Station: NTPC - Simhadri BHEL Ref No.

PS - DC - 186 500 0038

NTPC Ref No. SIM / 1 / TS / 1 / 38

Sheet 1 of 15

Plant Area: BOILER

PROCEDURE FOR COMMISSIONING OF CC PUMPS
SL. NO.

LIST OF CONTENTS

1.

PLANT DETAILS

2.

OBJECTIVES

3.

PROPOSALS

4.

SERVICES REQUIRED

5.
6.
7.
8.
9.
10.

SAFETY PRECAUTIONS
EMERGENCY PROCEDURES
STATE OF THE PLANT
METHOD
COMPLETION CRITERIA
APPENDICES
a) DRAWING
b) LOG SHEETS

Signatures
NTPC
Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 500 0038
NTPC Ref No. SIM / 1 / TS / 1 / 38
Plant Area: BOILER

BHEL
Sheet 2 of 15

PROCEDURE FOR COMMISSIONING OF CC PUMPS

1.0

PLANT DETAILS

STATUS

1.1. In a controlled circulation Boiler, circuating pumps plays an important role in

the performance of the Boiler. For 500 MW Units, 3 Nos of circulating
pumps are given and these pumps are placed in the down comer circuits to
ensure proper circulation of water through the4 water walls.
Feedwater entering the boiler drum via Ecomiser, flows from the drum
through the down comers ( 6 Nos) to the pump sction manifold. The boiler
circulating pumps takes water from the suction manifold and discharges via
the pump discharge lines in to the furnace lower front inlet header, furnace
lower water wall right and left side headers and rear headers.
In the water wall inlet header, the boiler water passes through strainers and
then through orifices which feed the furnace wall tubes, the economizer
recirculating lines.
1.2

The associated systems of boiler circulating pumps consists of the following.

a) Fill and purge line system
This system consists of supply lines from High Pressure water source and
also low pressure water source, removable strainer basket, HP fill and
Purge cooler, filter, orifice and all connected lines both inlet and outlet
circuits. The removable strainer basket and HP fill and purge cooler are
common for all the three circulating pumps.

Signature
NTPC
Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 500 0038
NTPC Ref No. SIM / 1 / TS / 1 / 38
Plant Area: BOILER
PROCEDURE FOR COMMISSIONING OF CC PUMPS
b)Auxiliary cooling water system

BHEL
Sheet 3 of 15

This system is supplied with LP coolant from ECW System / station auxiliary
cooling water system and also from a separate emergency cooling water from
over head tank source. This supplier cooling water to

1.3

1.4
1.5

1.6

i)

LP Cooler for Pump Motor and

ii)

HP fill and Purge cooler.

The boiler circulating pumps are operated through H.T.Motors which are
provided with cavity in which DM Water is filled by a specific procedure
described in Section 8.0 and this cavity filling is for cooling the motor while
the motor is in operation.
When the unit is in operation, Circulation pumps are operated in parallel or all
the three pumps together as per the actual requirement.
Plant item completion lift for the system for Mechanical, Electrical and C&I
areas are to be prepared at site.
Schematic drawing of Circulation Pumps (Drg.No.4:PS:tsx:0069:00)
enclosed in Section 10.0

Signature
NTPC
Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 500 0038
NTPC Ref No. SIM / 1 / TS / 1 / 38

BHEL
Sheet 4 of 15

Plant Area: BOILER

PROCEDURE FOR COMMISSIONING OF CC PUMPS
2.0

OBJECTIVE
To commission the C.C. Pumps and make it available for commissioning and
operation of the unit.

3.0

PROPOSAL: It is proposed to commission the CC pumps as per the

following proposal.

3.1

Flushing of fill & purge lines

3.2

Flushing of Auxiliary cooling water system.

3.3

Motor Cavity filling and venting.

3.4

Trial run of pump for 8 hour.

4.0

SERVICES REQUIRED

4.1

Availability of O&M Manual for CC Pumps

4.2

Availability of auxiliary cooling water

4.3

Availability of H.T Powersupply

4.4

Availability of lighting, communication facility at the test area.

4.5

Availablity of portable fire extinguishers.

4.6

Availability of working crew with Technician for attending minor problem

during commissioning of CC Pump.

4.7 Availability of DM Water.

Signature
NTPC

Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 500 0038

NTPC Ref No. SIM / 1 / TS / 1 / 38

BHEL

Sheet 5 of 15

Plant Area: BOILER

PROCEDURE FOR COMMISSIONING OF CC PUMPS
5.0

SAFETY PRECAUTIONS

5.1

Availability of first aid kit at test area.

5.2

The team commissioning the CC pump should be aware of the procedure

adopted.

5.3

Agencies working in the boiler area / are informed about the test / cleared
from the test area (As per the actual requirement).

5.4

All loose materials around the CC pump area are cleared.

5.5

Required approach stair cases, platforms and hand rails are erected prior to
testing.

Signature
NTPC

Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 500 0038

NTPC Ref No. SIM / 1 / TS / 1 / 38

BHEL

Sheet 6 of 15

Plant Area: BOILER

PROCEDURE FOR COMMISSIONING OF CC PUMPS
6.0

EMERGENCY PRECAUTIONS:

6.1

The group conducting the test should be aware of action to be taken on the
event of injury to personnel.

6.2

The group shall be aware of operating instruction of portable fire

extinguishers.
6.3

The test team should be aware of the steps to be taken to trip the running
equipment in case any emergency / abnormal observations are notified to
them.

Signature
NTPC

BHEL

Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 500 0038

NTPC Ref No. SIM / 1 / TS / 1 / 38
Plant Area: BOILER
PROCEDURE FOR COMMISSIONING OF CC PUMPS
7.0

STATE OF THE PLANT

7.1

Boiler Hydraulic test is completed.

7.2

Erection of the following are completed.

-----

CC Pumps impellers along with motor is mounted into pump casing

flange.
HP fill and purge lines system.
Auxiliary cooling water lines
Overhead tank for emergency cooling water supply.

Sheet 7 of 15

7.3

All permanent supports are provided in the pump suction manifold, suction
and discharge lines and other associated lines.

7.4

All local instruments of the pumping unit including fill and purge lines and
auxiliary cooling water system are installed. (Required list is to be prepared at
site). Pressure and temperature indicators are to be duly calibrated.

7.5

Remote indicators at control room are made available (list to be prepared at

site).

7.6

Free operation of pump discharge valves ensured.

7.7

Temperature measurement pads are fixed on the pump casing and suction
manifold and suitable thermocouples are installed.

Signature
NTPC
Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 500 0038
NTPC Ref No. SIM / 1 / TS / 1 / 38

BHEL
Sheet 8 of 15

Plant Area: BOILER

PROCEDURE FOR COMMISSIONING OF CC PUMPS
7.8

The following electrical checks are ensured

7.8.1 All protection for H.T. motor is made available at breaker .

7.8.2 Insulation resistance value of motor winding is to be measured with 1000V
meggar when the unit is filled up with water at ambient temp and it should be
more than 5 mega ohm.
7.9

The following Instrumentation checks are ensured

7.9.1 Cavity temperature controller is calibrated and set at 135 F and 140 F for
alarm and Trip respectively.

7.9.2 L.P. cooling water flow rator is adjusted at 32 GPM.

7.9.3 Differential pressure switches and transmitter are calibrated and be kept ready.
7.10 The following start permissives and Trip interlocks are checked before going
for pump trial.

Signature
NTPC

BHEL

Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 500 0038

NTPC Ref No. SIM / 1 / TS / 1 / 38

Sheet 9 of 15

Plant Area: BOILER

PROCEDURE FOR COMMISSIONING OF CC PUMPS
7.10.1 Start Permissives
-----

Low pressure cooling water flow greater than 32 GPM.

Differential temp. between pump casing and suction manifold is less
than 100oF.
Motor cavity temp. is more than 40oF and less than 160oF.
Pump discharge valves are fully open.

7.10.2 Trip interlocks

-----

Motor cavity temperature more than 140oF fore more than 5

seconds.
Pump differential pressure remains less than 10 PSI on all pmps for 5
seconds.
Pump discharge valve not fully open.
In addition to the above start/trip interlock, a load limit signal is

generated at the following conditions.

a. Any 2 pumps running with D.P. less than 18 P.S.I. for more than
5 seconds.
Any 2 pump motor breakers open.

Signature
NTPC
Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 500 0038
NTPC Ref No. SIM / 1 / TS / 1 / 38

BHEL
Sheet 10 of 15

Plant Area: BOILER

PROCEDURE FOR COMMISSIONING OF CC PUMPS
8.0

METHOD

8.1

Flushing of fill and purge lines

8.1.1 Preparation of fill and purge system and auxilliary cooling water system
Fill and purge water is taken from 2 independent sources viz.
1.
2.

From Boiler feed pump discharge.

From Condensate pump discharge.

8.1.2 Flushing of the fill and purge lines

The flushing is to be done in 2 stages with D.M. water till outlet is free of
visible turbidity.
8.1.3 Refer the drawing no 4:PS:TSX:0069:00 attached.
Stage 1: In this stage, the line from fill and purge line source to individual

motor inlet shall be flushed without connecting the inlet line to the motor.
---

--

The common removable strainer basket shall be kept removed from

the strainer.
The flushing shall be done initially through the bypass line for the
individual filters installed in the purge line of each pump and after
establishing that the flushing water is free of any turbidity, the filters
and orifices can be included in the flushing circuit.
After flushing is completed in this sections, set the Valve no. C58
(for Pump A) such a way that the purge water flow rate of 2.6 lit/min
is established to facilitate motor cavity filling for the subsequent
stage flushing.

Signature
NTPC
Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 500 0038
NTPC Ref No. SIM / 1 / TS / 1 / 38

BHEL
Sheet 11 of 15

Plant Area: BOILER

PROCEDURE FOR COMMISSIONING OF CC PUMPS
8.1.4 Stage 2: Connect the motor inlet and flush the LP cooler for pump motor and
letting the water to flow out through the bottom connection of
heat exchanger. While filling the motor cavity a flow rate of 2.6
lit/min is to be maintained. Then increase the flow rate to
maximum purge rate possible through the orifice no. 41. Once
the outlet water is clear of visible turbidity declare the flushing
operation and connect the heat exchanger bottom line to the
motor.
8.2

Flushing of Auxiliary cooling water system

8.2.1 Auxiliary cooling water for HP cooler and fill and purge line cooler shall be
supplied from two sources.
a)
From station auxiliary cooling water source.
b)
Emergency cooling water from over head tank.
Auxiliary cooling water piping is to be flushed with same quantity of water
used for station auxiliary cooling water purpose. In order to achieve effective
flushing the auxiliary cooling water line is flushed in the following stages.

8.2.2 H.P. fill and purge cooler lines

The hoses of supply and return lines shall be inter connected and flushed.
Once clear water is established, cooler is also included in the circuit and
fluthed till clear water obsereved at the outlet point.
8.2.3 Motor cooler lines
The hoses of supply and return lines are to be interconnected and flushed
through the flow rators bypass line. Then the hoses are to be normalised and
flushed through the motor cooler by passing flow rator initially and including
flow rator subsequently till clearer outlet water is achieved in each stage.

Signature
NTPC
Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 500 0038
NTPC Ref No. SIM / 1 / TS / 1 / 38

BHEL
Sheet 12 of 15

Plant Area: BOILER

PROCEDURE FOR COMMISSIONING OF CC PUMPS
8.3

Motor Cavity filling and venting.

8.3.1 Charge the HP fill and Purge line manifold through temporary low pressure fill
source.
Motor cavity is to be filled at rate less than 2.6 litre / min with D.M. Water
(Condense quality DM water). This rate has to be ensured before admitting
the water into the motor by opening the fill and purge line Valves No. C43,
C58, C61 and the Drain Valve C73 and closing the Valves C59 and C62.
(The Valves nos. are given for Pump A. For corresponding valves for Pump
B and C please refer the drawing enclosed). The flow through the drain
Valve C73 is to be measured and set the opening of the Valve No. C58 such
a way that the recommended flow rate is achieved. Then admit the purge
water in to the motor after closing the drain valve no. C73 through the filter
and Orifice O.
8.3.2 Venting:
With the purge water flow established as described in section 8.3.1, keep
open the vent valves C90, C91, C92, C144 and C145 till air free water
comes out through the valve. Then close the vent valves.
8.4 Trial run of pump
8.4.1 Ensure motor cavity of all pumps are filled as described above before taking
up trial of any pump.

8.4.2 Fill the boiler drum upto normal operating level. This is to ensure availability
of sufficient NPSH for pump to run without cavitation.
8.4.3 Ensure the cooling water flow through the motor cooler.
8.4.4 Ensure the pump discharge valve fully opened.

Signature
NTPC
Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 500 0038
NTPC Ref No. SIM / 1 / TS / 1 / 38

BHEL
Sheet 13 of 15

Plant Area: BOILER

PROCEDURE FOR COMMISSIONING OF CC PUMPS
8.4.5 Flick start the selected pump for 5 seconds and stop.
(Caution): The motor runs upto full speed in approximately 1 second. If the
motor fails to start after 5 seconds, press the stop button and do
not attemp to restart the pump for 20 minutes.
8.4.6 After 10 minutes pause, run the pump for further (2nd) 5 seconds.
8.4.7 During this run check the following
a)
c)

Motor Current.
Differential Pressure: When the check valves are open the differential
pressure should rise immediately to approximately 10 P.S. I.

Note: If the differential pressure doesnt rise, stop the motor immediately. It
may be an indication that the motor is running in reverse direction. This is
corrected by interchanging of the position of the motor leads at the terminal
box/ H.T breaker end as the case may be .
8.4.8 After further 10 minutes pause flick start the motor for 5 seconds (3 rd) and
observe the motor current and differential pressure.
8.4.9 After further 10 minutes pause, energise the motor (4 th) and run for 20
minutes.

Signature
NTPC

BHEL

Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 500 0038

NTPC Ref No. SIM / 1 / TS / 1 / 38
Plant Area: BOILER
PROCEDURE FOR COMMISSIONING OF CC PUMPS
8.4.10 During this running period check the following
a)
check motor vibration and record
b)
check for rubbing or excess bearing noise by holding a listening
rod against the pump and motor case
c)
check the motor operating temperature at regular intervals
d)
check that cooling water pipe line entering the motor cooler is
warmer than the outlet pipe connected at the bottom of the
motor cooler. This ensures correct functioning of heat
exchanger.
e)
check motor current and differential pressure readings at every
5 minute interval and record
f)
check for any leakage in valve glands and flanges
8.4.11 Trial run of other pumps are also to be done as illustrated above for 20
mi nutes.
8.4.12 After completion of the trials and tests on individual pumps parallel
operation of 2 pumps and 3 pumps is done for 20 minutes.
8.4.13 During parallel operation of pumps, the following observations are made
and recorded during each operation.
a)
Differential pressure
b)
Motor current
c)
Drum level readings on right and left.
8.4.14 After the above observations are recorded all pumps are allowed to run
for 8 hours trial run.
During the trial, the parameters like Differential pressure, motor current

Sheet 14 of 15

may be recorded at every half an hour interval.

Signature
NTPC
Station: NTPC - Simhadri BHEL Ref No. PS - DC - 186 500 0038
NTPC Ref No. SIM / 1 / TS / 1 / 38

BHEL
Sheet 15 of 15

Plant Area: BOILER

PROCEDURE FOR COMMISSIONING OF CC PUMPS
9.0

COMPLETIONCRITERIA

9.1

Commissioning of C.C Pumps completed by carrying out the proposals as

given in Section 3.0

Signature
NTPC

BHEL

Log Sheet
Station

Unit

Date:

Activity :
Sl.
No

Pump in
Service

Time
A

Differential
Pressure

Current
C

Time

Remarks

Signature
NTPC

BHEL

PROCEDURE FOR COMMISSIONING OF CC PUMPS