CIVIL

R MECH
E
LOG DATE : V ELECT
I
IN COMM NO : E I&C
W
A APPROVED SUPPORT

B APPROVED AS NOTED CONTRACTOR

C NOT APPROVED RECORD

D
I INFORMATION I WORKING DOCUMENT
S
T
APPROVAL DOES NOT RELIEVE CONTRACTOR R
FROM RESPONSIBILITY FOR ERROR OR I
DEVIATIONS FROM CONTRACT B
REQUIREMENTS U
T
I
BY DATE : O
N
LOG DATE :

OUT COMM NO :

PT. PERUSAHAAN LISTRIK NEGARA (PERSERO)

AGENCY OF THE MINISTRY OF MINES AND ENERGY
GOVERMENT OF THE REPUBLIC OF INDONESIA

CONTRACT NO : 0436.PJ/DAN.02.01/DIR/2015

PT. PLN (PERSERO)

PUSAT ENJINIRING KETENAGALISTRIKAN
MicroStation v8.11.9.578
1=1

2018.03.14 2018.03.14 2017.03.14

d Modify according to BV comments
Shi Bin Bill.D D.Z
REV. MODIFICATION MODIFIED CHECKED APPROVED

SEP. PARTS LIST: NO FORMAT D DESIGN GROUP SULZER PUMPS THIRD ANGLE PROJECTION

REPLACED BY: - SUBSTITUTE FOR: - ORIGINAL SCALE: -

DRAWN:
HPT LOGIC DIAGRAM/ CAUSE AND EFFECT DIAGRAM 2017-6-16
SHIBIN
200-330-6s HPT-TD Pump CHECKED: 2017-6-16
BILL.D
Lontar Extension FEED WATER PUMP
A4

APPROVED: 2017-6-16
100241334 - Zou Daniel
PART NO.
--- EN PLD1002413340010-01 1/1

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 Sulzer Pumps Suzhou Ltd. Boiler Feed Pump
Control System Description LONTAR EXTENSION
COAL FIRED STEAM POWER PLANT (1X315MW)
SO. 100241334-0010 / 0020 Rev: "0" 2017.6.18

Section Page

1. Section
INTRODUCTION 2
2. BOILER FEED PUMPSET LUBE OIL SYSTEM 3
3. BOILER FEED PUMPSET MECHANICAL SEAL SYSTEM 4
4. SUMMARY OF PUMP MOUNTED INSTRUMENTATION SUPPLIED 5
5. BOILER FEED PUMPSET CONTROL LOGIC 7

D Added 5.2.1.13 Shi Bin 2018.03.14 Daniel Zou 2018.03.14

C Added 5.3.6 / 5.3.8 Shi Bin 2017.12.03 Daniel Zou 2017.12.03
B Modified according to BV comments Shi Bin 2017.7.14 Daniel Zou 2017.7.14
A First Issue For Comment/Approval Shi Bin 2017.6.16 Daniel Zou 2017.6.18
Rev. Description Compiled Date Approve Date

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 Sulzer Pumps Suzhou Ltd. Boiler Feed Pump
Control System Description LONTAR EXTENSION
COAL FIRED STEAM POWER PLANT (1X315MW)
SO. 100241334-0010 / 0020 Rev: "0" 2017.6.18

1. INTRODUCTION
1.1. Purpose.
1.1.1. This Control System Description outlines the basic control & interlock logic for the
Mechanical protection of the Boiler Feed Pumpset.
1.1.2. This description only covers the basic operating procedures associated with the machinery
protection, monitoring & control. As such, this document does not cover the procedures for
the initial commissioning/start-up of the package or for the process normal operation or
upset conditions of the pump; the philosophy covers the protection & interlock logic for the
pump only.
1.1.3. Full details on the commissioning & operation of the Boiler Feed package & specific items of
equipment are contained in the Sulzer Installation Operation & Maintenance Manual.
1.1.4. All alarm, control & trip settings are included in the respective Instrument Schedule; the
settings given herein are nominal values only.
1.2. Scope of Supply.
1.2.1. A summary of the equipment supplied by Sulzer & supplied by others is detailed below;
1.2.2. Supplied by Sulzer
1.2.2.1. Boiler Feed Pump - HPT 200-330-6S, with mechanical seals, sleeve type
journal bearings and titling pad type thrust bearings
1.2.2.2. Booster Pump – ZF250-5560
1.2.2.3. Booster Pump Motor - HYUNDAI
1.2.2.4. Coupling and Guard (between motor-booster pump) - Trumy
1.2.2.5. Local - package - mounted, temperature, pressure for main equipment & seal
system, all cabled to junction boxes.
1.2.3. Supplied by Others;
1.2.3.1. Package Pump/System process control & shutdown logic - part of the 'DCS'
systems, along with the associated local 'process' instrumentation.
1.2.3.3. All interconnecting cabling between Boiler Feed Pump packages, DCS system(s).
1.3. Hazardous Area Installation.
All Boiler Feed pump mounted instrumentation supplied by Sulzer shall be suitably certified for
Safe Area install

Associated Drawings

Title Description Sulzer Doc. No.

1.3.1 Pump General Arrangement PGA1002413340010-01/02
1.3.2 P & I Diagram PPI1002413340010-01
1.3.3 Terminal Block Diagram PWD1002413340010-01
1.3.4 Instrument List PIL1002413340010-01
1.3.5 Pump Performance Curve PPC1002413340010-01
1.3.6 Utility Consumption List PUC1002413340010-01

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 Sulzer Pumps Suzhou Ltd. Boiler Feed Pump
Control System Description LONTAR EXTENSION
COAL FIRED STEAM POWER PLANT (1X315MW)
SO. 100241334-0010 / 0020 Rev: "0" 2017.6.18

2. Lube Oil System

2.1. The purpose of the turbine integral lube oil system is to provide the necessary (pressurized)
supply of lube oil to the Boiler Feed pump as follows;
2.1.1. Prior to starting the package; so that the pump is lubricated before starting the turbine
2.1.2. Continuously whilst the package is running.
2.1.3. After the package has been stopped/shutdown, to ensure that the pump is lubricated
during the time the pump takes to run-down to a stationary – complete stop - condition.

2.2. The Lube oil system is provided by others and as such all control is outside the scope of Sulzer.
We recommend:
2.2.1. Loss of the lube oil supply (detected by ‘low-low’ lube oil pressure) whilst the package is
running will cause immediate shutdown of the main turbine drive to prevent serious damage
to the pump bearings.
2.2.2. A Lube oil low pressure alarm causes immediate change over to the motor driven lube oil
pump – which is maintained in operation until the package is shut down by other means e.g.:
process stop.
2.2.3. When a stop command is issued to the pump set , the lube oil pump should continue to run for
minimum 20 minutes (via a timer in the DCS) after the pump has come to a complete stop.
2.2.4 Continuous monitoring of the lube oil temperature, to initiate alarm and trips as necessary on
lube oil high-high temperature.

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 Sulzer Pumps Suzhou Ltd. Boiler Feed Pump
Control System Description LONTAR EXTENSION
COAL FIRED STEAM POWER PLANT (1X315MW)
SO. 100241334-0010 / 0020 Rev: "0" 2017.6.18

3. Mechanical seal system

3.1. The purpose of the Pump Seal System is to seal the high temperature boiler feed water around the
rotation shaft , allowing only a small leakage of cool water. The pressure to be sealed is the pump
suction pressure, both at the drive end and the non-drive end where the balancing drum leakage is
connected to the suction piping.

The BFP pump is fitted with two Mechnical seals, one at the pump DE (drive end) & one at the
pump NDE (non-drive end).

3.2 The Pump Seal System then basically comprises of:

3.2.1 Two ’single’ mechanical seals fitted on the main feed pump and one ‘single’ mechanical
seal fitted on the booster pump.

3.2.2 Seal loop fluid coolers, water cooled, provided to remove the heat generated by the
mechanical seals in the barrier fluid.

3.2.3 Seal loop fluid magnetic filter, designed with a bypass piping also with magnetic filter for
maintain, fitted with valves for manual changeover.

3.3 The seal fluid is circulated by pumping rings in each seal - around a closed circuit through the
cooler, filter and back to the seal.

Temperature gauges (40LAC11CT621 40LAC21CT621 40LAC21CT622) are located on the seal return
pipes to detect high temperatures of each seal loop.

Pressure switches (40LAC21CP101 40LAC21CP102) are located on the filter to detect the clogging.

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 Sulzer Pumps Suzhou Ltd. Boiler Feed Pump
Control System Description LONTAR EXTENSION
COAL FIRED STEAM POWER PLANT (1X315MW)
SO. 100241334-0010 / 0020 Rev: "0" 2017.6.18

4. SUMMARY OF PUMP MOUNTED INSTRUMENTATION SUPPLIED.

4.1. Process Instrumentation.
4.1.1. Process instrumentation:
4.1.1.1 Booster Pump suction pressure - 40LAC11CP501
4.1.1.2 Booster Pump discharge pressure - 40LAC11CP502
4.1.1.3 Boiler Feed Pump suction pressure - 40LAC21CP501
4.1.1.4 Boiler Feed Pump discharge pressure - 40LAC21CP502
4.4.1.5 Boiler Feed Pump interstage take-off pressure - 40LAC21CP503

4.2. Mechanical seal flush piping Instrumentation.

4.2.1. The Mechanical seal flush piping is supplied with the following instrumentation:
4.2.1.1. Booster pump seal water return temperature - 40LAC11CT621
4.2.1.2. Boiler Feed Pump ‘DE’ seal water return temperature - 40LAC21CT621
4.2.1.3. Boiler Feed Pump ‘NDE’ seal water return temperature - 40LAC21CT622
4.2.1.4. Boiler Feed Pump ‘DE’ seal water filter diff. pressure - 40LAC21CP101
4.2.1.5. Boiler Feed Pump ‘NDE’ seal water filter diff. pressure - 40LAC21CP102

4.3. Machine Temperature Monitoring.

4.3.1. The following temperature sensors (RTD's) are fitted on the package, where only one of the
duplex elements or one of the simplex elements are cabled to skid edge junction boxes.
The signals are monitored at the DCS/IPS (by others), where high temperature alarms & hi-hi
temperature shutdowns are provided.
Boiler Feed Pump:
4.3.1.1. ‘DE’ Lube Oil Drain Temperature - 40LAC21CT623
4.3.1.2. 'NDE' Lube Oil Drain Temperature - 40LAC21CT624
4.3.1.3. Upper Casing Temperature - 40LAC21CT605
4.3.1.4. Lower Casing Temperature - 40LAC21CT606
4.3.1.5. 'DE' Journal Bearing Temperature - 40LAC21CT601
4.3.1.6. 'NDE' Journal Bearing Temperature - 40LAC21CT602
4.3.1.7. 'NDE' 'I/B' Thrust Bearing Temperature - 40LAC21CT603
4.3.1.8. 'NDE' 'O/B' Thrust Bearing Temperature - 40LAC21CT604
Booster Pump
4.3.1.9. Antifriction Bearing Temperature (Journal) - 40LAC11CT601
4.3.1.10. Antifriction Bearing Temperature (Thrust) - 40LAC11CT602
Booster Pump Motor
4.3.1.11. Motor 'U' Phase Winding Temperature - 40LAC11CT605
4.3.1.12. Motor 'U1' Phase Winding Temperature(Spare) - 40LAC11CT606
4.3.1.13 Motor 'V' Phase Winding Temperature - 40LAC11CT607
4.3.1.14 Motor 'V1' Phase Winding Temperature(Spare) - 40LAC11CT608
4.3.1.15 Motor 'W' Phase Winding Temperature - 40LAC11CT609
4.3.1.16 Motor 'W1' Phase Winding Temperature(Spare) - 40LAC11CT610

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 Sulzer Pumps Suzhou Ltd. Boiler Feed Pump
Control System Description LONTAR EXTENSION
COAL FIRED STEAM POWER PLANT (1X315MW)
SO. 100241334-0010 / 0020 Rev: "0" 2017.6.18

4.3.1.17 Motor 'DE' Journal Bearing Temperature - 40LAC11CT603

4.3.1.18 Motor 'NDE' Journal Bearing Temperature - 40LAC11CT604

4.4. Machine Vibration Monitoring.

4.4.1. Non-contacting ‘eddy current’ type probes are fitted as follows, with (remote mounted) monitors forming
part of the Unit Control Panel (UCP), with high vibration pre-alarms & hi-hi vibration shutdowns;
Boiler Feed Pump:
4.4.1.1 'DE' Shaft Displacement (X-Plane) - 40LAC21CY601
4.4.1.2 'DE' Shaft Displacement (Y-Plane) - 40LAC21CY602
4.4.1.3 'NDE' Shaft Displacement(X-Plane) - 40LAC21CY603
4.4.1.4 'NDE' Shaft Displacement(Y-Plane) - 40LAC21CY604
Booster Pump:
4.4.1.5 Bearing Housing Vibration (Horizontal) - 40LAC11CY601
4.4.1.6 Bearing Housing Vibration (Vertical) - 40LAC11CY602
Booster Pump Motor
4.4.1.7 'DE' Bearing Housing Vibration (X-Plane) - 40LAC11CY603
4.4.1.8 'DE' Bearing Housing Vibration (Y-Plane) - 40LAC11CY604
4.4.1.9 'NDE' Bearing Housing Vibration (X-Plane) - 40LAC11CY605
4.4.1.10 'NDE' Bearing Housing Vibration (Y-Plane) 40LAC11CY606

4.5. Speed Monitoring.

4.5.1.1 BFP Key Phasor - 40LAC21CS601
4.5.1.2 BFP Speed Sensor - 40LAC21CS602
4.5.1.3 BFP Reverse Rotation Sensor - 40LAC21CS603
4.5.1.4 BFP Speed Pickup With Detection of Rotation - 40LAC21CS001
4.5.1.5 Booster Pump Key Phasor - 40LAC11CS601

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 Sulzer Pumps Suzhou Ltd. Boiler Feed Pump
Control System Description LONTAR EXTENSION
COAL FIRED STEAM POWER PLANT (1X315MW)
SO. 100241334-0010 / 0020 Rev: "0" 2017.6.18

5. Boiler Feed Pumpset Control Logic

5.1. Boiler Feed Pumpset Start Permissives.

5.1.1. The following 'start permissives' should to be satisfied before the package pump can be started;
5.1.1.1. All 'pumps shutdown' conditions are healthy & reset (see Para 5.2).
5.1.1.2. All stop commands are 'normal' - i.e., not operated.
5.1.1.3. Package pump suction pressure is OK/adequate.
5.1.1.4. Package pump discharge valve is closed (unless system pressure in the discharge
manifold is sufficient enough to start against, in which case the discharge valve can
be open, with manifold pressure being held against the non-return valve. The package
pumps cannot be started against an open valve/no system pressure).
5.1.1.5. Minimum Flow Valve is open sufficiently to maintain a path for minimum flow
protection.
5.1.1.6. Lube system is charged.
5.1.1.7. Cooling water supply is OK/adequate.
5.1.1.8. All process conditions are normal. Note, the stop command should be interlocked with
process start permissions so that the package pumps can ‘t be started unless process
conditions are normal (i.e. suction manifold isolation valve open).

5.2. Boiler Feed Pumpset Shutdown Protection.

5.2.1. The following conditions are to be continually monitored by the DCS in the event of a fault
condition arising:-
5.2.1.1. Boiler Feed pump journal and thrust bearing temperatures hi-hi.
5.2.1.3. Boiler Feed pump Shaft vibrations hi-hi.
5.2.1.4. Booster Pump journal and thrust bearing temperatures hi-hi.
5.2.1.5. Booster Pump bearing housing vibration hi-hi.
5.2.1.6. Booster Feed pump journal or thrust bearing temperatures hi-hi.
5.2.1.7. Motor Journal Bearing Temperature hi-hi.
5.2.1.8. Motor Winding Temperature hi-hi.
5.2.1.9. Motor Bearing Housing Vibration hi-hi.
5.2.1.10. BFP Mechanical Seal Water Filter Diff. Pressure hi.(alarm only).
5.2.1.11 BFP Mechanical Seal Water return temperature hi.(alarm only).
5.2.1.12 Reverse rotation sensor.
5.2.1.13 Pump speed.

5.2.2. Operation of the either lube oil supply pressure low-low trip (associated low-
pressure alarm) are inhibited or masked whilst the main drive motor is not
running.
5.2.3. All trips initiated should lockout on fault until the fault condition has returned to normal & the
system manually reset by the operator

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 Sulzer Pumps Suzhou Ltd. Boiler Feed Pump
Control System Description LONTAR EXTENSION
COAL FIRED STEAM POWER PLANT (1X315MW)
SO. 100241334-0010 / 0020 Rev: "0" 2017.6.18

6-Jun-2022 it was
noticed casing was
5.3. Boiler Feed Pumpset Start Sequence.
70 deg , but vendor
5.3.1. The basic procedure for STARTING the package is as follows;
allows to bypass
5.3.1.1. Check start permissive conditions (see Para 5.1).
5.3.1.2. Reset all pump shutdown conditions (see Para 5.2).
this interlock .
5.3.1.3. Start lube oil supply.
However vendor
5.3.1.4. Start cooling water supply. The cooling water system is always active. should clarify what
5.3.2. Pump filled, suction and minimum flow valve open. is the requirement.
5.3.3. Once the lube oil supply & cooling supply are running, the start sequence is now held pending
lube oil system pressure being established at the pump bearings.
5.3.4. Once lube oil pressure is established, (sensed by the relevant pressure transmitter), the turbine
driver may be started.
5.3.5. Turning gear speed is 100 rpm. The turning gear has to engage automatically during coast
down of the pump. The pump can only be restarted at specified conditions if it has not come to
a standstill. Otherwise, it has to cool down to naturally to 60°C casing temperature (at top and
bottom) before it can be restarted.

5.3.6. After the booster pump start, the turbine driver should be started, minimum flow control (by others)
should be maintained at all times when the pumps are running to avoid min. flow damage to the
pumps. The turbine speed will gradually from 0 up to ~ 800 RPM, and then rise to 2000 RPM in
an hour.So the minimum flow valve should be fully open to maintain the minimum flow.
If the Booster pump flow is less than the minimum flow rate during this period, and the booster
pump vibration will be higher.
If the vibration value is lower than 8mm/s , it’s acceptable and does not affect the booster pump
operation.
5.3.7. Once the package is running command the discharge valve to open. Minimum flow protection
is provided upstream of the discharge isolation valve, therefore opening of the discharge
valve in a certain time is not necessary. Minimum flow protection is provided based on a
measured flow, closure of the minimum flow valve will occur as a consequence of the
measured condition.

5.3.8. The TDBFP pump being stopped (no turning gear engagement) and then can’t be re-started
immediately.
6-Jun-2022 As per vendor now min flow tripping for
booster not needed instead vibration
( LAC11CY601/602 and LAC12CY601/602) 8 mm/s
will trip the booster and 4.5 will alarm .
5.4. Normal Operation/Running Value 11mm/s now changed to 8 and alarm set at
5.4.1. Once started, the Boiler Feed Pumpset should4.5
run .without
Refer L4214_t_10
manual ,L4204_t_10
intervention, as alarm & for flow now its
forced manual.
shutdown conditions shall be continuously monitored at the DCS. L4214_5 and L42

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 Sulzer Pumps Suzhou Ltd. Boiler Feed Pump
Control System Description LONTAR EXTENSION
COAL FIRED STEAM POWER PLANT (1X315MW)
SO. 100241334-0010 / 0020 Rev: "0" 2017.6.18

5.5. Boiler Feed Pumpset Normal Stop & Shutdown.

5.5.1. The basic procedure for STOPPING the package, either on receipt of a stop command from
the DCS, or on a trip/emergency stop condition arising, is as follows;
5.5.1.1. Press the “Stop” button to stop the turbine. Check that they run down smoothly.
5.5.1.2. Command the discharge valve to close. Ignore this command if there is system pressure
in the discharge manifold (see Para 5.1.1.4). Operation of discharge valve is independent of
pump stop.
5.5.1.3. Operation of the low-low flow trip (by others) should be inhibited or masked whilst the
pump is running down to stand-still. Minimum flow protection is maintained during shutdown.
5.5.1.4. Leave lube oil systems and coolant supplies operating for a minimum of 20
minutes after pumpset shutdown. Normally the lube oil pump continues to operate to protect
the bearings if the pump is rotated by the process fluid and so that the main pump remains
available to start with minimal delay.
5.5.2. The Boiler Feed pumpset stop sequence is now complete.
5.5.3. With all trip conditions 'reset' & start permissives 'healthy'/satisfied, the Boiler Feed pump package can be
restarted as noted in above.

Addendum for turbine driven frame C pump: The turning gear has to engage automatically during coast
down of the pump. The pump can only be restarted at specified conditions if it has not come to a standstill.
Otherwise, it has to cool down to naturally to 60°C casing temperature (at top and bottom) before it can be
restarted.

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