Station: NTPC- Simhadri Plant area: TURBINE

BHEL Ref No.PS-DC-186-500-105 NTPC Ref no SIM/1/TS/1/105

Sheet 1 of 12

PROCEDURE FOR COMMISSIONING OF CENTRAL LUBE OIL STORAGE & PURIFICATION SYSTEM SL. NO 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 PLANT DETAILS OBJECTIVE PROPOSAL SERVICES REQUIRED SAFETY PERECAUTIONS EMERGENCY PROCEDURE STATE OF THE PLANT METHOD COMPLETION CRITERIA APPENDICES A. DRAWING LIST OF CONTENTS

Station: NTPC- Simhadri Plant area: TURBINE

BHEL Ref No.PS-DC-186-500-105 NTPC Ref no SIM/1/TS/1/105

Sheet 2 of 12

PROCEDURE FOR COMMISSIONING OF CENTRAL LUBE OIL STORAGE & PURIFICATION SYSTEM SL.NO 1.0 1.1 STATUS PLANT DETAILS Central lube oil storage, purification and transfer system which is common for both the units and is used for following functions. I. Storage and purification of turbine lube oil during normal running of the set.

II. Emptying the unit lube oil system of any of the units and filling back to the system. III. Adding new oil into the system as per normal periodic makeup requirement. 1.2 The system consists of the following equipments-I. One clean oil tank, common for station, of 60 Cu.M capacity for storing clean oil.

II. One dirty oil tank, common for station, of 60 Cu.M capacity for storing dirty oil. III. One clean oil transfer pump of 8250 LPH capacity for transferring oil from clean oil tank to any of the unit oil tanks. IV. One dirty oil transfer pump of 8250 LPH capacity for transferring oil from dirty oil tank to central oil purifier. V. One central oil purifier, common for station, of capacity 7500 LPH. VI. One oil unloading vessel of capacity 1 Cu.M for unloading oil from barrels or tanker.

Signatures NTPC BHEL

Station: NTPC- Simhadri Plant area: TURBINE

BHEL Ref No.PS-DC-186-500-105 NTPC Ref no SIM/1/TS/1/105

Sheet 3 of 12

PROCEDURE FOR COMMISSIONING OF CENTRAL LUBE OIL STORAGE & PURIFICATION SYSTEM SL.NO 1.3 The clean and dirty oil tanks are of rectangular type and located at 0.0 M inside T.G. Hall alongwith oil transfer pumps. The central lube oil purification unit consists of feed pump, indirect water bath electric heater, centrifuge separator, oil discharge booster pump and associated piping, valves, instruments, interlocks, drive motors, control panel etc. in a package. STATUS

1.4

2.0

OBJECTIVE The objective of this procedure is to commission the Central Lub-oil Storage Purification System and make it available for Unit Operation. PROPOSAL Commissioning of Central Lub-oil Storage and Purification System is proposed through the following proposals.

3.0

3.1 3.2

Acid cleaning of oil lines. System charging and commissioning of a) Clean oil Transfer Pump b) Dirty oil Transfer Pump c) Central oil Purifier

Signatures NTPC BHEL

Station: NTPC- Simhadri Plant area: TURBINE

BHEL Ref No.PS-DC-186-500-105 NTPC Ref no SIM/1/TS/1/105

Sheet 4 of 12

PROCEDURE FOR COMMISSIONING OF CENTRAL LUBE OIL STORAGE & PURIFICATION SYSTEM SL.NO 4.0 4.1 4.2 SERVICES REQUIRED Availability of required manpower to unloading oil and attending leakages if any, taking place during filling. Availability of lighting and Communication at the central oil-storage and purifier area and also MOT area of individual units. Availability of oil transfer arrangement into oil unloading vessel. Availability of Service air and Equipment cooling water. Availability of tools, Tackles and consumables like kerosene / Diesel, Markin cloth required for cleaning of oil purifier and filters. Availability of recommended oil in required quantity. SAFETY PRECAUTIONS Portable fire extinguisher suitable for oil fires are kept near the test area. Sand buckets are kept in sufficient numbers near the test area. Area is suitably cordoned unauthorised personnel. off to avoid trespassing by STATUS

4.3 4.4 4.5 4.6 5.0 5.1 5.2 5.3 5.4

Arrangements to be made to avoid oil spillage as well to clean oil spillage immediately, if any such thing takes place.

Signatures NTPC BHEL

Station: NTPC- Simhadri Plant area: TURBINE

BHEL Ref No.PS-DC-186-500-105 NTPC Ref no SIM/1/TS/1/105

Sheet 5 of 12

PROCEDURE FOR COMMISSIONING OF CENTRAL LUBE OIL STORAGE & PURIFICATION SYSTEM SL.NO 6.0 6.1 EMERGENCY PRECAUTION The test team should be aware of the entire lay-out of the Central lub-oil storage and purification system, in order to react for any emergency notified to them. This is required to take appropriate action, even it requires stopping of running equipments. The test team should be aware of steps to be undertaken in case of damage to machinery or injury to any personnel. This system being the major oil system in the power house building, all the precautions against oil fire to be ensured (Dos and Donts with regard to oil fire to be displayed prominantly at all locations in the test area.) STATE OF THE PLANT Erection of the following equipments/Items completed as per drawing. a) One clean oil tank (with level gauges & switches) b) One Dirty oil tank (with level gauges & switches) c) One clean oil transfer pump d) One dirty oil transfer pump e) One central oil purifier f) One oil unloading vessel g) All connected pipelines / valves etc. Signatures NTPC BHEL STATUS

6.2 6.3

7.0 7.1

Station: NTPC- Simhadri Plant area: TURBINE

BHEL Ref No.PS-DC-186-500-105 NTPC Ref no SIM/1/TS/1/105

Sheet 6 of 12

PROCEDURE FOR COMMISSIONING OF CENTRAL LUBE OIL STORAGE & PURIFICATION SYSTEM SL.NO STATUS

7.2 7.3 7.4 7.5 7.6

All the tanks and pipe lines are ensured for cleaning while erection. All the supports for the tank and pipe lines are completed. Insulation at recommended location/area are completed. Electrical system required for commissioning the system are erected, tested and available for commissioning the plant. Required quantity of recommended oil is moved to the unloading point. Arrangements for unloading the oil into unloading vessel is also made available. Required local/remote I/c inputs for tanks, pumps are made available.

7.7

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Station: NTPC- Simhadri Plant area: TURBINE

BHEL Ref No.PS-DC-186-500-105 NTPC Ref no SIM/1/TS/1/105

Sheet 7 of 12

PROCEDURE FOR COMMISSIONING OF CENTRAL LUBE OIL STORAGE & PURIFICATION SYSTEM SL.NO 8.0 8.1 8.1.1 METHOD System Description (Refer Drg. No. PE-DG-186-100-0108) During normal operation, the unit oil purifiers associated with each TG set will be drawing oil from the associated unit oil tanks & after purification pumping it back into the unit oil tanks. The system is operating on unit basis. The dirty oil tank is used for storing the oil drained from the unit oil tanks by gravity & by opening the valve L0-12. The oil from dirty oil tank is passed through the central oil purifier by means of dirty oil transfer pump and the purified oil is stored in the clean oil tank through Valve L0-30 and L0-32. Alternatively the clean oil from the central oil purifier can be directly sent to any of the unit oil tanks. Unit oil tanks can also be drained into the clean oil tank by opening the valves L0-11, L0-18, L0-23, L0-24 & L0-30. The clean oil which is stored in the clean oil tank can be supplied to any of the unit oil tanks by running the clean oil transfer pump. In this case the clean oil transfer pump shall be running and the inlet valve L0-2 to any of the unit oil tanks as required can be opened in order to fill the unit oil tank. The inlet to the clean oil tank valve L0-30 should be normally closed. The central oil purifier can be used as a standby if any of the unit oil purifier is out of service. For example if the unit oil purifier of unit No. 1 is out of service the oil from the unit oil tank no. 1 can be drawn by gravity and supplied to the central oil purifier through valve L0-11, the purified oil then flows to the unit oil tank by opening vale L0-2. STATUS

8.1.2

8.1.3

8.14

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Station: NTPC- Simhadri Plant area: TURBINE

BHEL Ref No.PS-DC-186-500-105 NTPC Ref no SIM/1/TS/1/105

Sheet 8 of 12

PROCEDURE FOR COMMISSIONING OF CENTRAL LUBE OIL STORAGE & PURIFICATION SYSTEM SL.NO STATUS

8.15

The clean oil transfer pump can work as a standby to dirty oil transfer pump or vice-versa in case of emergency. For this purpose the transfer pumps are inter connected on suction as well as the discharge with isolating valves as shown in the drawing. Thus any of the above operations where dirty oil pump is used can be carried out by using clean oil pump also. Similarly any operation requiring clean oil pump can be carried out by dirty oil pump also. The connections are provided on clean oil header and dirty oil header for adding oil into the BFP turbines lube oil system and for emptying the BFPT oil tank respectively. For adding new oil into the system for periodic make-up requirements, oil from barrels is unloaded to the oil unloading vessel. Depending upon the quality of the oil, it can be stored either in clean oil tank or dirty oil tank by running transfer pumps. A suitable mono rail arrangement shall be provided outside C row for unloading oil from barrel, as shown in drg. No. PE-DG186-106-003 (TG Equipment Plan at 0.0M). Barrel shall be lifted with the help of chain pulley block arrangement and oil shall be unloaded manually into the unloading vessel. A connection is provided with an isolating valve each at the dirty oil pump discharge and clean oil pump discharge for emptying out the tanks.

8.1.6

8.17

8.18

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Station: NTPC- Simhadri Plant area: TURBINE

BHEL Ref No.PS-DC-186-500-105 NTPC Ref no SIM/1/TS/1/105

Sheet 9 of 12

PROCEDURE FOR COMMISSIONING OF CENTRAL LUBE OIL STORAGE & PURIFICATION SYSTEM SL.NO STATUS

8.1.9

When the temperature of the oil in the dirty oil tank is very low, the oil is heated up with the heater of the purifier and is sent back to the dirty oil tank through recirculation line. This is required, so that before entering the centrifuge the viscosity of the oil is brought to that which is most suitable for separation in centrifuge. The above operations such as drainage, transfer, filling etc. are manual and no automatic operations are envisaged. Dirty oil tank and clean oil tank are provided with level gauges and level switches for high and low level annunciation. Oil transfer pumps suction strainer choking condition shall be annunciated when the differential pressure across the strainer exceeds the set value. Acid cleaning of oil lines. All the oil lines connected to clean oil, dirty oil and central oil purifier system are to be acid cleaned before commissioning the system. (Drain lines can be excluded). Procedure given in Document No. PS-DC-186-500-0013A / NTPC Ref. No. SIM/1/TS/1/003A to be referred for acid cleaning procedure. All the oil lines commissioning. are normalised and made ready for

8.1.10

8.1.11 8.1.12

8.2 8.2.1

8.2.2

8.2.3

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Station: NTPC- Simhadri Plant area: TURBINE

BHEL Ref No.PS-DC-186-500-105 NTPC Ref no SIM/1/TS/1/105

Sheet 10 of 12

PROCEDURE FOR COMMISSIONING OF CENTRAL LUBE OIL STORAGE & PURIFICATION SYSTEM SL.NO STATUS

8.3 8.3.1

System Charging Oil from barrels or directly from tankers is topped up into oil unloading vessel and oil level in both, clean oil tank and dirty oil tank slowly raised to about 40-50% level. (Required oil level to be decided at site). Required valves are lined up for pump commissioning. Refer enclosed drawing no. PE-DG-186-100-0108. Start the clean oil transfer pump and put under re-circulation through L0 30 valve. The pump shall be run for 2 hour trial run and during this trial run, load current, pump discharge pressure and vibration are noted down at one hour interval. (Totally 3 sets of reading). Commission dirty oil transfer pump on the same lines as explained above. After completing the trial of clean oil transfer pump, oil lines lined up to input point of central lub-oil purifier. Start the central lub-oil purifier ensuring that dirty oil transfer pump is in service. Put the central lub-oil purifier under 2 hours trial run and observe for the performance of booster pump and purification bowl system. Fill the clean oil tank in this process slowly.

8.3.2 8.3.3 8.3.4

8.3.5 8.3.6 8.3.7 8.3.8

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Station: NTPC- Simhadri Plant area: TURBINE

BHEL Ref No.PS-DC-186-500-105 NTPC Ref no SIM/1/TS/1/105

Sheet 11 of 12

PROCEDURE FOR COMMISSIONING OF CENTRAL LUBE OIL STORAGE & PURIFICATION SYSTEM SL.NO STATUS

8.3.9

To observe the performance of central oil purifier, oil can be recirculated from clean oil tank to suction of dirty oil transfer pump, purifier and back to clean oil tank. With the readiness of dirty and clean oil tank and with the commissioning of dirty and clean oil transfer pumps, lub-oil can be filled up through the central oil purifier into MOT of Unit I, II, and lub-oil reservoir of Unit I BFPT A & B and Unit II BFPT A & B. COMPLETION CRITERIA Commissioning of Central Lub-oil storage and Purification System completed with the completion of proposals given in Section 3.0

8.3.10

9.0

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PROCEDURE FOR COMMISSIONING OF CENTRAL LUBE OIL STORAGE & PURIFICATION SYSTEM