OPGS POWER GUJARAT PVT LTD DOC NO:

2X150 MW THERMAL POWER PLANT OPGS/0/TUR/OPN/19/31/00

DOC TITLE SOP FOR BFP REV NO 0 DATE 07-02-2017

BOILER FEED PUMP

(BFP)

PREPARED BY APPROVED BY

DATE DATE

Page 1 of 11
 OPGS POWER GUJARAT PVT LTD DOC NO:
2X150 MW THERMAL POWER PLANT OPGS/0/TUR/OPN/19/31/00

DOC TITLE SOP FOR BFP REV NO 0 DATE 07-02-2017

Applicable Elements of Standard:

ISO 14001(2004) 4.4.4.6 Operational control
OHSAS 18001 (2007) 4.4.6 Operational control

1. OBJECTIVE
This procedure covers all the operational activities related to starting & operating the Boiler Feed
Pump, which are carried out by operation personnel for safe operation of equipment and which will improve
the equipment availability always.

2. DESCRIPTION
Each unit is provided with two boiler feed pumps of 100% capacity each. One pump is in normal
service and the other is intended to be at standby.

The Boiler feed pump is a 6 stage centrifugal pump. The capacity of the pump is 605m 3/hr. Its
differential pressure is 193.2 kg/cm2 at a speed of 5135 rpm. The Boiler Feed pump itself is fed by the
booster pump.

Booster pump is a single stage double suction centrifugal pump and is also driven by the feed pump
motor, coupled to the other end shaft of the motor. The booster pump has its suction from the Deaerator and
delivers the water at a higher pressure thereby providing the net positive suction head (NPSH) for the feed
pump. The differential pressure of the booster pump is 9.8 kg/cm2.

The 6.6kv feed pump drive motor is of capacity 4900kw with a rated speed of 1485 rpm. The power
is transmitted from the motor to the feed pump through a variable speed hydro coupling. It consists of a step
up gear of gear ratio 143/40 followed by the hydro-coupling. The variable speed for the feed pump is
achieved by positioning of the servo operated scoop tube. The necessary working oil for the hydro coupling
is supplied by the working oil pump. Requirement of lube oil for the bearings of the motor, the feed pump,
booster pump and the bearings of the hydro coupling is met by a lube oil pump. Both the working oil pump
and the lube oil pump are mounted on a single shaft and are driven by the input shaft of the hydro coupling.
These two pumps draw oil from a common sump at the bottom of the hydro coupling and supply oil for the
hydro coupling and lubrication of various bearings separately.

An external motor driven lube oil pump is also provided to supply lube oil during start-up, tripping
and break down periods.

A pneumatically operated recirculation valve is provided on the recirculation line to ensure a

minimum flow of 100m3/hr through the feed pump. The feed pump is provided with mechanical seals at
both the ends and a seal water cooler is provided to cool the seal water with the help of the closed circulating
auxiliary cooling water.

Page 2 of 11
 OPGS POWER GUJARAT PVT LTD DOC NO:
2X150 MW THERMAL POWER PLANT OPGS/0/TUR/OPN/19/31/00

DOC TITLE SOP FOR BFP REV NO 0 DATE 07-02-2017

The Boiler feed pump discharge the feed water to the boiler drum through two high pressure heaters,
feed water control station and two banks of the economizer coils to the boiler drum. Tapping is taken from
feed water line before feed control station for attemperation of Super Heater spray and ReHeater spray.
Another tapping is taken from BFP discharge before HP heaters for attemperation of HP bypass system.

3. REFERENCE DOCUMENT
1. Operation and maintenance manual and Quality test document of M/s. BHEL
2. Scheme of documents: PE-DG-337-100-N105
HY-DG-1-18000-56942
HY-DG-1-18000-56941

4. SAFETY PRECAUTIONS
1. Availability of the first aid kit.
2. Field operator should wear the safety shoes, helmet, safety hand gloves, safety goggle.
3. Oil collection tray to be made available.

5. TECHNICAL SPECIFICATION

5.1 BOILER FEED PUMP

MAKE BHEL
DISCHARGE (m3/hr) 605
WATER TEMPERATURE (0C) 150.9
POWER (kw) 3690.9
EFFICIENCY (%) 79
DYNAMIC HEAD (mlc) 1932
SPEED (rpm) 5135
NPSH Required (mlc) 27.5

5.2 BOOSTER PUMP

MAKE BHEL
DISCHARGE (m3/hr) 605
WATER TEMPERATURE (0C) 150.9
POWER (kw) 186.04
EFFICIENCY (%) 79.5
DYNAMIC HEAD (mlc) 98
SPEED (rpm) 1485
NPSH Required (mlc) 4.5

5.3 BFP DRIVE COUPLING

Page 3 of 11
 OPGS POWER GUJARAT PVT LTD DOC NO:
2X150 MW THERMAL POWER PLANT OPGS/0/TUR/OPN/19/31/00

DOC TITLE SOP FOR BFP REV NO 0 DATE 07-02-2017

TYPE HYDRAULIC COUPLING
SPEED RATIO (N2/N1) 143/40

5.4 DRIVE MOTOR

MAKE BHEL
SPECIFICATION OF INDUCTION MOTOR IS: 325
TYPE Sq. Cage induction motor
CAPACITY 4900 KW
STATOR VOLTAGE 6600 V
STATOR CURRENT 497 Amps
SPEED 1485 rpm
PHASE 3
FREQUENCY 50 HZ
CLASS OF INSULATION F
CONNECTION STAR
DEGREE OF INSULATION IP 55
METHOD OF COOLING WATER COOLING
COOLING WATER REQUIRMENT 490 LPM
PERMISSIBLE TEMPERATURE OF COOLING
380C
WATER INLET
PERMISSIBLE TEMPERATURE OF COOLING
430C
WATER OUTLET
MAXIMUM TEMPERATURE OF COLD AIR
500C
INLET TO THE MOTOR
MAXIMUM TEMPERATURE OF COLD AIR
750C
OUTLET

5.5 LUBRICATION
Any one of the below oils can be used,
HYSPIN AWH 32 CASTROL
HYSPIN AWS 32 CASTROL
ENKLO VT 32 HP
SERVO SYS HLP 32 IOCL
SHELL TELLUS 32 SHELL
BHARAT HYD ROL HLP 32 BHARAT PETROLEUM

5.6 AUXILIARY OIL PUMP MOTOR

Page 4 of 11
 OPGS POWER GUJARAT PVT LTD DOC NO:
2X150 MW THERMAL POWER PLANT OPGS/0/TUR/OPN/19/31/00

DOC TITLE SOP FOR BFP REV NO 0 DATE 07-02-2017

CAPACITY 5.5 Kw
RATED CURRENT 10.5 A
SPEED 1450 rpm

5.7 OIL PUMPS

PUMPS PRESSURE (kg/cm2)

AUXILLIARY OIL PUMP 3
MAIN OIL PUMP 3
WORKING OIL PUMP 1.5

5.8 LUB OIL FILTER

MAKE VOITH INDIA

NUMBERS 2(1S+1W)
MAXIMUM OPERATING PRESSURE 8 bar

5.9 LUB OIL SYSTEM HEAT EXCHANGER

MAKE VOITH INDIA

NUMBERS 2(1S+1W)
OIL FLOW (m3/hr) 16.8
COOLING WATER FLOW (m3/hr) 25.8

5.10 WORKING OIL SYSTEM HEAT EXCHANGER

MAKE VOITH INDIA

NUMBERS 2(1S+1W)
OIL FLOW (m3/hr) 36.72
COOLING WATER FLOW (m3/hr) 69.76

Page 5 of 11
 OPGS POWER GUJARAT PVT LTD DOC NO:
2X150 MW THERMAL POWER PLANT OPGS/0/TUR/OPN/19/31/00

DOC TITLE SOP FOR BFP REV NO 0 DATE 07-02-2017

6. PRECHECKS

6.1 FIELD OPERATOR CHECKS

1. Ensure the issued permit works for the equipment’s are completed.
2. Ensure the equipment and equipment areas are cleaned for safe operation.
3. Check that the Deaerator is filled to normal working level.
4. Check that instrument air and electrical supplies are available for the instrumentation and
valves.
5. Check that the booster pump and feed pump drain valves are closed.
6. Check that the recirculation valve and isolating valves near BFP and at Deaerator are
open.
7. Check that all the instrument tapping points and isolating valves are open and that all
drain and equalizing valves are closed.
8. Check that the pump discharge valve is closed.
9. Crack open the suction valve, for charging the feed pump.
10. Open the strainer, air vent and booster pump air vent valves and vent any trapped air.
When water comes out freely, close the valves.
11. Similarly open the boiler feed pump discharge pipe air vent in the recirculation line and
prime the lines. After venting out air, close the air vents.
12. Fully open the pump suction isolating valve.
13. Ensure that closed circulating cooling water pump is running and the water is available
for the pump.
14. Open the closed circulating cooling water inlet and outlet isolating valves for the feed
pump mechanical seal cooler.
15. Prepare the drive motor for starting.
16. Prepare the hydraulic coupling and lubricating oil system for starting. Check the oil level
is adequate in hydraulic coupling.
17. Ensure that all instruments and coolers have been primed and vented.
18. Check that the lubricating oil is flowing freely through the following flow indicators.
a. Booster pump drive end and free end bearings drain flow
b. Booster pump side and hydraulic coupling side drive motor bearings drain flow
c. Feed pump drive end and free end bearings drain flow.
19. Check that the closed circulating cooling water from the booster pump mechanical seals
is flowing freely through the flow indicators.
20. Check that the closed circulating cooling water from the feed pump mechanical seal
coolers is flowing freely through the flow indicators.
21. Charge the feed water line & HP heaters, if they are not already charged, by opening the
discharge valve. After charging the line, close the discharge valve.

Page 6 of 11
 OPGS POWER GUJARAT PVT LTD DOC NO:
2X150 MW THERMAL POWER PLANT OPGS/0/TUR/OPN/19/31/00

DOC TITLE SOP FOR BFP REV NO 0 DATE 07-02-2017

6.2 SWITCH GEAR ENGINEER CHECKS

1. Check all the permits issued for the equipment are returned.
2. Check 6.6kv VCB proper rack in and circuit breaker healthiness, spring charging
condition, trip circuit healthy, rated bus voltage.
3. If unit is in trip condition required VAR increased by using capacitor banks.
4. If above conditions ok give clearance to the control room engineer.

6.3 CONTROL ROOM ENGINEER CHECKS

1. Check all the permits issued for the equipment are returned.
2. Ensure all pump and motor protections are in-line.
3. Ensure that the hydraulic coupling auxiliary lubricating oil pump is running.
4. The following conditions must be ensured before the pump drive motor can be started.
a) Pump suction valve is fully open.
b) Recirculation valve is open.
c) Lubricating oil header pressure is adequate. i.e., >2 kg/cm2.
d) Deaerator level is not low.
e) Discharge valve is closed.
f) Closed circulating cooling water pressure to pump is normal.
g) Closed circulating cooling water to Motor & working oil cooler valve in open.
h) Differential temperature across suction and discharge temperature of pump should not
be more than 10oC.

7. PERMISSIVE
The Following Permissive must be satisfied
1. BFP motor winding temperature not high
2. BFP motor bearing temperature not high
3. BFP pump bearing temperature not high
4. Booster pump suction valve opened
5. Booster pump suction pressure adequate
6. Deaerator level normal/BFP standby selected
7. BFP master not operated
8. BFP switch gear available
9. BFP switch gear not disturbed
10. BFP condition standby or Discharge MOV close
11. BFP recirculation valve open or Standby
12. BFP lube oil header pressure adequate

Page 7 of 11
 OPGS POWER GUJARAT PVT LTD DOC NO:
2X150 MW THERMAL POWER PLANT OPGS/0/TUR/OPN/19/31/00

DOC TITLE SOP FOR BFP REV NO 0 DATE 07-02-2017

8. PROTECTION

TIME
S.NO FIRST OUT UNIT NORMAL ALARM TRIP
DELAY
BFP motor winding temperature
1 deg c 60-70 125 130 5sec
V.HIGH
BFP motor bearing temperature
2 deg c 50-60 80 90 5sec
V.HIGH
BFP pump bearing temperature
3 deg c 60-75 90 100 5sec
V.HIGH
BFP ON & pump suc/discharge
4 deg c +2 to +3 +10 +15 2sec
diff V.HIGH
5 BFP DP across suction strainer mmwc 500-1000 2000 2500 10sec
Working oil temp at cooler inlet
6 deg c 90-100 >110 130 15sec
V.HIGH
7 Deaerator level V.LOW mmwc 100 -567 -2267 Nil
BFP ON & lube oil pressure
8 kg/cm2 3.0 <1.5 <1.0 Nil
V.LOW
Booster pump suction valve not
9 - - - Nil
opened
BFP ON & suction pressure
10 kg/cm2 13.5 - 11.5 15sec
V.LOW
11 BFP Bearing vibration V.HIGH mm/sec 10-14 17 23 20sec

Note: For Motor Protection, Recommended starts per hour: 03 (02times from cold & 01time from hot).

Page 8 of 11
 OPGS POWER GUJARAT PVT LTD DOC NO:
2X150 MW THERMAL POWER PLANT OPGS/0/TUR/OPN/19/31/00

DOC TITLE SOP FOR BFP REV NO 0 DATE 07-02-2017

9. STARTING PROCEDURE
1. Start the feed pump drive motor
2. Check that the drive motor current is normal.
3. Check that all pressure and temperature readings are normal.
4. Check the pump bearing vibration.
5. Ensure that the lubricating oil is flowing freely through the following flow indicators,
a) Booster pump drive end and free end bearings drains flow,
b) Booster pump side and hydraulic coupling side drive motor bearings drain flow,
c) Feed pump drive end and free end bearings drains flow,
6. Ensure that the closed cooling water from the booster pump mechanicals seals is flowing
freely through the flow indicators.
7. Ensure that the closed cooling water from the feed pump mechanical seal coolers is flowing
freely through the flow indicators.
8. Ensure for any undue noise or vibration.
9. Ensure all joints and valve glands for leakage.
10. Ensure the security of all fastenings, paying particular attention to the holding down bolts.
11. When the pump is running normally the recirculating valve ensures a minimum flow of
100m3/hr.
12. The Auxiliary lubricating oil pump should be stopped when lube oil header pressure is
adequate.

10. SHUTDOWN PROCEDURE

1. Ensure the second BFP is not in standby condition.
2. Stop the feed pump drive motor.
3. AOP will auto ON and ensure the lube oil header pressure is >2 kg/cm2.
4. Bring down the scoop to minimum position.
5. Close the discharge valve.
6. Run AOP for 30 minutes to bring down the pump and motor bearing temperature.
7. Stop AOP after 30 minutes.

11. CHANGEOVER PROCEDURE

1. Consider BFP-A is running.
2. Take BFP -A scoop in manual mode and maintain drum level.
3. Before starting standby pump BFP B, check all required permissive in DCS and LOCAL.
4. Start standby BFP-B, ensure minimum flow in recirculation valve and run the pump for
10minutes.
5. Check any abnormalities in BFP B pump in DCS and LOCAL.
6. Note down the feed water flow for that present load.

Page 9 of 11
 OPGS POWER GUJARAT PVT LTD DOC NO:
2X150 MW THERMAL POWER PLANT OPGS/0/TUR/OPN/19/31/00

DOC TITLE SOP FOR BFP REV NO 0 DATE 07-02-2017

7. Open the discharge valve of BFP B.
8. Increase the BFP B’s scoop, simultaneously suction flow will increase in BFP B.
9. Maintain the boiler drum level and feed water flow in feed control station by increasing BFP-
B suction flow and decreasing BFP-A suction flow parallely.
10. Gradually reduce BFP A’s scoop and make it in minimum.
11. While BFP-B discharge flow reaches above 365 m3/hr its RC get auto close.
12. When required feed water flow established in Feed control station put BFP B scoop in auto
mode by selecting three element loop control and put scoop control on auto and monitor the
response of scoop for few minutes.
13. Stop the BFP-A.
14. Keep discharge valve in open condition and RC in close condition, put it in stand mode.

12. STANDBY OPERATION PROCEDURE

If following conditions are satisfied, BFP A will be in standby

1. BFP A off feedback.

2. RC valve close.
3. Discharge valve open.
4. AOP ON.
5. BFP A Lube oil header pressure adequate more than 2 kg/cm2.
6. BFP A discharge header pressure adequate more than 55 kg/cm2.
7. BFP A Scoop mode manual.
8. BFP A Standby selection from HMI.

If, BFP is in standby mode and running BFP trips, following sequence will be executed.
1. Standby BFP will start automatically without any delay.
2. If main BFP was running with more than 40% scoop position, then standby scoop will be
positioned at 40%, after 5 sec delay of getting ON feedback.
3. If main BFP was running less than 40% scoop position then standby BFP scoop will be
positioned at same position of running BFP after 5 sec delay of getting ON feedback.
4. Operator has to adjust scoop position manual to maintain drum level.
5. If drum level is stable, operator can put scoop in auto mode (3E drum level control or DP
across FCS control).

Page 10 of 11
 OPGS POWER GUJARAT PVT LTD DOC NO:
2X150 MW THERMAL POWER PLANT OPGS/0/TUR/OPN/19/31/00

DOC TITLE SOP FOR BFP REV NO 0 DATE 07-02-2017

13. CONCLUSION
The purpose of this procedure is for proper understanding about the interlock and protection of
the Boiler feed pump & safe operating procedure.

14. RECORD
Turbine desk log book
Turbine local log book

15. AMENDMENT HISTORY

PREVIOUS
CONDITION PREVIOUS
PRESENT CONDITION CURRENT REV.
S.NO (BEFORE REV. NO.&
(REASON MADE) NO & ISSUE DATE
THIS ISSUE DATE
REVISION)
1.
2.
3.

Page 11 of 11