PROCEDURE FOR SITE PERFORMANCE GUARANTEE TEST OF BFP

PROJECT :2x 210KHAPERKHEDA TPS UNITS 3 & 4

CUSTOMER : MSEB

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 :

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.T’s 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 TEST METHODOLOGY :

6.1 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 Preliminary test shall be conducted for checking up of instruments.

6.3 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 Two tests will be conducted on each pump set.

7.0 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) : 343.9 (per BFP)

Dynamic head (mlc) : 1890 (BFP + BP)

Temperature (°C) : 159.50

Specific Wt. (kg/m3) : 907.77

Motor input power (kW) : 2660 (per BFP)

Total Auxiliary Power (kW) : 5320

NOTE : Auxiliary power is guaranteed with ‘ZERO’ interstage flow i.e. interstage valve in closed condition.

9.0 LIST OF INSTRUMENTS :

------------------------------------------------------------------------------------

PARAMETER TYPE AND RANGE OF

TAG NO. ACCURACY REMARKS

Booster Pump Suction Pr.

Pressure Transmitter 0-10kg/sq.cm.

PT1 ± 0.1%

BFP suction Pressure

Pressure Transmitter 0-30kg/sq.cm.

PT2 ± 0.1%

BFP discharge Pressure

Pressure Transmitter 0-300kg/sq.cm.

PT3 ± 0.1%

BFP suction Flow

Diffl. Pr. Transmitter (Range will be selected based on flow nozzle data)

DPT ± 0.1%

BFP Suction RTD 0 - 200°C TE 1/3 DIN

Temperature

BFP speed Optical non-contact Digital Tachometer. N ± 1 RPM

Booster Pump Speed

Optical non-contact Digital Tachometer. N ± 1 RPM

Motor input Power. Watt transducer W 0.25%

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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. = 150 °C

Sp. wt. of feed water = 916.9 kg/m3 from standards

Flow = 345 t/hr

Booster pump suction pressure = p1 kg/cm2

BFP suction pressure = p2 kg/cm2

BFP discharge pressure = p3 kg/cm2

Booster pump speed = 1510 rpm

BFP speed = 4800 rpm

Power input to motor terminals = 2770 kW

From the above data : Flow = 345/0.9169 = 376.27 m3/hr

Booster pump head = {(p2 - p1) x 10} / 0.9169 = say 105 mlc

BFP head = {(p3 – p2) x 10} / 0.9169 = say 1952 mlc

B. Estimated auxiliary power based on tested data :

i. Booster Pump :

Tested flow corrected to design speed = (1485/1510)x376.27=370 m3/hrEfficiency at corrected flow from design curve = 77%

916.9 x 376.27 x 105

Power input to pump = ------------------------= 128 kW

102 x 3600 x 0.77

ii. Boiler Feed Pump:

Tested flow corrected to design speed = (5075/4800)x376.27=398m3/hrEfficiency at corrected flow from design curve = 81%

916.9 x 376.27 x 1952

Power input to pump = --------------------------= 2264 kW

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 = 95 %

Power input at Motor terminals = 2680/0.95

= 2821 kW

C. Auxiliary Power measured at site :

Auxiliary power measured at test speed = 2770 kW

D. 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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