Академический Документы
Профессиональный Документы
Культура Документы
1.
OBJECTIVE
2.
TEST CODE
3.
TEST SCHEMATIC
4.
SELECTION OF INSTRUMENTS
5.
AGEING
6.
TOLERANCES
7.
FREQUENCY OF OBSERVATIONS
8.
DURATION OF TESTS
9.
10.
11.
12.
13.
14.
15.
16.
PROGRAMME OF TESTING
17.
18.
19.
1.0
OBJECTIVE
The Performance Guarantee Tests on Khaperkheda Thermal Power Project, unit # 3 & 4 210 MW TG
shall be carried out to prove the Guaranteed Heat Rate and Output of the TG Set.
This Procedure has been prepared to carry out the tests at site as mentioned above for the following
conditions.
S.No.
A
01.
Guarantee Conditions
Guarantee Values
TG PACKAGE
Gen. Output at rated throttle pressure & temp with
condenser backpressure of 67 mm of Hg (abs) at
rated turbine parameters.
210 MW
02.
03.
B.
1939 .3 Kcal/Kwh
5320 Kw
Total Aux. Power
440 Kw
5950 Kw.
190 Kw
MANUFACTURED PACKAGES
Pump.
Aux. Power Consumption of all aux. Mentioned above (sr. no. 3) will be measured during PG
test with 67 mm of Hg (abs) condenser backpressure and 0% make up. Excitation Power shall be
measured with plant instruments. HT Aux. Will be measured with DPM/Power Transducers and LT
Aux. Will be measured with clamp on meter.
2.0
TEST CODE
The HEAT RATE Tests shall be carried out in line with the recommendations of ASME PTC-6, 1976 Test
Code and in line with approved Document No. PE-4-183-100-211 Rev. 05 for method for computation
of Heat Rate.
3.0
TEST SCHEMATIC
The approved test scheme titled PERFORMANCE GUARANTEE TEST INSTRUMENTATION SCHEME, NO.
PE-3-183-100-210 REV. 02 shall be used.
4.0
SELECTION OF INSTRUMENTS
The instruments meeting accuracy requirements, as specified in ASME-PTC-6 1976 TEST CODE shall
be used.
Instruments selected and proposed to be used shall be as per the TG PG TEST INSTRUMENTATION
SCHEME/LIST which specifies the type of instruments and their ranges etc.
The brief details of the instruments to be used during the P.G. Test are
S.No.
PARAMETER TO BE
RANGE
MEASURED
MEASURING
INSTRUMENT
01.
Differential pressure
0-2.5 Kg/Sq. Cm
Transmitters
02.
Pressure
0-250 Kg/Sq. Cm
Transmitters
03.
0-780 mm Hg.
Transmitters
03.
Temperature
0-300 Deg. C
PRT - 100
04.
Temperature
300-600 Deg. C
K Type T.C.
05.
Generator Power
0-1000 Watts.
0-5 Amps.
0-65 Volts.
06.
Speed
0-1000 rpm
5.0
AGEING
If the test is carried out after 4 months of the date of first commissioning, due to any reason what so
ever, the specific heat consumption shall be increased by following amounts for each month or part of
a month by which the period between the initial commissioning and the acceptance test exceeds 4
months.
0.01% for the following 8 months
0.06% for the period there after.
6.0
TOLERANCES
FREQUENCY OF OBSERVATIONS
DURATION OF TESTS
As per ASME-PTC-6, tests shall be carried out at a steady state run of minimum 2 hours duration.
However duration will be mutually decided, depending upon the conditions prevailing during
conductance of P.G. Tests, Minimum two test for heat rate at 100% MCR and one for output test shall
be conducted.
9.0
9.01 During the pretest unit commissioning/erection period, every effort shall be made by BHEL to
ensure the provision of all test tapping points as per test scheme. BHEL shall inform to MSEB in
advance for any missing point measurement which is not possible to be used due to unavoidable
reasons and mutually agreed upon. Minimum two tests for heat rate at 100% MCR and one for output
test shall be conducted.
9.02 Welded type thermowells shall be used by BHEL for temperature measurement on all critical
high temperature lines. These thermowells shall remain permanently installed on the pipe lines.
9.03 Screwed type thermowells shall be used in low pressure lines (pressure less than 40 ata) for
temperature measurement and shall be installed in the unit, just prior to the test. For these
thermowells, matching stub with suitable plug will be provided in the engineering stage itself. In case
these thermowells are found missing then these are to be obtained from the respective unit and
supplied & installed during erection stage itself.
9.04 All the pressure test tappings as mentioned in PG Test Instrumentation Scheme No. PE-3-193100-210 Rev. 02 are supplied with single or double root valves depending upon the pressure rating of
the pipe lines. They are supplied by BHEL piping centre in line with the erection drawings released for
construction. In case some of the pressure tappings are not available, the same shall be provided or
alternatively, either a T-off shall be taken from the operational tapping point or operational point
shall be used, as mutually agreed. Impulse pipe of suitable size shall be laid during pretest
preparations. The pressure lines will be strong enough to withstand any type of vibrations and will
have uniform gradient.
9.04a For Pressure and temperature tapping points in case not available/constraint in its use is
observed before the commencement, alternate operational points will be used after mutual
agreement.
9.05 Test CTs and PTs (MSEB scope) of 0.2 accuracy class are to be provided by BUS DUCT
supplier. The installation and/or test data for ratio and phase angle errors at different VA burdens and
power factors shall be provided by.
MSEB for accurate power calculations. Additionally test certificates giving the above
information, as submitted by the generator bus duct supplier shall also be arranged by MSEB.
9.06 CT terminals should be provided with termination arrangement for shorting or opening links.
Effects of connecting leads shall be neutralized in power calculations by measuring voltage drop
across PT terminals and measuring point.
9.07 It has to be checked during erection stage that no pipeline or installation etc. Fouls the test
tapping. Test temperature element are 450 mm along. Enough space should be available for each
tapping point so that the test temperature elements can be inserted without any difficulty. In case of
any obstruction an alternate test stub is to be provided as per point No. 9.02 & 9.03 if possible.
9.08
link.
Test CTs & PTs terminals to be brought to UCB panel. CT terminals be provided with shorting
10.0
Efforts are to be made to ensure that all the TG systems/equipments are brought into service within
reasonable period of the first synchronisation and trial run should also be completed by this period.
Normally with the increase in running hours, salt deposits take place and also turbine clearances
change. This deteriorates the turbine performance and thus the test should be conducted preferably
within four months after first synchronisation.
The unit readiness for conducting the PG Tests is to be ensured as per the checklist.
10.01 To ensure that all LP & HP heaters are in normal operation and drips of these heaters are
cascaded properly as per the cycle. It is to be checked that there is no by passing of the drips either
to condenser or to deaerator and this is to be ensured for sufficient time before actual
commencement of the test.
10.02 To check that there should not be any leakage in the tubes of HP & LP heaters tubes.
10.03 To ensure the cleanliness of condenser tubes and to get the same cleaned if required during
the shut down prior to the tests.
10.04 To ensure that the machine is able to run on orie vacuum pump only. Further the vacuum
obtained with this running pump should preferably be nearer to the design value.
10.05 To ensure that pressure of Main Steam First Stage, Cold Reheat. Hot Reheat Extractions to
various heaters and condenser back pressure are near the design values at 210 MW load.
10.06 To ensure that the test flow assembly is available at site with all its matching flanges and
fasteners.
10.07 To ensure that the CW pressure drop across the inlet and outlet of the condenser is within the
design figure and there is no tube leakage in condenser. Conductivity and Oxygen content at
condenser hot well should also be within the prescribed limits.
10.08 To ensure the cleanliness of the E.S.V. and I.V. strainers. In case of the excessive pressure
drop, same should be cleaned.
10.09 To ensure that the unit is capable of attaining and maintaining the full load design parameters
i.e. Main Steam pressure and temperature, Hot Reheat temperature and Condenser Back Pressure.
10.10 To ensure that all the local gauge glasses of the condenser, hot well deaerator and HP & LP
heaters are working and are clean and visible. There should not be any gauge glass leakage.
10.11 To ensure that there is adequate light to observe the levels at all places where the operators
will log the test readings.
10.12 A system tightness check i.e. Deaerator Drop Test shall be done by keeping the
interconnection on steam and load side isolated and also by closing the make-up inlet and by keeping
the CBD, EBD, SOOT Blowing and steam supply to fuel oil heating, atomisation etc. shut off. The
deaerator level is to be raised to the maximum permissible before this exercise. Fall in deaerator
level i.e. system losses are then to be observed and calculated. It is to be ensured that the unit is
able to run in the above condition for at least three hours. The problem if any, is to be rectified and
the efforts shall be made to bring down the system unaccounted leakage.
10.13 To ensure the availability of coal in sufficient quantity so that the machine may be loaded to
full load for any desired interval of time and the constancy of test conditions may be attained as per
ASME-PTC-6 code.
10.14 To ensure the tightness of the system, steam/feed & condensate drain line valves connected to
turbine flash tank for non passing as per the designed heat and mass balance diagram.
10.15 To ensure the availability of all tapping as per test scheme. This includes tapping points for
individual equipment performance which may not be required for contractual tests.
10.16 To ensure that the HP & LP Bypass valves to the condenser are not passing.
10.17 To ensure the availability of all the BFPs, CEPs, CWPs coal mills, ID, FDA PA fans etc. so that
there is no constraints in achieving and maintaining full load for at least 8 hrs. a day.
10.18 To ensure tightness of the vales as per the design heat & mass balance. For this purpose a
specific list of isolation of valves & systems bearing valve numbers shall be prepared in advance of
test.
11.0
After it is ensured that the unit is ready for the test, a suitable shut down shall have to be agreed
between BHEL and MSEB. BHEL shall then supply the calibrated test instruments, prior to the start of
the shut down. Major activities to be carried out during this shut down shall be as follows.
11.01 Mounting/installing missing screw type thermowells, test flow assembly, provision for T-off
and laying of
impulse pipe lines etc.
11.02 Providing any additional test tapping points if found necessary/applicable/missing.
11.03 Necessary arrangement/rectification for meeting the system requirements.
11.04 Necessary arrangement/rectification for meeting the requirement of system isolation i.e.
attending the defective/passing valves identified during the joint inspection before shut down. To this
effect, a list of valves to be kept closed during the test shall be jointly finalised with MSEB, prior to
the test and the system shall be isolated as per this list.
11.05 In case of prolonged operation, if necessary the internals of the turbine shall be checked for
its cleanliness.
11.06 The demagnetisation of test PTs and CTs will be carried out.
11.07 Mounting of temperature elements in identified hot areas and laying their cables.
11.08 Laying impulse pipe line (if not already laid) from the root valves in hot zones and terminating
with isolating valves. Their root valves to be kept open.
11.09 Condenser tube cleaning and condenser air tightness checks to be done and leakages to be got
attended.
12.0
The lead resistance voltage drop in the circuit of PTs shall be measured along with MSEB
representative and protocol for the same made before starting the P.G. Test.
The digital power meter will be connected to the identified CTs and PTs terminals preferably in three
phase four wire mode.
12.05 LEVEL MEASUREMENT
Level measurements of all the storage tanks shall be noted by means of local gauge glass level
indicators equipped with metric scales. It shall be ensured before carrying out the test, that the level
indicators are in good working condition. Readings are to be recorded on the Data Sheet sample
enclosed.
Apart from it, the Control Room readings for levels of all storage tanks shall also be additionally
recorded for reference.
13.0
13.01 All electrical instruments should be placed away from any magnetic field. Their proper leveling
should also be ensured.
13.02 If felt necessary, the mounting adjustable coupling can be removed and in that case T/Cs PRTs
should be properly tied and pressed downward with a piece of wire. Stub projections and sensor
stems, which are protruding out of thermowells should be covered with asbestos rope for providing
thermal insulation.
13.03 Demagnetisation of CTs.
14.01 All the test instruments except Pressure Transmitters shall be duly calibrated at recognised
Test Houses.
14.02 The calibration certificates shall be furnished to MSEB before dispatching the instruments to
site.
14.03 Pressure Transmitters reading shall be additionally corrected for height corrections by
measuring the difference in levels between center of the transmitter & center of pipeline.
14.04 Pressure Transmitters shall be calibrated at site by BHEL Engineer before the conductance of
the tests in the presence of MSEB representative and the calibration certificates shall be jointly
signed.
14.05 Correction due to actual mercury density and actual barometric pressure shall also be applied
wherever applicable.
15.0
PROGRAMME OF TESTING
16.01 The completion of test preparations, mounting of instruments and isolation of thermal cycle
are to be checked before start of test.
16.02 The load is raised to rated capacity at rated parameters for taking a set of trial readings of all
instruments and for aquatinting the observers with the operation of instrument. All observers shall be
allotted with their respective junctions and shall note down the readings on the prescribed logsheets
to be supplied by BHEL.
16.03 The readings of the trial test are analysed. If the results differ much from the design values,
the case is to be investigated and rectification to be carried out wherever required. To this effect, it is
essential that the load is maintained at rated values. The mock test can be repeated until the results
are satisfactory. Then the time for test can be mutually decided.
16.04 During the trial test, it is checked that all the instruments are functioning/indicating properly
and verified wherever necessary. The pressure transmitters are isolated after the trial test.
16.05 The load is raised to rated capacity at rated parameters at least one hour before the start of
the test and the parameters shall be maintained constant throughout the test.
16.06 The system is isolated so that no unaccounted flow goes out of comes into cycle. The makeup
quantity shall be measured by noting down the various storage tanks levels at regular intervals of the
test.
16.07 Consistency of the load shall be accomplished by load limiter. Once the control valves have
been set, they shall be left undisturbed throughout the test.
16.08 The operations which shall not be carried out during the test which are to be isolated are for
the following which the isolations are to be carried out.
Soot Blowing
Continuous Blow Down.
Dusting of the Associated Boiler Unit.
Steam Supply to fuel Atomisation.
Fuel Heating and SCAPH
Chemical dozing.
Water and Steam Sampling etc.
16.09 PRDS control valve spindle cooling water, atmospheric valve gland sealing water flow shall be
adjusted for minimum flow.
16.10 Proper sealing water supply to vacuum system specially to atmospheric valve seals shall be
ensured.
16.11 All efforts shall be made to maintain the parameters constant throughout the test.
16.12 After the preparations have been completed, the test shall be started by synchronising the
watches of the observers with that of the control room.
16.13 The test readings shall be logged in the data logger and manual readings shall be noted down
in the prescribed log sheets in triplicate, which shall be signed by the observers and countersigned by
MSEB and BHEL at the end of the tests.
16.14 One set of the test readings shall be handed over to MSEB and two sets shall be retained by
BHEL for their analysis at their works.
16.15 Sensitivity of the condenser hot well level control shall be reduced or preferably the level be
controlled manually to avoid excessive fluctuation in the condensate flow to Dearator.
17.0
PG test low measuring assemblies for measurement of test flow are normally supplied directly to
site assembled condition in 2 halves. Flow measurement is an important measurement which effects
the PG Test results appreciably.
A minor dent on the sharp edge of the orifice or on its plain surface or on the inside surface of the
flow nozzle causes a large inaccuracy in flow measurement. Thus orifice plates/nozzles should never
be hung with a wire or a rope passing through their inner bore which may cause dent on them. Even
the adjoining pipe pieces encompassing the orifices/nozzles, which are normally machined from
inside, should be carefully handled during installation. In all cases these assemblies should be stored
in covered shed and protected from corrosion as any roughness on them may add to inaccuracy.
In view of above, it is needless to emphasize the importance of proper preservation of these
assemblies.
Also flow measuring assemblies received in assembled condition, should not be dismantled as it is
calibrated before supply. Dismantling may affect its calibration.
18.0
Before starting the performance test the plant has to be in a good state. To be familiar with the plant
during operation and for finding out deficiencies, if any and for checking of all the measuring
instruments, customer has to allow pretests with the plant.
It is sufficient that the whole plant cycle is provided as presumed in the guarantee agreement. All
cross connections to other units must be closed and all drainages must be ensured absolutely tight.
Piping which are not utilized they have to be blanked off or it not possible they have to be checked
for tightness.
A special care will be used in isolating test cycle from any connection extraneous to the test, whether
inside or outside the unit. These shall be attended in case founding passing.
The following is the general list of the lines and the unit component that will be isolated or put out of
service during test. A specific list of isolation of valves & systems bearing valve numbers for each
valve shall be prepared in advance of the test which shall be used during performance testing.
All the LP turbine by pass
Make up line
Auxiliary steam header
Turbine sprays
Drain lines on stop intercept and control valves
Tag
Service
Instrument
Accuracy
Range
No.
1
P201
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
P202
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
P203
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
P204
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
P205
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
P206
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
P207
HP EXHAUST (TE)
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
P208
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
(L).
9
P209
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
10
P210
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
(R).
11
P211
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
12
P212
MS TO APRDS
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
13
P213
APRDS SPRAY
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
14
P214
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
15
P215
FW HPH-6 INLET
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
16
P216
FW HPH-6 OUTLET
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
17
P218
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
18
P219
PR. TRANS.
0.1%
0-25Kg./Sq.Cm.
19
P220
PR. TRANS.
0.1%
0-25Kg./Sq.Cm.
20
P221
FW HPH-5 INLET
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
21
P222
FW HPH-5 OUTLET
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
22
P223
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
23
P225
BFP-A DISCHARGE
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
24
P226
BFP-B DISCHARGE
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
25
P227
BFP-C DISCHARGE
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
26
P229
SH SPRAY PR.
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
27
P230
RH SPRAY PR.
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
28
P231
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
29
P232
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
Instrument
Accuracy
PRESSURE POINTS
Sr. No.
Tag No.
Service
Range
P102
PR. TRANS.
0.1%
0-10Kg./Sq.Cm.
P104
PR. TRANS.
0.1%
0-10Kg./Sq.Cm.
P105
PR. TRANS.
0.1%
0-10Kg./Sq.Cm.
P106
PR. TRANS.
0.1%
0-10Kg./Sq.Cm.
P107
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
P108
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
P109
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
P110
BFP-A SUCTION
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
P111
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
10
P112
PR. TRANS.
0.1%
0-10Kg./Sq.Cm.
11
P113
PR. TRANS.
0.1%
0-10Kg./Sq.Cm.
12
P114
PR. TRANS.
0.1%
0-10Kg./Sq.Cm.
13
P115
PR. TRANS.
0.1%
0-10Kg./Sq.Cm.
14
P116
PR. TRANS.
0.1%
0-780mm. Hg.
15
P117
PR. TRANS.
0.1%
0-780mm. Hg.
16
P118
PR. TRANS.
0.1%
0-780mm. Hg.
17
P119
STEAM TO GSC
PR. TRANS.
0.1%
0-10Kg./Sq. Cm.
18
P120
LP BYPASS (R)
PR. TRANS.
0.1%
0-60Kg./Sq. Cm.
19
P121
LP BYPASS (L)
PR. TRANS.
0.1%
0-60Kg./Sq. Cm.
20
P122
CEP SUCTION
PR. TRANS.
0.1%
0-780mm. Hg.
21
P123
CEP DISCHARGE
PR. TRANS.
0.1%
0-25Kg./Sq. Cm.
22
P124
PR. TRANS.
0.1%
0-10Kg./Sq. Cm.
23
P125
APRDS AFT.
PR. TRANS.
0.1%
0-25Kg./Sq. Cm.
DESUPERHEATER
24
P126
25
P127
26
P128
27
P129
28
DP. TRANS.
0.1%
0-2.5Kg./Sq. Cm.
DP. TRANS.
0.1%
0-2.5Kg./Sq. Cm.
P130
CONDENSER VACUUM
PR. TRANS.
0.1%
0-780mm. Hg.
29
P131
CONDENSER VACUUM
PR. TRANS.
0.1%
0-780mm. Hg.
30
P132
CONDENSER VACUUM
PR. TRANS.
0.1%
0-780mm. Hg.
31
P133
CONDENSER VACUUM
PR. TRANS.
0.1%
0-780mm. Hg.
32
P134
CONDENSER VACUUM
PR. TRANS.
0.1%
0-780mm. Hg.
33
P135
CONDENSER VACUUM
PR. TRANS.
0.1%
0-780mm. Hg.
34
P136
BFP-B SUCTION
PR. TRANS.
0.1%
0-10Kg./Sq. Cm.
35
P139
CEP SUCTION
PR. TRANS.
0.1%
0-780mm. Hg.
36
P140
BFP-C SUCTION
PR. TRANS.
0.1%
0-10Kg./Sq. Cm.
37
P141
DC INLET
PR. TRANS.
0.1%
0-25Kg./Sq. Cm.
Instrument
Accuracy
FLOW POINTS
Sr. No.
Tag No.
Service
Range
F101A
MAIN CONDENSATE
DP. TRANS.
0.1%
0-2.5Kg./Sq.Cm.
F101B
MAIN CONDENSATE
DP. TRANS.
0.1%
0-2.5Kg./Sq.Cm.
F102A
RH SPRAY
DP. TRANS.
0.1%
0-2.5Kg./Sq.Cm.
F102B
RH SPRAY
DP. TRANS.
0.1%
0-2.5Kg./Sq.Cm.
F103A
SH SPRAY
DP. TRANS.
0.1%
0-2.5Kg./Sq.Cm.
F103B
RH SPRAY
DP. TRANS.
0.1%
0-2.5Kg./Sq.Cm.
Instrument
Accuracy
TEMPERATURE POINTS
Sr. No.
Tag No.
Service
Range
T101
T/C
1/2 DIN
250-550 Deg. C
T102
T/C
1/2 DIN
250-550 Deg. C
T103
T/C
1/2 DIN
250-550 Deg. C
T104
T/C
1/2 DIN
250-550 Deg. C
T105
T/C
1/2 DIN
250-550 Deg. C
T106
T/C
1/2 DIN
250-550 Deg. C
T107
T/C
1/2 DIN
250-550 Deg. C
T108
T/C
1/2 DIN
250-550 Deg. C
T109
T/C
1/2 DIN
250-550 Deg. C
10
T110
T/C
1/2 DIN
250-550 Deg. C
11
T111
T/C
1/2 DIN
250-550 Deg. C
12
T112
T/C
1/2 DIN
250-550 Deg. C
13
T114
T/C
1/2 DIN
250-550 Deg. C
14
T116
T/C
1/2 DIN
250-550 Deg. C
15
T117
T/C
1/2 DIN
250-550 Deg. C
16
T118
T/C
1/2 DIN
250-550 Deg. C
17
T119
T/C
1/2 DIN
250-550 Deg. C
18
T120
T/C
1/2 DIN
250-550 Deg. C
19
T121
MS TO APRDS
T/C
1/2 DIN
250-550 Deg. C
20
T122
SPRAY TO APRDS
PRT Pt-100
1/2 DIN
250-550 Deg. C
21
T123
T/C
1/2 DIN
250-550 Deg. C
22
T124
T/C
1/2 DIN
250-550 Deg. C
23
T125
FW HPH-6 INLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
24
T126
FW HPH-6 INLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
25
T127
FW HPH-6 OUTLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
26
T128
FW HPH-6 OUTLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
27
T131
PRT Pt-100
1/2 DIN
0-300 Deg. C
28
T132
PRT Pt-100
1/2 DIN
0-300 Deg. C
29
T133
T/C
1/2 DIN
250-550 Deg. C
30
T134
T/C
1/2 DIN
250-550 Deg. C
31
T135
T/C
1/2 DIN
250-550 Deg. C
32
T136
T/C
1/2 DIN
250-550 Deg. C
33
T137
FW INLET TO HPH-5
PRT Pt-100
1/2 DIN
0-300 Deg. C
34
T138
FW INLET TO HPH-5
PRT Pt-100
1/2 DIN
0-300 Deg. C
35
T139
FW HPH-5 OUTLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
36
T140
FW HPH-5 OUTLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
37
T141
T/C
1/2 DIN
250-550 Deg. C
38
T142
T/C
1/2 DIN
250-550 Deg. C
39
T143
T/C
1/2 DIN
250-550 Deg. C
40
T144
T/C
1/2 DIN
250-550 Deg. C
41
T145
PRT Pt-100
1/2 DIN
0-300 Deg. C
Instrument
Accuracy
TEMPERATURE POINTS
Sr. No.
Tag No.
Service
Range
46
T146
PRT Pt-100
1/2 DIN
0-300 Deg. C
47
T147
SH SPRAY
PRT Pt-100
1/2 DIN
0-300 Deg. C
48
T148
RH SPRAY
PRT Pt-100
1/2 DIN
0-300 Deg. C
49
T149
BFP-A DISCHARGE
PRT Pt-100
1/2 DIN
0-300 Deg. C
50
T150
BFP-B DISCHARGE
PRT Pt-100
1/2 DIN
0-300 Deg. C
51
T151
BFP-C DISCHARGE
PRT Pt-100
1/2 DIN
0-300 Deg. C
52
T152
T/C
1/2 DIN
250-550 Deg. C
53
T153
T/C
1/2 DIN
250-550 Deg. C
54
T154
T/C
1/2 DIN
250-550 Deg. C
55
T155
T/C
1/2 DIN
250-550 Deg. C
56
T156
T/C
1/2 DIN
250-550 Deg. C
57
T157
T/C
1/2 DIN
250-550 Deg. C
TEMPERATURE POINTS
Sr. No.
Tag No.
Service
Instrument
Accuracy
Range
T201
PRT Pt-100
1/2 DIN
0-300 Deg. C
T202
PRT Pt-100
1/2 DIN
0-300 Deg. C
T203
PRT Pt-100
1/2 DIN
0-300 Deg. C
T204
PRT Pt-100
1/2 DIN
0-300 Deg. C
T205
PRT Pt-100
1/2 DIN
0-300 Deg. C
T206
PRT Pt-100
1/2 DIN
0-300 Deg. C
T207
PRT Pt-100
1/2 DIN
0-300 Deg. C
T208
PRT Pt-100
1/2 DIN
0-300 Deg. C
T209
PRT Pt-100
1/2 DIN
0-300 Deg. C
10
T210
PRT Pt-100
1/2 DIN
0-300 Deg. C
11
T211
LPH-3 INLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
12
T212
LPH-3 OUTLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
13
T213
PRT Pt-100
1/2 DIN
0-300 Deg. C
14
T214
PRT Pt-100
1/2 DIN
0-300 Deg. C
15
T216
PRT Pt-100
1/2 DIN
0-300 Deg. C
16
T217
PRT Pt-100
1/2 DIN
0-300 Deg. C
17
T218
PRT Pt-100
1/2 DIN
0-300 Deg. C
18
T219
PRT Pt-100
1/2 DIN
0-300 Deg. C
19
T220
LPH-2 OUTLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
20
T221
LPH-2 INLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
21
T222
EXTN. TO LPH-1
PRT Pt-100
1/2 DIN
0-300 Deg. C
22
T223
LPH-1 DRAIN TO DC
PRT Pt-100
1/2 DIN
0-300 Deg. C
23
T224
LPH-1 DRAIN TO DC
PRT Pt-100
1/2 DIN
0-300 Deg. C
24
T225
LPH-1 OUTLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
25
T226
DC OUTLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
26
T227
LPH-1 INLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
27
T228
PRT Pt-100
1/2 DIN
0-300 Deg. C
28
T229
PRT Pt-100
1/2 DIN
0-300 Deg. C
29
T230
DC INLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
30
T232
STEAM TO GSC
PRT Pt-100
1/2 DIN
0-300 Deg. C
31
T233
PRT Pt-100
1/2 DIN
0-300 Deg. C
3
32
T234
GSC INLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
33
T235
GSC OUTLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
34
T236
CW INLET-A
PRT Pt-100
1/2 DIN
0-300 Deg. C
35
T237
CW INLET-A
PRT Pt-100
1/2 DIN
0-300 Deg. C
36
T238
CW OUTLET-A
PRT Pt-100
1/2 DIN
0-300 Deg. C
37
T239
CW OUTLET-A
PRT Pt-100
1/2 DIN
0-300 Deg. C
38
T240
CW OUTLET-A
PRT Pt-100
1/2 DIN
0-300 Deg. C
39
T241
CW OUTLET-A
PRT Pt-100
1/2 DIN
0-300 Deg. C
40
T242
CW OUTLET-A
PRT Pt-100
1/2 DIN
0-300 Deg. C
41
T243
CW OUTLET-A
PRT Pt-100
1/2 DIN
0-300 Deg. C
42
T247
CW INLET-B
PRT Pt-100
1/2 DIN
0-300 Deg. C
43
T248
CW INLET-B
PRT Pt-100
1/2 DIN
0-300 Deg. C
44
T249
CW OUTLET-B
PRT Pt-100
1/2 DIN
0-300 Deg. C
45
T250
CW OUTLET-B
PRT Pt-100
1/2 DIN
0-300 Deg. C
46
T251
CW OUTLET-B
PRT Pt-100
1/2 DIN
0-300 Deg. C
47
T252
CW OUTLET-B
PRT Pt-100
1/2 DIN
0-300 Deg. C
48
T253
CW OUTLET-B
PRT Pt-100
1/2 DIN
0-300 Deg. C
49
T254
CW OUTLET-B
PRT Pt-100
1/2 DIN
0-300 Deg. C
50
T258
CEP SUCTION
PRT Pt-100
1/2 DIN
0-300 Deg. C
51
T259
CEP DISCHARGE
PRT Pt-100
1/2 DIN
0-300 Deg. C
52
T260
PRT Pt-100
1/2 DIN
0-300 Deg. C
53
T261
PRT Pt-100
1/2 DIN
0-300 Deg. C
54
T262
PRT Pt-100
1/2 DIN
0-300 Deg. C
55
T263
PRT Pt-100
1/2 DIN
0-300 Deg. C
56
T264
PRT Pt-100
1/2 DIN
0-300 Deg. C
57
T265
BFP-A SUCTION
PRT Pt-100
1/2 DIN
0-300 Deg. C
58
T266
BFP-A SUCTION
PRT Pt-100
1/2 DIN
0-300 Deg. C
59
T267
BFP-B SUCTION
PRT Pt-100
1/2 DIN
0-300 Deg. C
60
T268
BFP-B SUCTION
PRT Pt-100
1/2 DIN
0-300 Deg. C
61
T269
BFP-C SUCTION
PRT Pt-100
1/2 DIN
0-300 Deg. C
62
T270
PRT Pt-100
1/2 DIN
0-300 Deg. C
63
T271
PRT Pt-100
1/2 DIN
0-300 Deg. C
64
T272
APRDS AFT.
PRT Pt-100
1/2 DIN
0-300 Deg. C
DESUPERHEATER
65
T273
LP BYPASS (R)
T/C
1/2 DIN
250-550 Deg. C
66
T274
LP BYPASS (L)
T/C
1/2 DIN
250-550 Deg. C
67
T275
BFP-C SUCTION
PRT Pt-100
1/2 DIN
0-300 Deg. C
68
T276
CEP SUCTION
PRT Pt-100
1/2 DIN
0-300 Deg. C
69
T277
CEP SUCTION
PRT Pt-100
1/2 DIN
0-300 Deg. C
Tag No.
Service
Instrument
Accuracy
Range
No.
1
PAX-1
PR. TRANS.
0.10%
0-10 Kg./Sq.Cm.
PAX-2
PR. TRANS.
0.10%
0-10 Kg./Sq.Cm.
PAX-3
PR. TRANS.
0.10%
0-10 Kg./Sq.Cm.
PAX-4
PR. TRANS.
0.10%
0-25 Kg./Sq.Cm.
PAX-5
PR. TRANS.
0.10%
0-250 Kg./Sq.Cm.
PAX-6
DP.TRANS.
0.10%
0-2.5 Kg./Sq.Cm.
PAX-7
PR. TRANS.
0.10%
0-10 Kg./Sq.Cm.
PAX-8
PR. TRANS.
0.10%
0-25 Kg./Sq.Cm.
PAX-9
PR. TRANS.
0.10%
0-250 Kg./Sq.Cm.
10
PAX-10
DP.TRANS.
0.10%
0-2.5 Kg./Sq.Cm.
11
PAX-11
PR. TRANS.
0.10%
12
PAX-12
PR. TRANS.
0.10%
0-60 Kg./Sq.Cm.
13
PAX-13
DP.TRANS.
0.10%
0-2.5 Kg./Sq.Cm.
TAX-1
RTD-100
1/2 DIN
0-300 Deg. C
TAX-2
RTD-100
1/2 DIN
0-300 Deg. C
TAX-3
RTD-100
1/2 DIN
0-300 Deg. C
P233
CW DISCH PR.
PR. TRANS.
0.10%
0-10 Kg./Sq.Cm.
P234
CW DISCH PR.
PR. TRANS.
0.10%
0-10 Kg./Sq.Cm.
F104
DP. TRANS.
0.10%
0-2.5 Kg./Sq.Cm.
DP. TRANS.
0.10%
0-2.5 Kg./Sq.Cm.
POWER-PLANT ASSEMBLY)
2
F105
ANNEXURES
1.
CORRECTION CURVES
1.1
FREQUENCY
POWER FACTOR
SH SPRAY
CONDENSER PRESSURE
RH SPRAY
FREQUENCY
POWER FACTOR
SH SPRAY
D/A LEVEL DROP (Ref. HRCC above)
1.3
RH SPRAY
1.4
1.5
2.0
3.0
4.0
5.0
6.0
DATA SHEET
7.0
HEAT BALANCE
DRG No. PE-3-183-100-101
8.0
HP-HEATER NO. 6
Z [H12 H7] = [M1+X+Y+Z-Mshs-MrhsMdea] (116-115) ............[A]
HP-HEATER NO. 5
Y.[H11-H8] + Z [117-118] = [M1+X+Y+Z- Mshs-mrhsMdea].(114-113) .. [B]
DEAERATOR
X.111+M1.H10+[Y+Z].119 = [M1+X+Y+Z].112 .................................[C]
Three unknown X, Y and Z can be calculated from equation [A], [B] & [C]
Feed water flow Mfw = M1 + X + Y + Z Mshs-Mrhs Mdea ............[D]
1) When there is an increase in the level f deaerator, -ve sign shall be used for Mdea
2) When there is a decrease in the level of deaerator, +ve sign shall be used for Mdea
Sum of storages [Msto] increases or decreased for the following tanks :a) Hotwell storage
NOTE :
b) Drum storage
c) Condensate make-up storage
d) Dearator storage
NOTE : For the above storages if there is a net increase in level, +ve sign is to be taken for Msto
and if there is a net decrease in level, -ve sign is to be taken for Msto to arrive at the unaccounted
Mms
NOTE :1.
2.
When there is increase in level of boiler drum, -ve sign shall be used for Mdrum
When there is decrease in level of boiler drum, +ve sign shall be used for Mdrum
Enthalpy of feed water at HPH5 inlet based on measurements P221 & T137, T138 .
H4
=
kcal/kg
Enthalpy of feed water at HPH-5 outlet based on measurements P222 & T139, T140
H5
= Enthalpy of feed water at HPH-6 inlet based on measurements P215 & T125, T126
.kcal/kg
H6
= Enthalpy of feed water at HPH-6 outlet based on measurements P216 & T127, T128
.kcal/kg
H7
= Enthalpy of HPH-6 drain based on measurements P218 & T131, T132
....................kcal/kg
H8
= Enthalpy of HPH-5 drain near heater based on measurements P111 & T270, T271
...kcal/kg
H10
H11
H12
2.0
HEAT RATE :-
HR
Mms[HmsHffw]+Mrh[Hrho-Hrhi]+Mshs[Hffw-Hshs]+Mrhs[Hrhi-Hrhs]
--
--------------------------------------------------------------------------------------------------------------------............ [G]
Pnet.
HR
= Heat Rate
kcal/kwh
Mms
= Main steam flow at HPT inlet
[as calculated] .. kg/hr
Mrh
= Reheat steam flow [as
calculated] ......kg/hr
Hms
= Enthalpy of
steam before ESV based on measurements P201, P203 & T101 to T104 kcal/kg
Hffw
= Enthalpy of final feed water after HP-heaters based on measurements P206 & T145, T146
.. Kcal/kg
Hrho = Enthalpy of hot reheat steam before IV based on measurements P208, P210 & T109 to
T112 kcal/kg
Hrhi
= Enthalpy of cold reheat steam based on measurements P207 & T107 to T108 . Kcal/kg
Hshs
= Enthalpy of superheater spray based on any two of the measurements {P227, T151},
{P226, T150} and {P225, T149} depending upon working BFPs.
Hrhsi
= Enthalpy of CRH after mixing of RH spray based on measurements P209, T106 & P211,
T105 .. kcal/kg
Pnet = Pgen 63 (Towards integral auxiliaries) ..kw
Pgen = Power measured at Generator terminals .. kw
3.0
Steam leakage through the glands A, B and C is calculated using the formula given below
Data for design case is given below [Refer HBD No. PE-3-183-100-101 REV 02]
PARAMETER
HPT INLET END
G
3.051
P1
41.27
P2
6.835
V1
*0.0838
* Based on 41.27 ata & 816.0 kcal/kg.
** Based on 41.27 ata & 349.6 DEG C.
For design case P1, P2, V1 and G are known and hence K can be evaluated.
K values calculated for the design case are as given below :
a)
For gland leakage from HPT inlet end K = 0.1394
b)
For gland leakage from HPT outlet end K = 0.1292
For test case, by putting this value of K and the test values of P1, P2 and V1 and computation of G
can be done.
For the test case, the values of P1, P2 and V1 are determined as given below :
NOTE :
1.
The heat rate is guaranteed with 0% make-up and hence no make-up will be supplied to the
condenser during the performance guarantee test. Under these conditions the storage in the
deaerator feed storage tank is utilised towards the leakage losses and the measured heat rate shall
be corrected using the correction curve viz. Change in heat rate vs. change in storage of feed water
storage tank.
2.
In case the temperature measured at the HP turbine exhaust (measurements T107 to T108) is
less than the temperature of extraction steam at HP Heater No. 6 inlet (measurements T123, T124)
then leakage through the HP bypass valve is suspected. The leakage shall be estimated as given
below :
Mhpb
where Mhpb = Quantity of steam leakage through the HP bypass valve . T/HR
The quantity of steam entering the HP turbine [Mms1] shall be corrected for the leakage through the
HP bypass as given below and shall be used in the equation (G) instead of Mms.
Mms1 = Mms Mhpbp
5.0
GUARANTEE CONDITIONS.
1.
2.
Instrument uncertainly shall be computed with accuracy classes of various instruments to be
used during the P.G. test in accordance with the document titled Guidance for evaluation of
measuring uncertainly in performance test of steam turbine A report by ASME Performance test
code committee G
3.
If the test is carried out after four months of the date of first commissioning, due to any
reason whatsoever, the specific heat consumption shall be increased by following amounts for each
month or part of a month by which the period between the initial commissioning and the acceptance
test exceeds 4 months.
0.10% for the following 8 months
0.06% for the period thereafter
4.
The pressure drop between MS strainer and ESV & between ESV and HPT in the MS line and
between HRH strainer and IV & between IV & IPT in HRH line have not been considered in the heat
balance calculations since same is to be accounted in the respective system piping pressure drops.
The actual pressure drops shall be estimated during the PG test based on layout envisaged and the
calculated steam flows and necessary corrections applied on the measured pressures.
6.0
A.
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
2 x 210
CUSTOMER
MSEB
UNITS 3 & 4
1.0
KHAPERKHEDA TPS
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 cl.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.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
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
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
Temperature (C)
159.50
907.77
5320
NOTE : Auxiliary power is guaranteed with ZERO interstage flow i.e. interstage valve in
closed condition.
9.0
LIST OF INSTRUMENTS :
Booster
Pump
Suction Pr.
PT1
0.1%
BFP suction
Pressure
PT2
0.1%
BFP
discharge
Pressure
PT3
0.1%
BFP suction
Flow
DPT
0.1%
TE
1/3 DIN
Optical non-contact
Digital Tachometer.
1 RPM
Booster
Optical non-contact
Pump Speed Digital Tachometer.
1 RPM
Motor input
Power.
0.25%
BFP Suction
RTD 0 - 200C
Temperature
BFP speed
Watt transducer
REMARKS
------------------------------------------------------------------------------------
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.
150 C
Flow
345 t/hr
p1 kg/cm2
p2 kg/cm2
p3 kg/cm2
1510 rpm
BFP speed
4800 rpm
2770 kW
B.
345/0.9169
376.27 m3/hr
BFP head
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 = ------------------------
128 kW
iii.
Hydraulic Coupling :
= 2264 kW
Mechanical losses
100 kW (Approximate)
(speed dependent)
5998 4800
=
------------------- x 2264
= 188 kW.
4800
Total losses in Hydraulic Coupling = 100 + 188
iv.
C.
= 288 kW
95 %
2680/0.95
2821 kW
D.
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.
RECORD OF REVISIONS
Rev.
No.
Date
Revision Details
Revised Approved
By
By
01
02
12.01.2001
Project
Customer
1.0
MSEB
INTENT :
The intent of the site test is to prove the auxiliary power consumption of the Condensate
Extraction Pump set measured at the input terminals of the CEP drive motor at guarantee
parameters.
2.0
GUARANTEE PARAMETERS :
The guarantee parameters of BFP set are given at cl. No. 8.0
3.0
TEST SET UP :
The schematic arrangement for the test is illustrated at page no. 5
4.0
MEASURING POINTS :
a.
FLOW :
The condensate water flow of the Condensate Extraction Pump is measured using
test Differential Pressure Transmitter across orifice in down stream of
gland steam condenser.
b.
HEAD :
The head measurement is done by test pressure transmitters in Pump suction and
discharge
branches.
c.
TEMPERATURE :
The temperature measurement is done by test RTD.
d.
SPEED :
The speed measurement is carried out by tachometer.
e.
POWER :
The power input at the motor terminals shall be measured by test Wattmeter/
transducers by
connecting these wattmeter/transducers to C.Ts and P.Ts provided in the switchgear.
5.0
PERFORMANCE TOLERANCES :
0.1
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
will
TEST METHODOLOGY :
The test instruments listed at cl.no. 9.0 will be connected as per the test scheme. Transducers
6.3
After stabilisation, the test will be conducted for about 1 hour and readings will be recorded at
(5) five
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
8.0
9.0
Flow (m3/hr)
Dynamic head (mlc)
Temperature (C)
:
:
:
498.5
219 (From Test Curve)
43.6
:
:
:
990
440
1485
LIST OF INSTRUMENTS :
-----------------------------------------------------------------------------------------------Parameter
Accuracy
Tag No.
------------------------------------------------------------------------------------------------Suction Pressure
Pressure transducer -1 to +1
kg/sq.cm.
PT1
0.1%
Discharge Pressure
Pressure transducer 0 - 40
kg/sq.cm.
PT2
0.1%
Flow
DPT
0.1%
Temperature
RTD
TE
1/3 DIN
Speed
1 rpm
Power
Watt transducer
0.25%
-----------------------------------------------------------------------------------------------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 correcting the site
tested parameters to the design speed.
A.
Speed
: 1513 rpm.
Discharge temp.
Flow
: 456 kW.
B.
1.
2.
C.
3.
4.
5.
411.15
= ---------- = 435 kW
0.945
1.
2.
D.
Evaluation:
Site measured auxiliary power at motor terminals, corrected to pump design
speed (C2) will be compared to the estimated auxiliary power (B5).
In case the measured power corrected to design speed is higher than the
calculated power, the difference of the two will be treated as excess auxiliary
power consumption.
RECORD OF REVISIONS
Rev.
Date
No.
01
Revision Details
26.12.2000
Revised
Approved
By
By
02
12.01.2001
IV
CUSTOMER
1.0
:
:
INTENT :
The intent of the site test is to prove the auxiliary power consumption of the Cooling water
Pump set measured at the input terminals of the CWP drive motor at guarantee points.
2.0
GUARANTEE PARAMETERS :
The guaranteed parameters shall be as per Annexure-I.
3.0
TEST SET UP :
The schematic arrangement for the test shall be as per Annexure- III for CWP Set.
4.0
MEASURING POINTS :
a)
DISCHARGE PRESSURE :
Discharge Pressure measurement is done by a calibrated pressure gauge.
b)
STATIC HEIGHT :
Static height of the pump discharge pressure gauge from the surface of the water line
in the sump shall be measured as below.
1.
Measure the height of pump discharge pressure gauge centre line from
the
operating floor level, Say "Z1".
2.
Measure the depth of water surface from the operating floor level, say
"Z2".
Static Height = (Z1 + Z2).
c)
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 Meters.
5.0
PERFORMANCE TOLERANCES :
An overall tolerance of 1.5% will be used while comparing measured power with the
guaranteed power due to measurement uncertainties on head and power.
6.0
CALCULATION PROCEDURE :
The auxiliary power consumption for CWP Set is valid for a given set of guaranteed
parameters of CWP Discharge flow and bowl head.
In case the CWP is operated at a point different from the guaranteed parameters, the input
power would be computed using the standard formula relating Q,H and Efficiency. And the
auxiliary power consumed at motor terminals is derived after considering pump efficiency and
motor efficiency corresponding to designed flow, with reference to tested curves of CWP.
Refer Annexure IV for sample calculations.
ANNEXURE 1
AUXILIARY POWER GUARANTEE
Project
Customer
MSEB
Flow (cum/hr)
13600
28.5
1260.7
ANNEXURE II
LIST OF INSTRUMENTS
Parameter
Tag
Accuracy Remarks
No.
MT
--
Discharge
pressure
PG
0.1%
Speed
Optical non-contact
Digital tachometer
1 RPM
Power
Watt Meter
0.25%
ANNEXURE IV
COMPUTATION OF POWER INPUT TO CWP MOTOR
(SAMPLE CALCULATIONS)
1.
2.
1.0 m
5.0 m
4.
(P1x10)+Z1+Z2+(V2/2g)+hr
hf
hf
HL
5.
13600
6.
Bowl efficiency
89%
7.
=
8. a
b
1193.5 kW
9 KW
Transmission loss
KW
=
9.
Total loss (a + b)
12 kW
1193.5 + 12
1205.5 kW
10.
Motor efficiency
96.0%
11.
1205.5/0.96
1255.73 kW