1x660 

MW Sagardighi TPS, Unit‐5
BFP Sizing Calculation (PE‐DC‐445‐100‐N112)
Sl. No. Customer's Comment  BHEL Reply  WBPDCL/DCPL Reply  BHEL Reply (dated 06.10.20) WBPDCL/DCPL Reply (21.10.20) BHEL Reply (dated 02.11.20)
1 Please clarify how "as per case" values are  Case values are determined after adding  Noted.
determined margins as mentioned in the case description Point Closed
2 Not available in HBD. Extraction line pressure  Deaerator pressure is saturaion presuure of the  Noted.
only available. feedwater coming out of the deaerator Point Closed
3 Not indicated in HBD Boiler Terminal Point Pressure are taken as per  Noted.
BHEL Trichy (SG maufacturer) inputs which are 
internal to BHEL.We confirm the inputs are in 
order. Point Closed
4 Can only be reviewed upon receipt of all  Details provided are in order. After receipt of GADs, if any correction is 
relevant GADs needed , BHEL shall incorporate the same. Confirmed
5 Please add the following condition as case‐VI: BMCR flow is considered for underfrequency  Noted.
VWO output, 1% make‐up, worst condenser  case inline with specification (amendments) 
pressure (MDBFP should meet the requirement  requirement and the same is in order.
at 47.5 Hz). 
Point Closed
6 Please confirm that discharge flow is exclusive  Confirmed Noted.
of seal flow, warm‐up flow & balance drum 
leakage flow. Point Closed
7 Inter‐stage bleed‐off for RH attemperation shall  RH attemperation flows are to be considered as  Please consider design value of 130.4 TPH 
be minimum 8% of max. reheat steam flow  per SG manufacturer's (BHEL Trichy)  for inter‐stage RH attemperation as per 
rate. recommendation and the same is in order. sl.no. 7 of calculation.

As discussed during virtual meeting 
dtd. 21.10.20, please consider max. 
Considered inline with our SG  quantity of RH attempearation flow 
manufacturer's recommendadtion  from BFP inter‐stage considering all 
and practice followed for all  operating condition and different fuel  Noted and revised inline with the 
sub/super critical projects. firing. discussion.
8 Please confirm that the pressure corresponds  In case III. Pressure corresponding to lowest  Noted.
to lowest safety valve set pressure of steam  safety valve pressure at superheater outlet is 
separator considered, inline with the specification 
requirement. Point Closed
9 Pressure drop to be calculated based on "as per  Pressure drop shall be calculated on actual  As per sl. no. 1.0 c)iii) of annexure‐I, sec‐III,  BHEL confirmed during virtual 
case" flow values values as per HBDs. 10% margin in piping  vol. IIC, 10% margin over total pressure  meeting dtd. 21.10.20 that density 
pressure drop as per spec is already provided.  drop (except static height & terminal  difference in feed water with increase 
pressure requirement) to be considered.  Piping pressure drop is already  in temp. through HP heaters have 
Hence, consider 10% margin on drop  considered and the same is in  been duly considered in pressure 
through heaters and other equipment. order. Margin in equipment  drop calculation. BHEL shall furnish a 
pressure drop shall not be  specimen calculation to show the 
considered. same.  Noted and attached.
10 Additional 10% margin to be considered on  Piping pressure drop margin is already  Please exlain why pressure drop figures 
frictional drop on both suction and discharge  considered during sizing calculation. Same will  through heaters and piping reduced from  As feed water system engineering still 
side. be mentioned suitably. previous submission. Latest inputs received by different  not frozen, BHEL shall confirm that 
units and departments has been  pressure drop figures considered in 
updated in the document. calculation shall not exceed later. Confirmed. 
11 Inter‐stage bleed‐off for RH attemperation shall  refer reply to point no7 Please consider design value 130.4 TPH for  refer reply to point no7
be minimum 8% of max. reheat steam flow  inter‐stage RH attemperation as per sl.no. 
rate. 7 of calculation. Refer reply above. Refer reply above at point no 7
12 Not considered in calculation. This is for interstage design, actual requirement  As actual requirement is 24.8 TPH only,  It is to meet specification 
shall be considered for RH attemperation flow  please explain why design value is  requirements.
inline with standard practice followed for our  consiered  as 130.4 TPH.
all projects. Refer reply above. Refer reply above at point no 7
13 Please include HP‐LP bypass condition with 
one TDBFP running as case VI. As per cl. No. 1.01.03 of sec‐III, vol‐
IIC, BFP shall be adequately designed 
for by‐pass condition, hence this case 
is to be included and shown that 
selected pump will be capacble of 
stable operation at this point.  As per 
HBD no. S‐0226, two BFPs are 
Pumps selection is in order and as  working at HP‐LP bypass condition, 
per specification requirement. please include this case accordingly. Noted and incorporated
14 Why 2076.70 m3/hr is not considered for  Steam flow is mentioned only. For 
BMCR 1% MU, as per HBD S0230 ? Pump Calculation feed flow of 
2076.7 T/hr is considered only , 
refer case IV. Noted. Point Closed
16 Shall be calculated at 2054.48 TPH flow
Pressure drops are calculated at 
2029.68 only and then 
recalculated for different flow as 
per HBDs. Calculation is in order. Noted. Point Closed
18 These figures do not match. Please explain Unit is different
Please refer reply above for sl. No. 9. Refer reply above at point no 9
Kindly clarify how the MDBFP rating is met  Underfrequency case considered  Noted.
following clause No. 1.0 (d) of Annexure‐I  in case IV of sizing calculation. 
of V‐IIC/S‐III MDBFP parameters selected are 
inline with spec requirements of 
mentioned clause.

Point Closed
As per cl.no. 4.01.06 of sec‐III, vol‐IIC, 
vendor to ensure that NPSH (A) at 
design point with lowest deaerator 
level and maximum pressure drop 
across the strainer shall be at least 
2.5 times the NPSH (R) at 3% head  BHEL checked and confirms to meet 
drop for booster pump as well as  the mentioned specification 
main pump. requirement of NPSH(A)
 BOILER FEED PUMP SIZING CALCULATION DOC NO.: PE-DC-445-100-N112
BHEL
PEM
PROJECT TITLE : WBPDCL - SAGARDIGHI TPP, PHASE III, 1X660 MW SHEET NO.: 2 OF 5

INPUT DATA SHEET

SIZING CRITERIA AS PER CUSTOMER TECHNICAL SPECIFICATION

DISCH. DISCH.
SUCTION SUCTION DEAERATOR BOILER TP
FLOW (T/Hr) FLOW SUCTION
DESCRIPTION FLOW (T/Hr) FLOW (T/Hr) PRESSURE PRESS
(AS PER (T/Hr) (AS TEMPERATURE ( oC)
(AS PER HBD) (AS PER CASE) (kg/cm2a) (kg/cm2a)
HBD) PER CASE)

CASE-I : DESIGN CAPACITY - 10% MARGIN OVER

FEED FLOW CORRESPONDING TO VWO, 1%MU & 2029.68 2280.65 2029.68 2232.65 12.49 322.9 188.9
CORRESPONDING HEAD. Ref HBD No. S0211

03
CASE-II : BEST EFFICIENCY POINT
CORRESPONDING TO TMCR, 0% MU UNDER 1872.47 1872.47 1872.47 1872.47 11.95 316.2 186.9
RATED CONDITIONS. Ref HBD No. S0201 03
02

CASE-III : EMERGENCY POINT - MAX PRESSURE

DURING SHO LOWEST SV POP-UP & FLOW
2029.68 2054.48 2029.68 2029.68 12.49 345.70 188.9
CORRESPONDING TO VWO, 1%MU. Ref HBD No.
S0211

CASE-IV : BMCR FLOW at 47.5 Hz & HEAD

CORRESPONDING TO RATED STEAM PRESSURE. 2076.70 2186.00 2076.70 2186.00 12.22 325.0 187.9
Ref HBD No. S0230

CASE-V :RUNOUT POINT- ONE PUMP CAPABLE OF

1166.67 1166.67 1166.67 1166.67 8.31 201.4 171.2
65% / 1% MU UNIT LOAD; Ref HBD No. S0231

03

CASE-V :HPLP BYPASS CONDITION- TWO PUMP

1430.09 1430.09 1430.09 1430.09 3.50 293.3 138.2
RUNNING Ref HBD No. S0226

BOILER INPUTS

BMCR STEAM FLOW (T/Hr) 2070

BOILER TP GEODETIC HEIGHT (M) 12.9

PRESSURE DROPS (kg/cm2) AT VWO FLOW = 2029.68 T/Hr (Discharge Side)

PRESSURE DROP IN THE THREE HP HEATERS

4.2
(INCLUDING DESUPERHEATER)

PRESSURE DROP IN DISCH. PIPING, FLOW ELEMENT ETC. 4.5

PRESSURE DROPS (kg/cm2) AT VWO FLOW = 2029.68 T/Hr (Suction Side)

PRESSURE DROP IN SUCTION PIPING(BP+BFP) &

0.40
FLOW ELEMENT
PRESSURE DROP ACROSS SUCTION
0.30
STRAINERS(BP+BFP) (MAXIMUM)

GEODETIC OF DEAERATOR LL LEVEL (M) 26.43

In the last submission of Heat Balance Diagram, BHEL has not indicated the HP heater drip
to Deaerator (K). In their reply BHEL PEM has stated that ' it shall be added in the next
revision'. Therefore unless the HBD is approved this document will be under CAT (2)
approval catagory.
 BOILER FEED PUMP SIZING CALCULATION DOC NO.: PE-DC-445-100-N112
BHEL
PEM
PROJECT TITLE : WBPDCL - SAGARDIGHI TPP, PHASE III, 1X660 MW SHEET NO.: 3 OF 5

RESULT SHEET

FLOW CALCULATION

PARAMETERS CASE-I CASE-II CASE-III

SUCTION FLOW (AS PER HBD) T/hr 2029.68 1872.47 2029.68

SUCTION FLOW (AS PER CASE) T/hr 2280.65 1872.47 2054.48

SUCTION FLOW THROUGH SYSTEM T/hr 2077.68 1872.47 2054.48

DISCHARGE FLOW (AS PER HBD) T/hr 2029.68 1872.47 2029.68

DISCHARGE FLOW (AS PER CASE) T/hr 2232.65 1872.47 2029.68

DISCHARGE FLOW THROUGH SYSTEM T/hr 2029.68 1872.47 2029.68

TEMPERATURE ON SUCTION SIDE OC 188.9 186.9 188.9

D/A PRESSURE (ata) 12.49 11.95 12.49

3
SPECIFIC VOLUME (m /kg) 0.0011399 0.0011371 0.0011399

NO. OF PUMPS IN OPERATION 2 2 2

SUCTION FLOW THROUGH EACH PUMP T/hr 1140.32 936.24 1027.24

DISCH. FLOW THROUGH EACH PUMP T/hr 1116.32 936.24 1014.84

RH SPRAY FROM INTERSTAGE T/hr 48.0 03 0.0 24.8

FLOW THRO' EACH PUMP AT DISCH. FLANGE T/hr 1116.32 936.24 1014.84

HEAD CALCULATION

DISCHARGE PRESSURE (kg/cm2)

BOILER TP PR. 322.9 316.2 345.7

BOILER TP GEODETIC HEIGHT 1.13 1.13 1.13

PRESSURE DROP IN THE THREE HP HEATERS

4.20 3.57 4.20
(INCLUDING DESUPERHEATER)

PRESSURE DROP IN DISCH. PIPING, FLOW ELEMENT ET 4.50 3.83 4.50

10% MARGIN OVER PIPING 0.45 0.38 0.45

DISCHARGE PRESSURE 333.18 325.12 355.98

SUCTION PRESSURE (kg/cm2)

D/A PRESSURE 12.49 11.95 12.49

D/A GEODETIC HEIGHT 2.32 2.32 2.32

SUCTION PIPING 0.42 0.34 0.41

10% MARGIN OVER PIPING 0.04 0.03 0.04

SUCTION STRAINER 0.30 0.30 0.30

SUCTION PRESSURE 14.05 13.60 14.06

2
TDH (kg/cm ) : 319.13 311.52 341.92

TDH (MLC) 3637.8 3542.2 3897.6

PARAMETERS CALCULATED :
3
FLOW PER PUMP (m /hr) 1299.9 1064.6 1171.0
HEAD (MLC) 3637.8 3542.2 3897.6

FINAL PARAMETERS SELECTED :

3
FLOW PER PUMP (m /hr) 1300 1065 1175
03
HEAD (MLC) 3640 3550 3900
 BOILER FEED PUMP SIZING CALCULATION DOC NO.: PE-DC-445-100-N112
BHEL
PEM
PROJECT TITLE : WBPDCL - SAGARDIGHI TPP, PHASE III, 1X660 MW SHEET NO.: 4 OF 5

FLOW CALCULATION

CASE-IV(A) CASE-IV(B)
PARAMETERS CASE-V CASE-VI
(TDBFP) (MDBFP)

SUCTION FLOW (AS PER HBD) T/hr 2076.70 2076.70 1166.67 1430.09

SUCTION FLOW (AS PER CASE) T/hr 2076.70 2186.00 1166.67 1430.09

SUCTION FLOW THROUGH SYSTEM T/hr 2076.70 2076.70 1166.67 1430.09

DISCHARGE FLOW (AS PER HBD) T/hr 2076.70 2076.70 1166.67 1430.09

DISCHARGE FLOW (AS PER CASE) T/hr 2076.70 2186.00 1166.67 1430.09

DISCHARGE FLOW THROUGH SYSTEM T/hr 2076.70 2076.70 1166.67 1430.09

TEMPERATURE ON SUCTION SIDE OC 187.9 187.9 171.2 138.2

D/A PRESSURE (ata) 12.22 12.22 8.31 8.31

SPECIFIC VOLUME (m3/kg) 0.0011385 0.0011385 0.0011160 0.0010779

NO. OF PUMPS IN OPERATION 2 2 1 2

SUCTION FLOW THROUGH EACH PUMP T/hr 1038.35 1093.00 1166.67 715.05

DISCH. FLOW THROUGH EACH PUMP T/hr 1038.35 1093.00 1166.67 715.05

RH SPRAY FROM INTERSTAGE T/hr 0.0 0.0 0.0 0.0

FLOW THRO' EACH PUMP AT DISCH. FLANGE T/hr 1038.35 1093.00 1166.67 715.05

HEAD CALCULATION
2
DISCHARGE PRESSURE (kg/cm )
BOILER TP PR. 325.0 325.0 201.4 293.3

BOILER TP GEODETIC HEIGHT 1.13 1.13 1.16 1.20

PRESSURE DROP IN THE THREE HP HEATERS

4.40 4.40 1.39 2.09
(INCLUDING DESUPERHEATER)

PRESSURE DROP IN DISCH. PIPING, FLOW ELEMENT ET 4.71 4.71 1.49 2.23

10% MARGIN OVER PIPING 0.47 0.47 0.15 0.22

DISCHARGE PRESSURE 335.24 335.24 205.43 298.82

SUCTION PRESSURE (kg/cm2)

D/A PRESSURE 12.22 12.22 8.31 3.50

D/A GEODETIC HEIGHT 2.32 2.32 2.37 2.45

SUCTION PIPING 0.42 0.42 0.13 0.20

10% MARGIN OVER PIPING 0.04 0.04 0.01 0.02

SUCTION STRAINER 0.30 0.30 0.30 0.30

SUCTION PRESSURE 13.78 13.78 10.24 5.43

2
TDH (kg/cm ) : 321.46 321.46 195.19 293.38

TDH (MLC) 3659.8 3659.8 2178.3 3162.4

TDH + MARGIN DUE TO UNDER FREQUENCY (FOR CASE-IVB ONLY) : 4055.2

PARAMETERS CALCULATED :
3
FLOW PER PUMP (m /hr) 1182.1 1244.4 1302.0 770.7
HEAD (MLC) 3659.8 4055.2 2178.3 3162.4

FINAL PARAMETERS SELECTED :

3
FLOW PER PUMP (m /hr) 1185 1245 1305 775
HEAD (MLC) 3660 4060 2180 3165
 BOILER FEED PUMP AND ITS DRIVE TURBINE PARAMETERS DOC NO.: PE-DC-445-100-N112
BHEL
PEM
PROJECT TITLE : WBPDCL - SAGARDIGHI TPP, PHASE III, 1X660 MW SHEET NO. 5 OF 5

1.0 Arrangement - TDBFP 2 x 50 % PER UNIT

2.0 TDBFP BFP SET PARAMETERS

BFP HEAD
FLOW/ (INCLUDING SPECIFIC
CONDITION
PUMP BOOSTER GRAVITY
PUMP)
(M3/hr) (MLC)

2.1 DESIGN POINT 03 1300 3640 0.877

2.2 BEST EFFICIENCY POINT 1065 3550 0.878

2.3 EMERGENCY POINT 1175 3900 0.877

2.4 BMCR POINT 1185 3660 0.878

2.5 RUN OUT POINT 03 1305 2180 0.896

2.6 HPBP CONDITION 775 3165 0.928

3.0 Arrangement - MDBFP 1 x 50 % PER UNIT

4.0 MDBFP BFP SET PARAMETERS

BFP HEAD
FLOW/ (INCLUDING SPECIFIC
CONDITION
PUMP BOOSTER GRAVITY
PUMP)
(M3/hr) (MLC)

4.1 DESIGN POINT 03 1300 3640 0.877

4.2 BEST EFFICIENCY POINT 1065 3550 0.878

4.3 EMERGENCY POINT 1175 3900 0.877

BMCR POINT WITH UNDER
4.4 1245 4060 0.878
FREQUENCY
4.5 RUN OUT POINT 1305 2180 0.896

4.6 HPBP CONDITION 775 3165 0.928

5.0 Pressure drop across suction strainer 03 0.15 kg/cm2 maximum with choked condition

6.0 Manufacturing Tolerance No negative tolerance

7.0 Rated discharge flow through interstage bleed off from feed pump for reheater attemperation shall not be less than
130.4 T/Hr (combined flow from two pumps). Min. RH Spray line pressure at Block valve shall not be less than 115
Kg/cm2(g) at BMCR flow. At best efficiency point, interstage bleed discharge to be considered as closed.
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Operating Flow Outer Thickness Specific Velocity Length Elbows Reducer Gate Valve NRV
SL. No. Line Description Pressure Temp ( T/Hr ) dia. (mm) (mm) volume (m3/kg) ( m/s ) (m) Pres. Drop 90o 45o Pres. Drop No. of Large Small Length Pres. Drop No. of Pres. Drop No. of Pres. Total Pres. Drop
(Kg/cm2) (oC) (kg/cm2) (kg/cm2) Dia. Dia. (mm) (kg/cm2) (kg/cm2) Drop (kg/cm2)
(mm) (mm) (kg/c
m2)

TD BFP DISCHARGE TMCR FLOW

TD BFP INDIVIDUAL DISCRAGE 332.76 195.1 1014.84 457 82 0.001121428 4.69 28 0.1309 6 1 0.1276 1 450 350 450 0.0095 1 0.0108 1 0.07 0.3465

COMMON HEADER UPTO HEATER INLET

(before isolation valve)
332.41 195.1 2029.68 610 114 0.001121454 5.52 40 0.1843 2 0.0498 1 0.0142 0.2838

COMMON HEADER UPTO HEATER INLET

(after isolation valve)
332.13 195.1 2029.68 508 70 0.001121 5.94 36 0.2014 5 1 0.1669 0.5346

HEADER TO HPH -7A 331.6 195.1 1014.84 368 50 0.001122 5.60 15 0.1081 4 1 0.1305 2 450 350 450 0.0272 1 0.0157 0.2816

HPH 7A TO 8A 331.31 226.9 1014.84 368 50 0.001167 5.83 59 0.4494 9 1 0.2792 2 450 350 450 0.0283 0.7570

HPH 8A TO 9A 330.56 280.5 1014.84 406.4 60 0.001273 5.57 13 0.0758 4 1 0.1121 1 450 350 450 0.0118 0.2150

HPH 9A TO 7A DESUPERHEATER FULL FLOW 330.34 306.6 1014.84 406.4 60 0.001346 5.89 11 0.0686 6 0.1501 1 450 350 450 0.0125 0.2670

HPH 9A TO 7A DESUPERHEATER 40% FLOW 330.07 307.6 405.936 273 40 0.001349 5.20 7 0.0511 2 0.0422 1 450 350 450 0.0097 0.1633

7A DESUPERHEATER TO HEADER 40 % FLOW 330.34 310 405.936 273 40 0.001357 5.23 11 0.0822 4 0.0849 1 450 350 450 0.0098 0.1768

7A DESUPERHEATER TO HEADER 330.07 310 1014.84 406.4 60 0.001357 5.94 21 0.1314 6 0.1513 2 450 350 450 0.0253 1 0.0144 0.3584

HEADER TO ECONOMISER INLET 329.91 310 2029.68 559 77 0.001357 5.94 48 0.1973 4 2 0.1290 0.4945
(Terminal point with boiler manufacturer)
3.8784

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