testing schedule for commissioning of condensate extraction pumps

Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-120

NTPC Ref no SIM/1/TS/2/120 Sheet 1 of 12

Plant area: TURBINE

TESTING SCHEDULE FOR COMMISSIONING OF

CONDENSATE EXTRACTION PUMPS

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LIST OF CONTENTS

PLANT DETAILS OBJECTIVE PROPOSAL SERVICES REQUIRED SAFETY PERECAUTIONS EMERGENCY PROCEDURE STATE OF THE PLANT METHOD COMPLETION CRITERIA APPENDICES

a) LOG SHEET



Plant area: TURBINE



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1.0

PLANT DETAILS Each unit of Simhadhri STPP is supplied with three numbers of condensate Extration Pumps of 50% capacity. The condensate Extraction Pump (CEP) take suction from the Hotwell and discharge to deaerator through gland steam condensor and LP Heaters. The important technical data of CEP are as follows: a. Manufacture : BHEL, Hyderabad b. Pump designation : EN6J 40/500 c. Type : Vertical canister d. Number of Stages : 6 e. Design flow rate : 790480 kg/hr. f. Inlet temperature : 49.2 Deg. C g. Specific gravity : 0.9881 h. Total discharge head : 275m. i. Shut off head : 390 m j. Pump Speed : 1486 rpm k. Power input to motor : 763 kw l. Efficiency of Pump : 81 % m. Minimum flow for continuous operation : 300 m3 /hr n. Radial Bearing : Cut less rubber, 10 Nos. 100 mm size o. Thrust bearing in pump :

Manufacturer : Michell Bearings Type : Vertical double thrust and guide bearing

P. Lubrication Type Radial bearing : Condensate Thrust bearing : Sump oil.

STATUS

Signatures

NTPC BHEL



Plant area: TURBINE



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3.0

3.1

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4.0

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q. Driving motor manufacturer : BHEL, Bhopal r. Coupling Manufacturer : Euroflex Type : Flexible coupling s. Suction strainer filtration size ; 315 microns. OBJECTIVE To commission three numbers condensate extraction pumps and associated auxiliaries and make them available for unit operation. PROPOSAL Commissioning of condensate Extraction Pumps proposed in the following steps. Commissioning of motor Commissioning of CEP. SERVICES REQUIRED Availability of manpower with required tools for attending any leak and cleaning of filter. Availability of operating personal 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.

STATUS

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NTPC BHEL



Plant area: TURBINE



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5.0

5.1

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6.0

6.1

6.2

Availability of Auxiliary Cooling water supply. SAFETY PRECAUTIONS Debris in and around CEP 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 / stair case / platform wherever required are made available. Portable fire fighting system made available at test area. 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 will aware of the procedures to be adopted in case of any abnormality in the activity.

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NTPC BHEL



Plant area: TURBINE



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STATE OF THE PLANT CEP, motor and associated system are erected as per recommended drawing. Detergent flushing of condensate pipelines completed and pipings are normalized. Condensor erection complete, Hotwell mechanical cleaning completed and boxed up. Hotwell level indication available at local / Hotwell filled to normal level with DM Water. CEP suction piping mechanical cleaning and flushing with DM water completed. CEP suction strainer erected in position in clean condition with DP indicator commissioned. Condensate suction, discharge and recirculation pipings supports are loaded to the rated value. All erection logsheets are followed up/signed by concerned agencies for CEP and associated system. All local and remote instrumentation for the system is complete. Erection of the following pipes complete with valves and orifices wherever required.

a. Canister vent to condensor b. Discharge vent to condensor c. Sealing water piping to seals from common

discharge header and from external source d. Cooling water piping to thrust bearing.

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Plant area: TURBINE



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8.1.6

Flushing of cooling water piping to thrust bearing and external seal water piping are complete. Commissioning of valves associated to the system are complete. (CEP discharge valve, suction valve and recirculation control valve) All flanged joints are checked for tightness and proper gaskets. Interlocks and protection system simulation checking completed. CEP suction piping bellows lock released. METHOD Commissioning of Motor Ensure motor decoupled from CEP. Ensure the meggar value of motor and ensure that the insulation values are 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 proper earthing of the motor. Ensure greasing of the motor bearings

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NTPC BHEL



Plant area: TURBINE



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8.2.1

82.2

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8.2.7

Ensure motor winding and bearing temperatures are available at control room/local. Bump the motor and ensure correct direction of rotation. Observe for any undue noise. 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. Stop motor after 8 hours trial run and observe coasting down of motor. Commissioning of CEP Ensure alignment of motor with CEP, the readings are logged and cleared for coupling. Couple motor with CEP. Check oil level in the gauge glass of thrust bearing oil sump. Top up if necessary. Ensure that the cooling water is available to the thrust bearing. Establish cooling water flow. Keep open suction isolating valve fully and vent out air from canister vent to condenser. Keep open solenoid valve in discharge vent to condensor. Ensure sealing water available for stuffing box.

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NTPC BHEL



Plant area: TURBINE



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Ensure discharge isolation valve closed. Keep open its bypass valve so that on starting of pump, discharge empty piping system gets filled slowly. Keep open minimum recirculation control valve fully. Ensure isolation to Deaerator, LP BP spray and excess return line. Ensure following start permissives available in DCS. a. Suction valve is open. b. Condensor Hotwell level not low. c. CEP discharge valve in closed condition d. Recirculation valve in wide open condition. Ensure the following CEP protection trippings are checked and available in service.

a. Hotwell 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

Ensure annunciation system available and checked Ensure vent valves in discharge piping system are open. Ensure discharge valve auto operation available and checked. Ensure all the instrument tapping points isolating valves are open and that all drain and equalizing valves are shut.

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NTPC BHEL



Plant area: TURBINE



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8.2.24

Start CEP and ensure adequate pressure developed. Check for undue noise or vibration. Check discharge valve opens automatically on sensing pressure adequate. Close all vents open to atmosphere in the discharge system Ensure discharge vent solenoid closes after time delay. Check recirculation flow more then 300 m3/hr. 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. Run the pump for 8 hours on recirculation and monitor all parameters. Stop the pump after completion of trial and ensure discharge isolation valve closes automatically. The other two CEPs are to be commissioned in same procedure as done for the first CEP.

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NTPC BHEL



Plant area: TURBINE



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9.0

9.1

COMPLETION CRITERIA Commissioning of CEPs completed by carrying out the proposals given in section 3.0.

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SHEET 11 OF 12

10.0 LOG SHEET 1

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

Time Hrs

Bus Voltage

Motor Current

Motor Bearing Temp. Motor Winding Temperatures

DE NDE 1 2 3 4 5 6

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SHEET 12 OF 12

LOG SHEET 2

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

Time Hrs

Motor Current

Motor Brg. Temp Pump Thrust Brg.

Temp

CW Temp

Suc.Pr. Disch. Pr. Suction filter DP

Vibrations

DE NDE Inlet Outlet Pump Motor

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testing schedule for commissioning of condensate extraction pumps

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