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Sulzer ISO 13709 (API 610) Type BB5 Barrel Pumps

Sulzer Pumps

The Heart of Your Process

Long History of Barrel Pumps

Sulzer Pumps

GSG Sales Presentation | slide 2

Barrel Pumps: Diffuser Style

Sulzer Pumps

45 MW SuperCritical Boiler FeedGSG Sales Presentation | slide 3

Types of Horizontal Multistage PumpsVolute - Horizontal Split Diffuser - Segmental Ring

Sulzer Pumps

Volute Barrel

BB3 BB4 Not used on H.C. BB5

Diffuser Barrel CasingBB5

High Speed Diffuser BarrelBB5

GSG Sales Presentation | slide 4

Volute vs. Diffuser CasingsRadial loads increase at lower flow, and at flow rates beyond best efficiency point. The result is an unbalanced radial load on the rotating element. Small, low flow pumps have relatively small radial loads. Single Volute Casing

Sulzer Pumps

FR

GSG Sales Presentation | slide 5

Volute vs. DiffuserA dual volute casing has an additional passageway 180 from the main throat area which will almost balance the generated radial force. Horizontally split, dual Volute Multistage Pumps have 1 throat are in the top half, 1 in the bottom half - to balance radial forces. Dual Volute Casing

Sulzer Pumps

FR ~ 0

GSG Sales Presentation | slide 6

MultiStage Dual (MSD) VoluteVolute throat in top half of casing. Volute throat in bottom half is on opposite side for radial force balance.

Sulzer Pumps

Top Half Casing

Bottom Half CasingGSG Sales Presentation | slide 7

Volute vs. DiffuserA diffuser has multiple discharge passageways with equal area distributed throughout the circumference resulting in radial load balance. Diffuser Casing

Sulzer Pumps

FR = 0

GSG Sales Presentation | slide 8

DiffusersDiffuser Discharge Side

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Diffuser Suction Side

Impeller runs in center Return Channels feed next stage

Stage casingsGSG Sales Presentation | slide 9

Axial Thrust DevelopmentOpposed Impeller Design

Sulzer Pumps

Fr Total = 0 Fr 1st Pd 1st Fr xst

X

X

Pd 1st Pd xst

X

X

Pd xst

Unbalanced pressure distribution on impellers results in a thrust in the direction of suction.Opposed impeller design offsets the unbalanced pressure distribution (thrust) effectively balancing axial thrust. When there are odd number of stages, thrust is handled by adjusting the diameter of the throttle bushing with residual handled by a thrust bearing.GSG Sales Presentation | slide 10

Axial Thrust DevelopmentInline Rotor Stack

Sulzer Pumps

Fr Total = Fr 1st+Fr xst Fr 1st Pd 1st Fr xst

FDrum ~ 85% Fr Total FDrum Pd xst Ps

X

X

Pd 1st Pd xst

X

X

Unbalanced pressure distribution on impellers results in thrust in the direction of suction. Stacked impeller design results in adding thrust in the direction of suction. Developed thrust must be compensated by a hydraulic balancing device. Residual thrust is handled by a thrust bearing.GSG Sales Presentation | slide 11

Axial Thrust Compensation Balance DrumClose clearance pressure breakdown

Sulzer Pumps

Balances 85 - 90% of generated thrust. Residual thrust handled by a thrust bearing. With inline rotor stack, this is most reliable design for transient conditions (start up and run down, temperature changes, daily starts and stops).

PSuction

PDischarge

Easy and safe axial rotor setting due to radial gap as compared to axial gap (explained on next slide). Rotor is fixed in the axially position by thrust bearing.Balance Drum Balance Drum Liner

Higher amount of leakage - less efficient.GSG Sales Presentation | slide 12

Axial Thrust Compensation balance disk - Not allowed by ISO 13709 (API 610)

Sulzer Pumps

Balances 100% of the generated thrust.Axial gap will adjust in response to thrust changes

No thrust bearing required. Rotor floats axially for proper operation. Least amount of leakage - higher efficiency. Disc lift off device required for frequent starts and stops ISO 13709 (API 610) Para. 5.7.1 requires radial running clearance be used for axial thrust balance. That precludes the use of this device.

PSuction

PDischarge

Counter Disk Balance Disk

Potential for contact causes this design to be considered less forgiving than balancing drumGSG Sales Presentation | slide 13

Inline Impellers vs. Opposed ImpellersSulzer GSG: Inline diffuser Barrel Pump

Sulzer Pumps

GSG Back-to-Back diffuser Barrel Pump

Sulzer CP: Opposed Impeller Volute Barrel PumpNote: All are ISO 13709 (API 610) type BB5GSG Sales Presentation | slide 14

Inline vs. Opposed Rotor StackDirect drive, inline diffuser barrel pumps are the least expensive barrel pumps to build. High Speed inline pumps require tilting pad thrust bearings and lube system, high speed seals, VFD or gear speed increaser, etc. which add to the cost.

Sulzer Pumps

GSG Sales Presentation | slide 15

Inline vs. Opposed Rotor StackISO 13709 (API 610) requires stable rotordynamics with 2 times normal ISO 13709 (API 610) specified wear ring clearances. Back to back diffuser stack is often used on smaller pumps or high energy pumps with many stages where rotordynamics require a midspan bearing. The Sulzer Thunderhorse 650 Bar, 13MW injection pumps are designed in this manner.

Sulzer Pumps

GSG Sales Presentation | slide 16

The K factor large barrel pumpsK factor2000 1800 1600 1400 1200 1000 800 600 400 200 0 Inline 3.38 Inline 4.25 B-B 3.38 0 40 20 K Factor Shaft Span, in. 120

Sulzer Pumps

Back to Back GSG, HPCP or CP

Rotor Wt. in lbs.100 80 60

Shaft Span, in. Shaft Dia. in. K=(W*L^3/D^4)^0.5

Some say K factor of 3 stages Radial load is balanced

Sulzer Pumps

GSG Sales Presentation | slide 29

Mixing of Impeller Hydraulics with Interstage Bleed OffPumped Medium Density Temperature kinem. Viscosity Head (design) Capacity (design) Total efficiency Pump Power6000

Sulzer Pumps

: : : : : : ::

Boiler Feed Water 909.2 kg/m 318 F 0.19 mm/s 4,600 ft 900 gpm 75.8 % 1,350 HP

Speed : 3570 rpm Stage Number : 8 nq : 20.0 Impeller Set : B/B/B Basis 4335.11.11/2 & 4335.11.11/2 & 4335.11.11/2 Extraction head : 1,268 ft Extraction capacity : 250 gpm

MD 100-300 / 8

Note the all BTender : /1 impeller hydraulics Characteristic : TS/1 Impeller diameter : 11.1 inch Impeller dia. (max) : 11.8 inch : 19 ft NPSHR

Note efficiency = 75.8% and power is 1,350 hp

5000

4000

RATED Max.

By mixing impeller hydraulics efficiency and power can be optimized2 Max. RATED

H [ ft ]

00 gpm

1000

2000

3000

200 gpm

400 gpm

600 gpm

800 gpm

1000 gpm

1200 gpm

1400 gpm

1600 gpm

1800 gpm

2000 gpm

GSG Sales Presentation | slide 30

Mixing of Impeller Hydraulics with Interstage Bleed OffPumped Medium Density Temperature kinem. Viscosity Head (design) Capacity (design) Total efficiency Pump Power6000

Sulzer Pumps

: : : : : : ::

Boiler Feed Water 909.2 kg/m 318 F 0.19 mm/s 4,600 ft 900 gpm 78.7 % 1,301 HP

Speed : 3570 rpm Stage Number : 9 nq : 20.0 Impeller Set : B/B/S Basis 4335.11.11/2 & 4335.11.11/2 & 4335.11.21/1 Extraction head : 1,268 ft Extraction capacity : 250 gpm

MD 100-300 / 9

Now the B hydraulics haveTender : /1 been replaced with S after Characteristic : TS/1 the interstage bleed Impeller diameter : 10.9 inch off. Impeller dia. (max) : 11.0 inch : 19 ft NPSHR

Efficiency now = 78.7% and power is 1,301 hp (49 hp reduction)

5000

4000

RATED Max.

By mixing impeller hydraulics efficiency and power can be optimized2 Max.

H [ ft ]

1000

2000

3000

RATED

00 gpm

200 gpm

400 gpm

600 gpm

800 gpm

1000 gpm

1200 gpm

1400 gpm

1600 gpm

1800 gpm

0

GSG Sales Presentation | slide 31

Bearing Type Selection

Sulzer Pumps

Power @ BEP - HP (3600 rpm)

5000 4000 3000 2000 1000 010 0% 11 0% 12 0% 13 0% 50 % 60 % 70 % 20 % 30 % 40 % 80 % 90 %Anti-Friction Thrust & Sleeve Radial Ring Oil Lube Pivot Shoe Thrust & Sleeve Radial Lube System required

Anti-Friction Thrust & Radial Ring Oil Lubrication

Pump Flow - % of BEP

Exact bearing system will depend upon application

GSG Sales Presentation | slide 32

Anti-Friction with Ring Oil Lubrication

Sulzer Pumps

Thrust Bearing

Radial Bearing

Cooling Fan Oil Reservoir Oil Rings

Ring Oil Lubrication Oil rings rotate with shaft, dip down into an oil reservoir and throw oil onto bearings. Grooves or channels are located in the bearing housing to distribute oil throughout the bearing(s). Shaft mounted cooling fans provide cooling up to a liquid temperature of 177o C (350 F).GSG Sales Presentation | slide 33

Anti-Friction Thrust & Sleeve Radial Bearings with Ring Oil Lubrication (GSG Back-to-Back only)Thrust Bearing

Sulzer Pumps

Radial Bearings

Cooling Fan Oil Rings Oil Reservoir

Ring Oil Lubrication Oil rings rotate with shaft, dip down into an oil reservoir and throw oil onto bearings. Grooves or channels are located in the bearing housing to distribute oil throughout the bearing(s). Shaft mounted cooling fans provide cooling up to a liquid temperature of 177o C (350 F). Opti