BOILER FEED

& PUMP SIZING

Presented by Cleaver-Brooks Steve Connor
and Grundfos’ Jim Swetye
TODAY’S AGENDA
• Brief review of a typical steam system
• The boiler size range, pressures and types we will be
addressing today
• Methods and importance of capturing condensate for boiler feed
• Typical pumps used for boiler feed water discharge
• Typical piping methods used
• Pump sizing criteria
• Criteria for calculating the base flow for the pump
• Understanding TDH and NPSH
• Sizing a pump for a specific application (example)
• Reading the pump curve for final selection
• Summary and Q&A

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TYPICAL STEAM SYSTEM
HP Steam LP Steam
Strainer PRV

T T
Trap Trap

Motive T T T
Force Trap Trap Trap
H P Cond Return LP Condensate Return
Vent
Legend
DA
D ATank
Tank Steam
Cond Rcvr Cond
& Pump Flash
Boiler Feed Pump Vapor
3

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BOILER SIZES AND
FEED PUMP SIZES

Typical
Typical
Boiler Max. Feed
Boiler HP Typical Feed Max. Feed Where
Pressure Pump
Range Pump Type Pump Used?
Range Flow
Head
Range
General
Vertical industry;
inline institutional;
100 to 150 to 500 10 to 125
multistage; 1250 feet universities;
1200 psi gpm
regenerative some
turbines commercial
buildings

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FIRETUBE

Watertube (IWT)

Integral burner

Gun burner
5
HORIZONTAL
FIRETUBE BOILERS
The Dryback

Baffles

Tubesheet
4

2
Refractory Filled Door 1
Two (2) Tubesheets
6
WATERTUBE OR IWT

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THE WATERTUBE
BOILER Outlet nozzle location Upper Steam Drum

• Opposite of Firetube
• Water in the Tubes Furnace
• Natural and Forced Circulation
• Large Furnace
• Upper & Lower Drums or
• Headers

Lower Mud Drum

8
FLUE GAS SEALING

100% Membrane Construction

Tangent Tube Furnace Design Also Available

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CONDENSATE IS
LIQUID GOLD!

A finite resource

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TYPICAL
STEAM SYSTEM
LP Steam
HP Steam
Strainer PRV

T T
Trap Trap

Motive T T T
Force Trap Trap Trap
H P Cond Return LP Condensate Return
Legend
DA
D ATank
Tank Steam
Cond
Flash
Condensate tank
Boiler Feed Pump Vapor
& Pump system

11
CONDENSATE
RETURN PUMPS

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FLASH STEAM
150 psig
366 F HP Steam LP Steam 15 psig
Strainer PRV
250 F

T T
Trap Trap

T T T
Motive Trap Trap Trap
Force H P Condensate Return
Flash
Tank
Feed Tank
D A Tank
or DA Low pressure
condensate
Cond. Pump line
Boiler Feed Pump
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Flash Tank Flash Tank w/Economizer

Use flash steam for

heating or deaerating? Why not recover the heat from the hot condensate?

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HOT CONDENSATE
RETURNED

Boiler Feed System Deaerator

Steam
diffusing tube

A vented receiver, wastes energy.

Pressurized receiver, saves energy.

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 Vent

H.P. Return
PRV
Steam

Exhaust Or
Flash Steam
Cold Make-Up
Level control Water

Make-Up Valve

Check Valve L.P. Condensate

Overflow
To Boiler Feed Drainer
Boiler Water Pump(s)
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SPRAY DEAERATOR
Spray cone

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TRAY DEAERATOR

Trays

steam

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PACKED COLUMN DA

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BOILER FEED
WATER TANKS
Spray DA Tray DA Column DA

Vented
Receiver

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HP CONDENSATE
RECOVERY

150 psig
366 F LP Steam
HP Steam 15 psig
Strainer PRV
250 F

T T
Trap Trap

Motive T T Trap T Trap

Trap
Force H P Condensate Return

Cond.
D A Tank Pump
Boiler Feed Pump
Feed Tank or DA

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HIGH PRESSURE
CONDENSATE
RECEIVER

• Takes high pressure

condensate directly from
the user.
• No need to deaerate.
• Pump directly into boiler
• Feed the HPR from the DA

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BOILER FEED WATER
TANK OPTIONS
Spray DA Tray DA Column DA

HPCR Vented
Receiver

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FEED WATER SYSTEMS
For multiple boiler Installations

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METHOD 1 –
Direct feed for multiple boilers

Deaerator

Boiler A
Controlle
r Boiler A
4-20mA signal
directly to
Grundfos E-
pump instead of
control valve

Boiler B
Controlle
r Boiler B
4-20mA signal
directly to
Grundfos E-
pump instead of
control valve

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METHOD 2 –
Booster sets for multiple boilers
Deaerator Pressure sensor

Bypass

Multiple
pump
controller

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STEAM BOILER
PUMP APPLICATIONS
AND TYPES
Boiler feed pumps
Collection tank pumps
Water treatment pumps
Condensate return pumps
Deaerator tank recycle pumps
Deaerator vacuum pumps (vacuum
deaerator tanks only)
Economizer pumps

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SIZING COMPLEXITY
FOR BOILER FEED PUMPS

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BASE FLOW
RATE CALCULATION

Base flow = Boiler maximum capacity horsepower X 0.069 X C

• C = 1.5 for On/Off intermittent operation

• C = 1.15 for continuous feed operation

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ADD FOR CONTINUOUS
BOILER BLOWDOWN FLOW

To the Base flow we MIGHT add if specified:

For Continuous Boiler Blowdown flow

• Approximately 5% to10% of the pump’s flow
rate at the Best Efficiency Point

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ADD FOR BYPASS
RECIRCULATION FLOW
Certain feed system control modes
require the use of a bypass line
back to the source tank – such as
back to the deaerator tank

Is orifice flow
Method Pump Speed
Name Duty by-pass line
# Type
required?
1 On/Off control and fixed speed pumps Fixed Intermittent No
2 Feed control valve and fixed speed pumps Fixed Continuous Yes
3 Feed control valve and variable speed pumps Variable Continuous Yes
4 Variable speed pumps only (no control valve) Variable Continuous No

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RECIRCULATION
FLOW

• The solid curve below shows the minimum

flow rate as a percentage of the nominal flow
rate in relation to the liquid temperature.
• Ignore the dotted line which indicates a pump
with special high-temperature construction.

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CALCULATING REQUIRED
FEED PUMP HEAD

Elevation of
DA tank

+ Suction side head

+ Discharge side head
= Total Dynamic Head

Elevation
of boiler

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FEED VALVE IMPACTS
PUMPING HEAD CALCULATION

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CALCULATING THE HEAD
FOR THE FEED PUMP
1) At the duty point flow rate:
Head in feet = Boiler operating pressure X 2.31 X 1.03 ÷ Liquid Specific Gravity
Example: Head = 130 psi X 2.31 X 1.03 ÷ 0.953 = 324 feet

2) At shutoff head (dead head):

Head in feet = Pressure relief valve setting X 2.31 X 1.03 ÷ Liquid Specific Gravity
Example: Head = 160 psi X 2.31 X 1.03 ÷ 0.953 = 400 feet

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NPSH –
FORMULA FOR CALCULATION
To avoid cavitation, NPSHa must be greater than NPSHr

NPSHr is obtained from the pump curve

Add two to four feet of safety factor to the NPSHr stated on the curve

NPSHa is calculated:

+ Absolute pressure in deaerator tank

± Elevation of minimum water level in tank above feed pump

- Vapor pressure of water in deaerator tank

- Suction line friction loss

= Net Positive Suction Head Available

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NPSH AND ELEVATION
Deaerator
tank

Minimum water level in DA tank

Difference in elevation

Location of eye of lowest impeller

Boiler
feed
pumps

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NPSH AND SUCTION
LINE CONSIDERATIONS

Critical suction line considerations here

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Check list for boiler feed pump selection
Step Action
1 Det ermine cont rol met hod t o be used

2 Calculat e BASE flow rat e

3 Add for Cont inuous Boiler Blowdown flow

4 Add for by-pass flow if required

5 Sum of base flow, by-pass flow, and Blowdown flow is t he t ot al flow required

6 Calculat e BASE pumping head

7 Add for all suct ion piping head component s

8 Add for all discharge piping syst em head component s (including feed valve if required)

9 Sum of all head component s = t ot al pumping head

10 Calculat e head at boiler safet y vavle set t ing plus t hree percent

11 Det ermine deaerat or t ank wat er t emperat ure

12 Perform NPSHa calculat ion

13 Make preliminary pump select ion

14 Assure t hat shut off head equals or exceeds t hree percent above safet y valve set t ing

15 Check NPSHr versus NPSHa

16 Assure mat erial compat ibilit y - chemical and t emperat ure

17 Make final pump select ion

39
BOILER FEED PUMPS:
USEFUL FORMULAS

40
SPECIFICATION
FOR EXERCISE
a) Control Method: Continuous duty fixed speed pump with bypass line and feed valve
b) Boiler maximum capacity = 250 HP
c) Boiler safety valve setting = 125 psig
d) Pressure safety factor = 3% above boiler’s safety valve setting
e) Boiler operating pressure = 100 psig
f) Continuous Boiler Blowdown flow - Required
g) Bypass recirculation flow – Required
h) Altitude – Sea level
i) Pressure in deaerator tank above atmospheric pressure = 5 psi (14.7 + 5 = 19.7 psi absolute)
j) Height of deaerator tank minimum water level above pump’s first impeller = 10 feet
k) Friction line loss through suction piping = .5 foot
l) Friction loss through suction side fittings = .5 foot
m) Friction loss through suction side valves = None
n) Friction loss through suction side strainer = 1 feet
o) Friction loss through discharge piping = 1 foot
p) Friction loss through discharge side fittings = 1 foot
q) Pressure drop across feed valve – 15 psi
r) Elevation of boiler maximum water level above pump’s discharge port = 5 feet
s) Liquid Specific Gravity = 0.953
t) Temperature of water in deaerator tank = 227 degrees F
u) Vapor pressure in deaerator tank = 19.7 psi
v) Pump materials all 316 stainless steel to resist treatment chemicals
w) Mechanical seal to be silicon carbide/silicon carbide/EPDM to withstand liquid temperature

41
CONTROL METHOD:

Fixed speed pumps with feed valve and recirculation line

Recirc line

Feed Feed valve

pumps

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STEP 1 –
Determine control method
Feed valve controlled system with a continuous duty fixed speed pump has been specified.

Step Action

X 1 Det ermine cont rol met hod t o be used

2 Calculat e BASE flow rat e

3 Add for Cont inuous Boiler Blowdown flow

4 Add for by-pass flow if required

5 Sum of base flow, by-pass flow, and Blowdown flow is t he t ot al flow required

6 Calculat e BASE pumping head

7 Add for all suct ion piping head component s

8 Add for all discharge piping syst em head component s (including feed valve if required)

9 Sum of all head component s = t ot al pumping head

10 Calculat e head at boiler safet y vavle set t ing plus t hree percent

11 Det ermine deaerat or t ank wat er t emperat ure

12 Perform NPSHa calculat ion

13 Make preliminary pump select ion

14 Assure t hat shut off head equals or exceeds t hree percent above safet y valve set t ing

15 Check NPSHr versus NPSHa

16 Assure mat erial compat ibilit y - chemical and t emperat ure

17 Make final pump select ion

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STEP 2 –
Calculate the BASE feed pump flow rate

The formula for this calculation is:

• Boiler maximum capacity in horsepower X 0.069 X C

• The maximum capacity in boiler horsepower is 250

• The C factor is 1.15 for continuous duty

Therefore:

250 X 0.069 X 1.15 = 20 gpm = BASE flow rate

44
STEP 3 –
Continuous Boiler Blowdown Flow

Determination:

1. The BASE flow rate has been established at 20 gpm

2. We will on next slide need to add for bypass flow, which can add
10 to 20 percent to the BASE flow rate

3. Blowdown flow is to be approximately 10 percent of flow at pump’s

Best Efficiency Point

4. So the total boiler blowdown flow required is approximately 3 gpm

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STEP 4 –
Add for by-pass flow

• Control is via feed valve with fixed speed pump and for continuous duty
• A bypass will be required

• Solid curve to right shows minimum flow rate

as a percentage of nominal flow rate in
relation to liquid temperature
• Ignore dotted line which indicates a pump
with special high-temperature construction

• At 227°F, we require a bypass flow that is

about 20% of BEP flow.
• Presuming we can find a pump with BEP at
about 25 or so gpm, the bypass flow must
be about 5 gpm

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STEP 5 –
Calculate total flow required
• BASE flow = 20 gpm
• Blowdown flow = 3 gpm
• Recirculation flow = 5 gpm
• Total flow required = 28 gpm
Step Action

X 1 Det ermine cont rol met hod t o be used

X 2 Calculat e BASE flow rat e

X 3 Add for Cont inuous Boiler Blowdown flow

X 4 Add for by-pass flow if required

X 5 Sum of base flow, by-pass flow, and Blowdown flow is t he t ot al flow required

6 Calculat e BASE pumping head

7 Add for all suct ion piping head component s

8 Add for all discharge piping syst em head component s (including feed valve if required)

9 Sum of all head component s = t ot al pumping head

10 Calculat e head at boiler safet y vavle set t ing plus t hree percent

11 Det ermine deaerat or t ank wat er t emperat ure

12 Perform NPSHa calculat ion

13 Make preliminary pump select ion

14 Assure t hat shut off head equals or exceeds t hree percent above safet y valve set t ing

15 Check NPSHr versus NPSHa

16 Assure mat erial compat ibilit y - chemical and t emperat ure

17 Make final pump select ion

47
STEP 6 –
Calculate BASE pumping head

Boiler operating pressure setting + 3%

Formula: BASE head in feet = Boiler operating pressure X 2.31 X 1.03 ÷ Specific
Gravity

BASE head = 100 psi X 2.31 X 1.03 ÷ 0.953 = 250 feet

48
STEP 7 –
Add for suction piping system head components

From specification:
Absolute pressure on deaerator tank = 19.7 psi X 2.31 = - 46 feet
Water elevation above first impeller = - 10 feet
Friction loss through suction piping = + .5 feet
Friction loss through suction fittings = + .5 feet
Friction loss through suction side valves and strainer = + 1 feet
Total = - 54 feet

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STEP 8 –
Add for discharge piping system head components

From specification:
Friction loss through discharge piping = + 1 foot
Friction loss through discharge fittings = + 1 foot
Friction loss through feed valve is 15 psi X 2.31 = + 35 feet
Elevation of boiler maximum water level above pump = + 5 feet
Total = + 42 feet

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STEP 9 –
Sum of all head components

BASE head with safety factor = + 250 feet

Suction side piping system head = - 54 feet
Discharge side piping system head = + 42 feet
Total = + 238 feet

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STEP 10 –
Pressure safety valve considerations
At shutoff head (dead head):
Head in feet = Pressure relief valve setting X 2.31 X 1.03 ÷ Liquid Specific Gravity
Example: Head = 125 psi X 2.31 X 1.03 ÷ 0.953 = 312 feet
Step Action

X 1 Det ermine cont rol met hod t o be used

X 2 Calculat e BASE flow rat e

X 3 Add for Cont inuous Boiler Blowdown flow

X 4 Add for by-pass flow if required

X 5 Sum of base flow, by-pass flow, and Blowdown flow is t he t ot al flow required

X 6 Calculat e BASE pumping head

X 7 Add for all suct ion piping head component s

X 8 Add for all discharge piping syst em head component s (including feed valve if required)

X 9 Sum of all head component s = t ot al pumping head

X 10 Calculat e head at boiler safet y vavle set t ing plus t hree percent

11 Det ermine deaerat or t ank wat er t emperat ure

12 Perform NPSHa calculat ion

13 Make preliminary pump select ion

14 Assure t hat shut off head equals or exceeds t hree percent above safet y valve set t ing

15 Check NPSHr versus NPSHa

16 Assure mat erial compat ibilit y - chemical and t emperat ure

17 Make final pump select ion

52
STEP 11 –
Determine deaerator tank water temperature

From specification: 227°F

53
STEP 12 –
NPSHa calculation

NPSHa equation:

± Elevation + Absolute pressure – Vapor Pressure – Suction Line Friction = NPSHa

10 feet + (19.7 psi X 2.31) - (19.7 psi X 2.31) - 2 feet = NPSHa

10 feet + 46 feet - 46 feet - 2 feet = 8 feet NPSHa

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STEP 13 –
Preliminary pump selection

Conditions of Service:
Flow = 28 gpm
Head = 238 Feet

Does this 10
stage pump
pump meet the
required flow
and head
conditions of
service?

YES

55
STEP 14 –
Pressure safety valve considerations

56
STEP 15 –
Check NPSHa vs NPSHr

Conditions of Service:
Flow = 28gpm
Head = 238 Feet
NPSHa = 8 Feet

• Pump meets or exceeds

flow/head requirement
• Low-NPSHr first stage = 4 feet
required
• NPSHr safety factor = 2 to 4
feet
• Target NPSHr = 8 feet
• NPSHa = 8 feet

Does NPSHa equal or exceed NPSHr?

YES
57
STEP 15 –
NPSH - Continued
Conditions of Service: Flow = 28 gpm Head = 238 Feet NPSHa = 8 Feet
The NPSHa is equal to or exceeds the NPSHr of 8 feet
Step Action

X 1 Det ermine cont rol met hod t o be used

X 2 Calculat e BASE flow rat e

X 3 Add for Cont inuous Boiler Blowdown flow

X 4 Add for by-pass flow if required

X 5 Sum of base flow, by-pass flow, and Blowdown flow is t he t ot al flow required

X 6 Calculat e BASE pumping head

X 7 Add for all suct ion piping head component s

X 8 Add for all discharge piping syst em head component s (including feed valve if required)

X 9 Sum of all head component s = t ot al pumping head

X 10 Calculat e head at boiler safet y vavle set t ing plus t hree percent

X 11 Det ermine deaerat or t ank wat er t emperat ure

X 12 Perform NPSHa calculat ion

X 13 Make preliminary pump select ion

X 14 Assure t hat shut off head equals or exceeds t hree percent above safet y valve set t ing

X 15 Check NPSHr versus NPSHa

16 Assure mat erial compat ibilit y - chemical and t emperat ure

17 Make final pump select ion

58
STEP 16 –
Check material compatibility

• Pump materials: 316 stainless steel

• Mechanical seal materials: Silicon carbide/silicon
carbide/EPDM

59
STEP 17 –
Final pump selection
Pump meets all specification requirements
Step Action

X 1 Det ermine cont rol met hod t o be used

X 2 Calculat e BASE flow rat e

X 3 Add for Cont inuous Boiler Blowdown flow

X 4 Add for by-pass flow if required

X 5 Sum of base flow, by-pass flow, and Blowdown flow is t he t ot al flow required

X 6 Calculat e BASE pumping head

X 7 Add for all suct ion piping head component s

X 8 Add for all discharge piping syst em head component s (including feed valve if required)

X 9 Sum of all head component s = t ot al pumping head

X 10 Calculat e head at boiler safet y vavle set t ing plus t hree percent

X 11 Det ermine deaerat or t ank wat er t emperat ure

X 12 Perform NPSHa calculat ion

X 13 Make preliminary pump select ion

X 14 Assure t hat shut off head equals or exceeds t hree percent above safet y valve set t ing

X 15 Check NPSHr versus NPSHa

X 16 Assure mat erial compat ibilit y - chemical and t emperat ure

X 17 Make final pump select ion

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61
SUMMARY
• Steam condensate is a very valuable commodity which needs to saved and used as much as possible.
• Most commonly used boilers for process are industrial firetubes and watertube boilers, IWT,s.
• High pressure condensate flash steam can be used for various purposes such as unit heaters or the
DA
• Condensate can be returned to vented receivers or pressurized deaerators (Spray, Tray & Column)
• Sometimes high pressure condensate receivers are employed. Save considerable losses.
• Boiler feed pump selection involves 17 decision points which need to be carefully considered.
• Calculating the pump’s base flow rate differs when the pump operates continuously (15% safety factor)
or on/off (50% safety factor)
• Sometimes the base flow rate needs to include for continuous pump re-circulation and maybe for
continuous blow down
• Total Dynamic Head (TDH) is a that pressure the pump must overcome to get water in the boiler, and
includes the positive pressure at the pump’s inlet after suction pipe losses, and the piping losses
through the discharge piping before overcoming the boiler’s operating pressure.
• Net Positive Suction Head (NPSH) is the pressure required at the pump’s suction to mitigate
cavitation.
• NPSHA is the NPSH available after all the friction losses on the suction side have been determined in
light of the pump’s minimum and maximum flow rates.
• The seal selection for the pump is very important and can vary based on the boiler’s operating
pressure/temperature, chemicals in the feed water, etc.

62
 QUESTIONS?
Gregg Achtenhagen
[email protected]

Jim Swetye
[email protected]

Over 25,000 Grundfos parts are available through your local Cleaver-Brooks Representative.
Visit cleaverbrooks.com/reps for all boiler sales and service.

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