Turbine Driven Boiler Feed Pump Commng
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Transcript of Turbine Driven Boiler Feed Pump Commng
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TURBINE DRIVEN BOILER FEED PUMP COMMNG PART-I-
ABC OF THERMAL POWER PLANT
PART-I
Before starting the pre-commissioning activities of BFP ( TD – TURBINE DRIVENe!"ipments nee# to $e in#ivi#"a%%& chec'e# for rea#iness "pto a %imit point
Booster p"mp) *ear$o+) T"r$ine) BFP an# associate# s&stem are erecte# as per
recommen#e# #ra,ing an# rea#ings are recor#e# for rea#& reference
Aci# c%eaning an# oi% f%"shing comp%ete# for %"$e oi% an# ,or'ing oi%) ac'ing oi% an#
governing oi% piping as per test proce#"re an# %ines are norma%i.e# The proce#"re has
a%rea#& $een #isc"sse# in m& ear%ier $%ogs
Detergent f%"shing of fee# ,ater s"ction) #ischarge an# recirc"%ation piping are
comp%ete# an# a%% piping norma%i.e# These f%"shing is $eing #one in parts as /DBFP
comes first at initia% stage that time pipe%ines for TDBFP ma& not $e rea#& Therefore a
scheme to $e ma#e to "n#erta'e this 0o$ ,itho"t interr"pting the commissioningactivities This sho"%# $e 'ept in min# 1ther,ise to comp%ete the %ine an# #o the
c%eaning in one go is the $est
A%% piping s"pports are %oa#e# to the rate# va%"e an# a%% temporar& s"pports remove#
from the pipe%ine
Deaerator an# F2T fi%%e# ,ith Fresh D/ ,ater F2T %eve% s,itches an# Deaerator %eve%
s,itches are chec'e# In fact these s,itches are ca%i$rate# #"ring /DBFP tria% r"n
Rechec'e# #"ring TDBFP commissioningF%"shing of fo%%o,ing pipe %ines comp%ete#
3oo%ing ,ater %ines of Booster p"mp an# BFP (2ea% 4ater coo%er an# sea% $o#&
Ba%ancing %ea' off %ines of main p"mp
T"r$ine e+ha"st hoo# spra& %ine
T"r$ovisor& instr"ments for t"r$ine ( ie e+pansion meas"rement of t"r$ine
Vi$ration ) temperat"re )press"re etc ca%i$rate# an# insta%%e#
2team $%o,ing of pipe%ines again in phase# manner is to $e comp%ete# It is notice# that
steam %ines of TDBFP are not get rea#& #"ring steam $%o,ing activit& of the "nit This is
to $e #one at %ater #ate therefore a scheme of #ra,ing steam an# #rain to con#enser
5f%ash tan' to $e ma#e an# e+ec"te# as per the scheme
Ins"%ation of t"r$ine an# pipe%ines is comp%ete#Erection of g%an# steam s"pp%& piping comp%ete 2"pports) steam $%o,ing an# ins"%ation comp%ete
T"r$ine #rain piping an# a%% steam piping #rain %ines are comp%ete For initia% ro%%ing orifice p%ates in #rainsare remove# to avoi# choc'ing
T"r$ine e+ha"st piping comp%ete ,ith s"pports "pto con#ensor
B"rsting #iaphragm is erecte# an# hea%t&
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*%an# %ea' off piping erection comp%ete to con#ensor (inc%"#ing s"pports an# ins"%ation
A%% motori.e# va%ves re%ate# to t"r$ine inc%"#ing %ive steam iso%ation va%ves) t"r$ine #rain va%ves arecommissione#
*%an# steam press"re contro%%er commissione# avai%a$%e for operation
*overning va%ves erecte# an# protection #evices %i'e overspee# trip #evice) han# trip #evice are mo"nte#proper%&
Fee# ,ater s"ction strainer erecte# in position in c%ean con#ition ,ith DP in#icator commissione#
Instr"ment an# service air %ine for the Fee# p"mp s&stem erecte# an# the air is ma#e avai%a$%e foroperation
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TURBINE DRIVEN BOILER FEED PUMP -ABC OF THERMAL
POWER PLANT
3hec' c%earances of Thr"st $earing of BFP an# Booster P"mp-Fe%%er *a"ge 5 Dia%
*a"ge
Ens"re specifie# c%earances $et,een g"i#e s%ips 'e& (at the $ottom of p"mp casing)
an# then
,e%#ing of 'e& $%oc' on $ase frame-Vernier5 Tape
9&#ra"%ic testing of coo%ers (,atersi#e - Press"re *a"ge sho"%# $e ca%i$rate#
Note= 3oo%ers if a%rea#& h&#ro teste# at man"fact"ring ,or's an# test certificatesavai%a$%e) nee# not $e h&#ro teste# at site
3omp%etion of ,e%#ing an# NDE of ,e%#s of fo%%o,ing %ines=
a
a BFP #ischarge %ine
$ BFP s"ction %ine
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c
c Booster P"mp 2"ction %ine
#
# Booster P"mp #ischarge %ine
Ens"re pre heat treatment an# post-,e%# heat-treatment of ,e%#
Ens"re that the entire pipe%ine is s"pporte# $& permanent s"pports $efore ma'ing the
%ast fo"r 0oints
of B112TER PU/P /AIN PU/P s"ction an# #ischarge
Ensure that the piping doesn’t exercise any pull on pump nozzles. This isextremely important in the
case of BFP suction & discharge, which are welded oints!. This is true for any
nay maor or minor
rotating machine . That means "nal connection to #e done when piping is infree f%oat This can $e
achieve# if a%% the pipe%ines are erecte# as per #ra,ing an# permanent s"pports area#0"ste# as per
#ra,ing va%"e In fact in BFP ,e chec' that pipe %ines can $e move# $& han# on%&,itho"t an&
#iffic"%t& 2ame phi%osoph& is app%ica$%e for B112TER PU/P a%so 9o,everB112TER PU/P
connection is thro"gh fastners on%& therefore can $e manip"%ate# easi%& so not critica%as /AIN
PU/P Instances are avai%a$%e that after fina% connection a%ignment ,as #ist"r$e# som"ch that
pipe%ine ,as c"t an# re-,e%# after necessar& correction This area is ma0or $one ofcontention
$et,een piping engineer an# p"mp engineer
Distances an# a%ignment rea#ings $et,een co"p%ing ha%f faces of Booster P"mp *ear $o+) *ear
$o+ Drive t"r$ine shaft) Drive t"r$ine shaft BFP after comp%eting pipe connections
4e%#ing of 'e& $%oc' on $ase frame after ens"ring specifie# c%earance $et,een g"i#e s%ips 'e& (At
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the $ottom of p"mp casing
2ma%% $ore pipe%ine connection of oi% %ines of #rive t"r$ine ) 3oo%er %ines oi% an# ,ater ) 2ea%ing %ines
of p"mps *overing s&stem insta%%ation an# other steam %ines to $e connecte# an# comp%ete# Fina%
connection to $e #one after ens"ring ) oi% f%"shing )steam $%o,ing ),ater f%"shing )chemica% c%eaning
etc is comp%ete# as per re!"irement "n#er %ai# #o,n proce#"re An& short c"ts ,i%% $ring pro$%ems
after,ar#s That is #"ring sta$i%isation of "nits
Necessar& instr"mentation on oi% tan' )oi% %ines ) $earings )gear $o+es an# p"mps are ca%i$rate# an#
insta%%e# as per #ra,ing 2pecia%%& T"r$ovisor& instr"ments for #rive t"r$ine ) governing contro%
s&stem are insta%%e# caref"%%&
PR13E22 F1R PRE 31//I22I1NIN* AND 31//I22I1NIN*
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contin"e# to part -iii
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TURBINE DRIVEN BOILER FEED PUMP EREC. &COMMNG
-ABC OF THERMAL POWER PLANT
As state# in ear%ier posts there are three Boi%er Fee# P"mps (?+ in a therma%
po,er station of /4 an# a$ove :+ t"r$ine #riven BFP ( norma%%& ,or'ing ,hen
"nit is r"nning a$ove certain %oa# an# other is 8+ /DBFP ,hich "s"a%%& r"ns
#"ring start "p
4e have a%rea#& e+p%aine# in %ast fe, $%ogs a$o"t erection an# commissioning of /DBFP For TDBFP p"mps are same ,hether it is $ooster p"mp or main p"mp
Instea# of /1T1R #riven ,e have varia$%e spee# t"r$ine ,ith #isconnecting co"p%ing
$oth si#es In this $%og ,e ,i%% #isc"ss on%& the t"r$ine as p"mps are simi%ar
Technica% #ata of T"r$ine
a /a+im"m o"tp"t << 74
$ Design rating
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(Economica% rating <?: 74
c 2pee# :< RP/
# 2pee# range 8>C>-< RP/
e Initia% 2team Press"re ?? ata
f Initia% steam Temperat"re :GC 3
g E+ha"st press"re 8> ata1i% 2&stem
a 6"$e oi% p"mp : Nos
$ Emergenc& 1i% p"mp 8 No
c ac'ing 1i% P"mp 8 No
# 1i% vapo"r e+tractor fans : Nos
PR13E22 = ERE3TI1N 39E37
Fo"n#ation chec'ing of e%evation )p%an that is #ifferent poc'et ho%es an# other meas"ra$%e items as per given approve# #ra,ing This the protoco% for ta'ing
fo"n#ation from civi% ven#or for erection p"rpose (e%evation ,ithinHmm5-8mm
3hec' that #epth an# vertica%it& of each poc'et is 17 3hec'ing to $e #one $& ,ater
%eve% 5#"mp& %eve%5 tota% station
Distance from fi+e# reference a+is eg A-ro,) B-ro, 3o%"mns (8mm 5 metre) ± mm
/a+- Esta$%ishing centre %ine as given in the #ra,ing $& p"tting #istances from fi+e#
point This can $e #one $& meas"ring tapes or $& tota% stations
/ar'ing of e!"iva%ent a+es on fo"n#ation P%"m$ Bo$ 5 tota% station
Fitting of ha%f co"p%ings to a%% e!"ipment after ens"ring correspon#ing fits For taper
co"p%ing) ens"re aro"n# G contact $et,een shaft co"p%ing
B%"e matching the top s"rface of fo"n#ation frame ,ith correspon#ing $ottom s"rfaces
of e!"ipment ,ith aro"n# G contact
Positioning an# a%ignment of a%% e!"ipment on the fo"n#ation /eas"re #istance
$et,een co"p%ing ha%f faces of fo%%o,ing e!"ipments $& Vernier 5 /icrometer 5 Tape
Booster P"mp an# *ear$o+ *ear$o+ an# Drive t"r$ine
Drive t"r$ine an# BFP
*ro"ting of Fo"n#ation Bo%ts 3hec' that n"t has f"%% contact ,ith fo"n#ation frame after
tightening
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6eve%ing an# a%ignment of e!"ipment $& 0ac' $o%ts (,ithin 8 mm 5 / D"mp& 5
Precision 2pirit %eve% an# #ifferent thic'ness pac'er p%ates
Foundation frame grouting. $ow a days grouting is done with ready mix
concrete of %'g #ags main supplier is ()), P(*E+ ,F-) etc. This is a
specialised o# it is ad/isa#le to do concreting in presence of suppliersrepresentati/e to a/oid any complicacy afterwards. Please insist on test
certi"cate and cu#e testing on one day and three day sample. This may #e%a&
the process ho,ever $& passing an& of the test ma& comp%icate the sit"ation after,ar#s
/a0or chec's of e!"ipment are a%rea#& to%# #"ring m& ear%ier $%og P%ease go thro"gh it
A%ignment (%atera% an# ang"%ar $et,een $ooster p"mp gear$o+) gear$o+ Drive
t"r$ine shaft) Drive t"r$ine shaft BFP) /eas"re #istances $et,een co"p%ing f%anges
This is #one ,itho"t an& pipe connection ( ,ater %ine )oi% %ine an# steam %ine This is
pre fina% rea#ing an# after #oing fina% connection fina% rea#ing to $e ta'en 9o,ever
#"ring co"rse of erection this rea#ing is chec'e# to fin# the effect of connection Dia%*a"ge5/icrometer
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to 'no, a$o"t PT3 p%ease rea# m& other $%og ;common man;
3ontin"e# to part –ii ( TDBFPPoste# $& De$asish *"ha at 8:=:< 8 comment= Emai% ThisB%ogThis@2hare to T,itter2hare to Face$oo'2hare to Pinterest
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BOILER FEED PUMP ERECTION AND COMMISSIONING
FINAL PART-ABC OF THERMAL POWER PLANTTYPICAL INTERLOCK & PROTECTION REQUIRED FOR BFP COMMISSIONING
Ensure completion, installation and readiness of all instrumentation wor's, as perinstrumentation
schedule, on BFP0 Booster pump0 1otor0 2ydraulic coupling0 de3aerator.
)ali#ration, setting and testing of primary instruments.
Pressure gauges0 switches0 transmitters cali#ration and installation and wiring up to 4B.
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Temp gauges0 switches0 transmitters cali#ration and installation up to 4B.
+e/el gauges0 switches0 transmitters.
+imit switches.
5nstallation of 4Bs, ca#ling & termination in local and control room.
eadiness of control supply to Panels6
(/aila#ility of +T & 2T supplies and readiness of electrical protectioninstruments.
eadiness of mechanical system.
il system
7e8aerator
)ompressed air system. 9 )ompressed air is re:uired for pneumatic /al/eoperation.
)harging and testing of panels.
)ommissioning of motorized /al/es, actuators & pneumatic re circulation/al/e.
)hec'ing of 5nterloc's, protections & (larms6
.9i! )ali#ration of speed control de/ice li'e scope tu#e 0thyrister control
etc9ii! il pressure low9iii! ;uction /al/e open9i/! 7e3aerator le/el low9/! Feed pump suction0 discharge temperature high.9/i! Balancing lea' o< pressure. high9/ii! e circulation /al/e open/iii! Bearings /i#rations high 9where/er pro/ided!ix! emote0 local tripping
TRIAL RUN OF HYDRAULIC COUPLING
eadiness of lu#rication oil & wor'ing oil coolers and a/aila#ility of cooling water.
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)harge lu#rication oil and wor'ing oil coolers.
)hec'ing of 2) interloc's & protections
Ensure alignment of 2ydraulic coupling with BFP motor.
Ensure proper earthing of 2ydraulic coupling.
)hec' oil le/el in hydraulic coupling sump.
;tart (P and monitor lu#rication oil header pressure.
;tart trial run of 2ydraulic coupling.
)hec' regulating oil pressure and set, if re:uired.
1onitor all parameters of hydraulic coupling= *auges are a/aila#le 0mounted on thee:uipment
5. +u#rication oil and egulating oil pressure. ii. 1otor current. iii. 2ydraulic coupling #earings temperatures. i/. +u#rication oil temp at +. . cooler inlet and outlet. /. >or'ing oil temp at >.. cooler inlet and outlet. /i. 1otor winding temps.
T5(+ ?$ F BFP
@ Ensure free rotation of BFP #y hand #eforecoupling.
% Ensure completion of alignment6
5. 1otor & Booster pump ii. 1otor & hydraulic coupling. iii. 2ydraulic coupling & BFP
;pecial attention to #e gi/en on pipe line "nal connection.Pipes to #e ensured asfree #ody through
hanger adustment. $o tension on pipes is permitted otherwise alignment will #edistur#ed.
A Flushing of mechanical seal cooling water lines for BP as well as BFP &1echanical seal water
cooler cooling water lines.
ptimisation of oil Cow through #earings #y using ori"ce plates
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unning of (P
D )harging of all system69i! +u#rication oil0 wor'ing oil coolers
9ii! ;eal water coolers
9iii! ;uction /al/e opening9i/! e circulation /al/e 95solation /al/e! opening
9/! )harging of )&5 local panels
Fill de8aerator and maintain normal le/el.
5nterloc's & protections chec'ing.
G ;tart BFP.
@H 1onitor all parameters of BFP and motor=
5. )urrent ii. BFP suction pressure. iii. BFP discharge pressure. i/. Balancing lea' o< pressure. /. 7e3aerator le/el. /i. BFP suction0 discharge 7i<erential Temperature. /ii. +u#rication oil0 wor'ing oil pressures and temps. /iii. Booster pump0 BFP0 1otor0 2ydraulic )oupling #earings and drainoil temps.
ix. )ooling water temps. x. ;eal water0 seal water coolers temps. xi. 1otor winding temps.
xii. Bearing /i#rations.
TURBINE DRIVEN BOILER FEED PUMP COMMNG PART-II
ABC OF THERMAL POWER PLANT PART -II ( TDBFP 31//N*
3ontin"e# from PART-I
A%% %oca% an# remote instr"mentation for the s&stem is comp%ete
Ins"%ation of the fo%%o,ing comp%ete#
a Re-circ"%ation %ine of main p"mp
$ 2"ction an# #ischarge %ine of $ooster p"mp an# main p"mp
c /ain p"mp an# $ooster p"mp $o#&
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3ommissioning of va%ves re%ate# to the fee# p"mp s&stem are comp%ete# (2"ction
iso%ating va%ve) #ischarge iso%ating va%ve) re-circ"%ation va%ve an# motor coo%ing ,ater
iso%ating va%ve etc
A%% instr"mentation %oca% )remote comp%ete# ) an# a%so Inter%oc' an# protection s&stem
sim"%ation chec'ing comp%ete#
"ommissioning of Oil System an* Turning 3ear Operation of 40P Tur!ine5 4H$6make
1i% f%"shing of %"$rication oi% s&stem comp%ete# an# %ines are norma%i.e# ( note=-
temporar& pipes )$en#s etc remove# 'ept it for "se of ne+t p"mp oi% f%"shing ne+t p"mp
T"r$ine is #isconnecte# from gear $o+ an# main p"mp an# 'ept in iso%ation
3omp%etion of %"$e oi% in%et %ines ,ith thrott%es 5 orifices press"re ga"ges an# ret"rn %ines
,ith vie, g%ass an# temperat"re ga"ges
3hec' hea%thiness of $earing meta% temperat"re #etectors of t"r$ine) main p"mp an#
$ooster p"mp ( In genera% ,e "se P%atin"m RTD ( 8 ohm #egree or Ni-3r-Ni
thermo-co"p%e >8:mv58 #eg increase therefore as per vis"a% chec' ,ith a meter a%%
,i%% sho, room temperat"re
Ens"re proper mo"nting of spee# pro$es an# t"r$ine s"pervisor& pro$es ( a+ia% shift )
therma% e+pansion ) overa%% therma% e+pansion ,ith #o,e%%ing after necessar&
ca%i$ration
Ens"re the comp%etion of ac'ing 1i% of %ines ,ith thrott%e va%ve) NRV ( non ret"rn va%ve
an# iso%ating va%ve
Ens"re hea%th& fi%ter e%ements in /1P) A1P) E1P s"ction %ines) /1P) A1P an# E1P
#ischarge %ines an# 1P s"ction %ine
1i% is fi%%e# in /1T thro"gh centrif"ge to a#e!"ate %eve% ( 2ervo prime > or e!"iva%entfrom an& other compan&
7eep open the vents of %"$e oi% coo%ers an# fi%ter to p"rge air from the s&stem
7eep the changeover va%ve of %"$e oi% coo%er an# fi%ter in s"ch a ,a& that on%& one
coo%er a# fi%ter ,i%% $e in service
Drains of %"$e oi% coo%ers) fi%ters sho"%# $e in c%ose# position to avoi# an& %oss of oi%
2tart one of the oi% vapo"r fans ,ith its s"ction va%ve open con#ition
2tart one of the %"$e oi% p"mps ens"ring f%o, thro"gh recirc"%ation
A#0"st %"$e oi% hea#er press"re contro% va%ve to maintain %"$e oi% press"re of : 'g5cm:
( appro+ after contro% station
A#0"st %"$e oi% #ischarge press"re to 8'g5cm:(appro+ $& setting re-circ"%ationcontro% va%ve
B& operating iso%ating va%ve of recirc"%ation contro% va%ve) chec' the safet& va%ve
popping an# a#0"st if re!"ire#
3hec' the %"$e oi% f%o, to the $earing of t"r$ine) main p"mp an# $ooster p"mp
/onitor %"$e oi% #"p%e+ fi%ter DP
2top the p"mp an# start other %"$e oi% p"mp an# chec' its #ischarge safet& va%ve
popping an# a#0"st if re!"ire#
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2top r"nning p"mp an# start D3 E1P ( Emergenc& 1i% P"mp
Ens"re a#e!"ate %"$e oi% press"re an# f%o, 7eep D3 E1P r"nning for > ho"rs to chec'
the hea%thiness of the s&stem ,ith E1P
2top D3 E1P an# 'eep %"$e oi% p"mp in service
3harge the s"ction %ine of 1P from %"$e oi% hea#er
2tart 1P an# a#0"st the safet& re%ief va%ve to 88 'g5cm: A#0"st press"re reg"%ating va%ve to 8 'g5cm:
A#0"st the thrott%e va%ves in ac'ing oi% s"pp%& to front an# rear 0o"rna% $earings s"ch
that the rotor %ifts aro"n# to 8 mm 2top 1P an# start again 3hec' an# recor#
the ac'ing oi% press"res an# rotor %ifts in the t"r$ine front an# rear 0o"rna% $earings
3hec' an# ens"re the freeness of rotor for rotation $& engaging han# $arring %ever an#
then stop 1P
Ens"re a"to operation of A1P I) A1P II an# D3 E1P thro"gh correspon#ing press"re
s,itches operation ( Part of protection chec'ing an# a"to operation 3"t in of D3E1P
in emergenc& is most important aspect
7eep A1P I in service) A1P II an# E1P on a"to1i% temperat"re is a$ove > #egree 3
3harge coo%ing ,ater to coo%er an# ens"re oi% temperat"re contro% va%ve a"to operation
2tart 1P an# open t"rning gear va%ve
1nce the rotor pic's "p spee#) t"rning gear va%ve ma& $e c%ose# for chec'ing the rotor
for possi$%e r"$$ing at en# g%an# sea%s) heat shie%#s) oi% ga"r#s etc) ,hi%e coasting
#o,n
If the rotor is fo"n# smooth ti%% it comes to stan#sti%%) t"rning gear va%ve ma& $e opene#
f"%%
T"rning gear spee# of aro"n# : RP/ an# smooth r"nning
1$serve an# recor# $earing meta% temperat"res) vi$rations) eccentricit& etcan# r"n for
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/1P /AIN 1I6 PU/P
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1P A37IN* 1I6 PU/P
D3 E1P E/ER*EN3K 1I6 PU/P ( DIRE3T 3URRENT