Protection of Boiler Feed Pomp Against

G. S. LIAO
Engineering Group Supervisor,
Los Angeles Power Division,
Bechtel Power Corp.,
Los Angeles, Calif, Mem. ASME
Transient Suction Pressure Decay
In a previous paper [I],1 the analysis of pump suction pressure decay utilizing the
varying condensate temperature approach was first introduced. Although the paper
provided power plant engineers with an accurate analytical method for determining the
magnitude of feedwater pump suction pressure decay, no protective method to prevent
or alleviate the pressure decay under instant turbine load rejection was mentioned.
As unit size has rapidly increased in recent years, the power plant deaerator requires
not only a larger storage capacity but also must be elevated higher to protect the boiler
feed pumps against suction pressure decay under load rejection. Since this trend is
expected to continue, the cost of supporting the power plant deaerator may soon become
prohibitive. Several protective methods have been previously introduced. However, the
evaluation of the methods was invariably based on the constant-condensate-temperature
approach, which is not suitable for central station regenerative cycle units. This paper
reevaluates those methods in general and recommends the on-off type deaerator by-
pass system as the most effective and economical method. The use of this protective
method will not only reduce deaerator storage capacity to the absolute minimum
as required solely for surge, but will also largely preclude the provision of additional
static head for instant load reduction. As a result, enormous savings can be expected
both from the deaerator itself and its supporting structures. The magnitude of savings in
supporting structures alone may amount to more than a half million dollars for a 750
MW fossile unit. Based on the varying condensate temperature approach, mathe-
matical equations expressing the deaerator pressure decay as well as design parameters
required for designing the protective system have been derived. The paper also presents
a detailed description of the recommended protective system and discusses some ad-
vantages of this system over the others. Finally, a few engineering examples are in-
cluded to illustrate the application in system design.

Introduction
L HE RAPID INCREASE in power generating unit ca-
pacity in recent years has necessitated the installation of corre-
spondingly larger boiler feed pumps in central stations. Be-
cause of this growth in pump size, the provision of a sufficient
static suction head to cope with the suction pressure decay under
transient load reduction becomes increasingly difficult and
costly. A thorough analysis of determining the boiler feed pump
1 solution would be to prevent transient suction pressure decay, so
Numbers in brackets designate References at end of paper.
Contributed by the Power Division and presented at the Winter
Annual Meeting, Detroit, Mich., November 11-15, 1973, of THE
AMERICAN SOCIETY OF MECHANICAL ENGINEERS. Manuscript re-
ceived at ASME Headquarters, July 10, 1973. Paper No. 73-
WA/Pwr-1.
suction pressure decay under instant turbine load rejection was
published recently [1]. The analysis revealed that the transient
suction pressure decay increases as boiler feed pump size in-
creases. In order to handle such an increasing transient suction
pressure decay, a deaerator not only requires a larger storage
volume but also must be elevated higher. However, raising a
deaerator equipped with a large storage tank can be very costly
in an earthquake area; it may also present the problem of freeze
protection, if the deaerator is to be located above the power plant
enclosure in a locality with severely cold weather.
It is this ever-increasing transient suction pressure decay which
requires the introduction of some protective methods. The ideal
that the pump suction system could be designed only for maxi-
mum steady turbine load operation. If the provision of addi-
tional suction head for transient suction pressure decay is not
required, there are two immediate advantages: the reduction

Journal of Engineering for Power JULY 1974 / 247

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 in deaerator height equal to the magnitude of transient suction
pressure decay, and the use of a smaller deaerator storage tank
sized merely for system surge.
Several approaches for protecting boiler feed pumps against
transient suction pressure decay were offered previously [3-15].
However, the quantitative analysis justifying these approaches
was generally limited, and was conducted invariably on the basis
of assuming the temperature of condensate entering the deaerator
to be constant. Since this constant-condensate-temperature
assumption deviates considerably from the actual transient
conditions of regenerative cycle units, the direct application of
the existing quantitative analysis in system design may result in
significant error.
It is the purpose of this paper to determine the optimum pro-
tective method, which is not only fully substantiated by technical
analysis but also applicable to regenerative,cycle power generat-
ing units. Following the reappraisal of those existing processes
and approaches, on-off type deaerator bypass system has been
determined to be the most effective and inexpensive method.
Since bypassing large quantities of cold and nondeaerated con-
densate across the deaerator is objectionable, the bypass flow
should be carefully determined and limited to a minimum. Ac-
cordingly, a comprehensive analysis for the on-off type deaerator
bypass system was conducted on the basis of varying temperature
of condensate entering the deaerator. From this analysis, mathe-
matical equations expressing deaerator pressure, pump suction
vapor pressure, required bypass flow, and maximum transient
suction pressure decay were derived. This paper also presents
a description of the recommended protective system, together
with some example calculations to illustrate the application and
to substantiate the merits of the system in actual design.
Protection Against Transient Suction Pressure Decay
The available approaches and methods, as well as pump suc-
tion system parameters, for protecting boiler feed pumps from
transient suction pressure decay are summarized in the following:
1 Increasing static suction head by raising deaerator;
2 Increasing deaerator storage capacity; '
3 Reducing suction pipe resident capacity;
4 Increasing low pressure heater and interconnecting piping
volume;
5 Lowering deaerator operating pressure;
6 Reducing .temperature rise of condensate in deaerator
relative to temperature rise in low pressure heaters under normal
operation; r
7>; Adding antiflash baffle in deaerator;
8 Increasing feedwater flow by recirculation;
9 Injecting steam into, deaerator;
10 Injecting cold water into pump suction.
Of the foregoing 10 methods, only approaches 9 and 10 are
capable of effectively preventing transient suction pressure decay,
whereas the other approaches merely accommodate or alleviate
it. Since approaches 1 and 2 require heavier supporting struc-
tures,, a larger deaerator storage tank, or both, these are con-
sidered to be the most expensive methods. Although it can

.Nomenclature.

a = (ht — hi)/Mu = enthalpy
gradient of warm conden-
sate, Btu/lb 2
1 Ms
= e M =
factor
Hai = static suction head for boiler
feed pumps, ft
Hf = friction loss through pump
suction line, ft
AH = transient suction pressure de-
cay, ft
Affmax = maximum transient suction
pressure decay, ft
h„ = enthalpy of condensate enter-
ing deaerator, Btu/lb
h = enthalpy of saturated water
in deaerator at the instant
of load rejection (corre-
sponding to pi), Btu/lb
h% = enthalpy of saturated water
in deaerator. at the end of
transient (corresponding to
p>), Btu/lb
hi = enthalpy of warm condensate
entering deaerator at the
time of load rejection, Btu/
lb
hs = enthalpy of hot-well con-
densate, Btu/lb
hi = enthalpy of saturated water
in deaerator after x lb of
(NPSH)r. = required NPSH at pump
feedwater has entered the
boiler feed pump, Btu/lb
248 / JULY 1974
hi' = enthalpy of saturated water
at pump suction after x lb
of feedwater has entered
the boiler feed pump (with-
out bypass), Btu/lb
ha = enthalpy of saturated water
at pump suction after x lb
of feedwater has entered
the, boiler feed pump (with
bypass), Btu/lb
Ah =-h, - ta, Btu/lb
Ahmax = maximum Ah during tran-
sient period, Btu/lb
M = mass of water in deaerator
storage compartment, lb
M vent transient suction pres-
M' = = adjusted mass of
1 —R
water in deaerator storage
compartment, lb
M„, = mass of water in mixing zone,
lb
Ms = mass of water in pump suc-
tion line, lb
M,
M„' = = adjusted mass of
1 —R
water in pump suction line,
lb
• Mw = mass of warm condensate
:
contained in low-pressure
heaters and interconnect-
ing piping, lb
suction, ft
Pi = deaerator pressure at the in-
stant of load rejection, psia
pi = final deaerator pressure; pres-
sure at which deaerator is
pressurized by other source
of steam, psia
= deaerator pressure after x lb
Pd
of feedwater has entered
the boiler feed pump, psia
= vapor pressure at pump suc-
V-
tion after x lb of feedwater
has entered the boiler feed
pump, psia
R = required bypass ratio; ratio
of bypass flow to feed-
water flow required to pre-
sure decay
Rmxx = maximum required bypass
ratio; maximum bypass
ratio required during tran-
sient period
Vi = specific volume of saturated
water in deaerator (corre-
sponding to pd), cu ft/lb
va = specific volume of saturated
water at pump suction
(corresponding to ps), cu
ft/lb
x = cumulative mass of feed-
water has entered boiler
feed pump after load re-
jection, lb
Wb = bypass flow, lb/min
Wf = feedwater flow, lb/min
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 alleviate transient suction pressure decay, approach 3 is not an
effective solution because the pipe resident capacity cannot be
completely eliminated. Approaches 4, 5, 6, and 7 are either
ineffective or uncontrollable by power plant engineers.
Contrary to the foregoing, approach 8 is one of the positive
solutions for alleviating transient suction pressure decay. Boiler
feed pump recirculation, based on a numerical case study apply-
ing the constant-condensate-temperature assumption to each
subdivided step, was found to be an effective measure many
years ago, although no general quantitative conclusion was
reached [6]. It was not determined until recently that the maxi-
mum transient suction pressure decay with a constant storage
capacity will vary directly proportional to the effective suction
pipe resident capacity which, in turn, varies in proportion to the
ratio of condensate flow to feedwater flow [2], Therefore, the
magnitude of the suction pressure decay can be reduced propor-
tionally, if the ratio of condensate flow to feedwater flow is in-
tentionally reduced by feedwater recirculation. For example,
if feedwater flow is increased 25 percent by recirculation, the
ratio of condensate flow to feedwater flow reduces to 80 percent,
as does the maximum suction pressure decay. If the boiler feed
pump minimum flow is being returned to the deaerator, a recircu-
lation can be readily achieved by overriding the minimum flow
control to have the valve opened under load rejection. How-
ever, the same objective can be achieved with the provision of a
separate control valve or an independent line with a valve.
Approach 9 is one of the two most effective methods, but has
the following disadvantages:
1 A large quantity of auxiliary steam, which is not available
from the main unit under load rejection, must be supplied from
other sources.
2 Since deaerator pressure must be reduced to the pressure
corresponding to a new load after a sudden load reduction, the
steam injection.system must allow deaerator pressure to decay,
and is thereby unable to avoid transient suction pressure decay.
3 This method must rely on the other systems which supply
auxiliary steam and, therefore, is less reliable.
• 4 Both initial cost and operating cost of the steam injection
system could be higher. •' • '
Approach 10, the injection of cold water into the pump suction,
has been known for many years [3, 4], and is a very, effective
method for protecting, boiler feed pumps, against transient suc-
tion pressure decay. In addition, this is the only method t h a t is
capable of almost completely preventing transient suction pres-
sure decay. However,, there are two disadvantages associated
with this method; i.e., the introduction of nondeaerated water
into the boiler, and the possibility of chilling the pumps. In
order to avoid or minimize the foregoing adverse effects, an ac-
curate determination of bypass, flow is essential. Since it is
generally less.than .10 percent of total feedwater flow, the injec-
tion of cold water is not considered detrimental to boilers, es-
pecially when the injection is so infrequent and for such a short
duration: An abrupt change in feedwater temperature at the
pump suction can also, be minimized, if the quantity of bypass
flow is precisely determined and held to a minimum, and an ade-
quate mixing zone ahead of the pump suction, is provided to avoid
stratification. I t should .be noted, however, that this.mixing
zone, due to its resident capacity, will result in a suction pressure
decay, which must be compensated for by an additional static
head.
Although cold injection water can be obtained from, several
sources, bypassing a portion of the condensate flow across the
deaerator is considered superior for the following reasons:
1 The deaerator bypass flow is the most reliable source of
cold injection water supply; it is available whenever the deaerator
is being fed with the condensate causing transient suction pressure
decay.
2 With regenerative cycle units; the temperature of the by-
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pass flow is generally high when deaerator pressure is high and
decreases as deaerator pressure decays. This minimizes the tem-
perature difference between the deaerator water and bypass
flow, thereby not only keeping the bypass flow throughout the
transient period fairly constant but also reducing the volume.of
the required mixing zone in the suction line.
Concerning the actuation of deaerator bypass, an on-off type
control is considered to be the most effective and inexpensive
method for protecting boiler feed pumps against transient suc-
tion pressure decay. The "on-off type deaerator bypass system"
recommended in this paper is to bypass just sufficient flow to
suppress the vapor pressure entering the pumps equal to or below
the deaerator pressure, thereby preventing suction pressure decay
under load rejection. Karassik introduced an excellent elaborate
control system to protect boiler feed pumps from N P S H defi-
ciency [4, 15]. The major difference is that Karassik's method
uses a continuous modulating control of bypass flow to satisfy
the pump required N P S H under any conditions, whereas the
method recommended in this paper is an on-off type actuated
under rapid load reduction to prevent transient suction pressure
decay. The signals to actuate the bypass valve are entirely
different; Karassik uses the actually measured N P S H at the pump
suction, whereas this method utilizes signals indicating turbine
load reduction and cutoff of outside steam supply.
A similar on-off type deaerator bypass system has been used
before [15]; it diverts most of the condensate flow to the boiler
feed pump suction. This system has the following disadvan-
tages :
1 It requires an oversized bypass valve and line and is,
therefore, costly.
2 It can cause a chilling effect on the pump.
3 Since most of condensate flow is being bypassed, the de-
aerator receives only a small portion of condensate flow, resulting
in a very slow deaerator pressure decay. This system un-
necessarily prolongs the transient operation and thereby intro-
duces a relatively large quantity of nondeaerated water into the
boiler.
4 It cannot protect the pump from suction pressure decay
under gradual turbine load reduction.
The on-off type deaerator bypass system in connection with a
precise determination of the bypass flow presented herein will
eliminate the foregoing problems.
Maximum Required Bypass Ratio
In order to simplify the analysis, it is assumed that the tem-
perature of the bypass flow injected into the pump suction is
equal to the temperature of the condensate entering the deaerator.
If R represents required bypass ratio, condensate admitted to the
deaerator can be expressed by a ratio 1 — R as shown in Fig. 1.
The enthalpy of condensate entering the deaerator together with
deaerator pressure decay equations for the bypass system can be
derived in a similar manner as (1):
1. x < M„
ha = hi — ax (1)
h„ = o ( M ' - x) + h - {aW - h + hi)e-*'M' (2)
2. x > Ma
ho = h (3)
hi = h + [aM'(eM»/M' - 1) + (/>, ~ hi)]e-*'M' (4)
where
JULY 1974 / 249
 In order to prevent suction pressure decay under instant tur-
bine load rejection, the temperature of feedwater at the pump
suction should be suppressed to that corresponding to the de-
aerator. If the enthalpies of water inside the deaerator and at
the pump suction before mixing with bypass flow are hd and hd',
respectively, the required bypass ratio R to reduce hd to hd at
the pump suction can be obtained from mass and energy balance
as follows:
hi1
R =
hd ho
The analysis presented in Appendix A concludes that the maxi-
mum required bypass ratio throughout the transient operation
can be expressed as
•M.'/M'
Rm 1 - e =_ 1 -M,/M
where
M.'
It is also noted that the required bypass ratio increases as the
transient operation proceeds and finally reaches its maximum
required bypass ratio Rmax, when the cold condensate from the
condenser hotwell is admitted to the pump suction, i.e., x =
M,' + Ma. R remains at Rmax thereafter until the completion
of deaerator pressure decay.
Recommended Protection System
The recommended on-off type deaerator bypass system is
shown in Fig. 2. The system should be provided with an auto-
matic quick-opening valve of the on-off type to bypass a pre-
determined quantity of low temperature condensate.
The valve should be sized to pass a flow not less than I —
e ~ M'iM of the maximum feedwater flow. The available pressure
drop for the valve is generally sufficient, even if the deaerator
level control valve is located upstream of the bypass takeoff.
The minimum available pressure drop is the static head measured
between the condensate spray header in the deaerating section
and the normal water level in the storage tank, plus pressure
drop across the spray nozzles.
The signals to initiate the opening of the bypass valve should
be those that represent an inadequate steam supply to the de-
aerator. Fig. 2 shows one of several methods that can be used. A
turbine load reduction signal indicates that extraction steam pres-
V
v
h
d /
'
BYPASS
VALVE
' still taking the mixing zone into consideration are as follows:
Fig. T Deaerator-pump suction system under transient
250 / JULY 1974
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(S).
(6)
LOW PRESSURE
CLOSED FEEDWATER
HEATERS
Fig. 2 On-off type deaerator bypass system
sure to the deaerator will drop shortly, followed by deaerator
pressure decay. If another source of steam is used for deaera-
tor pegging at a lower pressure, a position switch on the pressure
regulator can be utilized to indicate that the valve is at the closed
position. These two signals signify an inadequate steam supply;
thereby, they can be used to initiate bypass valve opening. In
order to cover the effect of resident capacity and to prevent the
valve from hunting, an adequate: time lag for closing of the by-
pass valve following the restoration of steam supply should bo
provided.
In order to prevent adverse chilling effect on the boiler feed
pumps, or localized flashing due to stratification, the bypass
flow should not be introduced directly into the pump suction.
A liberal mixing zone between the point of bypass flow injection
and the pump suction should be provided. It should be noted,
however, that the mixing zone which constitutes a suction pipe
resident capacity is a direct cause of transient suction pressure
decay. Therefore, the on-off type deaerator bypass system has
its maximum transient suction pressure decay at the end of the
first replacement of the mixing zone.
As noted from the previous analysis, the maximum bypass
flow is required after a cumulative condensate mass of M,' + Mu
has been admitted to the deaerator; i.e., the cold hotwell con-
densate has reached the pump suction. Therefore, the use of
an on-off type bypass valve to introduce the maximum required
bypass flow from the instant of load rejection will suppress the
vapor pressure at the pump suction far below the deaerator
pressure during the earlier part of the transient operation. This
is advantageous because there is a possibility of an unsteady
condition immediately following turbine load rejection. The
introduction of an excess bypass flow during this period will en-
sure no deficiency in suction pressure. In addition, the required
bypass ratio throughout the transient period is fairly constant;
consequently, the low cost on-off type control is sufficient to pro-
tect transient suction pressure decay economically.
Analysis of Qti-Off Type Deaerator Bypass System
Some conservative assumptions that simplify analysis while
1 The temperature of bypass flow at the pump suction (not
at the point of injection) is equal to the temperature of con-
densate at the deaerator inlet.
Transactions of the ASME
 M, From equations (3), (12), and (13),
2 Adjusted pump suction resident capacity is
-1 Amax
, 'M. - Mm h, = hi + [abM(eM»'hM - 1) + (fci - hi)]e-^bM (17)
stead of — + Mm.
A *tmax
3 The bypass ratio is constant and equal to i? m a x throughout Differential Enthalpy Between hs and hd, or Ah,

the transient period; therefore, the bypass factor defined in the 1 x < Mm
following is also constant.
From h, = hi, and equation (8),
1
6 = (7)
Ru Ah = h, — hd

Deaerator Pressure Decay. If M' is substituted by bM in equa- = (hi - hi) - a(bM - x) + (abM - h + ht)e -x'hM
tions (2) and (4), deaerator pressure decay equations are obtained
as follows: = (h - ht)(l - e-*'hM) + abM ( - j - - 1 + e-x'bM\
\oM )
1 x < M„
Then,
hd = a(bM - x) + hi - (abM - hi + ln)e-^bM (8)

2 x > Mu dAh hi — hi -x/bM

dx -• 0 ( 1 - . - ^ ) + \ M -
hi =h+ [abM (fiMJbM _ i ) + (/n _ hi-)]e-x/bM (9)

dAh
Feedwater Enthalpy at Pump Suction Without Injection. Except for Both Ah and its first derivative ——- are positive; therefore, Ah
dx
the first replacement of the suction pipe volume, the enthalpy of
increases with an increase in x, and reaches its maximum at
feedwater at the pump suction without injection can be obtained
from equations (8) and (9) with a substitution of x — bMs for x, x = Mm.
and hd' replacing hd.
2 Mm < x < bM,
1 x < bM,
From equations (8) and (14),
hd' = hi (10)

2 bMs < x < bM, + M„ Aft = ( ( A , - hi)(e-*?bM - -\

hd' = a[b(M + M.) - x] + ht x bM

+ a bM(l - e- ? ) - -
- (abM - h + hi)be-^hM (11) b

3 x > bM, + Ma dAh 1

[aM - (abM - h + hi)e~x>bM]
dx ~ bM
hd' = h + [abM(eM»>bM - 1) + (h - hi)]be"x/bM (12)
Vapor Pressure at Pump Suction. The enthalpies of feedwater at
If x = 0,
the boiler feed pump suction after mixing with the bypass flow Ah = -(hi - hi)(l - e-M»'M) < 0
can be determined by mass and energy balance and are expressed
by
If x = bM„
h, = h0 + 7 (hd' — h0)
b
(13) Ah -aMy eM,/M _ x
M]
<0

With a substitution of suitable and adequate equations into dAh hi — hi

equation (13), the vapor pressure at the pump suction can be > 0
dx b2M
expressed as follows:
The foregoing analysis indicates that, after injection water has
1 x < bM,
reached the pump suction, deaerator pressure pd is greater than
From equations (1), (10), and (13), pump suction vapor pressure p,; therefore, a negative suction
pressure decay exists throughout this period. However, this
negative suction pressure decay is decreasing as x increases when
h. = T [hi + (hi - ax)(b - 1)] (14)
o x = bM,.

2 bM, < x < Mw 3 bM, < x < Ma

From equations (1), (11), and (13), From equations (8) and (15),
x hM
K = a(M + M, - x) + hi - (abM - h + ht)e' ' (15) M\
Ah = -aM{eM-'M - 1 - <0
3 Ma < x < bM, + Ma
M)

From equations (3), (11), and (13), A negative Ah exists in this period and its magnitude remains
constant. However, owing to nonlinearity between saturated
M^ _ x\ liquid enthalpy and corresponding pressure, negative suction
M + M,+ b b/ pressure decay is not necessarily constant.
<
+ h - (abM - h + hi)e-x'bM (16) 4 Mu < x < bM, + M„

4 x > bM, + Ma From equations (9) and (16),

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 bM, + Ma - x
Ah = -aM
Ik bM- )'
+ :5!\ bM J+ " '' J
Afc, = 0, when a; = 6M", + Af„
The negative suction pressure decay continues to decrease as x
increases in this period, and finally diminishes a t the end of this
period.
5 x > bM„ + Ma
Since deaerator pressure decay and pump suction pressure decay
are identical, Ah is equal to zero; consequently, no suction pres-
sure decay exists during this period.
Maximum Suction Pressure Decay. From t h e analytical results
obtained in the section entitled "Vapor Pressure at Pump Suc-
tion," the maximum suction pressure decay will occur at the end
of the first replacement of the mixing zone; i.e., x = Mm. T h e
deaerator pressure p,i can be obtained from equation (8) by sub-
stituting M„t for x, whereas pump suction vapor pressure p , re-
mains pi_. This positive suction pressure decay must be provided
in the form of static head over and above t h e normal operating
requirement.
Conclusion
In order to restrain t h e ever-increasing cost of providing an
adequate suction head for boiler feed pump to handle transient
suction pressure decay, t h e on-off type deaerator bypass system
substantiated by the analytical solution presented in this paper
is recommended. The analyses reveal t h e following major
points:
1 Cold water injection into the pump suction line in the form
of deaerator bypass is a reliable and very effective method for
avoiding transient suction pressure decay.
6 Baron, S., "Detect Recirculating BF Pump Load-Drop Cavi-
tation Mathematically," Power Engineering, July 1954, pp. 75-77.
7 Karassik, I. J., "Steam Power Plant Clinic—Part III," Com-
bustion, Oct. 1958, pp. 55-56.
8 karassik, I. J., Bosworth, G. H., and Elston, W. D., "Sudden
Load Drop in Open Feed Cycles of Steam Turbine Power Plants,"
The International Operating Engineer, July, Aug., Sept., and Dee
1957, and Jan. 1958.
9 Karassik, I. J., "Steam Power Plant Clinic—No. 4," Power
Engineering, Nov. 1957.
10 Karassik, I. J., "Steam Power Plant Clinic—Part VIII,"
Combustion, May 1959, pp. 53-55. ' '
11 Karassik, I. J., Zabel, L. E., and Hess, E. K., "Steam Power
Plant Clinic—Part XIII," Combustion, Nov. 1959, pp. 49-51.
12 Hardie, P. H., Karassik, I, J., and Zabel, L. E., "Protecting
Boiler Feed Pumps Against Flashing," Combustion, Feb. 1960, pp.
37-40.
13 Karassik, I. J., "Steam Power Plant Clinic—Part XVIII,"
Combustion, July 1960, pp. 51-53.
14 Strub, R. A., "Reduction of the Suction Pressure of Boiler
Feed Pumps as a Result of Sudden Load Drops," Sulzer Technical
Review No. 3, 1960,
15 Karassik, I. J., "Steam Power Plant Clinic—Part XXXII,"
Combustion, June 1962, pp. 48-50.
APPENDIX A
Determination of Maximum Required Bypass Ratio
The whole transient operation is divided into four periods in
determining Umax-
Ms . , , . .
1 % < Ms' — —; from the instant of load rejection to the
1 — R
first replacement of the pump suction line.
Since h/ — hi, and h<s and h,i are expressed by equations (1)
and (2), required bypass ratio can be obtained from equation (5).
_ (fe - hi) - a(M' - x) + (aM' - h, + hje-*/*1'
h — hi + ax
If M' is assumed constant, the first derivative of R with respect
to x is

a>M'i e~*<M' lex'M' - 1- ~ \ + {^ - h,)(ax + hi - hi)e-^M'

dR
dx M'(hi - ht + axf

r/7?
2 The maximum required bypass ratio to prevent transient Since — is always positive for any x within this range, the
dx
suction pressure decay throughout the transient period can be
largest R is required when x ~ M/.
accurately determined and is expressed by 1 — e-Ms/M^ ^ i g j j j g
approximately t h e ratio of suction pipe capacity to deaerator
storage capacity. 2 M,' < x < Ma; from the first replacement of t h e suction
line to the first replacement of the low pressure heaters and inter-
3 Other parameters, such as deaerator operating pressure,
connecting pipings.
enthalpy and mass of warm condensate, deaerator pegging pres-
Both ha and h& are expressed by equation (2), except the latter
sure, etc., have no effect on the required bypass ratio.
lags b y Ms'.
4 The required bypass ratio throughout the transient period
is fairly constant. I t is slightly smaller in the beginning but in-
aM,' + (aM' ~ h + In) (1 - eMs'/M')e-x/M'
creases to its maximum when the hotwell condensate has been R =
admitted to t h e deaerator. I t remains a t t h e maximum there- a(M' + M,') - (aM' - hi + hi)eM-''M'e~'x'u'
after.
„MS'/M>
M{ ,-x/M'
a(aM' - hi + hi) 1 -
dR M'
References
dx [a(M' + M,') - (aM' - hi + ht)eM>'/M'e-x'M'\'
1 Liao, G. S., and Leung, P., "Analysis of Feedwater Pump
Suction Pressure Decay Under Instant Turbine Load Rejection,"
JOURNAL OF ENGINEERING FOR POWER, TRANS. ASME, Series A, dR ,
Vol. 34, Apr. 1972, pp, 83-90. Since — is always positive for any x within this range, the
2 Liao, G. S., and Leung, P., Authors' Closure to the foregoing dx
paper. largest R is required when x = Mu.
3 Karassik, I. J., "Certain Aspects of High-Pressure Centrifugal
Pumping Cycles," TRANS. ASME, Vol. 68, Jan. 1946, pp. 65-74. 3 Ma < x < M,' + Ma; the hot-well condensate entered the
4 Karassik, I. J., "Boiler Feed Pump Control," 17. S. Patent No. deaerator but has not yet reached the pump suction.
2,372,087, Mar. 20, 1945.
5 Baron, S., "Detect BF Pump Load-Drop Cavitation Mathe- Since ho and hd are expressed by equations (3) and (4), whereas
matically," Power Engineering, May 1954, pp. 69-72. h^ is expressed by equation (2) with a lag of M/,

252 / JULY 1974 Transactions of the ASME

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 V y OEAERATOR PRESSURE
, . VAPOR PHES5URL ^ ^
1 1 WITH BYPASS ' ^

! '/»„
S\
tr"
1/
/
* VAPOR PRESSURE
WITHOUT BYPASS

!
»4J

M
M * M e

Fig. 3 Deaerator pressure and pump suction vapor pressure under transient

B = 1 Without Protective System. If the analytical method introduced

previously [1] is applied,
[aM' (eM"/M' - 1) + (hi - ht)] e - * / M '
a(M' + M,' + Ma - x) - (aM' - h + hi)eM''/M' e~x'M' Affmax = 27.9 ft

dR _ a[aM' (eM»'M' - 1) + (h - ht)}(Ms' + Ma - x)e~x/M'

Hx ~ M'[a(M' + M.' + Ma - x) - (aM' - h + hs)eM''/M'e-x/M'V

dR
Let- 0. and solve for x.
dx

M.' + M„
This signifies t h a t maximum bypass ratio Rmax is required
when x = M.' + Ma.
Substituting x by M,' + Mw one obtains

Rn = 1 _ e-M,'/M' = i - e-M,/M

4 x > Ms' + Mu; after the hot-well condensate reaches the

pump suction.
Both hd and hi' are expressed by equation (4), except the
latter lags by M,'. If the foregoing equations together with ha =
h are substituted into equation (5), R is obtained as a constant.

R = 1 - MJM

which is equal to Rw

APPENDIX B
Example Calculations
Data
pi = 150 psia, hi = 330.6 B t u / l b
=P2 20 psia, h = 196.27 B t u / l b
hi = 272 B t u / l b
hi = 82 B t u / l b
M = 470,000 lb (5 min storage)
Ma = 134,000 lb
M, = 20,000 lb (two 14-in. lines)
Mm = 10,000 lb
(NPSH) r = 52 ft at 100 percent load
Wf = 94,000 lb/min
CUMULATIVE FEEDWATER, 1000 LBS
Hsl = 95 ft
Hf = 14.0 ft at 14.3 fps Fig. 4 Transient suction pressure decay

Journal of Engineering for Power JULY 1974 / 253

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 The minimum required static head is:
Hal = (NPSH) r + Hf + AHmaK = 93.9 ft < 95 ft provided
The elevation of the deaerator is, therefore, adequate.
Recommended Bypass System. With this protective system, Hst
can be reduced. If H3t is assumed to be 74 ft, M, will be 17,000
lb proportionally.
The maximum suction pressure decay due to the mixing zone
capacity Mm can be determined by substituting Mm for x into
equation (8).
hi = 329.1 B t u / l b
Since h, = hi, the corresponding pressures and liquid specific
volumes are:
Pd = 147.60 psia, vd = 0.01807
p, = 150 psia, v, = 0.01809
Then,
/0.01807 + 0.01809 \
Affmax = (150 - 147.6)( 1 = 6.3 ft
Hence, the minimum required static head is,
H„ = 52 + 14 + 6.3
= 72.3 ft, which is smaller than 74 ft assumed.
Therefore, the bypass system reduces the elevation of the de-
aerator by 21 ft. The required bypass flow is then,
DISCUSSION
I. J. Karrasik 2
Nothing gives an engineer as much pleasure as the opportunity
to discuss a technical paper on a familiar subject, written by a
congenial author from a point of view that is compatible to one's
own. Such is certainly the case today as I review Mr. Liao's paper.
That the subject is familiar to me can be readily demonstrated by
examining Mr. Liao's list of references; that his point of view is
compatible with mine is apparent from his recommendation to pro-
tect boiler feed pumps against transient conditions by means of a
control which I patented in 1945, even though Mr. Liao recom-
mends modifying it somewhat; finally you will have to take my
word for the fact that I find the author of this paper congenial.
All the preceding should not be interpreted to mean that there
are absolutely no differences of opinion between Mr. Liao and
myself. But the differences which do exist are not very important,
nor do they lead us to widely diverging conclusions or recommen-
dations. As a matter of fact, Mr. Liao implies some differences
which are really nonexistent, as I shall point out later on.
Let me first state my complete agreement with Mr. Liao's ap-
proach to the problem, which is to see that "the wolf must be fed
while the sheep remain safe." In other words, he has concentrated
on recommending means that would fully protect the boiler feed
pump against the unfavorable effects of sudden load reduction
without imposing unnecessary increases in the cost of the deaera-
tor or of its supporting structure. As he says, this approach
should produce "enormous savings" in the light of the rapid in-
creases taking place in the average unit size. But I submit that
the development of the automatic protection controls to which I
addressed myself as early as 1945 was intended for the same pur-
pose.
2
Vice-President and Chief Consulting Engineer, Worthington Corp.
254 / JULY 1974
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Wb = Wf (1 - e~M"M) = 33401b/min
which amounts to only 3.55 percent of the maximum feedwater
flow.
A computer was used to calculate deaerator pressure and pump
suction vapor pressure for the whole transient operation. The
results were plotted in Pig. 3 to compare the subject protective
system with the ordinary system. I t indicates that there are
negative suction pressure decays when cumulative feedwater *
is within the range between Mm and Ma + M%eM*>u; therefore
this protective system provides the pump with some excess
available N P S H during this period.
Recommended Bypass System with 3-Minute Deaerator Storage Ca-
pacity. Based on:
M = 282,000 lb and M, = 17,600 lb,
we obtain
Affmax = 10.0 ft
which is only 3.7 ft more than the deaerator with 5 min storage.
The required bypass flow increases to 5690 Ib/min, or 6.05
percent of maximum feedwater flow. Although it results in a
slight increase in both deaerator height and bypass flow, a re-
duction in deaerator storage capacity from 5 min to 3 min can be
a significant capital saving both from deaerator and its support-
ing structure.
The transient suction pressure decays in feet of liquid for the
foregoing three cases are shown in Fig. 4.
These controls, in their initial conception, were to be actuated
by signals originated from a measurement of the NPSH at the
pump suction, whereas Mr. Liao prefers and recommends signals
indicating turbine load reduction and cutoff of outside steam sup-
ply. It may well be that Mr. Liao is right and that his type of
control is both less expensive and more reliable. Basically, the
choice of the signal is not important. What is extremely impor-
tant is that the initiation of protective action be as near to 100
percent reliable as possible. If Mr. Laio finds that his choice of
signal has greater reliability, then by all means it should be pre-
ferred.
I am, however, just a bit unhappy that, my good friend Liao has
ascribed to me the intention of diverting "most of the condensate
flow to the boiler' feed suction." If I had, I would have to agree
with him that all the disadvantages he ascribes to such an ap-
proach would indeed exist. But I insist on my complete innocence
in this connection. A careful reading of the reference he cites 3 will
reveal that, on the contrary, I suggested a very modest bypassing of
condensate flow directly to the boiler feed pump suction. I quote:
"A nominal admixture of colder water is sufficient to add a sub-
stantial amount of surplus NPSH to the p u m p . " In the example I
used it was only necessary to provide 12.5 percent of the total
flow from the colder condensate source to achieve 50 ft of addi-
tional NPSH. I should add that there can be no difference what-
soever in the calculated amount of colder water admixture to
achieve a given NPSH increase, given the "immutability" of
steam tables and of the formulas for mixing flows of different
temperatures.
We now come to the differences between the various approach-
es for calculating the effects of sudden load reduction that I have
used in the past, and Liao's approach. It is entirely true that, for
the sake of simplicity, I had neglected changes in the temperature
of the condensate entering the deaerator after a load drop. The
results thus calculated were on the conservative side, but not
3
Karassik, I. J., "Steam Power Plant Clinic—Part XXXII," Combustion
June 1962, pp. 48-50, (Worthington Reprint 45-RP-1014-37).
Transactions of the ASME