Boiler Feed Pump (BFP) is one of the most critical auxiliaries in any thermal power plant or process industry boiler system. It ensures continuous supply of feed water to the boiler at the required pressure and flow. Any failure or improper start-up of the BFP can lead to boiler trip, tube damage, overheating, or even catastrophic failure.
In high-pressure systems, especially in plants designed as per Indian Boiler Regulations (IBR), strict start-up procedures are essential to ensure safety, reliability, and long equipment life.
As per standard, a single or running Boiler feed pump capacity (excluding stand by) should be 135% of Boiler MCR.
What is the significance of following Boiler feed pump pre-start up checks?
Boiler feed pump is the heart of Boiler as;
- It supplies feed water to the Boiler for steam generation
- It operates under high pressure and temperature
- It operates continuously at high rotational speed
- It ensures Boiler safety
- It supports load changes in Boiler
What happens if Boiler start up checks not followed?
As Boiler feed pump is a critical and heart of the Boiler, start up of this equipment needs more attention. If not followed results into following incidents;
- Cavitation
- Bearing failure
- Mechanical seal failure
- Pump and motor over loading
- Gasket and welding joints failure
- Personal safety
- Reverse rotation etc
How do following Boiler feed pump pre-start checks helps??
Structured start up of pump leads to;
- Equipment safety
- Personal safety
- Energy saving
- Reliable Boiler operation
- Reduced down time
Boiler feed pump start up checks;
| SL No. | Checks | Normal vaue/status | Actual value/status | Remarks |
| 1 | Maintenance activities on pumps | Completed | ||
| 2 | Pump normalised | Yes | ||
| 3 | Pump suction valve | Open | ||
| 4 | Pump discharge valve | Close | ||
| 5 | Pump recirculation line isolation valve | Open | ||
| 6 | Bearing oil level | 50+% | ||
| 7 | Pump Bearing temperatures | Normal or < 50 deg c | ||
| 8 | Motor bearing temperatures | Normal or < 50 deg c | ||
| 9 | Bearing cooling water line valves | Open | ||
| 10 | Suction pressure | +1.2 Kg/cm2 | ||
| 11 | Suction Temperature | Atmospheric or as per design | Should be more than deaerator operating temperature | |
| 12 | Balance leak off line valve | Open | ||
| 13 | All transmitters lines isolation valves | Open | ||
| 14 | Coupling and shaft | Free to rotate | ||
| 15 | Coupling guards | Fixed | ||
| 16 | Any looseness in pumps and motors | No | ||
| 17 | Pump and motors are clean | Clean | ||
| 18 | Deaeartor level | 65 to 75% | ||
| 19 | Mechanical seal leakage | No leakage | ||
| 20 | Mechanical seal cooling line valve | Open |
