Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 5 NTPC Ref No. S"# $ 1 $ TS $ 1 $ !

!8 P%ant &rea: B'"LER PR'CED(RE )'R C'##"SS"'N"N* ') CC P(#PS SL. N'. 1. 2. !. 3. 5. 6. 4. 8. 5. 1 . PL&NT DET&"LS 'B+ECT",ES PR'P'S&LS SER,"CES RE-("RED S&)ET. PREC&(T"'NS E#ER*ENC. PR'CED(RES ST&TE ') THE PL&NT #ETH'D C'#PLET"'N CR"TER"& &PPEND"CES a/ DR&0"N* 1/ L'* SHEETS L"ST ') C'NTENTS

!8

Sheet 1 of 15

Si6nat7re8 NTPC Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 5 NTPC Ref No. S"# $ 1 $ TS $ 1 $ !8 P%ant &rea: B'"LER !8 BHEL Sheet 2 of 15

PR'CED(RE )'R C'##"SS"'N"N* ') CC P(#PS 1. PL&NT DET&"LS ST&T(S

1.1. In a controlled circulation Boiler, circuating pumps plays an important role in the performance of the Boiler. For 500 MW Units, !os of circulating pumps are gi"en and these pumps are placed in the do#n comer circuits to ensure proper circulation of #ater through the$ #ater #alls. Feed#ater entering the %oiler drum "ia &comiser, flo#s from the drum through the do#n comers ' ( !os) to the pump sction manifold. *he %oiler circulating pumps ta+es #ater from the suction manifold and discharges "ia the pump discharge lines in to the furnace lo#er front inlet header, furnace lo#er #ater #all right and left side headers and rear headers. In the #ater #all inlet header, the %oiler #ater passes through strainers and then through orifices #hich feed the furnace #all tu%es, the economi,er recirculating lines. 1.2 *he associated systems of %oiler circulating pumps consists of the follo#ing. a) Fill and purge line system *his system consists of supply lines from -igh .ressure #ater source and also lo# pressure #ater source, remo"a%le strainer %as+et, -. fill and .urge cooler, filter, orifice and all connected lines %oth inlet and outlet circuits. *he remo"a%le strainer %as+et and -. fill and purge cooler are common for all the three circulating pumps.

Si6nat7re NTPC Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 5 NTPC Ref No. S"# $ 1 $ TS $ 1 $ !8 P%ant &rea: B'"LER PR'CED(RE )'R C'##"SS"'N"N* ') CC P(#PS %)/u0iliary cooling #ater system !8 BHEL Sheet ! of 15

*his system is supplied #ith 1. coolant from &2W 3ystem 4 station au0iliary cooling #ater system and also from a separate emergency cooling #ater from o"er head tan+ source. *his supplier cooling #ater to i) 1. ii) 1. 2ooler for .ump Motor and -. fill and .urge cooler.

1.$ 1.5

*he %oiler circulating pumps are operated through -.*.Motors #hich are pro"ided #ith ca"ity in #hich 5M Water is filled %y a specific procedure descri%ed in 3ection 6.0 and this ca"ity filling is for cooling the motor #hile the motor is in operation. When the unit is in operation, 2irculation pumps are operated in parallel or all the three pumps together as per the actual re7uirement. .lant item completion lift for the system for Mechanical, &lectrical and 28I areas are to %e prepared at site. 3chematic dra#ing of 2irculation .umps '5rg.!o.$9.39ts0900(:900) enclosed in 3ection 10.0

1.(

Si6nat7re NTPC Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 5 NTPC Ref No. S"# $ 1 $ TS $ 1 $ !8 P%ant &rea: B'"LER PR'CED(RE )'R C'##"SS"'N"N* ') CC P(#PS 2. 'B+ECT",E *o commission the 2.2. .umps and ma+e it a"aila%le for commissioning and operation of the unit. !8 BHEL Sheet 3 of 15

!. .1 .2 . .$ 3. $.1 $.2 $. $.$ $.5 $.(

PR'P'S&L9 It is proposed to commission the 22 pumps as per the follo#ing proposal. Flushing of fill 8 purge lines Flushing of /u0iliary cooling #ater system. Motor 2a"ity filling and "enting. *rial run of pump for 6 hour. SER,"CES RE-("RED /"aila%ility of ;8M Manual for 22 .umps /"aila%ility of au0iliary cooling #ater /"aila%ility of -.* .o#ersupply /"aila%ility of lighting, communication facility at the test area. /"aila%lity of porta%le fire e0tinguishers. /"aila%ility of #or+ing cre# #ith *echnician for attending minor pro%lem during commissioning of 22 .ump.

$.< /"aila%ility of 5M Water.

Si6nat7re NTPC BHEL

Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 5 NTPC Ref No. S"# $ 1 $ TS $ 1 $ !8 P%ant &rea: B'"LER PR'CED(RE )'R C'##"SS"'N"N* ') CC P(#PS 5. 5.1 5.2 S&)ET. PREC&(T"'NS /"aila%ility of first aid +it at test area.

!8

Sheet 5 of 15

*he team commissioning the 22 pump should %e a#are of the procedure adopted.

5. 5.$ 5.5

/gencies #or+ing in the %oiler area 4 are informed a%out the test 4 cleared from the test area '/s per the actual re7uirement). /ll loose materials around the 22 pump area are cleared. =e7uired approach stair cases, platforms and hand rails are erected prior to testing.

Si6nat7re NTPC BHEL

Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 5 NTPC Ref No. S"# $ 1 $ TS $ 1 $ !8 P%ant &rea: B'"LER PR'CED(RE )'R C'##"SS"'N"N* ') CC P(#PS 6. (.1 (.2 E#ER*ENC. PREC&(T"'NS:

!8

Sheet 6 of 15

*he group conducting the test should %e a#are of action to %e ta+en on the e"ent of in>ury to personnel. *he group shall %e a#are of operating instruction of porta%le fire

e0tinguishers. (. *he test team should %e a#are of the steps to %e ta+en to trip the running e7uipment in case any emergency 4 a%normal o%ser"ations are notified to them.

Si6nat7re NTPC Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 5 NTPC Ref No. S"# $ 1 $ TS $ 1 $ !8 P%ant &rea: B'"LER PR'CED(RE )'R C'##"SS"'N"N* ') CC P(#PS 4. <.1 <.2 ST&TE ') THE PL&NT Boiler -ydraulic test is completed. &rection of the follo#ing are completed. ?? ?? ?? ?? 22 .umps impellers along #ith motor is mounted into pump casing flange. -. fill and purge lines system. /u0iliary cooling #ater lines ;"erhead tan+ for emergency cooling #ater supply. !8 BHEL Sheet 4 of 15

<. <.$

/ll permanent supports are pro"ided in the pump suction manifold, suction and discharge lines and other associated lines. /ll local instruments of the pumping unit including fill and purge lines and au0iliary cooling #ater system are installed. '=e7uired list is to %e prepared at site). .ressure and temperature indicators are to %e duly cali%rated. =emote indicators at control room are made a"aila%le 'list to %e prepared at site). Free operation of pump discharge "al"es ensured. *emperature measurement pads are fi0ed on the pump casing and suction manifold and suita%le thermocouples are installed.

<.5 <.( <.<

Si6nat7re NTPC Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 5 NTPC Ref No. S"# $ 1 $ TS $ 1 $ !8 P%ant &rea: B'"LER PR'CED(RE )'R C'##"SS"'N"N* ') CC P(#PS <.6 *he follo#ing electrical chec+s are ensured !8 BHEL Sheet 8 of 15

<.6.1 /ll protection for -.*. motor is made a"aila%le at %rea+er . <.6.2 Insulation resistance "alue of motor #inding is to %e measured #ith 1000@ meggar #hen the unit is filled up #ith #ater at am%ient temp and it should %e more than 5 mega ohm. <.: *he follo#ing Instrumentation chec+s are ensured

<.:.1 2a"ity temperature controller is cali%rated and set at 1 5 F and 1$0 F for alarm and *rip respecti"ely.

<.:.2 1... cooling #ater flo# rator is ad>usted at 2 A.M. <.:. 5ifferential pressure s#itches and transmitter are cali%rated and %e +ept ready.

<.10 *he follo#ing start permissi"es and *rip interloc+s are chec+ed %efore going for pump trial.

Si6nat7re NTPC BHEL

Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 5 NTPC Ref No. S"# $ 1 $ TS $ 1 $ !8 P%ant &rea: B'"LER PR'CED(RE )'R C'##"SS"'N"N* ') CC P(#PS <.10.1 3tart .ermissi"es ?? ?? ?? ??

!8

Sheet 5 of 15

1o# pressure cooling #ater flo# greater than 2 A.M. 5ifferential temp. %et#een pump casing and suction manifold is less than 100oF. Motor ca"ity temp. is more than $0oF and less than 1(0oF. .ump discharge "al"es are fully open.

<.10.2 *rip interloc+s ?? ?? ?? Motor ca"ity temperature more than 1$0oF fore more than 5 seconds. .ump differential pressure remains less than 10 .3I on all pmps for 5 seconds. .ump discharge "al"e not fully open.

??

In addition to the a%o"e start4trip interloc+, a load limit signal is generated at the follo#ing conditions. a. /ny 2 pumps running #ith 5... less than 16 ..3.I. for more than 5 seconds. /ny 2 pump motor %rea+ers open.

Si6nat7re NTPC Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 5 NTPC Ref No. S"# $ 1 $ TS $ 1 $ !8 P%ant &rea: B'"LER PR'CED(RE )'R C'##"SS"'N"N* ') CC P(#PS 8. 6.1 #ETH'D Flushing of fill and purge lines !8 BHEL Sheet 1 of 15

6.1.1 .reparation of fill and purge system and au0illiary cooling #ater system Fill and purge #ater is ta+en from 2 independent sources "i,. 1. 2. From Boiler feed pump discharge. From 2ondensate pump discharge.

6.1.2 Flushing of the fill and purge lines *he flushing is to %e done in 2 stages #ith 5.M. #ater till outlet is free of "isi%le tur%idity. 6.1. =efer the dra#ing no $9.39*3B900(:900 attached.

3tage 19 In this stage, the line from fill and purge line source to indi"idual motor inlet shall %e flushed #ithout connecting the inlet line to the motor. ?? ?? *he common remo"a%le strainer %as+et shall %e +ept remo"ed from the strainer. *he flushing shall %e done initially through the %ypass line for the indi"idual filters installed in the purge line of each pump and after esta%lishing that the flushing #ater is free of any tur%idity, the filters and orifices can %e included in the flushing circuit. /fter flushing is completed in this sections, set the @al"e no. 256 'for .ump /) such a #ay that the purge #ater flo# rate of 2.( lit4min is esta%lished to facilitate motor ca"ity filling for the su%se7uent stage flushing.

??

Si6nat7re NTPC Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 5 NTPC Ref No. S"# $ 1 $ TS $ 1 $ !8 P%ant &rea: B'"LER PR'CED(RE )'R C'##"SS"'N"N* ') CC P(#PS 6.1.$ 3tage 29 2onnect the motor inlet and flush the 1. cooler for pump motor and letting the #ater to flo# out through the %ottom connection of heat e0changer. While filling the motor ca"ity a flo# rate of 2.( lit4min is to %e maintained. *hen increase the flo# rate to ma0imum purge rate possi%le through the orifice no. $1. ;nce the outlet #ater is clear of "isi%le tur%idity declare the flushing operation and connect the heat e0changer %ottom line to the motor. 6.2 Flushing of /u0iliary cooling #ater system !8 BHEL Sheet 11 of 15

6.2.1 /u0iliary cooling #ater for -. cooler and fill and purge line cooler shall %e supplied from t#o sources. a) From station au0iliary cooling #ater source. %) &mergency cooling #ater from o"er head tan+. /u0iliary cooling #ater piping is to %e flushed #ith same 7uantity of #ater used for station au0iliary cooling #ater purpose. In order to achie"e effecti"e

flushing the au0iliary cooling #ater line is flushed in the follo#ing stages. 6.2.2 -... fill and purge cooler lines *he hoses of supply and return lines shall %e inter connected and flushed. ;nce clear #ater is esta%lished, cooler is also included in the circuit and fluthed till clear #ater o%sere"ed at the outlet point. 6.2. Motor cooler lines *he hoses of supply and return lines are to %e interconnected and flushed through the flo# ratorCs %ypass line. *hen the hoses are to %e normalised and flushed through the motor cooler %y passing flo# rator initially and including flo# rator su%se7uently till clearer outlet #ater is achie"ed in each stage.

Si6nat7re NTPC Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 5 NTPC Ref No. S"# $ 1 $ TS $ 1 $ !8 P%ant &rea: B'"LER PR'CED(RE )'R C'##"SS"'N"N* ') CC P(#PS 6. Motor 2a"ity filling and "enting. !8 BHEL Sheet 12 of 15

6. .1 2harge the -. fill and .urge line manifold through temporary lo# pressure fill source. Motor ca"ity is to %e filled at rate less than 2.( litre 4 min #ith 5.M. Water '2ondense 7uality 5M #ater). *his rate has to %e ensured %efore admitting the #ater into the motor %y opening the fill and purge line @al"es !o. 2$ , 256, 2(1 and the 5rain @al"e 2< and closing the @al"es 25: and 2(2. '*he @al"es nos. are gi"en for .ump /. For corresponding "al"es for .ump B and 2 please refer the dra#ing enclosed). *he flo# through the drain @al"e 2< is to %e measured and set the opening of the @al"e !o. 256 such a #ay that the recommended flo# rate is achie"ed. *hen admit the purge #ater in to the motor after closing the drain "al"e no. 2< through the filter and ;rifice ;. 6. .2 @enting9 With the purge #ater flo# esta%lished as descri%ed in section 6. .1, +eep open the "ent "al"es 2:0, 2:1, 2:2, 21$$ and 21$5 till air free #ater comes out through the "al"e. *hen close the "ent "al"es. 6.$ *rial run of pump 6.$.1 &nsure motor ca"ity of all pumps are filled as descri%ed a%o"e %efore ta+ing

up trial of any pump. 6.$.2 Fill the %oiler drum upto normal operating le"el. *his is to ensure a"aila%ility of sufficient !.3- for pump to run #ithout ca"itation. 6.$. &nsure the cooling #ater flo# through the motor cooler.

6.$.$ &nsure the pump discharge "al"e fully opened.

Si6nat7re NTPC Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 5 NTPC Ref No. S"# $ 1 $ TS $ 1 $ !8 P%ant &rea: B'"LER PR'CED(RE )'R C'##"SS"'N"N* ') CC P(#PS 6.$.5 Flic+ start the selected pump for 5 seconds and stop. '2aution)9 *he motor runs upto full speed in appro0imately 1 second. If the motor fails to start after 5 seconds, press the stop %utton and do not attemp to restart the pump for 20 minutes. 6.$.( /fter 10 minutes pause, run the pump for further '2nd) 5 seconds. 6.$.< 5uring this run chec+ the follo#ing a) c) Motor 2urrent. 5ifferential .ressure9 When the chec+ "al"es are open the differential pressure should rise immediately to appro0imately 10 ..3. I. !8 BHEL Sheet 1! of 15

!ote9 If the differential pressure doesnCt rise, stop the motor immediately. It may %e an indication that the motor is running in re"erse direction. *his is corrected %y interchanging of the position of the motor leads at the terminal %o04 -.* %rea+er end as the case may %e . 6.$.6 /fter further 10 minutes pause flic+ start the motor for 5 seconds ' o%ser"e the motor current and differential pressure.
rd

) and

6.$.: /fter further 10 minutes pause, energise the motor '$ th) and run for 20 minutes.

Si6nat7re NTPC Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 5 NTPC Ref No. S"# $ 1 $ TS $ 1 $ !8 P%ant &rea: B'"LER PR'CED(RE )'R C'##"SS"'N"N* ') CC P(#PS 6.$.10 5uring this running period chec+ the follo#ing a) chec+ motor "i%ration and record %) chec+ for ru%%ing or e0cess %earing noise %y holding a listening rod against the pump and motor case c) chec+ the motor operating temperature at regular inter"als d) chec+ that cooling #ater pipe line entering the motor cooler is #armer than the outlet pipe connected at the %ottom of the motor cooler. *his ensures correct functioning of heat e0changer. e) chec+ motor current and differential pressure readings at e"ery 5 minute inter"al and record f) chec+ for any lea+age in "al"e glands and flanges 6.$.11 *rial run of other pumps are also to %e done as illustrated a%o"e for 20 mi nutes. 6.$.12 /fter completion of the trials and tests on indi"idual pumps parallel operation of 2 pumps and pumps is done for 20 minutes. 6.$.1 5uring parallel operation of pumps, the follo#ing o%ser"ations are made and recorded during each operation. a) 5ifferential pressure %) Motor current c) 5rum le"el readings on right and left. 6.$.1$ /fter the a%o"e o%ser"ations are recorded all pumps are allo#ed to run !8 BHEL Sheet 13 of 15

for 6 hours trial run. 5uring the trial, the parameters li+e 5ifferential pressure, motor current may %e recorded at e"ery half an hour inter"al.

Si6nat7re NTPC Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 5 NTPC Ref No. S"# $ 1 $ TS $ 1 $ !8 P%ant &rea: B'"LER PR'CED(RE )'R C'##"SS"'N"N* ') CC P(#PS 5. :.1 COMPLETION CRITERIA 2ommissioning of 2.2 .umps completed %y carrying out the proposals as gi"en in 3ection .0 !8 BHEL Sheet 15 of 15

Si6nat7re NTPC BHEL

Lo6 Sheet
3tation Unit /cti"ity S%. No 9 9 9 P7m9 in Ser:i;e & B C & C7rrent B C Differentia% Pre887re & B C Time Remar<8 5ate9

Time

Si6nat7re NTPC BHEL

PR'CED(RE )'R C'##"SS"'N"N* ') CC P(#PS