PART -II ( TDBFP COMMNG)
All local and remote instrumentation for the system is complete.
Insulation of the following completed.
a) Re-circulation line of main pump.
b) Suction and discharge line of booster pump and main pump.
c) Main pump and booster pump body.
Commissioning of valves related to the feed pump system are completed. (Suction isolating valve, discharge isolating valve, re-circulation valve and motor cooling water isolating valve etc)
All instrumentation local ,remote completed , and also Interlock and protection system simulation checking completed.
Commissioning of Oil System and Turning Gear Operation of BFP Turbine( BHEL make)
Oil flushing of lubrication oil system completed and lines are normalized. ( note:- temporary pipes ,bends etc removed kept it for use of next pump oil flushing next pump
Turbine is disconnected from gear box and main pump and kept in isolation.
Completion of lube oil inlet lines with throttles / orifices pressure gauges and return lines with view glass and temperature gauges.
Check healthiness of bearing metal temperature detectors of turbine, main pump and booster pump. ( In general we use Platinum RTD ( 100 ohm 0 degree or Ni-Cr-Ni thermo-couple 4.12mv/100 deg increase.) therefore as per visual check with a meter all will show room temperature.
Ensure proper mounting of speed probes and turbine supervisory probes ( axial shift , thermal expansion , overall thermal expansion with dowelling after necessary calibration.)
Ensure the completion of Jacking Oil of lines with throttle valve, NRV ( non return valve) and isolating valve.
Ensure healthy filter elements in MOP, AOP, EOP suction lines, MOP, AOP and EOP discharge lines and JOP suction line.
Oil is filled in MOT through centrifuge to adequate level. ( Servo prime 46 or equivalent from any other company.)
Keep open the vents of lube oil coolers and filter to purge air from the system.
Keep the changeover valve of lube oil cooler and filter in such a way that only one cooler ad filter will be in service.
Drains of lube oil coolers, filters should be in closed position to avoid any loss of oil..
Start one of the oil vapour fans with its suction valve open condition.
Start one of the lube oil pumps ensuring flow through recirculation.
Adjust lube oil header pressure control valve to maintain lube oil pressure of 2.5 kg/cm2 ( approx) after control station.
Adjust lube oil discharge pressure to 10.0kg/cm2(approx) by setting re-circulation control valve.
By operating isolating valve of recirculation control valve, check the safety valve popping and adjust if required.
Check the lube oil flow to the bearing of turbine, main pump and booster pump.
Monitor lube oil duplex filter DP.
Stop the pump and start other lube oil pump and check its discharge safety valve popping and adjust if required.
Stop running pump and start DC EOP. ( Emergency Oil Pump).
Ensure adequate lube oil pressure and flow. Keep DC EOP running for 4 hours to check the healthiness of the system with EOP.
Stop DC EOP and keep lube oil pump in service .
Charge the suction line of JOP from lube oil header.
Start JOP and adjust the safety relief valve to 110 kg/cm2.
Adjust pressure regulating valve to 100 kg/cm2
Adjust the throttle valves in Jacking oil supply to front and rear journal bearings such that the rotor lifts around 0.05 to 0.1 mm. Stop JOP and start again. Check and record the Jacking oil pressures and rotor lifts in the turbine front and rear journal bearings.
Check and ensure the freeness of rotor for rotation by engaging hand barring lever and then stop JOP.
Ensure auto operation of AOP I, AOP II and DC EOP through corresponding pressure switches operation. ( Part of protection checking and auto operation) . Cut in of DCEOP in emergency is most important aspect.
Keep AOP I in service, AOP II and EOP on auto.
Oil temperature is above 40 degree C .
Charge cooling water to cooler and ensure oil temperature control valve auto operation.
Start JOP and open turning gear valve.
Once the rotor picks up speed, turning gear valve may be closed for checking the rotor for possible rubbing at end gland seals, heat shields, oil gaurds etc., while coasting down.
If the rotor is found smooth till it comes to standstill, turning gear valve may be opened full.
Turning gear speed of around 200 RPM and smooth running.
Observe and record bearing metal temperatures, vibrations, eccentricity etc.and run for 8 hours. stop turning gear and observe coasting down etc,
MOP = MAIN OIL PUMP
AOP = AUXILIARY OIL PUMP
JOP = JACKING OIL PUMP
DC EOP = EMERGENCY OIL PUMP ( DIRECT CURRENT)