Static analysis of boiler feed pump shaft in steam power plants: Enhancing durability and operational efficiency

Authors

  • Muhammad Athar Altarisi Department of Mechanical Engineering, Universitas Negeri Padang, Indonesia
  • Rifelino Rifelino Department of Mechanical Engineering, Universitas Negeri Padang, Indonesia
  • Delima Yanti Sari Department of Mechanical Engineering, Universitas Negeri Padang, Indonesia
  • Wanda Afnison Department of Mechanical Engineering, Universitas Negeri Padang, Indonesia

DOI:

https://doi.org/10.58712/ie.v1i2.8

Keywords:

Centrifugal pump, Boiler feed pump, Computer-aided engineering simulation, Material fatigue, Safety factor

Abstract

Centrifugal pumps are commonly used in industrial and domestic sectors to transport fluids by increasing their flow rate to a specific pressure. One type of centrifugal pump, the Boiler Feed Pump (BFP), plays a crucial role in steam power plants. Designed for continuous operation, BFP shafts are prone to wear and failure due to extreme operational conditions. This study employs computer-aided simulation using SolidWorks software to analyze von Mises stress, displacement, strain, and safety factors of BFP shafts with three material variations: AISI 4140, AISI 316, and AISI 304. The results indicate that AISI 4140 material exhibits the highest safety factor of 2.7 and the lowest displacement of 0.453 mm. Fatigue simulation also shows that AISI 4140 has the lowest damage percentage and the highest fatigue life. These findings suggest that AISI 4140 is the optimal material choice to enhance the durability and efficiency of shafts in applications requiring high reliability, such as BFPs in steam power plants.

Downloads

Download data is not yet available.

References

D. Y. S. Low, P. E. Poh, and S. Y. Tang, “Assessing the impact of augmented reality application on students’ learning motivation in chemical engineering,” Education for Chemical Engineers, vol. 39, pp. 31–43, 2022, https://doi.org/10.1016/j.ece.2022.02.004

R. M. Perissinotto et al., “Flow visualization in centrifugal pumps: A review of methods and experimental studies,” J Pet Sci Eng, vol. 203, p. 108582, 2021, https://doi.org/10.1016/j.petrol.2021.108582

T. Aprianti et al., “A comparison of ground and air source heat pump performance for domestic applications: A case study in Perth, Australia,” Teknomekanik, vol. 4, no. 2, pp. 55–63, 2021, https://doi.org/10.1002/er.7133

G. Yang, X. Zhao, D. Zhang, L. Geng, X. Yang, and X. Gao, “Hydraulic components’ matching optimization design and entropy production analysis in a large vertical centrifugal pump,” Journal of Mechanical Science and Technology, vol. 35, no. 11, pp. 5033–5048, 2021, https://doi.org/10.1007/s12206-021-1021-2

X. Li, B. Chen, X. Luo, and Z. Zhu, “Effects of flow pattern on hydraulic performance and energy conversion characterisation in a centrifugal pump,” Renew Energy, vol. 151, pp. 475–487, 2020, https://doi.org/10.1016/j.renene.2019.11.049

B. R. Rode and R. Khare, “A review on development in design of multistage centrifugal pump,” Advances in Computational Design, vol. 6, no. 1, pp. 43–53, 2021, https://doi.org/10.12989/acd.2021.6.1.43

S. Selimli and S. Sunay, “Feasibility study of the energy and economic gain that can be achieved by driving the boiler feedwater pump with a backpressure steam turbine,” Proceedings of the Institution of Mechanical Engineers, Part A: Journal of Power and Energy, vol. 235, no. 5, pp. 1254–1266, 2021, https://doi.org/10.1177/0957650920969466

W. Safira Rahmania, H. Elvian Gayuh Prasetya, and F. Hesty Sholihah, “Maintenance analysis of boiler feed pump turbine using failure mode effect analysis (fmea) methods,” in International Electronics Symposium: The Role of Autonomous and Intelligent Systems for Human Life and Comfort, 2020, pp. 54–59. https://doi.org/10.1109/IES50839.2020.9231886

M. Moleda, A. Momot, and D. Mrozek, “Predictive maintenance of boiler feed water pumps using SCADA data,” Sensors (Switzerland), vol. 20, no. 2, pp. 1–19, 2020, https://doi.org/10.3390/s20020571

B. Ghorbani, S. Zendehboudi, and M. Moradi, “Development of an integrated structure of hydrogen and oxygen liquefaction cycle using wind turbines, Kalina power generation cycle, and electrolyzer,” Energy, vol. 221, p. 119653, 2021, https://doi.org/10.1016/j.energy.2020.119653

S. O. Oyedepo et al., “Thermodynamics analysis and performance optimization of a reheat – Regenerative steam turbine power plant with feed water heaters,” Fuel, vol. 280, no. July, p. 118577, 2020, https://doi.org/10.1016/j.fuel.2020.118577

R. A. Ufa, Y. Y. Malkova, V. E. Rudnik, M. V. Andreev, and V. A. Borisov, “A review on distributed generation impacts on electric power system,” Int J Hydrogen Energy, vol. 47, no. 47, pp. 20347–20361, 2022, https://doi.org/10.1016/j.ijhydene.2022.04.142

N. Kumar, R. Kumar, B. K. Sarkar, and S. Maity, “Condition monitoring of hydraulic transmission system with variable displacement axial piston pump and fixed displacement motor,” Mater Today Proc, vol. 46, pp. 9758–9765, 2019, https://doi.org/10.1016/j.matpr.2020.09.327

Q. Li, S. Abdullah, and M. R. M. Rasani, “A Review of Progress and Hydrodynamic Design of Integrated Motor Pump-Jet Propulsion,” Applied Sciences (Switzerland), vol. 12, no. 8, pp. 1–29, 2022, https://doi.org/10.3390/app12083824

N. Hou et al., “Failure modes, mechanisms and causes of shafts in mechanical equipment,” Eng Fail Anal, vol. 136, no. February, p. 106216, 2022, https://doi.org/10.1016/j.engfailanal.2022.106216

A. Shokri and M. Sanavi Fard, “Principles, operational challenges, and perspectives in boiler feedwater treatment process,” Environmental Advances, vol. 13, no. April, p. 100389, 2023, https://doi.org/10.1016/j.envadv.2023.100389

Y. Li, X. Zhao, Z. Liu, and X. Sun, “Vibration fault detection method of boiler feed pump based on Hilbert vibration decomposition,” International Journal of Manufacturing Technology and Management, vol. 37, no. 3–4, pp. 334–348, 2023, https://doi.org/10.1504/IJMTM.2023.133474

X. Liu, D. Xu, J. Lin, L. Zhang, Y. Zeng, and Q. Chen, “Failure analysis and factors influencing spline wear in hydraulic motors of charging pumps in nuclear power plants,” Eng Fail Anal, vol. 156, p. 107780, 2024, https://doi.org/10.1016/j.engfailanal.2023.107780

D. van Tonder, “Boiler feed pump low load – leak off recirculation study,” Faculty of Engineering and the Built Environment, 2020.

Y. Xiao, Z. Sun, G. Sun, and L. Wan, “Numerical study on dynamic response of double drive shafts of dual-coupled axial piston pump under various load ratios,” Eng Fail Anal, vol. 163, p. 108558, 2024, https://doi.org/10.1016/j.engfailanal.2024.108558

M. A. Sabtu, A. E. Admi, M. Mohamed, S. A. Osman, and S. A. Osman, “Finite Element Analysis of Stress Distribution in AL6061 Frame Structures Under Varying Applied Loads,” International Journal of Integrated Engineering (IJIE), vol. 16, no. 2, pp. 259–269, 2024, https://doi.org/10.30880/ijie.2024.16.02.027

S. Bidari, M. Kamyab, H. Ghandhari, and A. Komeili, “E?cacy of Computer-Aided Design and Manufacturing Versus Computer-Aided Design and Finite Element Modeling Technologies in Brace Management of Idiopathic Scoliosis: A Narrative Review,” Asian Spine J, vol. 15, no. 2, pp. 271–282, 2021, https://doi.org/10.31616/asj.2019.0263

I. Daniyan, K. Mpofu, L. Daniyan, F. Fameso, and M. Oyesola, “Computer aided simulation and performance evaluation of additive manufacturing technology for component parts manufacturing,” International Journal of Advanced Manufacturing Technology, vol. 107, no. 11–12, pp. 4517–4530, 2020, https://doi.org/10.1007/s00170-020-05340-8

W. Jarrett, S. P. Jeffs, F. Korkees, and M. Rawson, “The opportunities and challenges of hybrid composite driveshafts and their couplings in the aerospace industry: A review,” Compos Struct, vol. 320, no. June, p. 117203, 2023, https://doi.org/10.1016/j.compstruct.2023.117203

B. Regassa Hunde and A. Debebe Woldeyohannes, “Future prospects of computer-aided design (CAD) – A review from the perspective of artificial intelligence (AI), extended reality, and 3D printing,” Results in Engineering, vol. 14, no. June, p. 100478, 2022, https://doi.org/10.1016/j.rineng.2022.100478

M. N. Mastrone and F. Concli, “CFD simulations of gearboxes: implementation of a mesh clustering algorithm for efficient simulations of complex system’s architectures,” International Journal of Mechanical and Materials Engineering, vol. 16, no. 1, pp. 1–19, 2021, https://doi.org/10.1186/s40712-021-00134-6

I. Romanenko, Y. Martseniuk, and O. Bilohub, “Modeling the Meshing Procedure of the External Gear Fuel Pump Using a CFD Tool,” Computation, vol. 10, no. 7, pp. 1–19, 2022, https://doi.org/10.3390/computation10070114

A. Volk, U. Ghia, and G. R. Liu, “Assessment of CFD-DEM solution error against computational cell size for flows through a fixed-bed of binary-sized particles,” Powder Technol, vol. 325, pp. 519–529, 2018, https://doi.org/10.1016/j.powtec.2017.11.051

Z. Xie et al., “Effect of cell size on erosion representation and recommended practices in CFD,” Powder Technol, vol. 389, pp. 522–535, 2021, https://doi.org/10.1016/j.powtec.2021.05.066

M. Isiet, I. Miškovi?, and S. Miškovi?, “Review of peridynamic modelling of material failure and damage due to impact,” Int J Impact Eng, vol. 147, p. 103740, 2021, https://doi.org/10.1016/j.ijimpeng.2020.103740

G. L. Arumparithy, R. Adalarasan, M. Santhanakumar, and L. Mulugeta, “Parameter Design in Carbonitriding of EN36, 16MnCr5, and AISI 4140 Steels Using Principal Component-Based Grey Incidence (PGI),” Advances in Materials Science and Engineering, pp. 1–12, 2022, https://doi.org/10.1155/2022/8138198

N. Hou et al., “Failure modes, mechanisms and causes of shafts in mechanical equipment,” Eng Fail Anal, vol. 136, p. 106216, 2022, https://doi.org/10.1016/j.engfailanal.2022.106216

P. Foti, N. Razavi, A. Fatemi, and F. Berto, “Multiaxial fatigue of additively manufactured metallic components: A review of the failure mechanisms and fatigue life prediction methodologies,” Prog Mater Sci, vol. 137, p. 101126, 2023, https://doi.org/10.1016/j.pmatsci.2023.101126

K. Tang, Z. Du, P. Ferro, and F. Berto, “Crack initiation and propagation from geometric microdefects: Experiment and transition fatigue behavior,” Fatigue Fract Eng Mater Struct, vol. 44, no. 9, pp. 2323–2336, 2021, https://doi.org/10.1111/ffe.13492

Downloads

Published

2024-09-30

How to Cite

Altarisi, M. A., Rifelino, R., Sari, D. Y., & Afnison, W. (2024). Static analysis of boiler feed pump shaft in steam power plants: Enhancing durability and operational efficiency. Innovation in Engineering, 1(2), 73–95. https://doi.org/10.58712/ie.v1i2.8

Most read articles by the same author(s)