CIRCOR

Power (Steam)

Bill mill gear box lubrication

Coal plants use a mill machine to finely pulverize coal before burning. These mills use large speed reducers between the motor drive and the mill and pumped or forced oil lubrication systems lubricate this equipment. Lubrication pump(s) may be driven from the reduction gear box or separately driven using electric motors.

Three screw pumps are commonly used to provide lubrication oil in ball mill gear box applications. The primary benefit that the 3-screw pump delivers in this application is its high resistance to contaminated fluids‚ as the highly abrasive fine pulverized coal will migrate into the gears and the lube oil reservoir.

Flow Rates up to Pressures to up to Max Fluid Temperature CIRCOR Brand, Series & Pump type
2.7 m^3 / h 12 GPM
7 bar 101 psi
90C 194F
IMO AB ACD Three Screw
11 m^3/h 48 GPM
16 bar 232 psi
155C 311F
IMO AB ACE Three Screw
48 m^3/h 210 GPM
17 bar 250 psi
107C 233 F
IMO 3G Three Screw
51 m^3/h 225 GPM
16 bar 232 psi
180C 356F
IMO AB ACG Three Screw
91 m^3/h 400 GPM
35 bar 508 psi
121C 250F
IMO AB ACF Three Screw
450 m^3/h 1982 GPM
16 bar 232 psi
90C 194 F
IMO AB LCQ Three Screw

Waste Water Treatment

Waste water treatment facilities are a vital part of the power plant system. Wastewater like sewage‚ effluent‚ drainage and seepage is collected by using waste water pumps. When selecting pumps for this application it is important to consider the viscosity‚ speed required and fluid properties. These variables will influence not only the type of pump that is supplied but the materials that they are manufactured. CIRCOR has supported waste water treatment applications for once-through cooling water‚ cooling tower blowdown‚ flue gas desulphurization‚ coal pile runoff‚ metal cleaning wastewater‚ boiler blowdown‚ water treatment systems and miscellaneous floor drain wastes.

Progressive cavity pumps are frequently selected for their ability to handle a broad range of liquid properties and operational performance; however‚ centrifugal pumps are also used in select applications.

Flow Rates up to Pressures to up to Max Fluid Temperature CIRCOR Brand, Series & Pump type
0.6 m^3/h 2.65 GPM
12 bar 174 psi
150C 302F
Allweiler ADP Progressive Cavity
450 m^3/h 1‚980 GPM
40 bar 580 psi
150C 302F
Allweiler AE Progressive Cavity
480 m^3/h 2‚120 GPM
16 bar 232 psi
140C 284F
Allweiler NB Centrifugal
2‚300 m^3/h 10‚158 GPM
16 bar 232 psi
140C 284F
Allweiler NT Centrifugal

Hydrogen cooled generator seal oil

Very large generators have their casing filled with hydrogen to reduce windage losses from the huge rotating generator rotor. In order to contain the extremely volatile hydrogen in the casing‚ pumps are used to pump oil into the generator shaft labyrinth seals at a pressure higher than the hydrogen. This keeps the generator seals pressurized containing the hydrogen.

The oil gravity drains to a tank located about 2 meters above the oil pumps. As a result‚ the oil pump inlet pressure is extremely low. Three screw pumps are used for their high reliability and ability to operate at extremely low suction pressures as well as their ability to operate at higher speeds than comparable flow gear pumps. Other systems integrate the seal oil system into the lube oil tank and use centrifugal pump.

Each hydrogen cooled generator is served by a main and auxiliary seal oil pump driven by an AC motor. There is also an emergency DC motor driven pump to provide the critical oil in the event of a turbine trip where AC power is not available. This allows the generator to safely coast down with out leaking the hydrogen gas.

Flow Rates up to Pressures to up to Max Fluid Temperature CIRCOR Brand, Series & Pump type
51 m^3/h 225 GPM
16 bar 232 psi
155C 311F
IMO AB ACG Three Screw
51 m^3 / h 225 GPM
16 bar 232 psi
120C 250F
Allweiler ALLlub RUV Three Screw
91 m^3/h 400 GPM
34.5 bar 500 psi
120C 250F
IMO 3D Three Screw
180 m^3/h 793 GPM
16 bar 232 psi
130C 266F
IMO AB ACF Three Screw
317 m^3/h 1‚400 GPM
100 bar 1‚450 psi
250C 482F
Allweiler SN Three Screw
550 m^3/h 2‚500 GPM
16 bar 232 psi
120C 250F
Allweiler NSSV Centrifugal

Oil Service

PurLube:

If you’ve worked in a power plant‚ you know how difficult it is to keep water out of your machinery and lubrication systems. When water finds its way into a lube oil system‚ it increases the risks of corrosion‚ wear and premature failure.

Commonly installed in a kidney loop off of the main lube oil console; the Purlube is able to pull lubrication oil from the system and return it after treatment. Inside the PurLube‚ oil is heated to 180F without causing thermal or oxidative stress to the oil. Next‚ a venture draws air into the oil creating small air bubbles. When the air bubbles mix with the heated stream of lube oil‚ the volume and surface area of the bubbles expand causing any moisture that contacts the bubbles’ surface to evaporate into the heated air inside the bubbles. The oil stream is them passed through a settling tray allowing the bubbles to come to the surface and break‚ allowing the formerly entrained water to simply escape as evaporating water vapor.

The PurLube system removes all three forms of water contamination in lubrication oil – free‚ emulsified and dissolved – to lower than 100ppm. Additionally‚ the discharge does not contain any oil or emulsion and maintenance is relatively low because the system only has one moving part‚ the oil recirculation pump.

Oil Mist:

Oil mist is a centralized lubrication system used to lubricate specific rolling element bearings‚ pump bearings‚ electric motor drivers‚ bearing housing of small steam turbines with sleeve bearings and purge gearboxes.

The LSC Oil Mist in the oil mist system uses compressed air to atomize oil into micro-size particles‚ which can be effectively moved to lubrication points up to 600 feet (180 meters)‚ through piping and tubing. The benefits of oil mist and lubrication are well documented. Providing the right amount of lubrication to your rotating equipment lowers the bearing temperature‚ reduces energy loss and extends the life of your equipment. Oil mist has reduced bearing failures in centrifugal pumps and electric motors by 90% and increased mean time between failure for mechanical seals by 100%.

Chemical Metering

There are multiple chemical metering applications within power plants. In all applications high quality materials and requirements on sealing are high. CIRCOR is able to support your application with materials and sealing options that meet your environmental requirements. Two sample applications include –

Organometallic Magnesium Injection:

In combustion plants that use a heavy fuel or ash forming oils for combustion such as blends‚ crude and residual oils‚ a vanadium corrosion inhibitor like organometallic magnesium (Mag-Oxide) is injected into the fuel which prevents the high temperature corrosion in gas turbines caused by vanadium. Crude oils and heavy residual fuels usually contain organic vanadium which is extremely corrosive to the hot gas path of the turbine. Vanadium is not present in liquid fuels in a water soluble form and cannot be removed through the washing process.

Three Mag-Oxide additives are commonly employed in this process‚ magnesium sulfonate‚ magnesium oxide and magnesium sulfate. The final decision is largely dependent on the economics of the system and the amount of vanadium present in the fuel.

CIRCOR brand Zenith metering pumps are the choice for this application.

Flow Rates up to Pressures to up to Max Fluid Temperature CIRCOR Brand, Series & Pump type
31 m^3/h 7 GPM
69 bar 1000 psi
343C 645F
Zenith B-9000 Metering Gear
8.3 GPH
98 bar 1500 psi
148C 300F
Zenith B Series Metering Gear

Water Treatment

In steam plant and combined cycle plants‚ boiler feed water is treated to ensure that the ph is neutral. This minimizes the effects on the steam turbine. Chemical treatments are site specific and can be either with a base or acid solution. Chemical metering applications also include pumping algaecides and corrosion control chemicals into condenser cooling water.

Flow Rates up to Pressures to up to Max Fluid Temperature CIRCOR Brand, Series & Pump type
240 m^3/h 1057 GPM
25 bar 362 psi
160C 320F
Allweiler ALLCHEM Centrifugal
105 m^3/h 462 GPM
25 bar 362 psi
250C 482F
Allweiler ALLMAG Centrifugal

Fuel Unloading / Forwarding / Transfer

There are a wide range of fuels that a plant can burn and they arrive into a power plant through various means – rail car‚ ship‚ tank truck‚ etc.. Unloading pumps feed directly into a storage tank often times without a control valve/system and are found on the ‘vehicle’ or may be part of the tank storage system.

Our experience shows that when fuel is allowed to sit in a rail car‚ tank truck‚ etc. the viscosity of the fluid can increase. This change results increased input torque requirements and potentially the delivered. In positive displacement pumps‚ the delivered flow will increase and in centrifugal pumps the amount will decrease. It is important when sizing your pump to consider the properties of the fluid‚ pressure‚ supply and operational objectives.

Some storage systems use a “day tank” that holds about a day’s worth of “treated” (Filtered‚ additives added‚ and/or blended) fuel near the power plant leaving the larger volume storage somewhat more remote from the generating facility. Transfer pumps are needed to keep the day tank supplied as well to move oil from one tank to another. Also‚ transfer or forwarding pumps will be needed to send fuel oil to the inlet of the fuel injection pumps from either the day tank or the main storage tanks.

The distance that the fuel has to travel is an important consideration. Be sure to calculate the frictional loss in your pipeline so you know the maximum discharge pressure and the size of the driver required to overcome the pressure differential.

Commonly used pumps in this application include three screw‚ two screw and centrifugal.

Flow Rates up to Pressures to up to Max Fluid Temperature CIRCOR Brand, Series & Pump type
91 m^3/h 400 GPM
34.5 bar 500 psi
121C 250F
IMO 3D Three Screw
272 m^3/h 1‚200 GPM
70 bar 1‚015 psi
82C 180F
IMO 8L Three Screw
317 m^3/h 1‚400 GPM
100 bar 1‚450 psi
250C 482F
Allweiler SN Three Screw
480 m^3/h 2‚120 GPM
16 bar 232 psi
140C 284F
Allweiler NB Centrifugal
750 m^3/h 3‚300 GPM
21 bar 300 psi
260C 500 F
IMO 323F Three Screw
792 m^3/h 3‚500 GPM
97 bar 1‚400 psi
121C 250F
Warren FSXA Two Screw
1‚100 m^3/h 4‚844 GPM
16 bar 232 psi
100C 212F
Houttuin 216.40 Horizontal Two Screw
1‚100 m^3/h 4‚844 GPM
16 bar 232 psi
100C 212F
Houttuin 211.40 Vertical Two Screw
2‚300 m^3/h 10‚158 GPM
16 bar 232 psi
140C 284F
Allweiler NT Centrifugal
2‚500 m^3/h 11‚008 GPM
16 bar 232 psi
140C 212F
Houttuin 236.40 Horizontal Two Screw

Rotor Jacking

Large frame-sized turbines found in utility scale steam‚ combustion and combined cycle power plants use high-pressure hydraulic oil pumps to lift the turbine shaft from its sleeve bearings before the turbine is started. Hot turbines that are being shut down are put on “turning gear” drive. This allows the turbine to rotate very slowly while it cools so its shaft does not sag due to its weight. A hydraulic oil motor drives a gear which maintains this slow rotation of the turbine shaft.

When evaluating a pump for this application‚ ensure that the pump and inlet piping are properly sized to handle cold start conditions because lower temperature affects the viscosity of the lubrication oil and Net Positive Inlet Pressure Available (NPIPA). The lift capability of a pump decreases with temperature.

Suitable pumps here are three screw and crescent internal gear pumps.

Flow Rates up to Pressures to up to Max Fluid Temperature CIRCOR Brand, Series & Pump type
13 m^3/h 55 GPM
210 bar 3,046 psi
80C 176F
Allweiler SD Three Screw
28 m^3/h 125 GPM
345 bar 5000 psi
82C 180F
IMO CIG Crescent Internal Gear
91 m^3/h 400 GPM
151 bar 2‚200 psi
120C 250F
IMO 12D Three Screw

Lubrication

If it is large and rotates‚ it most certainly needs a pumped lubrication system. Pumps and engineered systems that supply lubrication oil to rotating equipment generally operate 24/7 making reliability of paramount importance.

On a typical lubrication oil skid‚ there are generally three pumps‚ a primary‚ a standby and an emergency backup pump. You may also find a seal oil pump included for the hydrogen cooled generators. These pumps and engineered system supply lubrication oil to the main journal bearings‚ generator bearings‚ reducing gear‚ accessory gear‚ high pressure hydraulic oil and generator seal oil.

The required flow rates depend on the size of the rotating equipment. In large steam and gas turbine applications flow rates as high as 2‚500GPM are required vs. stationary diesel applications where less than 500GPM required.

Users may have a choice between centrifugal and three screw pumps in these applications and there are trade offs between the technologies that engineers should be aware of. Centrifugal pumps typically have a lower initial cost; however‚ three screw pumps have a lower life cycle cost when you factor in operating efficiency and thus energy costs and maintenance costs.

CIRCOR also produces complete lubrication engineered systems for rotating equipment throughout the power plant. These applications include turbine‚ boiler feed‚ condensate‚ and recirculation pumps.

CIRCOR provides optimal pump technologies with three screw‚ two screw and centrifugal pumps.

Flow Rates up to Pressures to up to Max Fluid Temperature CIRCOR Brand, Series & Pump types
2.7 m^3/h 12 GPM
7 bar 101 psi
90C 194F
IMO AB ACD Three Screw
11 m^3/h 48 GPM
16 bar 232 psi
155C 311F
IMO AB ACE Three Screw
28 m^3/h 125 GPM
345 bar 5‚000 psi
82C 180F
IMO CIG Crescent Internal Gear
48 m^3/h 210 GPM
17 bar 250 psi
107C 225F
IMO 3G Three Screw
51 m^3/h 225 GPM
16 bar 232 psi
120C 250F
Allweiler ALLlub RUV Three Screw
51 m^3/h 225 GPM
16 bar 232 psi
180C 356F
IMO AB ACG Three Screw
91 m^3/h 400 GPM
34.5 bar 500 psi
121C 250F
IMO 3D Three Screw
180 m^3/h 793 GPM
16 bar 232 psi
121C 250 F
IMO AB ACF Three Screw
450 m^3/h 1‚982 GPM
16 bar 232 psi
90C 194F
IMO AB LPQ Three Screw
453 m^3/h 2‚000 GPM
16 bar 232 psi
150C 356F
Allweiler TriLub Three Screw
490 m^3/h 2‚158 GPM
16 bar 232 psi
80C 176F
Houttuin 215.10 Vertical Submersible Two Screw
550 m^3/h 2‚500 GPM
16 bar 232 psi
120C 250F
Allweiler NSSV Centrifugal
600 m^3/h 2‚642 GPM
16 bar 232 psi
80C 176F
Houttuin 211.10 Horizontal Two Screw
750 m^3/h 3‚300 GPM
21 bar 300 psi
260C 500F
IMO 323F Three Screw
1‚100 m^3/h 4‚844 GPM
16 bar 232 psi
80C 176F
Houttuin 216.10 Horizontal Two Screw

Fuel or Burner Injection

Fuel injection or burner pumps and the engineered systems that they are mounted on dispense fuel directly into the gas turbine or oil fired boiler. These pumps and engineered systems provide a mission critical operation for the power plant with the main pumps mounted in a three 50% capacity configuration: one as a hot standby; one for up to 50% load; and a third pump coming on for loads in the 50 to 100% range or two 100% capacity pumps (one running with one standby).

Pump applications require flow rates in the 50 to 400gpm range per pump for utility scale combustion‚ steam and combined cycle turbines with discharge pressures in the 700 to 1800 psi range. In specific applications‚ CIRCOR has worked with manufacturers to develop pump solutions that can handle discharge pressure of 2000 psi at a flow of 500GPM. Stationary diesel applications require lower flow rates and pressures.

Coal fired steam plants use Fuel or Burner injection pumps to pump oil into the burner to either keep the coal burning or speed the temperature rise in the boiler. In some applications where Bio-Mass fuel is incorporated the fuel or burner injection pumps will be operated in order to produce an even combustion temperature to compensate for varying BTU content in the Bio-Mass fuel. In combustion and combined cycle plants‚ liquid fuels (distillate‚ fuel oil #4‚ #6‚ etc.) are used as back up supply for the primary fuel natural gas.

Consistency of output and smooth pulsation free flow are primary criterion for purchase in fuel or burner injection pump applications making three screw‚ two screw or crescent internal gear pumps as the suitable choice. Often times‚ pumps are sized for 125 – 150% of the delivered flow requirements. Engineers design for future expansions and planned upgrades and design a bypass system to accommodate the excess flow delivered. Users should recognized that excess pumping costs money and running a bypass systems 24/7 can quickly eat up savings.

Finally‚ Allweiler brand ALLHEAT thermal oil centrifugal pumps are used in small decentralized biomass combined heat and power plants in an Organic Rankine Cycle (ORC) process. In this application‚ silicon oil is vaporized in a boiler and used in a steam turbine instead of water/steam. The heat cannot be transferred directly from the burner to the silicon oil as the heat is too high. Therefore‚ thermal oil is heated to around 150F/300C and this heat is then transferred to the silicon oil.

Flow Rates up to Pressures to up to Max Fluid Temperature CIRCOR Brand & Series
28 m^3/h 125 GPM
345 bar 5‚000 psi
82F 180C
IMO CIG Crescent Internal Gear
78 m^3/h 343 GPM
280 bar 4‚061 psi
150C 302F
Allweiler VH Three Screw
91 m^3/h 400 GPM
34.5 bar 500 psi
120C 250F
Imo 3D Three Screw
91 m^3/h 400 GPM
103 bar 1‚500 psi
120C 250F
IMO 6D Three Screw
91 m^3 / h 400 GPM
151 bar 2‚200 psi
120C 250F
IMO 12D Three Screw
272 m^3/h 1‚200 GPM
70 bar 1‚015 psi
82C 180F
IMO 8L Three Screw
750 m^3/h 3‚300 GPM
21 bar 300 psi
260C 500F
IMO 323F Three Screw
792 m^3/h 3‚500 GPM
97 bar 1‚400 psi
121C 250F
Warren FSXA Two Screw
1‚450 m^3/h 6‚380 GPM
25 bar 363 psi
400C 752F
ALLHEAT Centrifugal
2‚500 m^3/h 11‚008 GPM
80 bar 1‚160 psi
400C 752F
Houttuin Engineered Two Screw

Combined Cycle Overview

HOW A STEAM PLANT OPERATES:

Fuel such as coal‚ bio-fuel and oil‚ are burned inside a boiler system. This process generates heat in the combustors of large boilers which turns the plant process water inside the boiler tubes into superheated steam. The superheated steam is then directed to the turbine to drive the power turbine and generator ultimately producing electrical power. The exhaust steam is sent to a condenser where it is water or air cooled and returned to a liquid state for re-use.

Utility and OEM turbine customers demand uptime‚ reliability and availability of their suppliers and have trusted CIRCOR on many mission critical applications for decades.

CIRCOR CAPABILITIES:

CIRCOR brands Allweiler‚ IMO‚ IMO AB‚ Warren and Tushaco all supply pump and engineered systems into steam turbine plants; our product offering includes three screw pumps‚ two screw pumps‚ crescent internal gear pumps‚ progressing cavity pumps‚ and centrifugal pumps as well as lubrication oil service products like our PurLube Conditioner and Oil Mist as well as Engineered Systems.

Pump Applications Engineered System Applications Oil Service
Fuel Unloading/Transfer/Forwarding
Fuel Unloading/Transfer/Forwarding
PurLube
Ball Mill Gear Box Lubrication
Fuel or Burner Injection
Oil Mist
Rotor Jacking
Lubrication
Lubrication
Fuel or Burner Injection
Chemical Metering
Hydrogen Cooled Generator Seal Oil