
MCR is permitted .
• Boiler Operation with all boiler circulating pumps out of service is not
permitted.
• For start-up, it is recommended that at least two circulating pumps be in
service. The pumps must be in service before lighting up.
• THE DRUM VENTS MUST BE CLOSED BEFORE STARTING A PUMP TO
PREVENT BOILER WATER FROM BEING DISCHARGED.
• Before starting a pump, make sure the drum water Level is high (80% in
hydrastep). Maintain proper water level after the pumps have been
started.
 OPERATION
• During start up place only two pumps in service to
minimize flashing in the down comer.
• The third pump should be started before the boiler
drum pressure reaches 100 psig to minimize pump
starting temperature transients.
• Pumps should not be started during intervals of rapid
boiler water temp change (15 F in 15 min).
 OPERATION
• SGWC pump can be started when the following permissives are satisfied,
– Discharge valve -1 open
– Discharge valve - 2 open
– Motor cavity temperature Normal
– Suction manifold - Pump casing differential temperature normal
– Motor cooling water flow adequate
• Cold start:
– complete pre start check list.
– Open the discharge valves
– Place the pump in service
• Hot start:
– Complete pre start check list.
– Ensure casing –suction manifold DT is within limit.
– Place the pump in service.
 OPERATION
• Protections
Running SGWC pump trips in case of the following conditions:
– Discharge valve - 1 not fully open
– Discharge valve - 2 not fully open
– Motor cavity temperature high - >60oC

• Interlocks
Standby pump starts if,
– Any pump running and P < 10 psi
– Any running SGWC pump tripped
– Boiler load > 60 % and any two SGWC pumps in service and P < 18 psi

• CMC Runback:
– DP>18 Psi is used to count number of pumps in service and not the pump running
contacts.
 Operation
• Boiler “inadequate water wall circulation”
protection:
SGWC pump A
not in service
SGWC pump –A
Ineffective
OR

SGWC pump A
DP < 10 Psi SGWC pump –B
Ineffective 5s time MFT
AND delay

SGWC pump –C
Ineffective
 Operational checks
• Motor current (Cold duty:37A, Hot duty:25 A)
• Insulation resistance- >30megaohms with
• Motor cavity temperature initiate a high pressure
purge if cavity temperature exceeds limit (54oC).
– Excessive purge flow is not advisable – may lead to high
temp transients in pump casing. Adjust purge flow so that
cavity temp is slightly above limit.
• Cooling water Flow
• Check for leaks and vibration
• Instruments
 Fill source from CEP
MOTOR CAVITY PURGING DURING discharge
Fill source from Boiler
SERVICE STRAINER fill pump

Purge source from BFP

discharge
Fill and Purge cooler ECW IN

ECW OUT
TO PUMP A TO PUMP C

INTER TIE
STRAINER TO/FROM
casing PUMPS A & C
vent

drain

casing drain

SGWC
PP – B
MOTOR

drain
 CAVITY DRAINING
• If the motor should be drained after the
pumps have been filled, the pump the
discharge valves must be closed prior to
draining the boiler to prevent the
accumulation of sediment in the pump casing
• Draining boiler water from the pump casing
through the motor cavity will result in damage
to the motor
 Fill source from CEP
MOTOR CAVITY DRAINING discharge
Fill source from Boiler
STRAINER fill pump

Purge source from BFP

discharge
Fill and Purge cooler ECW IN

ECW OUT
TO PUMP A TO PUMP C

INTER TIE
STRAINER TO/FROM
casing PUMPS A & C
vent

drain

casing drain

SGWC
PP – B
MOTOR

drain
THANQ

BY RAJIREDDY
SR.ENGR(O)