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Friday, 19 June 2015

BOILER FEED PUMP ERECTION AND COMMISSIONING FINAL PART-ABC OF THERMAL POWER PLANT

TYPICAL INTERLOCK & PROTECTION REQUIRED FOR BFP COMMISSIONING

Ensure completion, installation and readiness of all instrumentation works, as per instrumentation

schedule, on BFP/ Booster pump/ Motor/ Hydraulic coupling/ de- aerator.                         
                                               
Calibration, setting and testing of primary instruments.                
                  
 Pressure gauges/ switches/ transmitters calibration and installation and wiring up to JB.                              

 Temp gauges/ switches/ transmitters calibration and installation up to JB.                           
                  
 Level gauges/ switches/ transmitters.                  
               
Limit switches.                 

Installation of JBs, cabling & termination in local and control room.                          

Readiness of control supply to Panels:                                                                  

Availability of LT & HT supplies   and readiness of electrical protection instruments.         

Readiness of mechanical system.                                                                                            

 Oil system                         

 De=aerator                       

Compressed air system.               ( Compressed air is required for pneumatic valve operation.     

Charging and testing of panels.                 

Commissioning of motorized  valves,  actuators & pneumatic re circulation valve.                              

Checking of Interlocks, protections & Alarms:                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                                    .                              
                (i)   Calibration of speed control device like scope tube /thyrister control etc                       
                (ii)  Oil pressure low                       
                (iii)  Suction valve open                                
                (iv)  De-aerator level low                             
                (v)   Feed pump suction/ discharge temperature high.                   
                (vi)  Balancing leak off pressure. high                     
                (vii)  Re circulation valve open                    
                viii)  Bearings vibrations high (wherever provided)                          
                ix)   Remote/ local tripping          

                TRIAL RUN OF HYDRAULIC COUPLING
               
               
Readiness of lubrication oil & working oil coolers and availability of cooling water.

Charge lubrication  oil and working oil coolers.

Checking of HC interlocks & protections

Ensure alignment of Hydraulic coupling with BFP motor.

Ensure proper  earthing of Hydraulic coupling.

Check oil level in hydraulic coupling sump.

Start AOP and monitor lubrication oil header pressure.

Start trial run of Hydraulic coupling.

Check regulating oil pressure and set, if required.

Monitor all parameters of hydraulic coupling; Gauges are available /mounted on the equipment

                   I.   Lubrication oil and Regulating oil pressure.
                   ii.   Motor current.
                   iii.  Hydraulic coupling bearings temperatures.
                   iv.  Lubrication oil temp at L. O. cooler inlet and outlet.
                   v.   Working oil temp at W.O. cooler inlet and outlet.
                   vi.  Motor winding temps.        

TRIAL RUN OF BFP
               
               
1      Ensure free rotation of BFP by hand before coupling.                                                                                                                               

2      Ensure completion of alignment:                                                                                                                              
                     I.    Motor & Booster pump
                     ii.    Motor & hydraulic coupling.
                     iii.   Hydraulic coupling & BFP

Special attention to be given on pipe line final connection.Pipes to be ensured as free body  through

hanger adjustment.  No tension on pipes is permitted otherwise alignment  will be disturbed.

3              Flushing of mechanical seal cooling water lines for BP as well as BFP & Mechanical seal water

cooler cooling water lines.

4              Optimisation of oil flow through bearings by using orifice plates

5              Running of AOP

6              Charging of all system:  
                (i)  Lubrication oil/ working oil coolers
                (ii)  Seal water coolers
                (iii) Suction valve opening 
                (iv)  Re circulation valve (Isolation  valve) opening
                (v)  Charging of C&I local panels

7              Fill de=aerator and maintain normal level.  


 8              Interlocks & protections checking.

9              Start BFP.

10           Monitor all parameters of BFP and motor;
                    I.    Current
                    ii.    BFP suction pressure.
                    iii.   BFP discharge pressure.
                    iv.   Balancing leak off pressure.
                    v.    De-aerator level.
                    vi.   BFP suction/ discharge Differential Temperature.
                    vii.   Lubrication oil/ working oil pressures and temps.
                    viii.  Booster pump/ BFP/ Motor/ Hydraulic Coupling bearings and drain oil temps. 
                    ix.   Cooling water temps.
                    x.    Seal water/ seal water coolers temps.
                    xi.    Motor winding temps.
                    xii.   Bearing vibrations.




Saturday, 6 June 2015

BOILER FEED PUMP ERECTION AND COMMISSIONING PART-VI ABC OF THERMAL POWER PLANT

FINAL COMMISSIONING OF BOILER FEED PUMP ( mdbfp)

Till my last dispatch we have discussed erection and commissioning of Boiler Feed pump including oil flushing of lubrication oil lines ,acid cleaning of the same , hydraulic test of coolers and other integral pipelines. Now we will discuss about Boiler feed pump commissioning as a whole. BFP( MDBFP) is one of the first major equipment need to be commissioned before Boiler light up.
Commissioning includes checking of following activities completion as per drawing and quality plan.
1              Erection completion of feed water lines.
2              Instrumentation stub parts completion.
3              Completion of Alkali/ detergent flushing of feed water system, as well as condensate system and heaters drip system.
4              Cleaning and normalisation of deaerator and feed lines
5              Checking & setting of hangers and supports of feed water lines including BFP suction lines, recirculation lines.
6              Deaerator filling with DM water.
7              Final flushing of the suction lines of Booster Pump & BFP .

Readiness of cooling water system

1 Erection completion of cooling water lines of,                                                                                                                                                                                                                                                                                                                                                                                                    
BFP Motor

                Lubrication  oil coolers and working oil coolers

                Seal water coolers of BP & BFP

2              Commissioning  of the motorised actuators of motor cooling water valve..

3              Checking & setting of hangers & supports of CW lines of CW system and motor cooler.

4              Availability & readiness of cooling water/ system.

5              Flushing of all cooling water lines of CW system and motor cooler.

Completion of  ACW  system and heat exchangers ,Pumps, tanks  ,pipelines with instrumentation.

Electrical and C&I work completion  of Feed Pump , Feed station , control valves ,actuators etc.

1              Meggering of BFP motor

2              Availability of HT supply

3              Ensure proper earthing of BFP motor and instruments panel..

4              Completion of instrumentation (bearing oil press & temp) impulse piping and mounting of

press/ temp gauges, and winding, temp RTDs

5              Filling of Hydraulic coupling sump with fresh oil after oil flushing & cleaning of sump

6              Oil pressure optimization  at motor bearings.

7              Ensure de-coupling of motor with booster pump and hyd. Coupling.

8              Ensure free rotation of motor by hand.

9              Checking of BFP motor protections and CW valve interlock.

10           Charging of CW system and lubrication  oil cooler.

11           Bumping of motor and checking DOR

12           Trial run of BFP motor

13           Monitoring of motor parameters.
                   I.    Motor current and voltage.
                   ii.   Motor winding temperatures.
                   iii.  Bearing temperatures.



Continued to concluding part