BFP Test Procedures
BFP Test Procedures
BFP Test Procedures
No.YDTD-TS03
Project name
To: Tengda Project Department of Sichuan Machinery & Equipment Import & Export Corporation
Now it is submitted for the examination and approval with the electrically driven feed pump commissioning technical measure of phase I of 2330MW project of Tengda Coal-fired power plant in India, Document No. is: QJCS-03.
Project principal Examination and approval opinions of the project supervision department:
Date
Supervision engineer:
Date
Date
Owner representative
Contractor: Sichuan Tongneng Power Technology Co. Ltd Mar. 2008
Date
2 21
Sichuan Power Industry Commissioning Test Institute Sichuan Tongneng Power Technology Co., Ltd
Mar. 2008
Review of the principal of professional group of Date: commissioni ng project Compiler of the technical document Date
content 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Compilation purpose .................. Compilation reference ................ Commissioning quality standard and object ............. 2 Responsibility division .............. System brief introduction ............ Conditions prior to commissioning .... Commissioning work procedure ......... Commissioning step ................... Safety measure ....................... Appendix .............................
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1.
1.1 1.2 1.3
Compilation purpose
To instruct and standardize the commissioning work of system and equipment, and guarantee safety and normal operation thereof, this measure is hereby compiled. Inspect the electrically driven feed pump electric and thermal work protection interlock and signal unit, and determine the reliability of the action. Inspect the system and equipment operation status, check the system performance, find out and eliminate the possible defects.
2. Compilation reference
2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 Thermal Power Plant Basic Construction Engineering Startup and Completion Acceptance Code (1996version) power construction [1996]159# Power Construction and Acceptance Technical Specification (Steam Turbine )DL5011-1992 Power Construction and Acceptance Technical Specification (Pipe )DL5031-1994 Standard for Quality Inspection and Evaluation of the Adjustment and Commissioning in Thermal Power Project, Construction Quality [1996]111# Regulations for the Startup and Commissioning of the thermal Power Projects, Construction Quality [1996]40# Manufactory drawings, installation and operation instructions, quality assurance book and ex-factory certifications Design documents, drawings, specifications, and commissioning documents as well as conference summary, etc. Equipments supply contract, and the international and national standards stated therein
4. Responsibility division
According to the statements of the administry newly issued Startup Regulation, and the Commissioning Contract, the responsibilities of each party are as following: 4.1 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 4.1.6 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.7 4.4 Installation unit: Responsible for individual equipment commissioning and trial operation work. Responsible for isolation work of the system. Responsible for repair, maintenance and defect elimination of the trial operation equipments. Prepare the necessary repair tools and materials. Cooperate with the commissioning unit for subsystem commissioning. Responsible for attestation work after trial operation of system sub-section. Manufacturing unit: Responsible for startup/closedown, operation regulation and accident treatment of system trial operation. Responsible for hanging the formal brand mark of the related systems and equipments. Prepare the regulations, tools, and record reports, etc.for operation; Responsible for patrol inspection and normal maintenance during trial opereation. Commissioning unit: Responsible for compiling trial operation scheme together with technical clarification. Prepare the apparatuses, instruments and tools for the related tests. Responsible for command and control work of subsystem commissioning. Responsible for test data record and sorting. Fill in trial operation quality evaluation table. Responsible for attestation work after trial operation of the system and subsystem. Compile the commissioning report. Individual commissioning of pump group will be responsibility of the installation unit, with parcitipation of commissioning unit. The sub-system commissioning of pump group will be responsibility of commissioning unit, with participation and cooperation of the installation unit and other units. The electrically driven feed pump system commissioning will be carried out with uniform instruction of trial operation team, it will be implemented by industrial water system commissioning professional team, the steam turbine discipline
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will take the lead, with cooperation of electric, thermal control and other disciplines.
centrifugal pump Pump medium: boiler water supply Flow 599.39 t/h inlet pressure 1.119 Mpa outlet pressure 1.526 Mpa lift 47 m shaft power 93 KW rotating speed 1490 r/min necessary net positive suction head 3.4 m efficiency 82.2% 5.2 motor model YKS710-4 power 5300 KW voltage 6.6 KV current 594 A startup current multiplying power 6 rotating speed 1490 r/min 5.3 Coupling model R71K.2E
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output/input rotating speed: 5900/1490 speed regulation scope 20% 97% rated transfer power 3984 KW 5.4 feed pump model CHTC5/6SP
r/min
mode horizontal double shell sectional multi-stage centrifugal pump pump medium boiler water supply lift 2406 m inlet pressure 1.526 Mpa outlet pressure 21.962 Mpa flow 638 t/h tap outlet pressure 9.5 Mpa tap flow 35.64m3/h necessary net positive suction head 35.64m efficiency 82.8% rotating speed 5586r/min rotating speed: clockwise rotation (look at the pump at the drive side) 5.5 Lubicating oil cooler cooling area 16 m2 cooling water quantity 120 m3/h cooling water temperature: 38 cooling water pressure 0.4 0.6 Mpa 5.6 Work oil cooler cooling area 54 m2 cooling water quantity 120 m3/h cooling water temperature: 38 cooling water pressure 0.4 0.6 Mpa
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6.1
The oil system circulatiion is qualified and completed (physical and chemical index and mechanical foreign substances content will meet the requirements), the pipeline system has been recoverd, the oil tank is filled by qualified new oil in the high level (level indicator), together with sufficient qualified oil.
6.2
Electric pump motor air cooler, lubricating oil cooler, work oil cooler cooling water system is flushed and qualified, and the pipeline connection is recovered; openness cooling water system, closeness cooling water system commissioning work is qualified, and it is normally put into operation.
6.3
Electrically driven feed pump electric circuit connection is proper and completed, the motor insulation test is qualified, and test and inspection of motor electric heater insulation, and motor winding resistance are qualified.
6.4
Electrically driven feed pump auxiliary oil pump trial operation is qualified, lubricating oil pressure switch setting value is completed, and lubricating oil pressure low interlock and protection have been inputted.
6.5
Electrically driven feed pump various interlock and protection tests have been completed and jointly signed, the interlock and protection have been putted into work with reliable property.
6.6
The low pressure water supply pipe, front mounted pump and main water feed pump connection pipes are flushed and qualified as per requirements of manufacturer; low pressure water supply pipe, front mounted pump and main feed pump connection pipe, main water supply pipe, recycle pipe, water balance pipe, intermediate tap pipe, etc. have been cleaned up, accepted and completed.
6.7
Condense water system commissioning is completed, one condense pump is normally operated, the deaerator main and secondary regulating gates have the normal function, and can satisfy with normal water requirements of deaerator.
6.8 6.9
Seal cooling water pipe flushing is qualified, together with conditions of operation. The electric pump front mounted pump packing cooling water pipeline is flushed and qualified with operation conditions.
6.10 Deaerator installation is completed, and carefully cleaned up, as well as filled by water to the normal level via the condense pump. 6.11 The motor ail cooling system watering is qualified and inputted. 6.12 Electroc pump recycle flow switch test and calibration are completed, commissiong of recycle gate actuator has been completed with normal action.
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6.13 Pump group shafting center acceptance is qualified, and secondary grouting strength meets the quality requirements. 6.14 Valve instruments and meters for all pump groups and related trial operation systems have been hung by nameplates. 6.15 All instruments and meters of thermal work and electric work with relation to pump groups have been mounted and commissioned. 6.16 The coupling scoop pipe is flexible, adjustable without seizing, and the electric and manual operation is normal. 6.17 The trial operation site and road are smooth with bright lighting, the feed pump panel and related panel work have been completed and cleaned up. 6.18 The firefighting equipment and preparation work have been carried out well, together with trial operation safety measures. 6.19 The trial operation organization has clear work division, and the trial operation and installation staffs are all ready. 6.20 System commissioning organization and supervision institution have been set up, with orderly work execution. 6.21 The commissioning document, tool, instrument, and record table have been prepared well.
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8. Commissioning step
8.1 8.1.1 8.1.1.1 8.1.1.2 8.1.1.3 8.1.1.4 8.1.1.5 Motor individual rotation Conditions inspection prior to startup Motor insulation inspection is qualified; The motor rotor is manually turned freely; Motor air cooler, lubricating oil cooler cooling water pipe flush is completed, and the cooling water system is inputted; The motor and electric pump front mounted pump, and the motor and hydraulic coupling are separated; Determine the oil system flushing is qualified, the bearing is cleaned up and recovered, the lubricating oil pump is started up on the operation statation, the oil pressure, oil temperature and bearing seat return oil statuses are checked, and the equipments and operation will be normal. 8.1.1.6 8.1.1.7 When the oil temperature is 35-45, the lubricating oil pressure is regulated as setting value; check the motor bearing temperature and the stator coil temperature indication;
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8.1.1.8
The feed pump power supply is placed at the test location, and the following interlock protection tests will be carried out:
a) Field accident button pump stop test; b) lubricating oil low pressure test; c) motor bearing temperature and coil temperature test; d) The temperature alarming signals are normal. e) After above interlock protection tests are qualified, input the motor power supply. 8.1.1.9 8.1.2 8.1.2.1 8.1.2.2 Input the motor protection and interlock. Motor trial operation Spot drive the motor on the operation station,and check whether the rotating direction of the motor is proper. Startup the motor on the operation station, and check its operation status, such as startup current, abnormal vibration, noise, friction firing or smoking, control room and field signal and instrument indication. 8.1.2.3 8.1.2.4 8.1.2.5 8.1.2.6 8.2 8.2.1 8.2.1.1 When inspection of above items is normal, record the operation parameters of the motor by set time. When the lubricating oil is 40, input the oil cooler water side, and exhaust the air. The feed pump motor trial operation will be over 8 hours, the operation parmeters will be stable and reaches the design requirements, and then stop the motor. Record the motor coasting operation time. Motor and coupling trial operation on the basis of completion of motor trial operation, carry out inspection in advance. Connection between the coupling and motor is completed with proper center, the wheels among motor/front mounted pump, and coupling/electric pump are all separated; 8.2.1.2 8.2.1.3 8.2.1.4 8.2.1.5 8.2.2 8.2.2.1 The instruments and meters on the coupling have been calibrated and installed, and inputted; The oil tank level is normal, and the lubricating oil strainer is inputted at one side; Start up the auxiliary oil pump, when the lubricating oil temperature is above 35, the lubricating oil pressure will be set value. Electric cooler, lubricating oil cooler and work oil cooler are all inputted. Motor and coupling trial operation Provide the coupling scoop pipe power supply, inspect the coupling scoop pipe
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manual and remote control action that will be proper and flexible, place the scoope pipe in the minimum speed location05. 8.2.2.2 8.2.2.3 8.2.2.4 8.2.2.5 8.2.2.6 8.2.2.7 8.2.2.8 8.2.2.9 8.2.2.10 The electric pump motor will transfer the power supply, and the electric pump will be started up on CRT. Inspect the motor and compling rotation direction. Inspect the coupling vibration without abnormal sound. Inspect the leakage status of the oil pipeline. Closely supervise the operation sound and vibration of the hydraulic coupling. Inspect the lubricating oil and work oil pressure. Inspect the system and record the main parameters. Input the oil cooler, regulate the oil temperature till it is stable. After the system is stable, slowly regulate the coupling scoop pipe, thus the coupling output speed is gradually increased, and it will be stayed by 10min for every 10% increse of scoop position, inspect the operation status, and record the operation parameters as per requirements. 8.2.2.11 The rotating speed is raised to nearly 5000rmin for stable operation inspection, and then it will be gradually lowered to approx. 1800rmin. 8.2.2.12 If the coupling operation is above 2 hours, stop it, and determine that the auxiliary oil pump is automatically started up, otherwise it will be manually started up and find out the reason thereof. 8.2.2.13 8.3 8.3.1 8.3.1.1 8.3.1.2 8.3.1.3 Record the motor coasting operation time. Feed pump group start up test Startup conditions The wheel connection between the coupling and main feed pump is completed, and the center protection cover is mounted. The pump group inlet pipe water flush is completed, and the system is recovered. The instruments and meters on the feed pump group have been calibrated and qualified, sewage discharge of the transducer and indication instrument tubes has been completed and in the input status; the pump group sequence control system (SCS) interlock protection has been completed. 8.3.1.4 8.3.1.5 Operate the circulating water, openness cooling water, closeness cooling water, and condense makeup water system. Deoxygenation water tank is filled by water to the normal level, and the deaerator
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level monitoring has been inputted with normal work. 8.3.1.6 8.3.1.7 8.3.1.8 8.3.1.9 8.3.2 8.3.2.1 8.3.2.2 8.3.2.3 Startup the front mounted inlet water gate, and fill water in the pump, then close it after exhausting the air; determine the closeness of electric pump outlet electric gate. According to deoxygenation water tank temperature and pump body temperature difference, determine whether it needs to heat the pump. The pump group bearing cooling water and seal water pipes are flushed and cleaned up; manually open the valve, and determine that the air is exhausted. The electric pump protection is completed, and the protection is inputted. Electric pump operation Start up the auxiliary lubricating oil pump, raise the oil temperature, and inspect the oil pressure, the lubricating oil pressure will be above 0.17MPa; Check whether the sealing water is normal. Start up the front and back stop valves of the recycle gate, input the recycle gate automatic unit and inspect the recycle opening location; to avoid the accident water cutoff in the electric pump operation period, during first time startup, the recucle gate front and back stop valves will be locked, after opening the recycle gate, the gas source will be cut off. 8.3.2.4 8.3.2.5 8.3.2.6 8.3.2.7 8.3.2.8 The scoop pipe will be set in the lowest rotating speed location. record all monitoring instrument initial values; Determine that the field accident button is normal, together with watching of appointed person. Input the feed pump power supply, and interlock protection; Select the electrically driven feed pump in the operation station, and start up it. Inspect the pump group operation status, such as startup/stable current, abnormal vibration/noise, oil/water system leakage, friction fire or smoing, and pressure difference of front mounted inlet strainer, etc, and the pump will be stopped immediately for any abnormal status for treatment. 8.3.2.9 8.3.2.10 When the lubricating oil reaches the set value, it is time lagged, and the auxiliary oil pump will be automatically stopped. After 20-30min trial operation, if normal, the speed will be gradually raised via coupling scoop pipe, every 10% increase of scoop pipe, all bearing vibration will be measured, and the scoop pipe position, inlet and outlet pressure, intermediate tap pressure, rotating speed, oil pressure, oil temperature, bearing temperature, motor coil temperature, etc. (the lubricating oil, work oil cooler and motor ail cooler will be
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inputted according to temperature rise status ). 8.3.2.11 When the feed pump outlet pressure reaches the rated one, overall inspect the system status fast, if normal, lower the rotating speed to 80% rated pressure for 2hours stable operation. 8.3.2.12 8.3.2.13 After 2hours stable operation, the water supply/temperature reduction pipes will be flushed at appropriate rotating speed. After completion of all trial operation items, the rotating speed will be gradually lowered, when the scoop pipe is in the lowest location, stop the motor and record the coasting operation time, when the lubricating oil pressure is 0.15MPa, the auxiliary oil pump will be automatically or manually started up. 8.4 8.4.1 High pressure water supply flush Flush purpose Flush the hard foreign substances as welding slag, rust skin,and mud sand, etc. remained in the pipe during manufacture, transport and installation process. 8.4.2 8.4.2.1 8.4.2.2 8.4.2.3 8.4.3 8.4.4 8.4.5 Flush conditions The pipe supports and hangers will be firm, and the temporary system drainage pipe will be taken by necessary reinforcing measures to avoid danger. All electric gates of the high pressure water supply system are commissioned and completed, with flexible switch, proper indication and action; The chemical workshop has sufficient desalt water stored. Flush scope: feed pump outlet, high pressure water heater bypass, water supply operation table, economizer inlet, temporary discharge pipe. flush method: after the feed pump part trial operation is qualified, start up the feed pump and flush by desalt water with great flow mode not exceeding rated current; Flush qualified standard: visually inspect the outlet water quality, if it is consistent with the one of inlet of water pump, it will be qualified.
9. Safety measures
9.1 9.2 9.3 The feed pump will be operated in the design operation cuve scope. During electrically driven feed pump water inflow, the air of the mechanical seal part will be exhausted repeatedly till it is completely exhausted, and the valve will be closed. After stop of the pump, the operation time of the auxiliary oil pump will be not less than 5min.
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9.4 9.5
After stop of the motor, it will have certain time interval for the next time startup, usually it is over 20min. During electric pump startup, the accident button will be controlled by appointed person, and the pump will be immediately stopped after startup for any abnormal and emergency statuses.
9.6
Within 2 seconds after closing the switching, if the electric pump cannot be operated, or it is tripped in the trial operation process, the trial operation will be immediately stopped, and cannot be started up again till the reason is found out.
9.7 9.8
During electric pump operation, the trial operation staff will leave the rotating part. The trial operation will be uniformly directed, and the communication between control room and field is smooth.
10. appendices
a) Conditions inspection table Electrically driven feed pump system trial operation conditions inspection table
System description: electrically driven feed pump system Determination and signature No. Conditions description Installation party Commissioning party Supervison party Owner
The oil system circulatiion is qualified and completed, the pipeline system has been
1
recoverd, the oil tank is filled by qualified new oil in the high level (level indicator), together with sufficient qualified oil. Electric pump motor air cooler, lubricating oil cooler, work oil cooler cooling water system is flushed and qualified, and the pipeline connection is recovered; openness cooling water system, closeness cooling water system commissioning work is qualified, and it is normally put into
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operation. Electrically driven feed pump electric circuit connection is proper and completed, the motor insulation test is qualified, and
3
test and inspection of motor electric heater insulation, and motor winding resistance are qualified. Electrically driven feed pump auxiliary oil pump trial operation is qualified, lubricating oil pressure switch setting value
is completed, and lubricating oil pressure low interlock and protection have been inputted. Electrically driven feed pump various interlock and protection tests have been completed and jointly signed, the interlock and protection have been putted into work with reliable property. The low pressure water supply pipe, front mounted pump and main water feed pump connection pipes are flushed and qualified as per requirements of manufacturer; low pressure water supply pipe, front mounted
pump and main feed pump connection pipe, main water supply pipe, recycle pipe, water balance pipe, intermediate tap pipe, etc. have been cleaned up, accepted and completed. Condense water system commissioning is completed, one condense pump is normally
operated, the deaerator main and secondary regulating gates have the normal function,
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and
can
satisfy
with
normal
water
requirements of deaerator.
The pump group bearing cooling water pipe, 8 mechanical seal cooling water pipe flush is qualified.
water to the normal level via the condense pump. The motor ail cooling system watering is
10
qualified and inputted. Electroc pump recycle flow switch test and calibration are completed, commissiong of
11
recycle gate actuator has been completed with normal action. Pump group shafting center acceptance is qualified, and secondary grouting strength meets the quality requirements. Valve instruments and meters for all pump groups and related trial operation systems have been hung by nameplates. All instruments and meters of thermal work and electric work with relation to pump
12
13
14
groups
have
been
mounted
and
adjustable without seizing, and the electric and manual operation is normal. The trial operation site and road are smooth with bright lighting, the feed pump panel
16
and
related
panel
work
have
been
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work have been carried out well, together with trial operation safety measures. The trial operation organization has clear work division, and the trial operation and installation staffs are all ready.
18
Date
day
month
2008
b) Logic inspection table Electrically driven feed pump system interlock logic inspection table
No. I. Start up conditions the front mounted valve inlet is opened. the recycle valve is fully opened. the deaerator level is normal The lubricating oil pressure is normal 0.17MPa Item Set value Interlock protection action
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scoop pipe openness no reverse rotation of the feed pump II. pump group protection conditions the the deaerator level is low
tripping of feed pump tripping of feed pump time lag tripping of feed pump tripping of feed pump tripping of feed pump tripping of feed pump tripping of feed pump tripping of feed pump tripping of feed pump tripping of feed pump tripping of feed pump tripping of feed pump tripping of feed pump tripping of feed pump tripping of feed pump tripping of feed pump tripping of feed pump tripping of feed pump
the feed pump is operated, and its inlet pressure is low. the feed pump is operated and the inlet electric 2 S gate is closed. 2s the lubricating oil pressure is low 0.08 Mpa the feed pump is operated, the pump inlet flow is t/h, and the recycle pump is not fully opened. The front mounted pump radial bearing 90 temperature is high the main pump radial bearing temperature is high 90 the main pump thrust bearing temperature is high 90 the coupling thrust bearing temperature is high the coupling radial bearing temperature is high the motor bearing temperature is high the work oil cooler inlet temperature is high the work oil cooler outlet temperature is high 95 95 90 130 85
the lubricating oil cooler inlet temperature is high 70 the lubricating oil cooler outlet temperature is 60 high the front mounted pump mechanical sealing 95 circulating liquid temperature is high the main pump mechanical sealing circulating 95 liquid temperature is high the motor stator coil temperature is high III. Pump group interlock A feed pump operation; B feed pump interlock input, and main pipe pressure is low. A feed pump operation; B feed pump interlock input; A feed pump switch separation signal is sent out. A feed pump operation; C feed pump interlock input, and main pipe pressure is low. A feed pump operation; C feed pump interlock input; A feed pump switch separation signal is sent out. B feed pump operation; C feed pump interlock input, and main pipe pressure is low. 130
Interlock startup the B feed pump. Interlock startup the B feed pump. Interlock startup the C feed pump. Interlock startup the C feed pump. Interlock startup the C feed pump.
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B feed pump operation; C feed pump input; B feed pump switch separation sent out. B feed pump operation; A feed pump input, and main pipe pressure is low. B feed pump operation; A feed pump input; B feed pump switch separation sent out. C feed pump operation; A feed pump input, and main pipe pressure is low. C feed pump operation; A feed pump input; C feed pump switch separation sent out. C feed pump operation; B feed pump input, and main pipe pressure is low C feed pump operation; B feed pump input; C feed pump switch separation sent out. IV. Auxiliary oil pump
interlock signal is interlock interlock signal is interlock interlock signal is interlock interlock signal is
Interlock startup the C feed pump. Interlock startup the A feed pump. Interlock startup the A feed pump. Interlock startup the A feed pump. Interlock startup the A feed pump. Interlock startup the B feed pump Interlock startup the B feed pump
sequential control startup or the feed pump is inputted for standby the feed pump is operated and the lubricating oil 0.15 Mpa pressure is low. electric pump reverse rotation feed pump is operated, and lubricating oil pressure 0.15 Mpa is high V. recycle gate flow of feed pump flow of feed pump m3/h m3/h
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