STEAG Energy Services India Pvt Ltd

2x600MW Singareni Thermal Power Plant Site

PRESENTATION
On

BCW OVERVIEW & OPERATION

PREPARED BY : ROHIT KUMAR VERMA
 INDEX

 Description

 Start Permissive

 Protection

 BCW Line Diagram

 BCW Cavity Filling

 Starting Procedure

 Post Starting Procedure

 Isolation Procedure

 Emergency Operation
BCW PUMP
 EQUIPMENT DESCRIPTION

EQUIPMENT DETAILS of BOILER CIRCULATING WATER PUMP

No. Description
1 3 Nos. BCW are produced by Torishima company. As per design 2 out of 3 pumps can run
full load operation. In order to increase the flexibility of operation, 3 pumps can be put into
service.

2 Three pumps are equipped with wet motor type HLAV2 X300-500/1C type.

TECHNICAL DATA

Boiler circulating water pump

Type model HLAV2 X 300-500/1C Design temperature 370ºC

2
Design pressure 215 Kg/cm Test pressure 322.5 Kg/cm2

3
Capacity 3748 m /h Head 32.5 m
Boiler water circulating pump motor
Type model HLV55/4 FQ45-335 Rated power 450 kW
Rated voltage 3300 V Rated current 122 A
Speed 1458 r/min Protection IP/68
 START PERMISSIVE

1 Electrical permit (Master trip and EPB operated)

2 Vent valve B-1,2,3,4,25,26,28 and 29 closed

3 Critical Protection ( cavity temp. High > 65°C)

4 LP coolant flow normal (08 m3/hr)

5 Suction manifold & casing temp difference normal <28°C

6 Discharge valve stem-1 open

7 Discharge valve stem-2 open

8 Emergency tank level adequate >50mm

9 Switch gear available

10 Motor cavity temp adequate > 2°C

 PROTECTION

1 Motor cavity temp very high (2/3) > 65°C

2 Discharge valve stem-1 not open

3 Discharge valve stem-2 not open

4 Electrical trip

5 Uncommanded trip
BCW LINE DIAGRAM
 BCW CAVITY FILLING

Ensure that Work permit on respective equipment's are closed and men and material are removed from these areas.
1

Ensure boiler is drained

2
Charge the basket strainer and HP fill & purge cooler from SGECW
3
Charge magnetic filter and check its DP
4
Cavity filling line through Boiler Fill pump charged by opening supply valve (Also can be done through feed regulating station)
5
Drain valve of 1st strainer kept open to ensure primary cooler & 1st strainer flushing
6
Then charge water up to 2nd strainer & its drain kept open & 1st strainer drain closed.
7
Flushing continued until water is qualified (PH > 8.5, temp <45 Deg C, Conductivity < or = 5 µs / cm, Solid Contents < 5 ppm , Halogen
8 spc. Chlorine < 50 ppm)

Ensure Pump vents are kept open & line drains are closed
9
Start cavity filling .
10
Maintain and ensure flow of 5 L/Min by throttling manual valve ( after 2nd strainer )
11
Do cavity air venting & flushing through pump vent.
12
Once cavity filled ensure water comes out from the vent. Take sample
13
Stop the filling.
14
Check Motor Megger value and it should be > 200 M-Ohm
15
 STARTING PROCEDURE

1 Ensure that Work permit on respective equipment’s are closed and men and material are removed from these areas.

2 Ensure that Boiler water circulating pumps motor cavity is properly filled and vented.

3 Local drum gauge glass is available. Hydra step and drum level recorder available in CCR.

4 Ensure Boiler Drum vent valves B3, B4, B25 & B26 are in closed condition and Healthy.

5 Ensure Boiler Drum vent valves B1, B2, B28 & B29 are in closed condition and Healthy.

6 SG DMCW pump and Emergency overhead tank system in service.

7 Maintain Drum level high (>200 mm)

8 Ensure LP cooler cooling water flow > 120 LPM.

9 Ensure Heat barrier cooling water flow > 25 LPM.

10 Open both discharge of BCW pump.

11 Charge pump casing heating equalizing line.

12 Start one BCW pump

 POST STARTING PROCEDURE

Ensure the pump draws about 60-75 amps and DP is >1 kg/cm2, If values are fluctuating immediate stop the
1
pump, vent thoroughly and ensure the Drum level.

2 Check that drum level is adequate, if not open the low range feed control valve to make it up.

3 Open Boiler Drum vent valves B1, B2, B28 & B29, as it takes auto close command with BCW Pump ON.

4 Start another BCW pump when Drum pressure will reach above 8 kg/cm2 and Check the following ;

a) Motor current

b) Motor cavity temp

c) Pump diff. press. & pump running condition OK at local

 ISOLATION PROCEDURE

0
1 To stop the BCW pump the suction manifold temperature should be. less than 90 C and differential drum metal temperature
0
should be less than 50 C.

2 Stop the BCW-pump and close the discharge valve.

3 Confirm BCW pump breaker off, breaker, switch off Control supply. Rack out the breaker.

4 Put Tag in breaker for respective PTW No.

5 If boiler is running do not isolate heat barrier and LP cooler line.

 EMERGENCY OPERATION OF BCW PUMP

0 0
1 Temperature of motor chamber high: In normal operation motor temperature is less than 50 C. When temperature exceeds 60 C alarm
will appear and pump will trip if the temperature is greater than 65°C.The following reasons may cause high temperature:-

a) Low pressure cooling water.

b) High pressure cooling water joint leakage.

c) Leakage of internal cooler.

d) Temperature sensor and alarm device malfunction.

e) Bearing Vibration or Noise high.

f) Motor cavity drain valve should be full closed and drain valve near motor should be hand tightened. There should not be any drop of
water leakage.

2 If the temperature rises continuously above 60 Deg C and reason not found and when cannot be corrected then stop the pump.

0
3 If Suction manifold and pump casing metal Diff. Temp is >50 C, pump start permissive not available, to avoid this open equalising line drain.

4 One running pump trips out of 3, it will affect the drum level, than control the drum level.

5 If 2 pumps trips unit will run back to reduce the load to 300 MW, bottom elevation 3 mill hold and AB elevation guns cut in.

6 If all the 3 running pump trip unit will trip on protection.