No.

Dokumen : KA-OP-007-20
PT PRIAMANAYA ENERGI
Tanggal Terbit : July 2020

STANDARD OPERATION PROCEDURE

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Clean pump and pipe.

Pump is clogged. Replace sealing ring.
Seal ring is worn severely. Increase pump rotating
Flow is than Rotating speed is low. speed.
estimated value Pipe resistance is high, thus pump Change operating
operates with small flow. parameters and working
conditions.
Consumption Replace impeller.
power is Impeller is worn. Adjust gate valve and
excessive. Water supply increases. decrease flow.

Adjust gate valve and

During operation, Gate valve is over opened.
sound becomes Suction pipe resistance is excessive. decrease flow rate.
Check suction pipe and foot
abnormal, and Water suction height is excessive.
valve.
flow decreases, Air leaks in suction opening.
Decrease suction height.
until water is Temperature of conveyed liquid is too Tighten or block up the leak.
interrupted.
high. Decrease liquid temperature.

Align the shaft central line of

Pump shaft and motor shaft are pump and motor.
misaligned.
Replace bearing.
Pump vibrates. Bearing is worn.
Dismantle to check the
Rotor rubs with casing, and the pump, and strengthen the
foundation is loose. foundation.
It is lack of oil or oil is not pure. Inject or replace oil.
Bearing is too hot. Water pump shaft and motor shaft Align the shaft central line of
are misaligned. pump and motor.


2.3 Operation of Feedwater System
2.3.1 System Overview
The system basic process flow is: deaerator water tankÆmotor driven
feedwater pumpÆ#2 HP heaterÆ#1 HP heaterÆboiler economizer. The
function of motor driven feedwater pump is to convey the feedwater in
deaerator water tank, which is pressurized by motor driven pump, and then
the feedwater flows through HP heaters in sequence, then goes to boiler
economizer, and at the same time it supplies desuperheating water for super
heater and bypass device. The unit uses two 100%-capacity motor driven
feedwater pumps. One is for operation, and the other is for standby. Water
level of boiler steam drum is regulated though rotating speed of motor
operated feedwater pump. Each motor driven feedwater pump is equipped
with one minimum flow recirculation valve. When motor driven feedwater
pump output is under 30%, the minimum flow recirculation valve automatically

ST AUX EQUIPMENT STANDARD OPERATING PROCEDURE OF KEBAN AGUNG LAHAT 2 X 135 MW

COAL-FIRED POWER PLANT
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 No.Dokumen : KA-OP-007-20
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opened to ensure the necessary minimum flow. When motor driven feedwater
pump output exceeds 40%, it automatically closes.

2.3.2 Flow Diagram of Feedwater System

2.3.3 Technical Specifications
2.3.3.1 Technical Specifications of Motor Driven Feedwater Pump
Motor Driven Feeswater Pump Spcification:

Type 135TSBII-J Shaft power 2997KW

Flow 544mϢ/h Rotating speed 4600r/min
Life 1824m Efficiency 82.8%
Essential net
Weigh 6650Kg positivesuction 6.0m
head
Manufacturer Zhengzhou Power Equipment Works

Feedwater pump motor specification:

Item Unit Specification Item Unit Specification
Three-phase
Mode --- YK3400-2/1180 Mode --- asynchronous
motor
Power KW 3400 Power factor --- 0.90
Stator

V 6300 Stator current A 359.5

Connecti
--- Y Frequency Hz 50
method
Efficienc Rotating
% 196.3 r/min 2987
speed
Counterclockwise(
Rotating From Insulatio
direction --- pump grade --- F
side)

Cooling
IC81W ˜closed
water-
Ambient
--- air  40
temperature
ST AUX EQUIPMENT STANDARD OPERATING PROCEDURE OF KEBAN AGUNG LAHAT 2 X 135 MW
COAL-FIRED POWER PLANT
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 No.Dokumen : KA-OP-007-20
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coolin
g˅
˅

Gross
Xiangtan Motor Group
kg 18900 Manufacturer Company.,
LTD

2.3.3.2Technical Specifications of Hydraulic Coupler
No Item unit specification
1 mode --- R17K.2E
Singal chamber scoop tube hydraulic
2 type ---
sdjustment
Rated output rotating
3 KW
speed
4 Input rotating speed r/min 2980
5 Rated output rotating speed r/min 4600
6 Speed adjustment range % 25~100
7 Rated slip % ˘3
8 Rotating direction ---
9 Gear speed ratio ---
10 Total efficiency %
11 Total valumn of oil tank ̉3
12 Oil type ---
13 weigh t
14 Manufacturer ---

2.3.4 Inspections before motordDriven water pump startup
2.3.4.1 Maintenance should be finished, check the equipment is complete with good condition.
Make sure the site is clean, and make good preparations for startup.

2.3.4.2 Check to make sure the instruments are complete and pressure gauge primary
valve is open, then inform instrument personnel to turn on the instrument power
supply. And contact electrical personnel to measure the motor, turn on the motor
power supply if it is acceptable. Put siren alarming signal into operation and
check it is in good condition.
2.3.4.3 Open mechanic sealing cooling water vave, water supply valve and return water
pump of motor driven feedwater pump. Open cooling water inlet and outlet valve
of A motor-operated feedwater lube oil cooler. Open cooling water inlet and
outlet valve of motor-operated working oil cooler. Open cooling water inlet and
outlet valve of motor-opated feedwater pump motor air cooler.

ST AUX EQUIPMENT STANDARD OPERATING PROCEDURE OF KEBAN AGUNG LAHAT 2 X 135 MW

COAL-FIRED POWER PLANT
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2.3.4.4 Check water level of deaerator is normal.

2.3.4.5 Check water inlet motor operated valve of motor-driven feedwater pump is
opened and water inlet pressure is not less than 1.13 times of saturation
pressure under this temperature, and water outlet valve of motor driven
feedwater pump is closed.

2.3.4.6 Check all instruments are completely installed, connection valve is open and the
air has been discharged. Check to put interlock of coupler oil pump into
operation, oil quality and level are normal.

2.3.4.7 Open water inlet valve of motor-driven feedwater pump, warm up the pump and
inject water to pump proper and pipe. Carefully check whether there is leakage.
Open all vent valves to fully discharge the air in proper and pipe. Note to check
condenser hot well and deaeretor water level.
2.3.4.8 Before startup, make sure the pipe is not blocked and turning rotor rotates smoothly.

2.3.4.9 Regulate scoop pipe of motor-driven feedwater pump hydraulic coupler to 5% to 10%.

2.3.5 Startup of Motor-Driven Feedwater Pump

2.3.5.1 Normal startup of motor-driven feedwater pump

Start auxiliary oil pump of motor-driven feedwater pump. Observe whether oil
circulation is clear from returned oil sight glass. Pressure before bearing
should exceed 0.15MPa.
Start motor-driven feedwater pump. Check the motor current, sound and
vibration are normal.
Check outlet valve of motor-driven feedwater pump should be open via
interlock.
Regulate scoop pipe opening according to boiler requirements and control
output of motor-driven feedwater pump. When the output is under 30% of the
flow, minimum flow valve automatically opens to make sure the minimum flow
for motor driven feedwater pump. When the output exceeds 40%, minimum
flow valve automatically close.
When lubrication oil pressure exceeds 0.3MPa, shut down auxiliary oil pump.
Check whether standby motor-driven feedwater pump meets the requirements
of warm standby. Put it under interlock standby if it the requirements are met.

2.3.5.2 Startup sequence of motor-driven feedwater pump

Start up auxiliary oil pump of motor-driven feedwater pump.

Open water inlet valve of motor-driven feedwater pump.
Close water outlet valve of motor-driven feedwater pump.
ST AUX EQUIPMENT STANDARD OPERATING PROCEDURE OF KEBAN AGUNG LAHAT 2 X 135 MW
COAL-FIRED POWER PLANT
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 No.Dokumen : KA-OP-007-20
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Set coupler construction at 5%~10%.

Open the minimum flow valve of motor-driven feedwater pump to 90%~100%.
Start up motor-driven feedwater pump, interlock to open outlet valve.
When lubrication oil pressure exceeds 0.3MPa, check auxiliary oil pump
should be shut down automatically.

2.3.6 Maintenance and Monitoring During Operation.

2.3.6.1 Maintenance During Operation.
Check inlet water temperature and pressure.
Check that the minimum flow valve works normally.
Check if every bearing temperature, temperature and pressure of lube. oil and
working oil and oil tank level are normal.
Regulate the balancing device and check the balancing clearance at each
stage when the pressure in the balancing chamber is 0.2MPa higher than that
in the pump inlet.
Thoroughly discharge lubricating oil and replace the new one when the MBFP
has been operating for 200h for the first time. Replace it again after 1000h
operation. Clean the lubricating area with gasoline or benzene to completely
eliminate the impurities in oil during replacement. It is required to replace
lubricating oil twice a year.

The vertical vibration of rotor at the bearing should not be bigger than 0.05mm.
Besides, the vibration at horizontal, axial direction and circular run-out should not
exceed 0.05mm. Try to eliminate the faults if the value exceeds the limits.

Seal water of gland side should be clear when motor-driven fedwater pump is
running or is at standby status.

2.3.6.2 Monitoring During MBFP Operation

The current and coil temperature of MBFP motor is normal.

Lube oil pressure is bigger thn 0.17MPa, if it is smaller than 0.15 MPa,the
auxiliary oil will be started automatically; If the pressure is smaller than
0.08MPa, motor-operated pump will be tripped due to lube oil pressure is low.
Working oil presse keeps within the range from 0.1 to 0.3MPa.

The normal inlet oil temperature of the lubricating oil cooler should be
between 45ć
ć-65ć. Give an alarm when the oil temperature is 65ć and the
pump should be immediately shut down when the oil temperature is 70ć.

The normal outlet oil temperature of the lubricating oil cooler should be
between 35ć-55ć. Give an alarm when the oil temperature is 55ć and the
pump should be immediately shut down when the oil temperature is 60ć

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 No.Dokumen : KA-OP-007-20
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The normal inlet oil temperature of the working oil cooler should be between
60 ć-110ć. Give an alarm when the oil temperature is 110ć and the pump
should be immediately shut down when the oil temperature is 130ć. Closely
monitor the working oil temperature when the opening of scoop tube is
between 60% and 70%.
The normal outlet oil temperature of the working oil cooler should be between
35 ć-65ć. Give an alarm when the oil temperature is 75ć and the pump
should be immediately shut down when the oil temperature is 80ć.

The temperature of support bearing and thrust bearing should be lower than
75 . The pump should be shut down when the oil temperature is85 .
The bearing temperature inside the hydraulic coupler should be lower than
65 and alarm when the oil temperature is90 .
The bearing temperature of motor should be lower than 75 and alarm when
the oil temperature is 80 .
The differential pressure of lubricating oil filter is lower than 0.06MPa, alarm.
The differential pressure of the inlet filter is lower than 0.03MPa,
alarm.

2.3.7 Normal Switchover of MBFP

2.3.7.1 Check that the MBFP B meets the startup requirements and the preparations have
been made before startup.
2.3.7.2 Remove the interlock of MBFP B.
2.3.7.3 Start up MBFP B and check that the outlet valve should be opened by interlock.
2.3.7.4 Slowly increase the opening of scoop tube in the MBFP until there is flow at outlet.
2.3.7.5 Gradually use MBFP B to take the load of MBFP A. Note that the minimum flow
valve on MBFP acts accurately.
2.3.7.6 Check that the MBFP B runs normally with load, the MBFP A loses output and keep
the minimum opening of scoop tube.
2.3.7.7 Shut down the motor of the MBFP A. The outlet valve should be opened by
interlock. If there is no maintenance work, put the pump in interlock standby. Outlet
valve should be open by interlock.

2.3.8 Shutdown of MBFP

2.3.8.1 Normal deactivation of MBFP
Confirm that the recirculation valve of MBFP is in auto mode.
Recirculating valve should act normally when slowly regulating scoop of
running pump to the smallest position during shutdown and put interlock of
standby pump out of service.
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Start up the auxiliary oil pump of the MBFP to confirm that the oil pressure is
normal.

Shut down the motor of MBFP.

After MBFP is deactivated, the oil pump should keep running for at least a half
hour before shutdown. The oil pump should not be shut down if it is in hot
standby.
Close the inlet and outlet MOV of MBFP. The inlet valve should not be closed
if it is in hot standby.
Close the inlet and outlet isolation valves of MBFP recirculation valve. They
should not be closed if they are in hot standby.

Record the coasting time when MBFP is shut

down.

2.3.8.2 Sequence Shutdown Procedures of MBFP

(a) Start up the auxiliary oil pump.

(b) Adjust the opening of scoop tube to 5%~10%.

c) Close the outlet valve.

d) Shut down the motor of MBFP.

2.3.9 Interlock Protection of MBFP
2.3.9.1 The operating MBFP will interlock trip if any of the following conditions exist.
a) Lube. oil pressure of motor-driven water pump is decreased to 0.08MPa.
b) Feedwater flow of feedwater pump is less than 30%, the opening of
recirculating valve should be lower than 20% when the feedwater pump is
running.
c) Working oil cooler inlet oil temperature increases to 130ć
ć
d) Feedwater pump bearing temperature increases to 90ć
ć

2.3.9.2Alarm and Interlock Protection of MBFP

Monitoring ,Alarm and

No Monitoring ,Alarm and Protection parameters
Protection items

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≥0.3MPa, interlock shut down the AUX oil pump(it should be

Inlet oil pressure of pump stopped manually)
1
and motor bearing ≤0.15MPa, interlock start up the AUX oil pump.
<0.08MPa, shut down the motor of feedwater pump.
2 Oil level of oil tank Alarm at the minimum oil level.
Motor bearing
3 t≥80ć
ć alarm
temperature
Pump bearing
4 t≥75ć
ć alarm
temperature
5 Pump bearing vibration >0.06mm alarm
N>motor rated powerˈ
ˈstop motor-driven feedwater pump
6 Motor shaft power
motor.
when motor-driven feedwater pump flow is less than 30%
Recirculating valve
7 (recirculating valve opening is smaller than 20% when the
refuses open
feedwater pump is running)
Working oil cooler inlet
8 >110ć
ć alarm
temperature
Working oil cooler outlet
9 >75ć
ć alarm
temperature
Lube oil cooler inlet
10 >65ć
ć alarm
temperature
Lube oil cooler outlet
11 >55ć
ć alarm
temperature
12 Hydraulic coupling bearing >90ć
ć alarm
temperature
13 Motor stator winding >135ć
ć alarm
temperature
Feedwater pump
14 mechanical seal return >80ć
ć alarm
water temperature
Feedwater pump
15 mechanical seal incoming >70ć
ć alarm
water temperature
Lube. oil filter pressure
16 >0.06MPa alarm
difference
Feedwater pump inlet filter
17 front and rear pressure >0.03MPa alarm
difference
18 Operating pump trips. Activate the standby pump by interlock.

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2.3.10 Troubleshooting of MBFP

2.3.10.1 Immediately press EMERGENCY button to shut down the pump in the following
conditions

If severe vibration suddenly occurs to pump or there is clear metal friction

sound inside the pump unit.

For any bearing, if there is oil interruption, smoke, or the temperature reaches
Ċ alarm value or the oil return temperature exceeds 80 .

The pressure of lubricating oil decreases to 0.15MPa and will continuously

decrease to 0.08MPa after the AUX oil pump is started up.
The inlet temperature of working oil cooler is higher than 130 or there is
smoke or fire in the coupler.
The personnel or equipment safety is threatened by serious leakage of pump
or the HP and LP feedwater pipes cannot be isolated for break.

Motor and hydraulic coupler cannot correctly rotate.

2.3.10.2 Startup standby pump and shut down the MBFP in the following conditions:
Cavitation occurs to MBFP.
The oil return temperature of any bearing is higher than 70 .
The motor current is up to rated value and the load decreasing is invalid.

2.3.10.3 Operation Procedures of Pump Emergency Shutdown

Locally press the EMERGENCY button or put the system in MANUAL mode
on the control panel to manually shut down MBFP.
Keep the scoop tube of coupler at minimum opening and close the outlet
valve of MBFP. Note that pumps should not rotate with reverse direction.
Oil pressure decreases to 0.15MPa and check that the AUX oil pump is
automatically started up. Or manually start up it immediately.
Other operations are the same as normal shutdown of pump.

2.3.10.4 MBFP cavitation.

Malfunctions
Decreasing and unstable current of MBFP
Decreasing and unstable outlet pressure of MBFP.
Decreasing and unstable flow of feedwater
Noise and water impact inside the pump and serious vibration.
Causes
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Sudden decreasing pressure of deaerator or excessively low water level.

The flow of feedwater is ≤30%, the recirculation regulating valve is closed
and the trip protection fails to act. The MBFP is operating with low flow in
a long time.

Troubleshooting

When there is cavitation in MBFP during boiler ignition and

pressurization, emergency shut down the MBFP and restore the pump
operation after eliminating the faults.
If there is cavitation in MBFP during load operation, the standby pump
should be started first and shut down the pump after its load is
ttransferred to the other one.

2.3.10.5 Abnormal oil system

Oil level of oil tank declines.

Ascertain the causes of oil level sudden decreasing 10mm~20mm.

Try to make up oil if the oil level declines. The pump should be
emergently shut down if it is invalid to take measures when the oil level
declines to the lowest level of coupler.

Oil level and pressure decrease simultaneously.

Simultaneous decreasing of oil level and pressure is generally caused by

leakage of pressure oil tube. Check whether the lubricating oil cooler and
working oil cooler are leaked. The pump for standby should be started up if
there is leakage. Shut down the pump after the load of this MBFP is taken by
the other one. Deactivate the leaked oil cooler and eliminate the leakage.

c) Oil pressure decreases.

The normal oil pressure should be higher than 017MPa and the AUX oil pump
should be interlock started up when it is lower than 0.15MPa. Or manually
operate the oil pump and ascertain the decreasing causes. If the oil pressure
continues to decrease to 0.08MPa after the AUX oil pump is started up, trip the
pump by protection or emergency shutdown.

2.4 Operation of Condensate System

2.4.1 General Description
The whole system should be continuously made up with the demineralized water
as a result of steam and water loss in the thermal system such as boiler blowdown
and pipe drainage. The makeup water from the chemical water treatment is led to
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