Station: NTPC Simhadri BHEL Ref No. PS - DC - 186 - 500 153 NTPC Ref No.

o. SIM / 1 / TS / 1 / 153 Plant Area: BOILER & TURBINE

Sheet 1 of 8

Testing Schedule: PROCEDURE FOR COMMISSIONING OF AUXILIARY COOLING WATER SYSTEM SL. NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. PLANT DETAILS OBJECTIVES PROPOSALS SERVICES REQUIRED SAFETY PRECAUTIONS EMERGENCY PROCEDURES STATE OF THE PLANT METHOD COMPLETION CRITERIA APPENDICES a) DRAWING b) LOG SHEETS LIST OF CONTENTS

Signatures NTPC BHEL

Station: NTPC Simhadri BHEL Ref No. PS - DC - 186 - 500 153 NTPC Ref No. SIM / 1 / TS / 1 / 153 Plant Area: BOILER & TURBINE

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Testing Schedule: PROCEDURE FOR COMMISSIONING OF AUXILIARY COOLING WATER SYSTEM 1.0 PLANT DETAILS The system consists of the following equipments and connected pipe lines and items. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 Pipe line (Suction) from main Sea-cooling water line to Secondary ACW Pumps. 3 Nos. of Secondary ACW Pumps (3 x 50%) 2 Nos. of Self cleaning filters (2 x 100%) Primary circuit of Plate type Heat Exchanger (3 x 50%) 1 No. flow element Heat Exchangers of Vacuum Pump. Pipe line (Return) from the above back to main Sea-cooling water system. For Technical Specification of the following equipments, viz Vacuum Pump HE Self Cleaning Filter Flow Element Plate Heat Exchanger, refer to the enclosed drawing no. PE DG 186 165 0101 (3 sheets). STATUS

1.9

Plant Item completion list for mechanical, electrical and C & I to be prepared at site.

1.10 Safety Rules Clearance Certificate to be signed before commencing the testing.

Signature NTPC Station: NTPC Simhadri BHEL Ref No. PS - DC - 186 - 500 153 NTPC Ref No. SIM / 1 / TS / 1 / 153 BHEL Sheet 3 of 8

Plant Area: BOILER & TURBINE Testing Schedule: PROCEDURE FOR COMMISSIONING OF AUXILIARY COOLING WATER SYSTEM 2.0 OBJECTIVE To commission the ACW System and make it available for plant operation in unison with equipment cooling water system. STATUS

3.0

PROPOSAL The system will be commissioned with following proposal.

3.1 3.2

To flush the suction line of Secondary ACW Pump upto pump suction. To flush the pump, discharge line through self cleaning filter (filter removed), Plate HE and Vacuum Pump HE and return line up to main line of Seacooling water return.

4.0 4.1 4.2 4.3 4.4 4.5

SERVICES REQUIRED Availability of sea water in the main circuit of Sea-cooling water through condenser. Availability of H.T. / L.T. Power Supply. Availability of operational staff. Availability of lighting, communication at test area. Availability of work force to attend leakages.

Signature NTPC BHEL

Station: NTPC Simhadri BHEL Ref No. PS - DC - 186 - 500 153 NTPC Ref No. SIM / 1 / TS / 1 / 153 Plant Area: BOILER & TURBINE

Sheet 4 of 8

Testing Schedule: PROCEDURE FOR COMMISSIONING OF AUXILIARY COOLING WATER SYSTEM 5.0 5.1 5.2 5.3 5.4 SAFETY PRECAUTIONS Availability of first aid kit at test area. Approach area to the pump is cleared off of all kinds of debris. Flushing area is well marked and all the other working agencies at that area are cautioned about the activity. Proper drainage arrangements are made for draining the flushed out water. Care should be taken to avoid flooding of any equipment in the test area. STATUS

6.0 6.1

EMERGENCY PRECAUTIONS The test teams should be aware of actions to be taken on the event of any emergency due to damage of equipment / machinery or due to injury to personnel. Arrangements should be made to suspend the activity on the event of any emergency notified to / by the operation staff or test team or any agency working in the area.

6.2

Signature NTPC BHEL

Station: NTPC Simhadri BHEL Ref No. PS - DC - 186 - 500 153 NTPC Ref No. SIM / 1 / TS / 1 / 153 Plant Area: BOILER & TURBINE

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Testing Schedule: PROCEDURE FOR COMMISSIONING OF AUXILIARY COOLING WATER SYSTEM 7.0 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 STATE OF THE PLANT Erection of the system with secondary ACW Pumps completed as per recommended drawing. Secondary ACW Pumps and motors are in decoupled condition. Filter elements of self cleaning filters are removed and kept outside. Erection of the Plate Heat Exchanger and Vacuum Pump Heat Exchanger completed. Required Local and Remote I&C inputs are made available. (Required list to be prepared at site). Permanent supports of the entire piping completed and protocols made. Vents / Drains of the system are completed and routed to safe locations. Permanent drainage system around the Secondary ACW Pumps and also at other required location along the pipe layout are completed. Main C.W. System is available for this testing. STATUS

7.10 Electrical System for operating the pump is made ready.

Signature NTPC Station: NTPC Simhadri BHEL Ref No. PS - DC - 186 - 500 153 NTPC Ref No. SIM / 1 / TS / 1 / 153 Plant Area: BOILER & TURBINE BHEL Sheet 6 of 8

Testing Schedule: PROCEDURE FOR COMMISSIONING OF AUXILIARY COOLING WATER SYSTEM 8.0 8.1 METHOD Suction line of the Secondary ACW Pump flushed sufficiently up to Pump Suction by keeping the Suction Valve in close condition (Valves CW-7, CW10 & CW-13) and Inlet Valves (CW-5 and CW-6) in open condition. Any flange opening near the pump to be made use of for this flushing. This flushing to be carried out sufficiently till clear water flows out. After flushing, the suction line is normalised with the pumps. After ensuring the insulation resistance of the motor at satisfactory level, motor started and run for 8 hours trial run. During trial run, motor load current and vibration are logged. After completing the motor trial run, coupling of the motor and pump completed. Charge the Suction Line and the pump slowly and prime the pump sufficiently. Start the pump and put under recirculation for 1 hour through RC line by opening valve CW-32. The system not charged by keeping the valves CW-16 and CW-18 in closed condition. Keeping the pump under re-circulation, slowly charge the system by opening the valves CW-16 and CW-18 and charge the system through all the circuits as mentioned in Section 3.0. STATUS

8.2 8.3 8.4 8.5 8.6 8.7 8.8

8.9

8.10 RC line to be slowly closed / regulated to required amount.

Signature NTPC BHEL

Station: NTPC Simhadri BHEL Ref No. PS - DC - 186 500 153 NTPC Ref No. SIM / 1 / TS / 1 / 153 Plant Area: BOILER & TURBINE

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Testing Schedule: PROCEDURE FOR COMMISSIONING OF AUXILIARY COOLING WATER SYSTEM STATUS 8.11 Flushing of the entire system carried out (1 hour through each sub-circuit comprising of either Plate Heat Exchanger or Vacuum Pump Heat Exchanger). 8.12 Simultaneously, the pump trial run also carried out for a period of 8 hours 8.13 After completing 8 hours trial run, the pump stopped and self cleaning filter normalised and system released for normal operation.

9.0 9.1 9.2

COMPLETION CRITERIA Flushing of Suction line carried out till clear water flows out through the pipe line. Flushing and commissioning of the pump completed with 8 hours trial run of the pump.

Signature NTPC BHEL

SHEET 8 OF 8

LOG SHEET
Station : Date :

Unit No. Activity : Vibration Sl. No. Motor Current Discharge Pressure Motor H V A H Pump V A Remark

Signature NTPC BHEL

PROCEDURE FOR COMMISSIONING OF AUXILIARY COOLING WATER SYSTEM