A.

INTRODUCTION
1. Background
In the development of technology, demand for power is being critical. So it
takes a lot of power plant, steam power plant is one of power plant that is growing. In
the system of steam power plants there are several major components.
Boiler and pump are vital component in the system of steam power plants.
Pumps used in the system is a boiler feed pump turbine (BFPT), required the
maximum performance of the two components so that the desired power is reached.
And also Boiler how can a steam power plant does not have any boiler. This
component has a main task for producing the steam.
Therefore, knowledge about the boiler and the pump is very important to
learn. the science of plant equipment required for the basic ability of students in the
working world. Where the science is about the theory, maintenance, engine
performance, engine specifications, etc. on the basis of the students know how to
operate and care about the component.
2.
1.
2.
3.

Objectives
To know about BFPT and Boiler Use in Power Plant.
To know how do BFPT and Boiler work and how do we maintain It.
To know several problems in BFPT and Boiler.

3. Limitation
We only discuss BFPT and Boiler in General
4. Formulation Of Problems
Boiler Feed Pump Water and Boiler are components that is played a vital
function in steam power plant. Bad performances or even the failure from these each
of componnets that will be affected to the performances of the power plant. So we
need to know the work condition and the maintenance of these componnets. Knowing
those things will lead us to know how we prevent and keep a sustainable good
performance of these factory equipments.

B. THEORY AND ANALYSIS

Power Plant has a cycle work to do the function of it. There are cycles
system that is used in power plant. Steam power plant is used rankyne cycle for
processing the energy. We can see it from the diagram below :

Figure. 1 BFPT In Steam Power Plant System

1. Boiler Feed Pump Turbine

Pump definition
The pump is a transport aircraft that aims to move the liquid through a
closed channel. On that basis, the pump should be able to raise the pressure of
the fluid that can flow or move. Displaced fluid is an incompressible fluid or
fluid that can not be compressed. Under certain conditions the pump can be
used to remove solids in the form bubukan or flour.

Pump classification
In general, the pump can be divided into two major groups, namely:

Dynamic Pump Group

1. Centrifugal Pump
A centrifugal pump consists of an impeller and the inlet channel in the
middle. With this design so when the impeller rotates, the fluid flows towards
the casing around the impeller as a result of centrifugal force. Casing serves to
decrease the velocity of fluid flow while high speed rotating impeller fixed.
Fluid velocity is converted into pressure by the casing so that the fluid can
travel to Point outlets.

Figure. 2 Centrifugal Pump

2. Axial Pump
Axial pump also called propeller pump. This pump produces the most
pressure from the propeller and the lifting force of the blade against the fluid.
These pumps are used in drainage and irrigation system.

Figure. 3 Axial Pump

3. Special-Effect Pump
A. Jet-Eductor Pump (injector)
Jet-eductor pump (injector) is a tool that uses the venturi effect and
convergent-divergent nozzle for converting pressure energy of a moving fluid
into mechanical energy into creating a low-pressure area, and can suck fluid
on the suction side.

Figure. 4 Jet Eductor Pump

B. Gas Lift Pump

Gas Lift Pump is a way to lift the fluid in a column by way of injecting
a specific gas that causes severe drop in hydrostatic and fluid so that the
reservoir can be lifted to the surface.
C. Hydraulic Ram Pump
Hydraulic Ram Pump is a cyclic water pump using hydro power
(hydropower).
D. Electromagnetic pump
Electromagnetic pump is a pump that moves the fluid metal by using
electromagnetic force.

Figure. 5 Electromagnetic Pump

Positive Displacement Pump

Positive Displacement Pumps work by providing a certain style to the
volume of fluid remains on the inlet side of the pump outlet to the point. The
advantages of using this type of pump is able to generate power density (force
per unit weight) is greater. And also provides transfer fluid that is fixed or
stable in every rotation. Various Positive Displacement pumps, namely:

1. Reciprocating Pump
In this type of pump, a volume of fluid into the cylinder through the
inlet valve at the time of entry and the next step is pumped out under positive
pressure through the valve outlet on moving ahead. The fluid that comes out
of the pump Reciprocating, throbbing and can only be changed if the pump
speed changes. This is because the volume of the inlet are constant.

Figure. 6 Reciprocating Pump

2. Rotary Pump
Rotary pump is the pump that moves the fluid by using the principle of
rotation. Vacuum formed by the rotation of the pump and then suck the fluid
entry. Rotary pump can be reclassified into several types, namely:
3. Gear Pump
A simple rotary pump where the fluid is forced to use two gears.

Figure. 7 Gear Pump

4. Screw Pumps
These pumps use two screws that meet and spun to produce fluid flow
as desired.

Figure. 8 Screw Pump

5. Rotary Vane Pumps

It has the same principle with a scroll compressor, which uses a
cylindrical rotor which rotates in harmony to produce a certain fluid pressure.

Figure. 9 Rotary Vane Pump

Boiler Feed Pump Turbine

A boiler feedwater pump is a specific type of pump used to
pump feedwater into a steam boiler. The water may be freshly supplied or
returning condensate produced as a result of the condensation of the steam
produced by the boiler. These pumps are normally high pressure units that
take suction from a condensate return system and can be of the centrifugal

pump type or positive displacement type. Function of BFPT is to increase of

preassure to main drum and pumping water to main drum too.

Figure. 10 Boiler Feed Pump Turbine

Boiler feed pump turbine use energy from steam turbine to get rotate
of impeller of pump. Rotation of steam turbine get transmitted to shaft of
impeller pump also Boiller feed pump turbine booster.

Figure. 11 Boiler Feed Pump Turbine Schematic

General Components Of Boiler Feed Pump Turbine

1. Turbine Driven
Supplies necessary torque to spin the pump at the design speed.
2. Main Pump
It has similar function as the general pump function. The type is multi-stage
centrifugal pump.
3. Booster Pump

Single or double stage, double suction centrifugal pump. Supplies required

NSPH to the main pump. The Booster pump takes suction from dearator.
4. Booster Pump Speed Reducer
It reduces the turbine shaft speed to the required operating speed of the
booster pump. This is usually around 1800 RPM.
Performances Of BFPT

Pump performance formulation

Talk about the performance of a machine of any kind, we are referring
to how well the machine was able to convert one form of energy into another
form of energy. Reduction of energy generated by a machine is due to the loss
or losis. Similarly, the efficiency of the pump that converts electrical energy
into mechanical energy to rotate the impeller so that the pump can transfer
fluid from the lower place to a higher place. Here is the formula to calculate
the efficiency of the pump:

Where
Pump efficiency (%)
Hydrolic Power (Kw)
Shaft Power (Kw)

1. Hydrolic power (Pw)

Calculate Hydrolic power

Where :
Q

= Flowrate (m3/s)

= density (kg/m3)

= Gravity accleration ( m/s2)

= Head (m)

If the capacity, density and gravitational acceleration has been found in

the specification and has been known, it will be seeking Head (H), the
following is the formula for calculating Head (H):

Dimana :

= Total Head Pump (m)

Ha

= Head Static pump (m)

= Different Pressure at two surface (m)

= losses (m)

= Gravity accleration (9,81 m/s)

2. Head static pump (Ha)
Static head is the difference in altitude (elevation) on the out
side (end process) pump with the suction side of the pump. Expressed
in units of meters (m).
3. Head at different pressure at two surface (hp)
Expressed by the formula

Where :
P1 = Pressure inlet (suction ) pump (Kgf/m)
P2 = pressure outlet pump (Kgf/m)

= density (kg/m3)

= Gravity accleration (m/s2)

Head Losses (Hf)

Head loss is head to overcome losses consisting of head frictional
losses in pipes, losses in bends, enlarging and reducing losses in pipes, losses
on branching and losses on the valves.
Before calculating the head loss would be nice to compute the data that has
not been in the can at the data source that the author collected. Some of these
data must be calculated before calculating the head loss is the capacity of each
flow in the pipe and the average speed on the flow of each pipe.

Spesification
Boiler Feed Pump Unit
Pump structure
BFP
oppositely

: Barrel with double valote, horizontal split inner casing, 4 stages

Booster BFP

: Double volute , vertical split casing. Back pull out, single stage.

Pump model No.

: MDG424 + MCL450 X 350M

Capasity (Suction)

: 1410 m3/h

Minimum flow

: 450 m3/h (200

Total head

: 2670 m : ( BFP 2590 m + Booster BFP 80 m)

Suction press

: 14.2 kg/cm2 design condition

Pumping temp

: 1870C

Pump speed

: 5720 rpm

Disch. Bore

: 350A BW

Suct. Bore

: 350A BW

Effeciency

: 84%

m3/h pada booster BFP)

Maker

: Mitsubishi Heavy Industries, Ltd.

Takasago Machinery Works

Several Problems And Maintenance Of BFPT

Kind of problem can happen at BFPT

1)The existence of foreign matter in impeller ( vibrasi excess and discharge less )
2)Misalignment (vibration)
3)Shaft get deformation ( high vibration and more heat at bearing )
4)Pump doesnt get full performance ( decrease effeciency)
5)Pressure inlet and discharge not enough

(decrease discharge, more

heat,vibration)
6)Bearing damaged / less lubracation ( more heat at bearing)

Foreign

Foreign

Component
Damage

Component
Damage

Bearing

Component
Damage

Component
Damage

Shaft
Figure. 12 Failure In BFPT

Maintenance :
1. lean bearing bracket from any oil if found.
2. Check oil drain plug.
3. Lubricate the bearings.

Shaft

4. Inspect suction and discharge flanges for any leak.

5. Inspect pump casing for any unusual damage signs.
6. Inspect the seal.
7. If the pump is offline check the coupling and its shims for any damage.
8. Make sure that the coupling guard s well tightened to pump base plate.
9. Check that motor alignment bolts are all in place.
2. Packaged Boiler
Boiler, also called Steam Generator, apparatus designed to convert a
liquid to vapour. In a conventionalsteam power plant, a boiler consists of
a furnace in which fuel is burned, surfaces to transmit heat from
the combustion products to the water, and a space where steam can form and
collect. A conventional boiler has a furnace that burns a fossil fuel or, in some
installations, waste fuels. A nuclear reactor can also serve as a source of heat
for generating steam under pressure.

Figure. 13 Boiler

The basic working principle of boiler is very very simple and easy to
understand. The boiler is essentially a closed vessel inside which water is
stored. Fuel (generally coal) is bunt in a furnace and hot gasses are produced.
These hot gasses come in contact with water vessel where the heat of these

hot gases transfer to the water and consequently steam is produced in the
boiler. Then this steam is piped to the turbine of thermal power plant. There
are many different types of boiler utilized for different purposes like running a
production unit, sanitizing some area, sterilizing equipment, to warm up the
surroundings etc.
In our discussion we will talk about packaged boiler because boiler has
several type of boiler. Packaged boiler is one of the type of it. It has several
advantage as below :

Small combustion space and high heat release rate resulting in faster
evaporation.

Large number of small diameter tubes leading to good convective heat

transfer.

Forced or induced draft systems resulting in good combustion efficiency.

Number of passes resulting in better overall heat transfer.

Higher thermal efficiency levels compared with other boilers.

Figure. 14 Packaged Boiler

The pressure vessel of a boiler is usually made of steel (or alloy steel),
or
historically
of wrought
iron. Stainless
steel,
especially
of
the austenitic types, is not used in wetted parts of boilers due to corrosion and
stress corrosion cracking. However, ferritic stainless steel is often used in
superheater sections that will not be exposed to boiling water, and electricallyheated stainless steel shell boilers are allowed under the European "Pressure
Equipment Directive" for production of steam for sterilizers and disinfectors.
In live steam models, copper or brass is often used because it is more
easily fabricated in smaller size boilers. Historically, copper was often used
for fireboxes (particularly forsteam locomotives), because of its better
formability and higher thermal conductivity; however, in more recent times,
the high price of copper often makes this an uneconomic choice and cheaper
substitutes (such as steel) are used instead.
Cast iron may be used for the heating vessel of domestic water heaters.
Although such heaters are usually termed "boilers" in some countries, their
purpose is usually to produce hot water, not steam, and so they run at low
pressure and try to avoid actual boiling. The brittleness of cast iron makes it
impractical for high-pressure steam boilers.
The Key Component of The Boiler

Burner The burner is the component of boiler that provides the heat that
heats the water of system. The fuels used can be natural gas or oil.

Heat exchanger The heat exchanger of boiler allows the heat from the
burner to heat the water in system. The job of the heat exchanger is to carry
the heat from the burner to the water without having direct contact with the
water. Its a similar idea to boiling water in a pot.

Supply lines Hydronic heating systems use piping to deliver the heated
water or steam to the distribution points, and the supply lines are the pipes
that distribute the hot water or steam to distributor.

Return lines When the water cools, or the steam cools and changes states
back to water, the return lines bring this water back to the boiler for reheating.

Firebox The firebox is where the fuel of system meets the air, creating a
flame

Steam Drum The steam drum is the upper drum of a water-tube boiler
where the steam separates from the liquid water. The lower drum is referred to
as the mud drum and it contains the liquid water.

Boiler Tubes The boiler tubes are the tubes through which the steam passes
as it makes its way through the boiler. High strength carbon steel is often used
in the fabrication of boiler tubes to make it more durable and to resist
problems associated with corrosion or mineral deposits.

Superheater The superheater is used to remove excess moisture content

from the steam by raising it above its saturation point. This is particularly
important if the steam is being used for power generation because water
droplets in the steam could damage the turbines. Because of the high
temperature demands placed on superheaters, a higher alloy steel is typically
used in their construction.

Attemperator Attemperators help control the degree of superheat and help

regulate superheat temperature. To do this, they partially de-superheat the
steam by injection of water into the superheat steam flow.
Boiler Performances
The percentage of total heat exported by outlet steam in the total heat
supplied

by

the

fuel(coal)

is

called

steam

boiler

efficiency.

It includes with thermal efficiency, combustion efficiency & fuel to steam

efficiency. Steam boiler efficiency depends upon the size of boiler used. A
typical efficiency of steam boiler is 80% to 88%. Actually there are some
losses occur like incomplete combustion, radiating loss occurs from steam
boiler surrounding wall, defective combustion gas etc. Hence, efficiency of
steam boiler gives this result.
Failure In Boiler
Most of the failure in boiler is the tube failure. Because it will be high
temperature inside and direct contact with the fluid. This direct contact means
high possibility to be corroded.
Tube failures are classified as in-service failures in boilers. These failures can
be grouped under six major causes:
1.

Stress rupture

2.

Fatigue

3.

Water side corrosion

4.

Erosion

5.

Fire side corrosion (Called also as High temperature Corrosion)

6.

Lack of quality control.

These lead to twenty-two primary causes that can cause a tube failure in a
high pressure boiler:

Short term overheating failure

Long term overheating failure (called also as creep failures)

Dissimilar metal weld failure

Fatigue caused by vibration

Thermal fatigue due to temperature fluctuation

Corrosion fatigue failures

Caustic corrosion inside the tube

Hydrogen damage in water wall internal surface

Tube internal pitting

Fly ash erosion

Falling slag erosion

Soot blower erosion

Coal particle erosion

Low temperature flue gas corrosion

Fire side waterwall corrosion

Coal ash corrosion

Maintenance of Boiler
To prevent the failure we need do some preventive maintenance
method such as this table below. This table contents contains check list of
maintenance.

Table. 1 Maintenance Check List Of Boiler

C. CONCLUSION
1. BFPT and Boiler has a vital function in steam power plant.
2. Each of this has several maintenances requirement to prevent and detect the
failures.
3. Most of the failures of these components happen because of the corrosion and
also because of the heat. These are because of the work condition of these
equipments