COMMISSIONING CHECKLIST DOC REF NO:

SECTIONFUEL OIL SYSTEM

COMMISSIONING CHECKLIST FOR LDO UNLOADING PUMP For

2X520 MW, IPP, VIZAG HINDUJA NATIONAL POWER CORPORATION LIMITED

PREPARED BY:

STEAG O&M COMPANY PVT LIMTIED

(A Joint Venture company of SESI and HEIL)

2 X 520 MW, IPP, Vizag

TITLE

APPROVAL FOR DOCUMENTS PROCEDURE & CHECKLIST FOR LDO UNLOADING PUMP COMMISSIONING REV. No:0

DOC No. PREPARED BY Mark Jude Isaac REVIEWED BY K Rupesh APPROVED BY ISSUE DATE

Standard Checklist: LDO Unloading Pump Commissioning DOC Ref No.:

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BHEL Engineer

SOMC Engineer

2 X 520 MW, IPP, Vizag

TABLE OF CONTENTS SECTIONS PAGE

1.0 COMMISSIONING CHECKLIST& PROCEDURE ......................................4 2.0 APPENDICES ..........................................................................................10 LOG SHEETS .....................................................................................................10

Standard Checklist: LDO Unloading Pump Commissioning DOC Ref No.:

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SOMC Engineer

2 X 520 MW, IPP, Vizag

1.0

COMMISSIONING CHECKLIST& PROCEDURE

Sl. No. 1.0

Description Preceding Activities Commissioning of suction strainers, filters is completed. The protocol is

Status (Yes/ No)

Remarks

a.

signed for the same and the document is handed over to the commissioning group. Steam/Air blowing and hydro test of LDO piping is completed. The

b.

protocol is signed for the same and the document is handed over to the commissioning group. The alignment of motor and pump is completed, the protocol is signed for

c.

the same and the document is handed over to the commissioning group (alignment values to be mentioned). Commissioning of local indicators, associated transmitters, switches etc.

d.

is completed. The calibration certificates are made available and the protocol is signed. The document is handed over to the commissioning group. All Alarms, Permissives, Interlocks and Protections are checked and

e.

protocol is signed for the same. All the Alarms, Permissives, Protections and Interlocks related to the system in question are kept in service except those essential for the trial. The document is handed over to the commissioning

Standard Checklist: LDO Unloading Pump Commissioning DOC Ref No.:

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SOMC Engineer

2 X 520 MW, IPP, Vizag

Sl. No.

Description group. The electrical setting and testing of electrical system including motor,

Status (Yes/ No)

Remarks

f.

cables, switchgear, protective relays etc. are completed and protocol signed for the same. The document is handed over to the commissioning group.

2.0 a.

Completeness of Erection General conditions satisfy the site standing instructions as listed in the Plant item commissioning essential pre-requisites". The name plate legend agrees with the approved HEIL plant nomenclature. It

b.

is clearly visible, securely fixed, and durable and correlates with remote labels.

c. d. e. f. g. h. i.

The installation is completed and correct in accordance with the latest drawing and specification. The same has been confirmed with the approved P&IDs. Confirm proper fitting of mechanical seals at both the ends of the screws. Check that the heating steam arrangement lines and all other pipe lines for the pump are provided as per the approved drawings. Access for adjustment maintenance and repairs is satisfactory. Correct lubricating oils and greases have been applied to the bearings. Check that oil level in DE and NDE bearing can be adequately monitored (if applicable). Confirm adequate facilities for filling and draining the oil.
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Standard Checklist: LDO Unloading Pump Commissioning DOC Ref No.:

BHEL Engineer

SOMC Engineer

2 X 520 MW, IPP, Vizag

Sl. No. j. k. 3.0 a. b. c. d. e. f. g.

Description Confirm that pump is free to rotate. . Check all rotating parts are adequately guarded. Safety Availability of Fire Tender, Fire Extinguishers and Ambulance near the equipment area. Motor earthing strip status is healthy. Check the suitability of EPB location and its functioning. A person is posted near emergency push button with walkie- talkie Medical Assistance is readily available. Availability of first aid kit at test area. The team commissioning the pump should be aware of the procedure adopted. Agencies working in the area associated with LDO system are informed about the test / cleared from the test area (As per the actual requirement). Oil collecting trays and sand buckets are made available at test area. The commissioning team is aware of the procedures to be followed in case of accidents causing injury to personnel. The commissioning team is aware of the operating procedures of the extinguishers. Services Availability of documents for LDO system.

Status (Yes/ No)

Remarks

h. i. j.

k. 4.0 a.

Standard Checklist: LDO Unloading Pump Commissioning DOC Ref No.:

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2 X 520 MW, IPP, Vizag

Sl. No. b. c. d. e. f. 5.0 5.1 a. b. c. d. e. 5.2 a. b. c. d. e. f.

Description Availability of working crew with Technician for attending minor problem during commissioning of the pump. Availability of power for HT/LT associated drives. Availability of sufficient quantity of oil and grease of correct quality. Adequate illumination for effective checking Effective communication facility is available between CCR, PLC room and operating area. Pre- Start Checkpoints (In addition to above) Before Motor Decouple Trial All PTWs are cancelled. All clearances are available for Motor Decoupled Trial Run. Motor Brg and Winding Temperatures are Normal. Motor Winding Cooling Air Fan Running and Normal (if applicable). Any start permissives are bypassed to enable test trial. (Mention them). Before Motor-Pump coupled Trial All PTWs are cancelled. All clearances are available for Motor coupled Trial Run. Suction/ Discharge Valves Supply are kept Normal (if motorized). Tank Level OK. Motor Winding Cooling Air Fan Running and Normal (if applicable). Motor Brg and Winding Temperatures Normal.

Status (Yes/ No)

Remarks

Standard Checklist: LDO Unloading Pump Commissioning DOC Ref No.:

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BHEL Engineer

SOMC Engineer

2 X 520 MW, IPP, Vizag

Sl. No. g. h. i. j. k. 6.0 6.1 a. b. 6.2 a.

Description Confirm satisfactory operation of the relief valve. Confirm for no leakages from mechanical seals. Recirculation valve Venting of the system is carried out, till oil is seen at the vents of strainers. Necessary Start Permissives By-passed. (Mention them). Trial Run Motor Decouple Trial Run Start the motor check for the correct direction of rotation of motor. Run the motor for 8 hrs and record the parameters as per attached log sheetI. Motor-Pump Coupled Trial Run If motor decoupled trial is found satisfactory, couple the pump with motor. Start the pump and note the parameters as per attached log sheet-II. The

Status (Yes/ No)

Remarks

b.

discharge valve is to be opened slowly for loading of the Pump. Record vibration and bearing temp every 15 min for first one hour of run and every hour till trial run is completed. Trial run shall be minimum of 8 Hrs.

c. d. e. f.

Check the pump is free to rotate and the direction of rotation as marked. No oil leakage should be found. Check for any abnormal noise in the pump. Complete vibration analysis to be made and recorded in the log sheet as base readings for future reference.
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Standard Checklist: LDO Unloading Pump Commissioning DOC Ref No.:

BHEL Engineer

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2 X 520 MW, IPP, Vizag

Sl. No. g.

Description If the trial run is not successful, Record should be made for the problem encountered and corrective actions taken. The procedure is to be repeated till the successful trial run of the equipment.

Status (Yes/ No)

Remarks

Standard Checklist: LDO Unloading Pump Commissioning DOC Ref No.:

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BHEL Engineer

SOMC Engineer

2 X 520 MW, IPP, Vizag

2.0

APPENDICES LOG SHEETS

LOG SHEET-I

Unit: Activity: LDO Unloading Pump - Motor Decoupled Trial Run Trial Records Time of Start: Starting Current (Amps): Normal Current in all 3 s (Amps): Direction of Rotation (DOR): Time of Stop: Vibration Reading Measuring point Motor DE Motor NDE Other Parameters Motor Bearing Temperature Time DE NDE Motor Wdg Temp Horizontal Dis Vel Vertical Dis Vel Dis Axial Vel

Date:

Remarks

Remarks

Standard Checklist: LDO Unloading Pump Commissioning DOC Ref No.:

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2 X 520 MW, IPP, Vizag

LOG SHEET-II Unit: Activity: LDO Unloading Pump -Motor Coupled Trial Run Trial Records Time of Start: Starting Current (Amps): Normal Current in all 3 s (Amps): Direction of Rotation (DOR): Time of Stop: Vibration Reading (Local Measured) Measuring point Motor DE Motor NDE Pump DE Pump NDE Horizontal Dis Vel Vertical Dis Vel Dis Axial Vel Remarks Date:

Standard Checklist: LDO Unloading Pump Commissioning DOC Ref No.:

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2 X 520 MW, IPP, Vizag

Other Parameters Bearing Temperatures Time DV Position Current Inlet Temp Discharge Temp Inlet Press Discharge Press Mot DE Mot NDE Pump DE Pump NDE Bearing Vibration (CCR) Pump DE Pump NDE

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Winding Temp Page 12