Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-118 NTPC Ref no SIM/1/TS/2/118

Sheet 1 of 16

Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF MOTOR DRIVEN BOILER FEED PUMP SLNO LIST OF CONTENTS 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 PLANT DETAILS OBJECTIVE PROPOSAL SERVICES REQUIRED SAFETY PERECAUTIONS EMERGENCY PROCEDURE STATE OF THE PLANT METHOD COMPLETION CRITERIA APPENDICES LOG SHEET

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-118 NTPC Ref no SIM/1/TS/2/118

Sheet 2 of 16

Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF MOTOR DRIVEN BOILER FEED PUMP STATUS SL.NO 1.0 PLANT DETAILS The Boiler feed system consists of three Boiler Feed Pump sets for each unit of simhadri SSTP. (2 Turbine driven and 1 motor driven). Each pumpset is of 50% capacity, which takes suction from the deaerator and discharge the feed water to series of HP heaters, economizer and finally to boiler drum. The important technical data of the equipment follows: 1.1 Boiler Feed Booster Pump: a. Manufacturer BHEL b. Type FA IB 75 c. Direction of rotation Anticlockwise (viewed on NDE) d. Liquid pumped Boiler Feed Water e. S.G. at suction temperature 0.9064 f. Suction temperature ; C 161.8 g. Suction pressure 8.43 ata h. Discharge Pressure 25.65 ata i. Differential Pressure 17.22 ata j. Differential Head 190 M k. Flow rate, m3/hr 1143.7 M l. Efficiency % 81 m. Speed rev/m 1494 n. Power absorbed, KW 662 o. Thrust Bearing i. Manufacturer Michell Bearing / Glacier ii. Type Double thrust. p. Mechanical seal manufacturer Burgmann, Germany q. Driver/Pump flexible coupling Euroflex, India Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-118 NTPC Ref no SIM/1/TS/2/118

Sheet 3 of 16

Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF MOTOR DRIVEN BOILER FEED PUMP STATUS SL.NO 1.2 Boiler Feed Pumps a. Manufacturer b. Type c. Suction Flow d. Suction pressure BHEL FK4E36 894960 kg/hr 26.85 ata 26.15 ata 209.19 ata 208.49 ata 5465 6233 81% 250 m3/hr.

MD TD e. Discharge Pressure MD TD f. Speed rpm g. Power consumption KW h. Efficiency i. Normal recirculation flow 1.3 Hydraulic coupling

a. Manufacturer VOITH b. Code : Bharat S 136 Simhadri c. Rotation seen in direction of power flow Input shaft CCW Output shaft CCW d. Motor Speed rpm 1494 e. Gear ratio U1 109/32 f. Primary Speed rpm 5089 g. Full load slip 2.24% h. Gear ratio U2 62/53 i. Max. output speed rpm 5820 j. Hydraulic oil type HLP32 to DIN 51524, Part 2 k. Oil tank filling 2500 litres.

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-118 NTPC Ref no SIM/1/TS/2/118

Sheet 4 of 16

Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF MOTOR DRIVEN BOILER FEED PUMP STATUS SL.NO 1.4 Auxiliary Lube Oil Pump a. Motor Type Power Rated speed Voltage Frequency Protection 2.0 OBJECTIVE To commission Motor Driven boiler feed pump and associated auxiliaries and make them available for Unit operation. 3.0 PROPOSAL Commissioning of Motor Driven boiler feed pump set proposed in the following steps 3.1 3.2 3.3 3.4 4.0 4.1 Commissioning of lube oil system Commissioning of Motor Commissioning of Hydraulic coupling (Voith Geared variable speed coupling) Commissioning of MDBFP set (witrh booster stage pump & main BFP) SERVICES REQUIRED Availability of manpower with required tools for attending any leak and cleaning of filter D 200 LA2 30 KW 2945 rpm 415 V 50 Hz IP 55

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-118 NTPC Ref no SIM/1/TS/2/118

Sheet 5 of 16

Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF MOTOR DRIVEN BOILER FEED PUMP STATUS SL.NO 4.2 4.3 4.4 4.5 4.6 4.7 5.0 5.1 5.2 5.3 Availability of operating personnal to carry out / coordinate activities. Availability of lighting arrangements and communication facilities in operating floors. Availability of instrument and service air Availability of LT/HT power supply Availability of auxiliary cooling water supply. Availability of portable fire extinguishers around BFP area. SAFETY PRECAUTIONS Debris in and around BFP area shall be removed First aid kit is available near the test area Operation of local start / stop push button shall be ensured for perfect operation to facilitate for stopping of equipment in case of necessity. Approach / staircase / platform wherever required are made available. Portable fire fighting system made available at test area. Coupling gaurds are properly fixed.

5.4 5.5 5.6 Signatures

NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-118 NTPC Ref no SIM/1/TS/2/118

Sheet 6 of 16

Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF MOTOR DRIVEN BOILER FEED PUMP STATUS SL.NO 6.0 6.1 EMERGENCY PROCEDURES The test team should be aware of the procedure to be adopted in case of damage to machinery / injury of any personnel connected to the activity. The test team should be well aware of the procedures to be adopted in case of any abnormality in the activity. STATE OF THE PLANT Booster Pump, Motor, Hydraulic coupling, BFP and associated system are erected as per recommended drawing. Acid cleaning and oil flushing completed for lube oil and working oil piping as per the Test procedure No.PS-DC-186-500-13B and lines are normalized. Detergent flushing of feed water suction, discharge and recirculation piping are completed and all piping normalized. All connected piping supports are loaded to the rated value. Deaerator filled with fresh DM water with proper level indication and instrumentation completed. Flushing of following pipelines completed. a) Cooling water lines of Booster Pump and BFP (seal water cooler and seal body) b) Cooling water lines of motor cooler c) Balancing leak off lines of Main pump. 7.7 Signatures NTPC BHEL Suction strainers erected in position in clean condition with DP indicator commissioned.

6.2 7.0 7.1 7.2

7.3 7.4 7.5 7.6

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-118 NTPC Ref no SIM/1/TS/2/118

Sheet 7 of 16

Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF MOTOR DRIVEN BOILER FEED PUMP STATUS SL.NO 7.8 7.9 7.10 7.11 All erection log sheets are followed up/signed by concerned agencies with respect to clearances and alignment data. Instrument and service air line for the feed pump system erected and the air is made available for operation. All local and remote instrumentation for the system is complete. Insulation of the following completed. a. Recirculation line of main pump. b. Suction and discharge line of Booster pump and main pump. c. Main pump and Booster Pump body. 7.12 Commissioning of valves related to the system are completed. (Suction isolating value, dischange isolating valve, recirculation valve, scoop tube actuator, motor cooling water isolating valve etc.) Interlocks and protection system simulation checking completed. METHOD Commissioning of lube oil system Ensure orifices in the lubricating oil inlet lines to thrust and journal bearings are erected. Ensure oil filling through centrifuge to the normal level in lubricating oil tank.

7.13 8.0 8.1 8.1.1 8.1.2

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-118 NTPC Ref no SIM/1/TS/2/118

Sheet 8 of 16

Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF MOTOR DRIVEN BOILER FEED PUMP STATUS SL.NO 8.1.3 8.1.4 8.1.5 8.1.6 8.2 8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6 8.2.7 8.2.8 8.2.9 Start the lube oil pump, (AOP) and check for leakages. Ensure oil return flow from all the bearings through the flow sight glass. Ensure AOP discharge pressure of around 2.5 kg/cm 2. If not adjust the relief valve to achieve required pressure. Monitor DP across lube oil filter. Commissioning of Motor Check the meggar value of motor and ensure that the insulation value is satisfactory. Check the winding resistance of the Motor and confirm that the values are satisfactory. Ensure all motor protections are available at the HT breaker. Ensure motor winding & bearing temperature indications are available at control room/local. Ensure AOP in operation for lube oil supply. Bump the motor and ensure correct direction of rotation. Charge cooling water for motor cooler and lube oil cooler. Start the motor and complete 8 hours trial run. During trial run, record the no load current, bearing and winding temperature at every one hour interval Motor vibration to be noted once during the trial run.

Signatures NTPC BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-118 NTPC Ref no SIM/1/TS/2/118

Sheet 9 of 16

Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF MOTOR DRIVEN BOILER FEED PUMP STATUS SL.NO 8.3 8.3.1 Commissioning of Hydraulic Coupling Ensure that the motor is aligned with Hydraulic coupling considering the thermal growth and the readings are logged and cleared for coupling. After completion of motor trial, motor shall be coupled to Hydraulic coupling. Check calibration of scoop tube actuator for min and max. position and its feed back signal. Ensure mechanical stoppers at min & max position Set the scoop tube to min position. Ensure AOP in service and oil flow through bearings. Ensure coolers venting on oil and water side and CW flow established. Start Hydraulic coupling for two hours trial run. After the motor run up to rated speed observe lube oil pressure increases more than 3.0 Kg/cm 2 by taking over of shaft driven oil pump. Ensure AOP trips automatically. Run the unit at minimum speed and observe smooth running, temperatures, lube pressure and filter condition. Check working oil pressure developed around 1.0 to 1.8 kg/cm 2 Ensure working oil termperature upstream of working oil cooler not exceeding 1100C.

8.3.2 8.3.3

8.3.4 8.3.5 8.3.6 8.3.7 8.3.8

8.3.9 8.3.10 8.3.11 Signatures

NTPC

BHEL

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-118 NTPC Ref no SIM/1/TS/2/118

Sheet 10 of 16

Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF MOTOR DRIVEN BOILER FEED PUMP STATUS SL.NO 8.4 8.4.1 Commissioning of MD BFP set Ensure alignment of motor with Booster pump and alignment of Hydraulic coupling with main pump, the readings are logged and cleared for coupling. Couple motor with Booster pump and Hydraulic coupling with main pump. Crack open suction isolating valve and vent out air in all the vents (Booster pump air vent, interconnecting pipe air vents, dischange line vent) Flush and shut the booster pump casing drain and BFP drain and interconnecting pipe drain. Check all the instrument tapping point isolating valves are open and that all drain and equalizing valves are shut. Open suction isolating valve fully. Check mechanical seal control isolating valves are open for Booster pump and BFP. Check magnetic separator isolating valves for BFP seal water are open. Ensure cooling water flow through all coolers a) b) c) d) e) f) Signatures NTPC BHEL Booster pump seal water cooler BFP seal water cooler Main motor cooler Lube oil cooler Working oil cooler Jacket cooling of mechanical seals of Booster pump and BFP.

8.4.2 8.4.3

8.4.4 8.4.5 8.4.6 8.4.7 8.4.8 8.4.9

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-118 NTPC Ref no SIM/1/TS/2/118

Sheet 11 of 16

Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF MOTOR DRIVEN BOILER FEED PUMP STATUS SL.NO 8.4.10 8.4.11 8.4.12 Ensure isolating valves in recirculation line and leak off line are open. Ensure AOP in service & oil flow through all bearing. Ensure start permissives hooked up in DCS are satisfied. The important permissives are a) b) c) d) e) f) Suction valve of BFP open Lube oil pressure adequate. Deaerator level above minimum permissible level. Recirculation valve in full open condition. Hydraulic coupling scoop tube in min. position. Differential temperature across BFP casing top & bottom is not more than 20 deg C. g) Cooling water header pressure normal. 8.4.13 Ensure protection trippings are checked by simulating the signals. A typical list of BFP protection are given below: a. Lube oil pressure in common header very low b. Working oil temperature high c. Working oil pressure low. d. Deaerator level very low e. Differential temperature between BFP suction and discharge feed water very high. f. Lube oil temperature very high g. Bearing temperatures very high for Booster pump/motor/Hydraulic coupling/BFP h. Motor winding temperatures very high. i. Any other protection as applicable and provided in DCS. (O & M may be referred for set values) 8.4.14 Signatures NTPC BHEL Ensure all alarms and measuring points available in DCS/local.

Station: NTPC- Simhadri

BHEL Ref No.PS-DC-186-500-118 NTPC Ref no SIM/1/TS/2/118

Sheet 12 of 16

Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF MOTOR DRIVEN BOILER FEED PUMP STATUS SL.NO 8.4.15 8.4.16 8.4.17 8.4.18 8.4.19 8.4.19 8.4.20 8.4.21 8.4.22 Ensure all flanged joints are tightened properly with proper gaskets. Start BFP and observe for abnormality. Keep the pump on recirculation with flow of approximately 250 TPH for 8 hours. Observe and record the parameters during trial operation as per log sheet enclosed. Take vibration measurement once during trial operation and evaluate performance. Check lube oil flow through return oil sight glasses. During trial, check the security of all keys and fasterings. Ensure holding down washers are free during expansion. Check for any undue noise, vibration in bearings, seals and pumps. Check scoop operation and obseve speed variation and discharge pressure variation during operation of the BFP for drum level control. Stop BFP and observe AOP cuts in. Observe coasting down of BFP. COMPLETION CRITERIA Commissioning of MD BFP set completed by carrying out the proposals given in section 3.0.

8.2.23 9.0 9.1

Signatures NTPC BHEL

TESTING SCHEDULE FOR COMMISSIONING OF MOTOR DRIVEN BOILER FEED PUMP

SHEET 13 OF 16 LOG SHEET 1 PROJECT : UNIT : EQUIPMENT ACTIVITY : DATE: : BFP MOTOR

Time Hrs

Bus Volta ge KV

Motor current

Lub oil Hdr.Pr.

Oil inlet Pr. BP end HC end

Drain oil tem BP end HC end

Motor Brg. Temp BP end HC end

Motor inlet air temp HC end BP end

Motor outlet air temp

Motor wdg Temp. 1 2 3 4 5 6

Signatures NTPC BHEL

Sheet 14 of 16 LOG SHEET 2 PROJECT UNIT EQUIPMENT ACTIVITY : : : HYDRAULIC COUPLING :

Working oil temp Bef. cooler After cooler DP across lube oil filter

DATE:

Lub oil temp. Time Hrs Scoop Position Lub oil Hdr. Pr. Bef. cooler After cooler Working oil pr.

Bearing Temperatures 1 2 3/4 5 6 7 8 9/10 11 12

Signatures NTPC BHEL

Sheet 15 of 16 LOG SHEET 3 PROJECT UNIT EQUIPMENT ACTIVITY : : : BOOSTER PUMP OF MDBFP : DATE:

Seal Water Temperatures Time Hrs Suc. Pr. Dischar ge Pr. Suction Strainer DP NDE Inlet Outle t DE Oil Pr. Oil

Mech Seal filter DP

Oil Pr. to BP NDE

Oil drain

Bearing Metal Temp Journal NDE DE

NDE

DE

Journ al

Thr ust

DE Journal

N D E

DE

Thru st

CW inlet pressure to BFP set

Signatures NTPC BHEL

Sheet 16 of 16 LOG SHEET 4 PROJECT UNIT EQUIPMENT ACTIVITY : : : BOILER FEED PUMP :
Mech Seal Filter DP Oil drain temp. DE ND E

DATE:

Seal water Temperatures Ti me Hr s BF P suc Pr. BF P disc har ge Pr. BF P suc Te mp. Dis cha rge tem p Suc stra ine r DP Barrel Temp. BC leak off press ure NDE Out let Inl et DE

Oil Pr. to BFP NDE

Bearing Metal temp Jou rnal DE Jou rnal ND E Thrus t NDE

Vibration DE NDE

ND E Inlet Outle t

DE

DE Jou rna l Th rus t

Signatures NTPC BHEL