PRO CE D URE FO R S IT E P ER FO RM A NC E G U AR A NT EE TE ST O F B FP PROJECT 210KHAPERKHEDA TPS UNITS 3 & 4 CUSTOMER 1.

0 INTENT : The intent of the site test is to prove the auxiliary power consumption of the Boiler Feed Pump set measured at the input terminals of the BFP drive motor at guaranteed parameters. 2.0 GUARANTEE PARAMETERS : The guaranteed parameters of the pump are given at Sl.no. 9.0 3.0 TEST SET UP : The schematic arrangement for the test is illustrated in page no. 6. 4.0 MEASURING POINTS : a) FLOW : The Feed water flow of the Boiler Feed Pump is measured using the plant flow nozzle and test differential pressure transmitter. b) HEAD : : MSEB :2x

The head measurement is done by test pressure transmitters in Booster pump suctions, BFP suction and BFP discharge. c) TEMPERATURE : The temperature measurement is done by test RTD . d) SPEED : The speed measurement is carried out by non-contact type digital tachometer. c) POWER : The power input at the motor terminals shall be measured by test watt transducers which shall be connected to C.T's and P.Ts provided in the switchgear. 5.0 PERFORMANCE TOLERANCES : An overall tolerance of 3.5% will be used while comparing measured power with the guarantee power due to measurement uncertainties on flow, head and power. This is as per Table-7 of BS-5316, Class C. 6.0 6.1 TEST METHODOLOGY : The test instruments listed at cl.no. 10.0 will be connected as per the test scheme. All transducers will be connected to a data logger. 6.2 6.3 Preliminary test shall be conducted for checking up of instruments. After stabilisation, the test will be conducted for about 1 hour and readings will be recorded at 5 minute intervals in the data logger. The data logger print out of the readings thus recorded shall be signed by Customer and BHEL Representatives. During the test, the customer shall try to maintain the flow through the BFP within 3% of the flow at guarantee point, for recording the various parameters. 6.4 7.0 Two tests will be conducted on each pump set. CALCULATION PROCEDURE : The auxiliary power consumption for BFP set is valid for a given set of guarantee parameters of BFP suction flow and the feed water temperature. In case the BFP is operated at a point different from the guaranteed parameters, the input power would be computed using the standard formulae relating Q, H and Efficiency, and the auxiliary power consumed at

motor terminals is derived after considering the motor efficiency, pump efficiency and hydraulic coupling losses corresponding to test flow, with reference to design curves of BFP and Booster pump. Evaluation is done by averaging the test results of the two test carried out on each pump. 8.0 AUXILIARY POWER GUARANTEE : BFP parameters corresponding to Auxiliary Power guarantee : (MRC Flow, 0% MU, 0.0911 ata back pr.) Suction Flow (m3/hr) Dynamic head (mlc) Temperature (C) Specific Wt. (kg/m3) Motor input power (kW) Total Auxiliary Power (kW) : : : : : : 343.9 (per BFP) 1890 (BFP + BP) 159.50 907.77 2660 (per BFP) 5320

NOTE : Auxiliary power is guaranteed with ZERO interstage flow i.e. interstage valve in closed condition. 9.0 LIST OF INSTRUMENTS :

-----------------------------------------------------------------------------------PARAMETER Booster Pump Suction Pr. BFP suction Pressure BFP discharge Pressure BFP suction TYPE AND RANGE OF Pressure Transmitter 010kg/sq.cm. Pressure Transmitter 030kg/sq.cm. Pressure Transmitter 0300kg/sq.cm. Diffl. Pr. TAG NO. PT1 ACCURACY REMARKS 0.1%

PT2

0.1%

PT3 DPT

0.1% 0.1%

Flow

Transmitter (Range will be selected based on flow nozzle data) TE N N W 1/3 DIN 1 RPM 1 RPM 0.25%

BFP Suction RTD 0 - 200C Temperature BFP speed Optical non-contact Digital Tachometer.

Booster Optical non-contact Pump Speed Digital Tachometer. Motor input Power. Watt transducer

-----------------------------------------------------------------------------------10.0 SAMPLE CALCULATIONS : During the site test, pump parameters like flow, head and speed may be different from those guaranteed. The following illustrates sample calculation for new auxiliary power based on site test parameters. A. Site tested data : Feed water temp. Sp. wt. of feed water Flow Booster pump suction pressure BFP suction pressure BFP discharge pressure Booster pump speed BFP speed Power input to motor terminals From the above data : Flow = 345/0.9169 = 376.27 m3/hr = = say 105 mlc say 1952 mlc = = = = = = = = = 150 C 916.9 kg/m3 from standards 345 t/hr p1 kg/cm2 p2 kg/cm2 p3 kg/cm2 1510 rpm 4800 rpm 2770 kW

Booster pump head = {(p2 - p1) x 10} / 0.9169 BFP head = {(p3 p2) x 10} / 0.9169

B.

Estimated auxiliary power based on tested data : i. Booster Pump : Tested flow corrected to design speed = (1485/1510)x376.27=370 m3/hr Efficiency at corrected flow from design curve = 77% 916.9 x 376.27 x 105 Power input to pump = kW 102 x 3600 x 0.77 ii. Boiler Feed Pump: Tested flow corrected to design speed = (5075/4800)x376.27=398m3/hr Efficiency at corrected flow from design curve = 81% 916.9 x 376.27 x 1952 Power input to pump = --= 2264 kW -----------------------------------------------= 128

102 x 3600 x 0.81 iii. Hydraulic Coupling : Mechanical losses = 100 kW (Approximate)

HC Prim. speed BFP Test speed Slip losses = ------------------x Input power (speed dependent) BFP Test speed 5998 4800 = ------------------- x 2264 ----------------------

= 188 kW . 4800

Total losses in Hydraulic Coupling = 100 + 188 = 288 kW iv. Total input power = (i) + (ii) + (iii) = 128+2264+288 = 2680 kW

Motor efficiency from motor design curve Power input at Motor terminals = = C. Auxiliary Power measured at site : Auxiliary power measured at test speed D.

95 %

2680/0.95 2821 kW

2770 kW

Auxiliary power at motor terminals measured at site (C) will be compared to the estimated auxiliary power (B-iv). In case the measured power is higher than the calculated power, the difference of the two will be treated as excess auxiliary power consumption.

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