Boiler-Feed Pump (BFW)
The boiler-feed pump is used in the Shiraz power plant to raise 1.8 Kg/cm2 input pressure to 64.8 kg/cm3 output. This equipment is manufactured by Worthinton, Germany, and was reverse-engineered, redesigned, and is currently in use in Shiraz Petrochemical Company with an exclusive order for two additional full pumps. In addition to reverse engineering and indigenous production, the body material has also been changed. The foreign model's body was made with A216 WCB, which was changed into ASTM A743 CA6M stainless steel for corrosion resistance and increased lifespan. This is among the most complex centrifugal pumps with six propellers that replaces 6 pumps in series.
Product Technologies
- Designing and mapping from used components
- Material casting technology and part casting complexity
- This casing has significantly less corrosion and repair than foreign samples.
- Even after changing the material, this casing costs 20% of the foreign equivalent.
Since comparison of new and original equipment wasn’t feasible, the company had to start reverse-engineering with a used component, which made designing and mapping with correct tolerances very difficult and complex. Meanwhile, modeling and casting had its own complexities and technologies, especially given the aforementioned material.
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Manufacturing Process
- Mapping with digital measurement tool
- Map correction and tolerancing
- Casting technology
- Model technology and production
- Melting and casting
- Cleaning and sandblast
- Machining
- Assembly grinding
- Hydrostatic testing
Design and manufacturing process
- Using the fiber-glast method to manufacture the model and the very complex core box like a puzzle with many pieces
- After 3D mapping, parts were produced with digital mapping and machined with boring and 4-axis CNC machines. Since 6 propellers needed to be assembled on the body shaft, the slightest misalignment in pump machining was prohibited.
- The part needed to pass quality system and design station, the most important of which included dimensional quantometry and assembly hydrostatic testing
- The pt-ut test was conducted.
Product Testing
- The tests were conducted in-house.
- Quantometry test according to DIN 1.4313
- Other tests specified by customers
The product's mandatory standards
- Upper and lower half materials according to the DIN 1.4313 standard
- Hydrostatic body testing up to 130 kg pressure after clamshell assembly
