Sulzer Pumps is one of the world leaders in state-of-the-art pumping solutions. Combining engineering and application expertise, Sulzer
Pumps’ solutions add value and strengthen the competitive position of its customers.
Thanks to a global network of manufacturing facilities, sales offices, service centers and repre sentatives, we are able to provide fast responses to customer needs.
HPT Global Manufacturing Facilities
Through its extensive experience in providing innovative solu tions to business partners, Sulzer Pumps is a well-recognized player in the following industries:
• Oil and Gas
• Hydrocarbon Processing
• Pulp and Paper
• Power Generation
• Water
• General Industry
• Chemical Process Industry
Elandsfontein, South Africa
2
HPT radially split barrel-casing pumps are specifically designed for boiler feed applications in thermal power stations. These pumps are optimized to provide high avail ability and high efficiency operation over an extended period of time, thus reducing operating and main tenance costs. Their robust con struction and tolerance of changing conditions makes them particularly suitable for cyclic operation.
The pump’s efficiency is a result of its advanced hydraulic design and therefore does not rely on the use of close internal clearances. This is also the case for the rotordynamic design, which ensures low vibra tion by providing a high degree of damping throughout the life of the pump, even with the clearances worn to their maximum values.
Although the HPT is a well-estab lished design, with many years of re liable operation, it has been continu ally updated to take advantage of technological developments. These include developments in precision casting, sealing technology and materials, as well as the applica tion of Finite Element (FE) analysis and state-of-the-art manufacturing techniques.
-
-
Suzhou, China
Leeds, UK
HPT Pump

The HPT benefits from an optimized thermal design which:
• allows operation under cyclic conditions, without any need for pre-warming
• minimizes thermal distortion to avoid the reduction of internal clearances
• handles thermal stresses thanks to a selection of high strength materials
• ensures secure sealing under all transient conditions thanks to graphite stationary seals
Computerized analysis to optimize temperature distribution under various conditions
Air barrier avoids heat transfer from hydraulic pump parts to sealing area
Cooling jacket decreases temperature in seal chamber
Mechanical seal
Thermosleeve with air gap
• •
• •
Bleed-off for high suction pressures, without bleed-off for low suction pressures
Cold condensate injection
• •
Cold condensate injection
•
• •
Hot (~180 °C)
Single Mechanical Seal
• Minimal leakage
• Low energy consumption
Cool (~60 °C) Drain
Fixed Throttle Bushing
• Simple and reliable design
• Less sensitive to dirt and flashing
With Floating Rings
• Moderate leakage
•
Drain
3

• Barrel design incorporates many design features resulting from
Sulzer/EPRI research contract
• Maximum safety due to double casing design
• Pipework connections remain undisturbed during disassembly
• Barrel casing design provides maximum rigidity and accepts high pipe loads
• Full cartridge pull out for rapid changeover
• Axial thrust compensation by balancing piston to avoid damage during transient conditions
• Long operating life regardless of the operating mode
• Design features to eliminate the need for prewarming in most installations
• Fully rated double acting tilting pad thrust bearing
• Top or bottom facing nozzles welded or flanged; can be positioned to suit the planned installation layout
4
• Design of close running clearances
• Optimized labyrinth—high efficiency and good rotordynamic behavior
• Radial grooves—increased radial stiffness, reduced effect on rotor tilting and good rotor dynamic behavior
• Swirl break at balancing piston to maintain rotor stability even when internal clearances are worn
• Removal of bolts, coupling hub, piston and thrust collar by means of a common hydraulic pump to simplify maintenance and reduce car tridge replacement time
• Centerline mounting
• Precision casting in chrome nickel steel
• Optimization of hydraulic profiles
• Kicker stage available

• Optional intermediate take-off possible
• Integral impeller wear rings for longer life dimen sioned to allow re-machining several times
• Double suction first stage available
• Pure graphite stationary seal rings at external joints
• Bearing housing fixed to pump cartridge through 360°
• Bearing provides high stiffness and damping to minimize shaft movement
• Anti-whirl journal bearings
• E-P o-rings at internal joints
• Forged, low alloy steel barrel casing as standard; designed for long term cycling operation and to re sist erosion-corrosion without the need for overlays
• High strength material to accept thermal shock
• Other materials possible to suit customer require ments
• Sliding pads to maintain align ment during thermal movements
Shaft forged in chrome nickel steel
• Low L/D ratio
• Stable operation without critical speed problems
• Reduced vibration levels
Optional Double Suction Optional Kicker Stage
Kicker stage flow •
Kicker stage forged design for flow < 50 m 3 /h
Kicker stage cast design for flow >= 50 m 3 /h
Balance drum leakage flow
Main discharge flow
•
•
•
•
5

Integral Cartridge Design
Advantages
• The cartridge is completely as sembled outside the barrel case
• Prior to installation of the car tridge, the mechanical seals are set, the rotor is radially and axi ally adjusted and the axial thrust bearing clearance is set
• Quick cartridge changes for increased productivity
• Cartridge support for increased safety
• Cartridge includes the shaft, coupling hub, static and dynamic hydraulic parts, shaft seals, radial bearings and thrust bearing, balancing system, suction and delivery cover
Step 1
Step 2
Step 3 Final Installation
•
Suspended and supported on rollers at the drive end (DE)
• Suspended for re-rigging
•
6
Rotor Design
Advantages
• Shrunk on parts allow for high rotor balancing quality
• Shrunk on parts avoid fretting corrosion and minimize stress concentrations
• Shrunk on parts avoid loose parts on shaft during operation and result in lower vibration
Rotor
Shrunk on thrust collar, oil press fit
•
Shrunk on balance drum, oil press fit
•
•
Impellers are shrunk on, have keys for torque transmission and use split ring for thrust loading
Shrunk on coupling, oil press fit, parallel stepped or taper fit
•

Diffuser and Impeller Design
Advantages
Precision castings
• High efficiency
• Small hydraulic unbalance
Thick impeller shrouds
• High strength for high head
• Natural frequency away from resonance, thus avoiding shroud breakage
Continuous channel diffuser
• High efficiency
Continuous channel diffuser
Thick impeller shrouds
Precision castings
Diffuser
•
•
Impeller
•
Stage 1 Stage 2 Stage 3 Stage 4
Tightening System for
Delivery Cover Studs
Advantages
• Accurate tensioning to required pre-load
• Fast cartridge change
Set up Tensioning Tool Tension Stud Bolt Turn Nut Release
Tensioning Tool
Pressure Retaining Parts
Advantages
• Hydro test (1.5 x or 1.3 x pD) of each pressure casing provides high safety
Analyzed with proven codes for high reliability:
• German vessel code AD, standard
• ASME section VIII, Division 1, optional
• Finite Element (FE) for selected cases
Diffuser
FE Model
7

8
Sulzer Leeds, UK
• Up to 18 MW electric motor at full speed (24,000 hp)
• Electric capacity up to 45 MW (60,300 hp)
• 18MW (24,000 hp) inverter + increasing gearbox with multiple ratios
• Flow capacity up to 20,000 m 3 /h (88,000 USgpm)
Sulzer Mantes, France
• Up to 10 MW electric motor at full speed (13,400 hp)
• Electric capacity up to 10 MW (13,400 hp)
• Increasing gearbox with multiple ratios
• Flow capacity up to 70,000 m 3 /h (300,000 USgpm)
Sulzer Suzhou, China
• Up to 11 MW electric motor at full speed (14,700 hp)
• Electric capacity up to 16 MW (21,400 hp)
• 12 MW VFD, output frequencies from 15 Hz to 100 Hz
• Flow capacity up to 15,000 m 3 /h (66,000 USgpm)
Sulzer Portland, USA
• Up to 15 MW electric motor at max speed 6,000 rpm (20,000 hp)
• Electric capacity up to 15 MW (20,000 hp)
• Multiple speed options and elevated temperature testing capability.
• Flow capacity up to 13,600 m 3 /h (60,000 USgpm)
Elandsfontein, South Africa
• Up to 4 MW electric motor at half speed (5,360 hp)
• Electric capacity up to 4 MW (5,360 hp)
• Various increasing and reduction gearbox with multiple ratios up to
2.5 MW
• Flow capacity up to 15,000 m 3 /h (66,000 USgpm)

Capacity Q ( USgpm )
10,000 Head H (m)
10,000
1,000 Head H (ft)
10,000
1,000
100 1,000 10,000
Metric Units
Pump sizes
Capacities up to 4,150 m 3 /h
Heads up to 4,200 m
Powers up to 47,500 kW
Temperatures up to 220 °C
Speeds
U.S. Units
From 150–260 to 500–505 up to 18,300 USgpm up to 13,800 ft up to 63,700 hp up to 430 °F up to 6,750 rpm
Part DIN material
Barrel casing 10 Cr Mo 9 10, forged
Delivery cover
Impeller
Diffuser
Stage casing
Suction casing
10 Cr Mo 9 10, forged
G-X 5 Cr Ni 13 4
G-X 5 Cr Ni 13 4
G 17 Cr Mo 9 10
A 217 Gr WC 9
Shaft X 4 Cr Ni 13 4
Balance drum
Stationary wear parts
Stud
Static seals (internal)
Static seals (external)
X 20 Cr Ni 17 2
X 20 Cr Ni 17 2
36 Ni Cr Mo 16
Ethylene-Prpylene
Pure Graphite
ASTM material
A 182 Gr F22
A 182 Gr F22
A 743 Gr CA-6MN
A 743 Gr CA-6MN
G-X 5 Cr Ni 13 4
A 743 Gr CA-6NM
A 182 Gr F6MN
A 276 Type 431
A 276 Type 431
Advantage
• High erosion resistance
• Good thermal transient properties
• High erosion resistance
• Good cavitation resistance
• High strength
• High fatigue resistance
• At least 50 HB hardness difference
• High erosion resistance
• High strength
• Good pressure / Thermal resilience
9

10
Pulau Seraya Power Station, Singapore
HPT 150-260/1d / 5 stage Pump
441 m 3 /h (1,941 USgpm) at 2,154 m (7,067 ft)
2,890 kW (3,875 hp) at 6,364 rpm
Neurath, Germany
HPT 500-505-6s
4,117 m 3 /h (18,113 USgpm) at 3,961 m (12,991 ft)
47,343 KW (63,488 hp) at 4,845 rpm
Neurath BoA 2 & 3 are lignite fired power plants with optimized system engineering located in Germany’s region of North Westphalia.
Developed according to the latest available technology and the best practices in the industry, the BoA 2 & 3 plants benefit from considerable improvements com pared to older plants.
The plant is a 2 x 1,100 MW lignite-fired power plant
(electrical power output) and has been commissioned in January 2012.
The HPT pump provided by Sulzer is the biggest boiler feed pump in Europe. It has a capacity of 887 kg/s at
332 bar discharge pressure (including booster pump) and 185 °C feed water temperature.
The electrical efficiency of the power plant is over 43%, which is, as of today, the world’s highest efficiency for a lignite fired power plant. The emission level of CO
2 should be reduced by 6 million tons per year com pared to older plants. On top of carbon emissions, specific SO
2
, NOX and dust emissions should also be significantly reduced.
Schwarze Pumpe, Germany
HPT 350-440 / 5 stage Pump
3,165 m
3
/h (13,926 USgpm) at 4,100 m (13,448 ft)
35,833 KW (48,050 hp) at 5,795 rpm
Waigaoqiao 3, China
HPT 500-505-5s Pump
3,867 m 3 /h (17,050 USgpm) at 3,457 m (11,342 ft)
36,258 kW (48,600 hp) at 4,717 rpm

Sulzer Pumps –
Customer Support Services
The continuous availability and high operating performance of pumps is the key target for our customer support service organization.
Through our highly experienced personnel and application knowl edge, we provide a full range of innovative service solutions to our customers to keep their pumps running including:
• Spare Parts
• Field Services
• Repair Services
• Retrofits
• Maintenance Agreements
• Operation Agreements
Flexibility
With services ranging in scope from supplying a spare part to operat ing the pump under contract, we are uniquely placed to make your process run smoother. A dedicated team of our services specialists based at either our manufacturing facilities or one of over 60 service centers located around the world is dedicated to maintain the perfor mance of our customers’ pumps and associated equipment. This service is not just limited to Sulzer products, all the pumps our cus tomers operate can benefit from the support of Sulzer Pumps.
Network of
Locations
Divisional Headquarters
Manufacturing Facility
Customer Support Service Center (CSS)
Sales Office
11

www.sulzer.com
E00616 (2) en 2.2013 (1,000), Copyright © Sulzer Pumps
This brochure is a general presentation. It does not provide any warranty or guarantee of any kind. Please, contact us for a description of the warranties and guarantees offered with our products. Directions for use and safety will be given separately. All information herein is subject to change without notice.