Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-119 NTPC Ref no SIM/1/TS/2/119
Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF TURBINE DRIVEN BOILER FEED PUMP
SLNO LIST OF CONTENTS 1.0
PLANT DETAILS
2.0
OBJECTIVE
3.0
PROPOSAL
4.0
SERVICES REQUIRED
5.0
SAFETY PRECAUTIONS
6.0
EMERGENCY PROCEDURE
7.0
STATE OF THE PLANT
8.0
METHOD
9.0
COMPLETION CRITERIA
10.0
APPENDICES
Sheet 1 of 21
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-119 NTPC Ref no SIM/1/TS/2/119
Sheet 2 of 21
Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF TURBINE DRIVEN BOILER FEED PUMP
SL.NO 1.0
STATUS
PLANT DETAILS
The The Boi Boile lerr Fee Feed sy syst ste em con consist sists s of three Boi Boile lerr Feed Feed Pum Pump se sets for each unit unit of Sim Simhadri hadri STP ST P P (2 Turbine Driven Driven and 1 motor motor driven). Each pump set 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 The imp import ortant ant te techn chnical ical dat data a of Boi Boiler ler Feed Feed boo boost ste er pu pumps and and Boiler Feed pumps are same as mentioned in testing schedule of MDBFP NO.PS NO.P S -DC-186-50 -DC-186-500-1 0-118 18 1.1
Technical Technical data of Turbine
a. Maxim Maximum um output b. Design Design rating (Economical (E conomical rating) rating) c. S peed peed d. S peed range range e. Initial S team P ressure ressure f. Initial steam T perat
7575 KW 5732 5732 KW 5275 52 75 RP M 1494 14 94-575 -5750 0 RP M 6.33 ata. 289.6 0 C.
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-119 NTPC Ref no SIM/1/TS/2/119
Sheet 3 of 21
Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF TURBINE DRIVEN BOILER FEED PUMP
SL.NO 3.0
STATUS
PROPOSAL
Commissioning of each turbine driven Boiler Feed pump set proposed in the following steps. 3.1
Commissioning of oil system and turning gear operation of BFP Turbine.
3.2
Commissioning of Governing System of BFP Turbine
3.3
Steam rolling and actual over speeding of turbine (solo run of turbine)
3.4
Commissioning of turbine driven Boiler Feed pump.
4.0
SERVICES REQUIRED
4.1
Availability of manpower with required tools for attending any leak, cleaning of filter and for adjustment of turbine governing system.
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-119 NTPC Ref no SIM/1/TS/2/119
Sheet 4 of 21
Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF TURBINE DRIVEN BOILER FEED PUMP
SL.NO
STATUS
4.8
Availability of steam for turbine.
5.0
SAFETY PRECAUTIONS
5.1
Debris in and around BFP 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.
5.4
Approach / stair case / platform wherever required are made available.
5.5
Portable fire fighting system made available at test area.
5.6
Coupling gaurds are properly fixed.
5.7
Safety appliances like helmet, hand gloves available for operating
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-119 NTPC Ref no SIM/1/TS/2/119
Sheet 5 of 21
Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF TURBINE DRIVEN BOILER FEED PUMP
SL.NO
STATUS
7.0
STATE OF THE PLANT
7.1
Booster pump, Gearbox, Turbine, BFP and associated system are erected as per recommended drawing.
7.2
Acid cleaning and oil flushing completed for lube oil and working oil, J acking oil and governing oil piping as per test procedure No.PS-DC-186-500-104 and lines are normalized.
7.3
Detergent flushing of feed water suction, discharge and recirculation piping are completed and all piping normalized.
7.4
All piping supports are loaded to the rated value.
7.5
Deaerator filled with fresh DM water with proper level indication and instrumentation completed.
7.6
Flushing of following pipe lines completed.
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-119 NTPC Ref no SIM/1/TS/2/119
Sheet 6 of 21
Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF TURBINE DRIVEN BOILER FEED PUMP
SL.NO
STATUS
7.11
Erection of gland steam supply piping complete. Supports, steam blowing and insulation complete.
7.12
Turbine drain piping and all steam piping drain lines are complete. For initial rolling orifice plates in drains are removed to avoid chocking.
7.13
Turbine exhaust piping complete with supports upto condensor.
7.14
Bursting diaphragm is erected and healty.
7.15
Gland leak off piping erection complete to condensor (including supports and insulation)
7.16
All motorized valves related to turbine including live steam isolation valves, turbine drain valves are commissioned.
7.17
Gland steam pressure controller commissioned available for operation.
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-119 NTPC Ref no SIM/1/TS/2/119
Sheet 7 of 21
Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF TURBINE DRIVEN BOILER FEED PUMP
SL.NO
STATUS
a) Recirculation line of main pump. b) Suction and discharge line of booster pump and main pump. c) Main pump and booster pump body. 7.24
Commissioning of valves related to the feed pump system are completed. (Suction isolating valve, discharge isolating valve, recirculation valve and motor cooling water isolating valve)
7.25
Interlock and protection system simulation checking completed.
8.0
METHOD
8.1
Commissio ning o f Oil System and Turning Gear Operation of BFP Turbine
8.1.1
Ensure oil flushing of lub oil system completed and pipings are normalized.
8.1.2
Ensure that the turbine is disconnected from gear box and main
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-119 NTPC Ref no SIM/1/TS/2/119
Sheet 8 of 21
Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF TURBINE DRIVEN BOILER FEED PUMP
SL.NO
STATUS
8.1.8
Ensure oil is filled in MOT through centrifuge to adequate level.
8.1.9
Keep open the vents of lube oil coolers and filters.
8.1.10
Keep the changeover valve of lube oil cooler and filter in such a way that only one cooler ad filter will be in service.
8.1.11
Ensure drains of lube oil coolers, filters are closed.
8.1.12
Start one of the oil vapour fans with its suction valve open condition.
8.1.13
Start one of the lube oil pumps ensuring flow through recircution.
8.1.14
Adjust lube oil header pressure control valve to maintain lube oil pressure of 2.5 kg/cm2 after control station.
8.1.15
Adjust lube oil discharge pressure to 10.0kg/cm2 by setting recirculation control valve.
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-119 NTPC Ref no SIM/1/TS/2/119
Sheet 9 of 21
Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF TURBINE DRIVEN BOILER FEED PUMP
SL.NO
STATUS
8.1.22
Stop DC EOP and keep lube oil pump in service
8.1.23
Charge the suction line of J OP from lube oil header.
8.1.24
Start J OP and adjust the safety relief valve to 110 kg/cm2.
8.1.25
Adjust pressure regulating valve to 100 kg/cm2
8.1.26
Adjust the throttle valves in J acking oil supply to front and rear journal bearings such that the rotor lifts around 0.05 to 0.1 mm. Stop J OP and start again. Check and record the J acking oil pressures and rotor lifts in the turbine front and rear journal bearings.
8.1.27
Check and ensure the freeness of rotor for rotation by engaging hand barring lever and then stop J OP .
8.1.28
Ensure auto operation of AOP I, AOP II and DC EOP through corresponding pressure switches operation.
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-119 NTPC Ref no SIM/1/TS/2/119
Sheet 10 of 21
Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF TURBINE DRIVEN BOILER FEED PUMP
SL.NO
STATUS
8.1.35
Ensure turning gear speed of around 200 RPM and smooth running.
8.1.36
Observe and record bearing metal temperatures, vibrations, eccentricity etc.,
8.1.37
Run for 8 hours. stop turning gear and observe coasting down.
8.2.0
Commissio ning of Governing System of BFP Turbine
8.2.1
Check that the connection from governing rack to governing elements and at the governing rack are as per governing scheme.
8.2.2
Ensure main and auxiliary control valves lift reference indicator is fixed and set to zero position.
8.2.3
Check the damping valve in HP and LP secondary oil lines are kept open by few turns.
8.2.4
Check the filter elements at the control rack of the duplex filter
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-119 NTPC Ref no SIM/1/TS/2/119
Sheet 11 of 21
Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF TURBINE DRIVEN BOILER FEED PUMP
SL.NO
STATUS
8.2.8
Ensure all pressure switches and pressure gauges in governing rack are charged and their drain valves are closed.
8.2.9
Reset the turbine locally and ensure following: a) Trip oil pressure more than 5.0 kg/cm2. b) Stop and control valves in closed condition. c) HP and LP secondary oil pressures less than 1.0 kg/cm2
8.2.10
Ensure oil temperature of 45-50 deg C during governing system adjustment.
8.2.11
Opening / closing of emergency stop valve.
8.2.11.1
Ensure power supply for solenoids 2220 and 2221. (It will be normally in deenergised condition)
8.2.11.2
Ensure no steam available ahead of ESV and live steam isolating valve in closed condition.
8.2.11.3
Give open command to ESV and observe the following sequential
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-119 NTPC Ref no SIM/1/TS/2/119
Sheet 12 of 21
Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF TURBINE DRIVEN BOILER FEED PUMP
SL.NO
STATUS
8.2.12
Reset the turbine from remote by energising solenoid 1050. Ensure the same solenoid gets automatically deenergised when trip oil pressure raises more than 4.5 kg/cm2 through pressure switch.
8.2.13
Switch on power supply to HP and LP I/H convertors.
8.2.14
Give 4 mA current to HP I/H convertor with external source or through governor panel.
8.2.15
Ensure HP sec. Oil pressure of 1.5 kg/cm2. If not set the pressure to 1.5 kg/cm2 by adjusting potentiometer XO in I/H convertor.
8.2.16
Check that the control valve servomotor pilot is rotating freely and having a slight up and down movements.
8.2.17
Check the main control valve servomotor is just opened, by 0.2 mm. The start of opening can be measured by fixing dial guage on servomotor.
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-119 NTPC Ref no SIM/1/TS/2/119
Sheet 13 of 21
Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF TURBINE DRIVEN BOILER FEED PUMP
SL.NO
STATUS
1. Current mA Vs HP sec oil pressure Vs main control valve lift. 2. Current to LP I/H convertor mA Vs LP sec-oil pressure Vs Auxiliary control valve lift. 8.2.23
Compare the characteristics and ensure these are in line with governing adjustment diagram/ shop floor test protocol.
8.2.24
Operate the tester for ESV and ensure partial closing of ESV and put back the tester in normal position, ESV opens back to full open position.
8.2.25
Energise the remote trip solenoid 2222 A/ 2222B and ensure the following. a) b) c) d)
8.3
ESV closed. Main control valve is closed Auxiliary control valve is closed. Trip oil pressure is zero.
Steam rolling and actual overspeeding of Turbine (solo run
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-119 NTPC Ref no SIM/1/TS/2/119
Sheet 14 of 21
Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF TURBINE DRIVEN BOILER FEED PUMP
SL.NO
STATUS
8.3.5
Check that all the temporary supports are removed from turbine casing, steam lines, oil lines etc.,
8.3.6
Ensure that the TD BFP foundation is separated from the main turbine foundation all around and the support spring assembly of TD BFP is properly placed.
8.3.7
Start oil system. Keep the turbine on hydraulic barring. Record the measurements of oil system and turbovisory.
8.3.8
Instal dial gauges for checking even expansion of the casing and pedestal.
8.3.9
Warm up gland sealing steam supply header measurement of sealing steam supply temperature.
8.3.10
Keep open casing drain and balance piston loop drain valves.
8.3.11
Observe vacuum created in turbine casing and exhaust line. Check for tightness of exhaust line and casing joints.
ensure
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-119 NTPC Ref no SIM/1/TS/2/119
Sheet 15 of 21
Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF TURBINE DRIVEN BOILER FEED PUMP
SL.NO
STATUS
e) f) g) h) i) j)
Trip oil pressure very low Bearing temperatures very high Vibrations very high. Turbine speed very high. Turbine axial shift very high Any other protection as applicable and provided in the system.
8.3.15
Keep open all drain valves in extraction 4 to TDBFP, CRH to TDBFP and auxiliary steam to TDBFP lines.
8.3.16
Ensure governing oil system charged and ESV in close Condition.
8.3.17
Warm up the steam inlet line to turbine (Steam supply can be taken from any one of the available sources)
8.3.18
Ensure steam inlet pressure, measurements are healthy.
8.3.19
Reset the turbine and observe the trip oil pressure is available.
temperature
and
flow
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-119 NTPC Ref no SIM/1/TS/2/119
Sheet 16 of 21
Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF TURBINE DRIVEN BOILER FEED PUMP
SL.NO
STATUS
8.2.25
Soak the turbine at 1500 rpm for about 30 minutes observe the parameters are stablised.
8.2.26
Raise the speed of the turbine gradually to rated speed as per start up curve, given in O & M manual.
8.2.27
Monitor the behaviour of control valve during warming up speed and at rated speed for any hunting.
8.2.28
At rated speed soak the machine for 15 minutes, observe for all parameters. Adjust lube oil flow to bearings if required.
8.2.29
Carry out oil injection test of overspeed governor for few times to check repeatability of the action.
8.2.30
Keep exhaust hood spray system on auto. Ensure its operation.
8.2.31
Carryout actual overspeeding test of the turbine if the parameters such as vibration within limits and the casing expansion is more
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-119 NTPC Ref no SIM/1/TS/2/119
Sheet 17 of 21
Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF TURBINE DRIVEN BOILER FEED PUMP
SL.NO
STATUS
8.4.2
Couple turbine with BFP and Gearbox. Couple gearbox with booster pump.
8.4.3
Crack open feed water suction isolating valve and vent out air in all the vents.
8.4.4
Flush and shut the booster pump casing drain and BFP drain and interconnecting pipe drain.
8.4.5
Check all the instrument tapping point isolating valves are open and that all drain and equalizing valves are shut.
8.4.6
Gradually open suction isolating valve keeping watch on the trend of differential temperature of top and bottom of the main pump casing.
8.4.7
Check mechanical seal water control isolating valves are open for Booster pump and BFP.
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-119 NTPC Ref no SIM/1/TS/2/119
Sheet 18 of 21
Plant area: TURBING TESTING SCHEDULE FOR COMMISSIONING OF TURBINE DRIVEN BOILER FEED PUMP
SL.NO
STATUS
8.4.12
Ensure all flanged joints are tightened properly with proper gaskets.
8.4.13
Ensure proper clearance at the holding down bolts of the booster pump and main pump.
8.4.14
Check the booster pump and main pump.
8.4.15
Ensure oil system in service. Start jacking oil pump.
8.4.16
Engage the main pump with turbine.
8.4.17
Check the freeness of Turbine rotor along with booster pump and main pump by hand barring.
8.4.18
Disengage the main pump and keep the turbine on hydraulic barring and prepare the turbine for steam rolling.
8.4.19
When the turbine is ready for steam rolling, stop the turbine and engage the main pump with turbine.
Station: NTPC- Simhadri
BHEL Ref No.PS-DC-186-500-119 NTPC Ref no SIM/1/TS/2/119
Sheet 19 of 21
Plant area: TURBINE TESTING SCHEDULE FOR COMMISSIONING OF TURBINE DRIVEN BOILER FEED PUMP
SL.NO
STATUS
8.4.25
Check the speed control and pressure variations during operation of BFP for drum level control.
8.4.26
During trial operation feed water suction strainers of Booster pump and BFP should be closely monitored.
8.4.27
Stop TDBFP after trial run, put turbine on hydraulic barring
8.4.28
The second set of TD BFP is to be commissioned in the same procedure as above.
9.0
COMPLETION CRITERIA
9.1
Commissioning of Turbine driven Boiler Feed pump set completed by carrying out the proposals given in section 3.0.
TESTING SCHEDULE FOR COMMISSIONING OF TURBINE DRIVEN BOILER FEED PUMP
SHEET 10.0
20 OF 21
LOG SHEET 1
DATE : PROJ ECT UNIT EQUIPMENT ACTIVITY
Time Hrs
Speed
: : : BFP TURBINE :
Lub oil Hdr. Pressure
Oil pressure to Bearings Front Journal
Front Thrust
Bearing temperatures Rear Journal
Front Journal
Signatures NTPC
BHEL
Front Thrust
Oil temperature Rear Journal
Bef. cooler
After cooler
SHEET 21 OF 21 LOG SHEET 2
DATE : PROJ ECT UNIT EQUIPMENT ACTIVITY Time Hrs
Speed
: : : BFP TURBINE : Live steam pressure
Live steam Temp.
Vibrations Front
Rear
Casing expansion
Ax ial shift
HP sec Oil pr.
LP sec oil pr
Signatures NTPC
BHEL
HP valve lift
LP valve lift
Turbine exhaust pr .
Turbine exhaust temp.
Gland steam pr .
Gland steam temp.