NTPC/TSTPS OPERATION DEPARTMENT TS-II/OPN/OI /TG/ /014

AREA TG Operating Instruction For Loading, Unloading REV 0.00

UNIT - 3/4/5/6 & Change over of BFPs Date : 15/10/2007

A PURPOSE: -

This document is prepared to guide the operating personnel while loading & unloading BFPs (TDBFP or
MDBP) in Stage- II Units.

B SCOPE: -

This shall be applicable to all the 4 units of Stage II (4X 500 MW units) , TSTPP, NTPC Ltd.

C INTRODUCTION : -
After unit synchronization when ever the unit load reaches around 220 MW , we
need to load second BFP to meet feed water requirement. Normally TDBFP A& B are kept rolled
condition before unit synchronization from CRH source or auxiliary steam on recirculation at 2500
3000 RPM . Again at about 300-330 MW , the 2nd TDBFP is loaded and MDBFP is unloaded . Also
BFP change over takes place during normal operation to attend various defects on TDBFP from
time to time . In case of any emergency situations like tripping of running TDBFP , the MDBFP is
started & loaded to meet the FW flow requirement . All these cases need careful operation to
avoid any exigencies , so that the ensuing emergencies are avoided . This document will guide
the operating Desk engineers while carrying out such operations .

D TECHNICAL DATA OF THE SYSTEM

Turbine Critical speed 7550 rpm

Type K1401-2 Turning gear speed 150 rpm
BHEL / Direction of rotation
Manufacturer (as viewed from steam admission CCW
Hyderabad
Maxm. Output 7575 KW end)
Design. rating (economical rating) 5732 KW Governing system Electrohydraulic
Turbine normal speed 5275 rpm Shaft power 5750 KW
1494 to 5750 Steam consumption 35.792 T/hr.
Speed range
rpm
Main PUMP
Specified initial steam pr. 6.33 kg/cm2 No. of Pumps 2 x 50%
Permissible dev. in st. pr. 12.0 kg/cm2 No. of Stages 4
Maxm. Wheel chamber pr. 11.0 kg/cm2 Suction temp. oC 164
Exhaust steam pr. 0.1064 kg/cm2 Suction pr. (bar) 25.7
Specified initial steam temp. 289.6oC Discharge pr. (bar) 202.5
Permissible deviation without NPSH at 3% head break down
320.0oC 50
limitation (bar)
No. of stages 14 Nos. Sp. gravity 0.904
No. of stop valve 1 No. Flow rate (T/hr.) 990
No. of Aux. C.V. 1 No. Speed (rpm) 5465
No. of control valves 5 Nos. Efficiency (%) 81
Ferostatic pick Power consumption KW 6223
Method of speed sensing
up Total dynamic head (m) for pump 2390
Overspeed trip 6330 rpm

Sheet 1 Of 5
Prepared By Reviewed By Approved By
Sri K.Ch. Satyanarayana,S(O) Sri R.N.Das , SS(O) Sri D.Sarkar , DGM(O)
 NTPC/TSTPS OPERATION DEPARTMENT TS-II/OPN/OI /TG/ /014
AREA TG Operating Instruction For Loading, Unloading REV 0.00
UNIT - 3/4/5/6 & Change over of BFPs Date : 15/10/2007

Recirculation required for cont. Suction temp. (oC) 164

400
minm flow (T/hr.) Suction pr. (bar) 8.3
Discharge pressure for the kicker NPSH at (3% head break down)
255.27 4.5
stage(bar) m
shut off head(m) 3000 Discharge pr. (bar) 20.3

Booster PUMP Pump speed rpm 1494
No. of Pumps 2 x 50% Power consumption, KW 608
Casing type Efficiency(%) 81.5
Direction of rotation (from driver
CCW
end)

E RESPONSIBILITY :

TG Desk Engr /UCE /SCE / Operation support group

F LOADING PROCEDURE FOR 1ST TDBFP ( WHILE UNIT START UP AT 220 MW)

PRE CONDITIONS OF THE UNIT :

Unit I is in synchronized condition, load 220 mw

MDBFP is in service and three element drum level control is active

TDBFP is in rolled condition

Feed water requirement 750-800 t/hr(at lower loads super heater spray is high)

PROCEDURE :

1. The difference in Speed reference of TDBFP and scoop of MDBFP reference is very high >30%
2. Check running TDBFP s discharge pressure and BFPS common discharge header pressure .
3. Give open command to TDBFPS discharge valve and wait till its full open (open feedback is coming in
CRT)
4. Slowly raise the TDBFPS speed reference and watch discharge pressure to reach closer to common
discharge header pressure.
5. When TDBFPS discharge pressure approaches near to common discharge header pressure and is
short by 5-7 KSC , Check TDBFPS thrust bearing temperature
6. Increase speed reference command by 0.5% selector in three element window .
7. When TDBFPS discharge pressure equals common discharge header pressure , increase speed
reference by another 0.5% to ensure pump discharging to common discharge header.
8. Slight Increase in TDBFPS suction flow and consequent reduction in MDBFPS suction flow indicates
that TDBFP has taken load
9. Put the TDBFP control in CAS mode from three element window
10. Close recirculation valve of TDBFP
11. Open or close recirculation of MDBFPS according to flow requirement. BFP near run out zone alarm is
given for individual pump in CRT to indicate inability of specific pump to meet the requirement
12. After both pumps are in CAS mode ensure they are sharing the load as unit load increases .

Sheet 2 Of 5
Prepared By Reviewed By Approved By
Sri K.Ch. Satyanarayana,S(O) Sri R.N.Das , SS(O) Sri D.Sarkar , DGM(O)
 NTPC/TSTPS OPERATION DEPARTMENT TS-II/OPN/OI /TG/ /014
AREA TG Operating Instruction For Loading, Unloading REV 0.00
UNIT - 3/4/5/6 & Change over of BFPs Date : 15/10/2007

G LOADING PROCEDURE FOR 2ND TDBFP & UNLOADING MDBFP ( WHILE UNIT START UP AT
300 MW OR MORE )

PRE CONDITIONS OF THE UNIT :

Unit is in synchronized condition, load 300 MW .

One TDBFP & MDBFP are in-service & on auto mode . Three element control is active.

Feed water requirement is around 1000-1100t/hr

Speed reference of rolled pump to running pump difference is very high >25%

PROCEDURE :
1. Check BFP common discharge header pressure and discharge pressure of BFP (to be loaded)
2. Give TDBFP discharge valve open command if it is not open .
3. Ensure discharge valve open feedback has appeared in CRT
4. Slowly raise the speed reference and watch discharge pressure to reach closer to common discharge
header pressure. (when reference deviations are high , 5% command selector can be used )
5. When discharge pressure of BFP (to be loaded) reaches near to common discharge header pressure
and short by 10-7 KSC , Check thrust bearing temperature .
6. Increase speed reference of BFP (to be loaded) by 0.5% selector command in three element control
window .
7. When BFPS (to be loaded) discharge pressure equals common discharge header pressure , increase
speed reference of BFPS (to be loaded ) by 0.5% to ensure pump has taken load & started
discharging to common discharge header
8. Slightly load this BFP .
9. Put the BFPS (to be loaded) in CAS mode from three element window
10. Now three pumps are in operation.
11. Close recirculation valve of TDBFP and when rise in feed water flow stabilized Open recirculation valve
of MDBFP .
12. Take MDBFP scoop control in manual and reduce it by 0.5% in one command for two to three time.
Reduction in MDBFPS suction flow and consequent increase in running TDBFPS suction flow indicates
the unloading of MDBFP . Slowly reduce scoop (5% command can be used) and keep it 35-40% , to
avoid suction flow lo-lo protection
13. Keep MDBFP running in recirculation for 30 minutes . then stop MDBFP & select it on auto standby
mode . AOP will stop in Auto mode after 30 minutes of pump stopping ..
14. Ensure MDBFP discharge valve is open and POSCLS feedback is coming to CRT

H LOADING PROCEDURE FOR MDBFP AND UNLOADING TDBFP

1. Check the availability of MDBFP ,i.e no PTW pending

2. If MDBFP selected in auto standby mode , then Deselect MDBFP to man mode .
3. Give discharge valve close command. (if BFPS common discharge header pressure >100 KSC
closing of discharge valve is not required )
4. Give zero % open command to scoop (which was tracking three element o/p)
5. When scoop is zero % check all start permissive are available & give start command to MDBFP .
6. AOP will take start in auto .
7. Observe motor current, starting current will come down to no load current 160-180 Amps.

Sheet 3 Of 5
Prepared By Reviewed By Approved By
Sri K.Ch. Satyanarayana,S(O) Sri R.N.Das , SS(O) Sri D.Sarkar , DGM(O)
 NTPC/TSTPS OPERATION DEPARTMENT TS-II/OPN/OI /TG/ /014
AREA TG Operating Instruction For Loading, Unloading REV 0.00
UNIT - 3/4/5/6 & Change over of BFPs Date : 15/10/2007

8. Give open command to discharge valve ( if not open )

9. Wait till discharge valve is open feed back comes to control CRT
10. Ensure motor cooling water valve is full open and feedback is coming to CRT (valve normally takes 60-
80 sec for full opening)
11. Increase scoop to 30-35% to maintain suction flow >250 T/H & minimum discharge pressure of 85
ksc .
12. Check running MDBFPS discharge pressure and common discharge header pressure.
13. Slowly increase the scoop command, initially 5% command in each step can be given. Wait for discharge
pressure to stabilized and continue till pressure is 10-8 Ksc less than common discharge header
pressure.
14. Now slowly raise scoop command use 0.5% increment in one step when MDBFP discharge pressure
equal common discharge header pressure equals. Put it in CAS (from three element window)
15. Now three pumps in service (recirculation valve of MDBFP is in open condition)
16. Close the recirculation of MDBFP and allow the momentarily disturbed feed water supply to stabilize.
17. Open recirculation of TDBFP (to be shut down) to be unloaded. Take it to manual mode & Reduce
speed reference slowly to 40-45%. Maintain suction flow near to 300 T/H
18. Check all parameters of MDBFP are with in limit .
19. Trip the specific TDBFP after fully unloaded & MDBFP stabilisd

J EMERGENCY LOADING PROCEDURE FOR MDBFP

PRECONDITIONS: UNIT LOAD 500-300 MW , FEED WATER REQUIREMENT 1600-1100 T/H

MDBFP IS SELECTED IN AUTO STANDBY MODE

DISCHARGE VALVE IS IN OPEN CONDITION

POSCLS(POSITION CLOSE FEEDBACK IS A/L IN MDBFP CRT)

SCOOP IS TRACKING THE THREE ELEMENT OUTPUT REFERENCE

ONE OF RUNNING TDBFP TRIPPED .

OBSERVATIONS AFTER ONE TDBFP TRIPS :

20. Command for AOP to take start will be extend on auto .
21. Command for solenoids ( SV-92 and SV-93) to energize will extend .
22. POSCLS feedback will come to CRT automatically .
23. Command for MDBFP to take start will extend automatically
24. MDBFP will take start automatically .
PROCEDURE :
25. Solenoid valve will remain energize for 8 Seconds (time delay for MDBFP to start-up,and starting current
to normalise)
26. After 8 seconds solenoids will de-energized and scoop will go to position governed by scoop alternator.
27. Give close command to recirculation valve. If not closed in auto
28. Match the scoop command to three element output .
29. Check command to motor cooling water valve is extended ,Ensure motor cooling water valve is full open
and feedback is coming to CRT (valve normally takes 60-80 sec for full opening)
30. Take scoop control to manual & stabilise the flow requirement by giving more flow through the
MDBFP .
31. After stabilisation Put MDBFP control in CAS .

Sheet 4 Of 5
Prepared By Reviewed By Approved By
Sri K.Ch. Satyanarayana,S(O) Sri R.N.Das , SS(O) Sri D.Sarkar , DGM(O)
 NTPC/TSTPS OPERATION DEPARTMENT TS-II/OPN/OI /TG/ /014
AREA TG Operating Instruction For Loading, Unloading REV 0.00
UNIT - 3/4/5/6 & Change over of BFPs Date : 15/10/2007

If MDBFP fails to take auto start for any reason .

Give start command to AOP and open(energize) command to rapid start up solenoids .

Give start command to MDBFP .

Give close command to rapid start up solenoids, scoop will immediately follow to tracked
three element output.
1. Give close command to recirculation valve. If not closed in auto (command comes from variable set point
or 540 T/H)
2. Match the scoop command to three element output . Put MDBFP control in CAS
3. The method discussed below will take time when BFPS common discharge header pressure is
below 100 KSC ,above this pressure since closing of discharge valve is not needed pump can be
start
4. Deselect MDBFP to man mode ..
5. Give discharge valve close command, if BFPS common discharge header pressure >100 KSC
closing of discharge valve is not required
6. Ensure discharge valve close feedback is coming to CRT(if pressure <100 KSC)
7. Give zero command to scoop (which was tracking three element o/p)
8. When scoop is zero give start command to MDBFP.
9. AOP will take start in auto
10. Observe starting current to stabilized to no load current 160-180 Amps
11. Increase the scoop equal to three element output
12. Ensure motor cooling water valve is full open and feedback is coming to CRT (valve normally takes 60-
80 sec for full opening)
13. Close recirculation valve
14. Put MDBFP control in CAS mode

$$ $$$ END $$ $$$

Sheet 5 Of 5
Prepared By Reviewed By Approved By
Sri K.Ch. Satyanarayana,S(O) Sri R.N.Das , SS(O) Sri D.Sarkar , DGM(O)