Jindal Power Limited

O.P.J.S.T.P.P, Tamnar, Raigarh

Commissioning Department

Project OPJSTPP (4X600 MW), Tamnar

Procedure Condensate Extraction Pump
Purpose of Document For Execution/Information
Document No. JPL Reference No: Turbine/Comm./023

Rev No. 00 Prepared By Reviewed By Approved By Date

Name

Sign

Copy No:

Issued To:
Station: JPL, Tamnar JPL Reference no: Sheet 1
Stage II: (4X600 MW) Turbine/Comm./023 of

Plant Area: Turbine

PROCEDURE FOR COMMISSIONING OF CONDENSATE EXTRACTION PUMPS

SLNO
LIST OF CONTENTS

1.0 PLANT DETAILS

2.0 OBJECTIVE

3.0 PROPOSAL

4.0 SERVICES REQUIRED

5.0 SAFETY PERECAUTIONS

6.0 EMERGENCY PROCEDURE

7.0 STATE OF THE PLANT

8.0 METHOD

9.0 COMPLETION CRITERIA

10.0 APPENDICES

a) LOG SHEET

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no: Sheet 1
Stage II: (4X600 MW) Turbine/Comm./023 of

Plant Area: Turbine

PROCEDURE FOR COMMISSIONING OF CONDENSATE EXTRACTION PUMPS

SL.NO STATUS

1.0 PLANT DETAILS

Each unit of JPL is supplied with three numbers of condensate

Extraction Pumps of 50% capacity. The condensate Extraction
Pump (CEP) takes suction from the Hot well and discharge to
Deaerator through gland steam condenser and LP Heaters.

The important technical data of CEP are as follows:

a. Manufacture : BHEL, Hyderabad

b. Pump designation :
c. Type : Vertical canister
d. Number of Stages :
e. Design flow rate :
f. Inlet temperature :
g. Specific gravity :
h. Total discharge head :
i. Shut off head :
j. Pump Speed :
k. Power input to motor :
l. Efficiency of Pump :
m. Minimum flow for
continuous operation :
n. Radial Bearing :
o.Thrust bearing in pump
Manufacturer :
Type :
P. Lubrication Type
Radial bearing :
Thrust bearing :
q. Driving motor manufacturer :
r. Coupling
Manufacturer :
Type :
s. Suction strainer filtration size:

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no: Sheet 1
Stage II: (4X600 MW) Turbine/Comm./023 of

Plant Area: Turbine

PROCEDURE FOR COMMISSIONING OF CONDENSATE EXTRACTION PUMPS

SL.NO STATUS
2.0 OBJECTIVE

To commission three numbers condensate extraction pumps

and associated auxiliaries and make them available for unit
operation.
3.0 PROPOSAL

Commissioning of condensate Extraction Pumps proposed in

the following steps.

3.1 Commissioning of motor

3.2 Commissioning of CEP.

4.0 SERVICES REQUIRED

4.1 Availability of manpower with required tools for attending any

leak and cleaning of filter.

4.2 Availability of operating personal to carry out/coordinate

activities.

4.3 Availability of lighting arrangements and communication

facilities in operating floors.

4.4 Availability of Instrument and service air.

4.5 Availability of LT/HT power supply.

4.6 Availability of Auxiliary Cooling water supply.

5.0 SAFETY PRECAUTIONS

5.1 Debris in and around CEP area shall be removed.

5.2 First aid kit is available near the test area.

5.3 Operation of local start / stop push button shall be ensured for
perfect operation to facilitate for stopping of equipment in case
of necessity.

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no: Sheet 1
Stage II: (4X600 MW) Turbine/Comm./023 of

Plant Area: Turbine

PROCEDURE FOR COMMISSIONING OF CONDENSATE EXTRACTION PUMPS

SL.NO STATUS
5.4 Approach / stair case / platform wherever required are made
available.

5.5 Portable fire fighting system made available at test area.

6.0 EMERGENCY PROCEDURES

6.1 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

6.2 adopted in case of any abnormality in the activity.

7.0 STATE OF THE PLANT

7.1 CEP, motor and associated system are erected as per

recommended drawing.

7.2
Detergent flushing of condensate pipelines completed and
piping are normalized.

Condenser erection complete, Hot well mechanical cleaning

7.3
completed and boxed up.

Hot well level indication available at local / Hot well filled to

7.4 normal level with DM Water.

CEP suction piping mechanical cleaning and flushing with DM

7.5 water completed.

7.6 CEP suction strainer erected in position in clean condition with

DP indicator commissioned.

7.7 Condensate suction, discharge and recirculation piping’s

supports are loaded to the rated value.

7.8 All erection log sheets are followed up/signed by concerned

agencies for CEP and associated system.

All local and remote instrumentation for the system is

7.9
complete.

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no: Sheet 1
Stage II: (4X600 MW) Turbine/Comm./023 of

Plant Area: Turbine

PROCEDURE FOR COMMISSIONING OF CONDENSATE EXTRACTION PUMPS

SL.NO STATUS
7.10 Erection of the following pipes complete with valves and
orifices wherever required.

a. Canister vent to condenser

b. Discharge vent to condenser
c. Sealing water piping to seals from common
discharge header and from external source
d. Cooling water piping to thrust bearing.

7.11 Flushing of cooling water piping to thrust bearing and external

seal water piping are complete.

Commissioning of valves associated to the system are

7.12
complete. (CEP discharge valve, suction valve and
recirculation control valve)
7.13 All flanged joints are checked for tightness and proper gaskets.

Interlocks and protection system simulation checking

7.14 completed.

CEP suction piping bellows lock released.

7.15
METHOD
8.0
Commissioning of Motor
8.1
Ensure motor decoupled from CEP.
8.1.1
Ensure the meggar value of motor and ensure that the
insulation values are satisfactory.
8.1.2
Check the winding resistance of the motor and confirm that the
8.1.3
values are satisfactory.

Ensure all motor protections are available at the HT breaker.

8.1.4
Ensure proper earthling of the motor.
8.1.5
Ensure greasing of the motor bearings
8.1.6

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no: Sheet 1
Stage II: (4X600 MW) Turbine/Comm./023 of

Plant Area: Turbine

PROCEDURE FOR COMMISSIONING OF CONDENSATE EXTRACTION PUMPS

SL.NO STATUS

8.1.7 Ensure motor winding and bearing temperatures are available

at control room/local.

8.1.8 Bump the motor and ensure correct direction of rotation.

Observe for any undue noise.

8.1.9 Start the motor and complete 8 hours trial run.

8.1.10 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.

8.1.11 Stop motor after 8 hours trial run and observe coasting down of
motor.

8.2 Commissioning of CEP

8.2.1 Ensure alignment of motor with CEP, the readings are logged
and cleared for coupling.

82.2 Couple motor with CEP.

8.2.3 Check oil level in the gauge glass of thrust bearing oil sump.
Top up if necessary.

8.2.4 Ensure that the cooling water is available to the thrust bearing.
Establish cooling water flow.

8.2.5 Keep open suction isolating valve fully and vent out air from
canister vent to condenser.

8.2.6 Keep open solenoid valve in discharge vent to condenser.

8.2.7 Ensure sealing water available for stuffing box.

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no: Sheet 1
Stage II: (4X600 MW) Turbine/Comm./023 of

Plant Area: Turbine

PROCEDURE FOR COMMISSIONING OF CONDENSATE EXTRACTION PUMPS

SL.NO STATUS

8.2.8 Ensure discharge isolation valve closed. Keep open its bypass
valve so that on starting of pump, discharge empty piping
system gets filled slowly.

8.2.9 Keep open minimum recirculation control valve fully. Ensure

isolation to Deaerator, LP BP spray and excess return line.

8.2.10 Ensure following start permissive available in DCS.

a. Suction valve is open.

b. Condenser Hot well level not low.
c. CEP discharge valve in closed condition
d. Recirculation valve in wide open condition.

8.2.11 Ensure the following CEP protection tripping are checked and
available in service.

a. Hot well level low

b. Discharge pressure very low with a time delay
c. Flow through pump low with a time delay.
d. CEP thrust bearing temperature very high
e. Motor bearing temperature very high
f. Motor winding temperature very high
g. Electrical protection of motor

8.2.12 Ensure annunciation system available and checked

8.2.13 Ensure vent valves in discharge piping system are open.

8.2.14 Ensure discharge valve auto operation available and checked.

8.2.15 Ensure all the instrument tapping points isolating valves are
open and that all drain and equalizing valves are shut.

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no: Sheet 1
Stage II: (4X600 MW) Turbine/Comm./023 of

Plant Area: Turbine

PROCEDURE FOR COMMISSIONING OF CONDENSATE EXTRACTION PUMPS

SL.NO STATUS
8.2.16 Start CEP and ensure adequate pressure developed. Check
for undue noise or vibration.

8.2.17 Check discharge valve opens automatically on sensing

pressure adequate.

8.2.18 Close all vents open to atmosphere in the discharge system

Ensure discharge vent solenoid closes after time delay.

8.2.19

8.2.20 Check recirculation flow more than …….m3/hr.

8.2.21 Charge seal water from discharge header. Ensure stuffing box
is not heating up excessively. Initially the temperature of
stuffing box will raise due to new gland packing. Hence allow
more leakage by keeping gland loose and tighten slowly
monitoring the temperature of gland.

8.2.22 Run the pump for 8 hours on recirculation and monitor all
parameters.

8.2.23 Stop the pump after completion of trial and ensure discharge
isolation valve closes automatically.

8.2.24 The other two CEPs are to be commissioned in same

procedure as done for the first CEP.

9.0 COMPLETION CRITERIA

9.1 Commissioning of CEPs completed by carrying out the

proposals given in section 3.0.

Signatures

JPL BHEL
 Station: JPL, Tamnar JPL Reference no: Sheet 1
Stage II: (4X600 MW) Turbine/Comm./023 of

Plant Area: Turbine

PROCEDURE FOR COMMISSIONING OF CONDENSATE EXTRACTION PUMPS

10.0
LOG SHEET 1

DATE:
PROJECT :
UNIT :
EQUIPMENT : CONDENSATE EXTRACTION PUMP MOTOR
ACTIVITY : TRIAL RUN

Motor Bearing
Motor Winding Temperatures
Temp.
Bus Motor
Time Voltage Current
Hrs DE NDE 1 2 3 4 5 6

Signatures

JPL BHEL
 Station: JPL, Tamnar JPL Reference no: Sheet 1
Stage II: (4X600 MW) Turbine/Comm./023 of

Plant Area: Turbine

PROCEDURE FOR COMMISSIONING OF CONDENSATE EXTRACTION PUMPS

LOG SHEET 2
DATE:
PROJECT :
UNIT :
EQUIPMENT : CONDENSATE EXTRACTION PUMP MOTOR
ACTIVITY : TRIAL RUN

Motor Brg. Temp Pump CW Temp

Suction Vibrations
Time Motor Thrust Disch.
Suc.Pr. filter
Hrs Current Brg. Pr.
DE NDE Inlet Outlet DP
Temp Pump Motor

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no: Sheet 1
Stage II: (4X600 MW) Turbine/Comm./023 of

Plant Area: Turbine

PROCEDURE FOR COMMISSIONING OF CONDENSATE EXTRACTION PUMPS

TESTING SCHEDULE FOR COMMISSIONING OF

CONDENSATE EXTRACTION PUMPS
4X600MW, JPL, TAMNAR

Signatures

JPL BHEL