KORBA WEST POWER COMPANY LIMITED Ref. No.

:-
CHHOTE BHANDAR, RAIGARH, CHHATTISGARH. KWPCL/COMM./Blr./16

COMMISSIONING PROCEDURE FOR CC PUMPS DATE :

(UNIT #1 600MW)

LIST OF CONTENTS

1. PLANT DETAILS

2. OBJECTIVE

3. PROPOSAL

4. SERVICES REQUIRED

5. SAFETY PRECAUTIONS

6. EMERGENCY PROCEDURES

7. STATE OF THE PLANT

8. COMMISSIONING PROCEDURE

9. COMPLETION CRITERIA

10. APPENDICES

a) LOG SHEETS

1.0 PLANT DETAILS

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 KORBA WEST POWER COMPANY LIMITED Ref. No.:-
CHHOTE BHANDAR, RAIGARH, CHHATTISGARH. KWPCL/COMM./Blr./16

COMMISSIONING PROCEDURE FOR CC PUMPS DATE :

(UNIT #1 600MW)

In a controlled circulation Boiler, circulating pumps play an important role in the performance of the Boiler. For 600
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 the water walls.
Feed water entering the boiler drum via economizer flows from the drum through the down comers (6Nos.) to the
pump suction manifold. The boiler circulating pumps take water from the suction manifold and discharges via the pump
discharge lines into 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 through orifices which feed the furnace
wall tubes, the economizer recirculating lines.

1.1 Technical parameter CC Pumps

Type Single Suction, Double

Discharge Pump size (2x12) x 16 x 19 DIFF
Make Hayward tayler
Capacity 3520 m3/hr.
Design Pressure 215 kg/cm2 g @ 371 C
Hydrostatic test pressure 322.5 kg/cm2 g
Differential Head (actual) 30.82m(g)
Temperature 355.1C
Motor Speed 1456 rpm
Design Pressure 215 kg/cm2 g @ 371 C
Test Pressure 322.5 kg/cm2 g
Motor rated output 440 kW
Motor service factor 1.0
Motor winding insulation XLP PE2+PA
Motor electrical supply 3300V 3Ph 50Hz
Full Load Current 104.5A
Max Starting Current 511A
Locked Rotor Current 444A
Maximum flow. The pump must not be operated beyond of 5100 m3/hr,
head of 21.1 m.
Minimum Flow The pump must not be operated below a minimum flow of
2000m3/hr, head of 38.7m

1.2 PUMP DETAIL

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COMMISSIONING PROCEDURE FOR CC PUMPS DATE :

(UNIT #1 600MW)

Hayward Tyler Glandless Motor Circulator Pump is designed for recirculating boiler water through the boiler water
systems of fossil fuel or liquid cooled nuclear reactor power stations and similar applications.
The circulators consist of a single stage centrifugal pump and a wet stator induction motor, which are mounted within a
common pressure vessel. The vessel consists of three main parts, a pump casing, motor housing and motor cover.

The motor is suspended beneath the pump casing and is filled with cold boiler water at full system pressure. No seal
exists between the pump and motor, but provision is made to thermally isolate the pump from the motor in the
following respect: -

1) Thermal Conduction. Because the pump temperature is so high, usually above 340C and the motor temperature is
limited to about 55C, a simple restriction, in the form of a 'neck', is provided to minimise heat conduction.

2) Hot Water Diffusion. To minimise diffusion of boiler water, a narrow annulus surrounds the rotor shaft, between the
hot and cold regions. A baffle ring restricts solids entering the annulus.

3) Motor Cooling. The motor cavity is maintained at a low temperature by a heat exchanger in a closed loop water
circulation system, thus extracting the heat conducted from the pump.

In addition, this water circulates through the stator and bearings, extracting the heat generated in the windings and
providing bearing lubrication. An internal filter is incorporated in the circulating system.

4) In emergency conditions, if low pressure coolant to the heat exchanger fails, or is

The associated systems of boiler circulating pumps consist 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.

b) Cooling water system

This system is supplied with LP coolant from ECW System and also from separate emergency cooling water from
overhead tank source. This supplies cooling water to

i) LP Cooler for Pump Motor and

ii) HP fill and Purge cooler.

The boiler circulating pumps are operated through H.T. Motors which is provided with
cavity in which DM Water is filled in cavity for cooling the motor while the motor is in operation.

When the unit is in operation, Circulation pumps are operated in parallel (2 working and 1 standby) or all the
three pumps together as per the actual requirement.

Plant item completion list for the system for Mechanical, Electrical and C&I areas are to be prepared at site.

2. OBJECTIVE:-

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CHHOTE BHANDAR, RAIGARH, CHHATTISGARH. KWPCL/COMM./Blr./16

COMMISSIONING PROCEDURE FOR CC PUMPS DATE :

(UNIT #1 600MW)

To commission the C.C. Pumps and ensure that it is supplied as per the designed specifications and to ensure rated
performance of the pump.

3. PROPOSAL
It is proposed to commission the CC pumps as per the following proposal.

Flushing of fill & purge lines

Flushing of equipment cooling water system.
Motor Cavity filling and venting.
Trial run of pumps for 8 hour.

4. SERVICES REQUIRED

Sl.
ACTIVITY STATUS REMARK
No.
1 Availability of O&M Manual for CC Pumps.
2 Availability of sufficient quantity of equipment cooling water.
3 Availability of H.T Power supply.
4 Availability of lighting, communication facility at the test area.

5 Availability of measuring tools for vibration and temperature.

6 Availability of portable fire extinguishers.

7 Availability of working crew with Technician for attending minor problem

during Commissioning of CC Pump.

8 Availability of service water for washing.

5.0 SAFETY PRECAUTIONS

Sl. No. ACTIVITY STATUS (Y/N) REMARK

1 Availability of first aid kit at test area.

2 The team commissioning the CC pump should be aware of the procedure
adopted.
3 Agencies working in the boiler area / are informed about the test / cleared from
the test area (As per the actual requirement).
4 All loose materials around the CC pump area are cleared.

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

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COMMISSIONING PROCEDURE FOR CC PUMPS DATE :

(UNIT #1 600MW)

6.0 EMERGENCY PRECAUTIONS:

Sl. ACTIVITY STATUS REMARKS

No. (Y/N)
1 The group conducting the test should be aware of
action to be taken on the event of injury to personnel
2 The group shall be aware of operating instruction of
portable fire extinguishers
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.

7.0 STATE OF THE PLANT

STATUS
Sl. No. ACTIVITY REMARK
(Y/N)
1 Boiler Final Hydraulic test is completed.

Erection of the following are completed:-

CC Pumps impeller along with motor is mounted into pump casing flange.

2 HP fill and purge lines system.

Equipment cooling water lines

Overhead tank for emergency cooling water supply and Emergency fill pump.

LP Cooler for Pump Motor and

HP fill and Purge cooler.

3 All permanent supports are provided in the pump suction manifold, suction and
discharge lines and other associated lines.
4 All local instruments of the pumping unit including fill and purge lines and
equipment cooling water system are installed.

5 Pressure and temperature indicators are to be duly calibrated.

6 Remote indicators at control room are made available

7 Ensured Free operation of pump discharge valves.

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COMMISSIONING PROCEDURE FOR CC PUMPS DATE :

(UNIT #1 600MW)

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

9 Ensure Corresponding HT switchgear commissioned and charged.

The following electrical checks are ensured

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

Insulation resistance value of motor winding is to be measured with

10 1000V
Megger when the unit is filled up with water at ambient temp and it
should be upwards of 200 mega ohm.

The motor windings should be protected by ground detection relays,

sufficiently sensitive to detect the development of a pinhole or minor
crack in the stator winding insulation

The following Instrumentation checks are ensured

Cavity temperature controller is calibrated and set at 63OC and 66OC for Alarm=63C
alarm and Trip respectively. Tripping=66C
L.P. cooling water flow rate is adjusted at 108 l/m @ 2 Ksc.

Differential pressure switches and transmitter are calibrated and is kept

11 ready.
Casing differential temperature switches and transmitter are calibrated
and is kept ready.
Ensure all P&I checks are completed and kept in service.

Ensure equipment cooling water system is charged.

Ensure that all preservatives are removed and cleaned before charging.

Emergency overhead tank is filled with water and is commissioned.

A flow/switch indicator is supplied for connecting into the low pressure

cooling water circuit.

8.0 COMMISSIONING PROCEDURE:

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CHHOTE BHANDAR, RAIGARH, CHHATTISGARH. KWPCL/COMM./Blr./16

COMMISSIONING PROCEDURE FOR CC PUMPS DATE :

(UNIT #1 600MW)

8.1 FLUSHING OF FILL & PURGE LINE & COOLING WATER LINE

Sl. ACTIVITY STATUS REMARK

No. (Y/N)
1 All standard check lists are duly filled.
2 Flushing of fill and purge lines.
3 Preparation of fill and purge system and equipment cooling water system
Fill and purge water is taken from the following independent sources viz.
-From Boiler feed pump discharge.
4 -From Condensate pump discharge.
-From boiler fill line.(Initial Filling)
Flushing of the fill and purge lines.
5 -The flushing is to be done in 2 stages with D.M. water till outlet is free of visible
turbidity and required quality (conductivity < 5 micro Siemens/cm)
6 Ensure the circulator is completely vented.
7 Ensure that the high pressure cold water purge at 20C maximum temperature is
connected but isolated.
8 Ensure that sufficient N.P.S.H. is available for the pump to run without cavitation.
Refer the drawing
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 of filter installed in
the purge line of pumps and after establishing that the flushing water is free of any
a turbidity, the filters and orifices can be included in the flushing circuit.
* After flushing is completed in this sections, set the Valve such a way that the
purge water flow rate
Approximately 2 litres/min. is entering into the motor through the fill line.

Stage 2: Connect the cooler 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 2.0 lit/min is to be maintained. Then
b increase the flow rate to maximum purge rate (5.0 lit/min) possible through the
orifice. Once the outlet water is clear of visible turbidity declare the flushing
operation and connect the heat exchanger bottom line to the motor.

9 Flushing of Equipment cooling water system

Equipment cooling water for HP cooler and fill and purge line cooler shall be
10 supplied from two sources.
a) From station Equipment cooling water source.
b) Emergency cooling water from overhead tank.

Equipment cooling water piping is to be flushed with same quantity of water used
for station Equipment cooling water purpose. In order to achieve effective flushing
11 the equipment cooling water line is flushed in the following stages.

H.P. fill and purge cooler lines

The hoses of supply and return lines shall be inter-connected and flushed. Once

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COMMISSIONING PROCEDURE FOR CC PUMPS DATE :

(UNIT #1 600MW)

clear water is established, cooler is also included in the circuit and flushed till
clear water observed at the outlet point.

Motor cooler lines

The hoses of supply and return lines are to be interconnected and flushed through
the flow raters bypass line. Then the hoses are to be normalized and flushed
through the motor cooler by passing flow rater initially and including flow rater
subsequently till clearer outlet water is achieved in each stage.

NOTE:

I) Ensure motor cavity is not filled till the required purity of water is reached in the fill & purge lines

II) Venting: With the purge water flow established. Keep open the vent valves till air free water comes out through
the valve. Then close the vent valves.

8.2 Trial run of pump

Sl. ACTIVITY STATUS REMARKS
No. (Y/N)
1 Ensure motor cavities of all pumps are filled as described above before taking up
trial of any pump.
2 Fill the boiler drum up to normal operating level. This is to ensure availability of
sufficient NPSH for pump to run without cavitation.
3 Ensure the cooling water flow through the motor cooler
4 Ensure the pump discharge valve fully opened
5 Flick start the selected pump for 5 seconds and stop to allow any air bubbles
remaining in the system to escape
6 The motor runs up to full speed in approximately 1 second. If the motor fails to
start after 5seconds, press the stop button
7 Do not attempt to restart the pump for 20 minutes.
After 20 minutes pause, run the pump for further (2nd) 5 seconds. Before
starting close the discharge valves to check the delivery head at Q = 0,
If the DOR (clockwise from motor end) of the motor is correct, the head at
8 zero flow of the pump is 40mwc head (assuming the water density is 1) If
the motor is running in the wrong direction the value is less than this
value.

Open the discharge the valve and start the motor after 20 minutes. During this run
check the following
a) Motor Current: Means
b) Differential Pressure :( If the differential pressure does not rise, stop the motor direction is
immediately) reverse
c) Casing differential temperature
9 d) Tightness of all gaskets and valves

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COMMISSIONING PROCEDURE FOR CC PUMPS DATE :

(UNIT #1 600MW)

e) Temperature of the motor cooling water

f) Check motor vibration and record
g) Check for rubbing or excess bearing noise by holding a listening rod against the
pump and motor case.
h) Check the motor operating temperature at regular intervals
i) 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

10 Trial run of other pumps are also to be done as illustrated above for 20 minutes

During parallel operation of pumps, the following observations are made and
11 recorded during each operation.
a) Differential pressure
b) Motor current
c) Drum level readings on right and left
After the above observations are recorded all pumps are allowed to run for 8 hours
trial run.
12 During the trial, the parameters like Differential pressure, motor current may be
recorded at every half an hour interval.

8.3 Stopping the pump

1 Press the stop button on the control console.

2 Check the run-down time is approximately 2.5 seconds.

3 Close the discharge valves.

4 Maintain the low pressure cooling water supply to the heat exchanger.

9.0 COMPLETION CRITERIA

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

Flushing of fill & purge lines

Flushing of Auxiliary cooling water system.

Motor Cavity filling and venting.

Trial run of pump for 8 hour.

10.0 APPENDIX:

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CHHOTE BHANDAR, RAIGARH, CHHATTISGARH. KWPCL/COMM./Blr./16

COMMISSIONING PROCEDURE FOR CC PUMPS DATE :

(UNIT #1 600MW)

A) Pump trial log sheet

B) Instrumentation list of CC Pump
C) Fault list chart

a) Pump trial run log sheet

SL PUMPS IN SERVICE CURRENT DIFFERENTIAL

NO. TIME PRESSURE REMARKS
A B C A B C A B C

KWPCL ERECTION KWPCL BHEL ERECTION BHEL

COMMISSIONING COMMISSIONING
NAME
SIGNATURE

B) INSTRUMENT LIST OF CC PUMP

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COMMISSIONING PROCEDURE FOR CC PUMPS DATE :

(UNIT #1 600MW)

S. TYP TAG No. Description Complet Date of Remar

N E ion Complet ks
o. ion

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COMMISSIONING PROCEDURE FOR CC PUMPS DATE :

(UNIT #1 600MW)

1 C & I HAG01CP401 Pressure Differential Transmitter of CC

Pump-A( Between suction & casing of Pump)
2 C & I HAG01CP402 Pressure Differential Transmitter of CC
Pump-A( Between suction & casing of Pump)
3 C & I HAG02CP401 Pressure Differential Transmitter of CC
Pump-B( Between suction & casing of Pump)
4 C & I HAG02CP402 Pressure Differential Transmitter of CC
Pump-B( Between suction & casing of Pump)
5 C & I HAG03CP401 Pressure Differential Transmitter of CC
Pump-C( Between suction & casing of Pump)
6 C & I HAG03CP402 Pressure Differential Transmitter of CC
Pump-C( Between suction & casing of Pump)
7 C&I HAG01CT004 Temperature Element in Suction Manifold
8 C&I HAG02CT004 Temperature Element in Suction Manifold
9 C&I HAG03CT004 Temperature Element in Suction Manifold
10 C&I HAG01CP502 Pressure Indicator in suction of CC Pump-A
11 C&I HAG02CP502 Pressure Indicator in suction of CC Pump-B
12 C&I HAG03CP502 Pressure Indicator in suction of CC Pump-C
13 C&I HAG01CT005 Temperature Element in CC Pump-A
14 C&I HAG02CT005 Temperature Element in CC Pump-B
15 C&I HAG03CT005 Temperature Element in CC Pump-C
16 C&I HAG01CP503 Pressure Indicator in Discharge of CC Pump-
A
17 C & I HAG01CP504 Pressure Indicator in Discharge of CC Pump-
A
18 C & I HAG02CP503 Pressure Indicator in Discharge of CC Pump-
B
19 C & I HAG02CP504 Pressure Indicator in Discharge of CC Pump-
B
20 C & I HAG03CP503 Pressure Indicator in Discharge of CC Pump-
C
21 C & I HAG03CP504 Pressure Indicator in Discharge of CC Pump-
C
22 C&I HAG01CP505 Pressure Indicator in CC Pump-A
23 C&I HAG02CP505 Pressure Indicator in CC Pump-B
24 C&I HAG03CP505 Pressure Indicator in CC Pump-C
25 C&I HAG01CT001 Temperature Element in CC Pump-A
26 C&I HAG01CT002 Temperature Element in CC Pump-A
27 C&I HAG01CT003 Temperature Element in CC Pump-A
28 C&I HAG01CT501 Temperature Indicator in CC Pump-A
29 C&I HAG02CT001 Temperature Element in CC Pump-B
30 C&I HAG02CT002 Temperature Element in CC Pump-B

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COMMISSIONING PROCEDURE FOR CC PUMPS DATE :

(UNIT #1 600MW)

31 C&I HAG02CT003 Temperature Element in CC Pump-B

32 C&I HAG02CT501 Temperature Indicator in CC Pump-B
33 C&I HAG03CT001 Temperature Element in CC Pump-C
34 C&I HAG03CT002 Temperature Element in CC Pump- C
35 C&I HAG03CT003 Temperature Element in CC Pump- C
36 C&I HAG03CT501 Temperature Indicator in CC Pump- C
37 C&I HAG01CT502 Temperature Indicator in O/L of LP Cooler
for Pump Motor of CC Pump-A
38 C & I HAG02CT502 Temperature Indicator in O/L of LP Cooler
for Pump Motor of CC Pump-B
39 C & I HAG03CT502 Temperature Indicator in O/L of LP Cooler
for Pump Motor of CC Pump-C
40 C & I HAG50CP503 Pressure Indicator in HP fill & Purge Line
Manifold
41 C & I HAG50CP503 Pressure Differential Indicator in HP fill &
Purge Line Manifold
42 C & I HAG50CP501 Pressure Indicator in HP fill & Purge Line
Manifold
43 C & I HAG50CT501 Temperature Indicator in HP fill & Purge Line
Manifold
44 C&I HAG40CP401 Pressure test Pocket at the Inlet of Strainer
45 C&I HAG40CP402 Pressure test Pocket at the Outlet of Strainer
46 C&I HAG01CP501 Pressure Indicator in LP Inlet Manifold
47 C&I HAG02CP501 Pressure Indicator in LP Inlet Manifold
48 C&I HAG03CP501 Pressure Indicator in LP Inlet Manifold
49 C&I HAG10CP501 Pressure Indicator in LP Inlet Manifold
50 C&I HAG10CP001 Pressure Transmitter in LP Inlet Manifold
51 C&I HAG10CT501 Temperature Indicator in LP Inlet Manifold

Emergency fill pump

1 C&I QHX32CP501 Pump - A suction pressure Gauge

2 C&I QHX32CP502 Pump B suction pressure Gauge

3 C&I QHX32CP101 Pump - A Discharge pressure switch

4 C&I QHX32CP102 Pump - B Discharge pressure switch

5 C&I QHX32CP503 Pump discharge header pressure gauge

Emergency cooling water tank for CC pump

1 C&I QHX32CL501 Tank level gauge

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COMMISSIONING PROCEDURE FOR CC PUMPS DATE :

(UNIT #1 600MW)

2 C&I QHX32CL502 Tank level gauge

3 C&I QHX32CL001 Tank level transmitter

4 C&I QHX32CL002 Tank level transmitter

D) Fault list chart

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