PRODUCT STANDARD Doc. No.

HY-DC-4-18000-51345

Rev No. 5
TD-106-1 PUMPS

Form No.
Rev No. 00
HYDERABAD PAGE 2 of 7

GSPC PIPAVAV 2x350 MW CCPP

SEQUENTIAL INTERLOCKING CONDITIONS FOR B.F.P. SET

LEGEND :

BFP - Boiler Feed Pump

The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED,

AOP - Auxiliary Oil Pump

It must not be used directly or indirectly in any way detrimental to the interest of the company.

MOP - Main Oil Pump

R.C.Valve - Recirculation Control Valve

Reference drawings :

Instruments schedule of BFP : HY-SC-4-18000-51344

COPYRIGHT AND CONFIDENTIAL

PID of Feed Water System of BFP : HY-DG-1-18000-56610

PID of Sealing & Cooling Water System of BFP : HY-DG-1-18000-56611

PID of Lube Oil & Working Oil System of BFP : HY-DG-1-18000-56612

INTRODUCTION :

BFP train consists of BFP, Hydraulic Coupling, Motor and Booster Pump. Start
permissive, Interlocks and annunciation are to be provided for the safe operation of the BFP
set. Primary instruments as listed in "instruments schedule of BFP" required for this purpose is
provided along with BFP (except limit switches on suction valve and level switches of
Deaerator which are to be supplied by the respective equipment supplier). The contacts of these
instruments are wired and terminated in local junction boxes.

However, a detailed write up is given below for engineering the controls required for
safe operation of BFP. This write-up does not include the electrical protection required for drive
motor.

A) OIL CIRCUITS :

A brief description of the oil systems is given below to understand the requirements of
protections. Detailed description required for operation and maintenance is covered in O&M
manuals.

Revisions : Prepared : Approved : Date :

Ref. Doc

Refer to record of revisions : B. RAJKUMAR 20.08.2008

B. PRAKASH
 PRODUCT STANDARD Doc. No. HY-DC-4-18000-51345

Rev No. 5
TD-106-2

Form No.
PUMPS Rev No. 00
HYDERABAD PAGE 3 of 7

LUBRICATION SYSTEM OF BFP :

a) Start up of BFP through hydraulic coupling :

The hydraulic coupling has an auxiliary oil pump AOP driven by its own 415v, 3-phase,
50Hz motor. In addition, the hydraulic coupling has a Main oil pump (MOP). On auto,
the AOP shall start automatically with start command given to HM to pre-lubricate the
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED .

step up gears and bearings of hydraulic coupling, Boiler feed pump, Booster pump and
motor. When a pressure of 0.8 Kg./Cm² is established, HM starts by the1/2 out of the
It must not be used directly or indirectly in any way detrimental to the interest of the company.

LVMs outputs from pressure transmitters tag.nos. LAV13CP001 & LAV13CP002 after
a time delay of 3 sec. When the HM starts, lube pressure increases due to AOP and also
MOP. When the lube oil pressure increases approximately to 2.9 Kg./Cm², AOP shall be
cut off through pressure transmitters tag nos.. LAV13CP001 & LAV13CP002 with 1/2
out of the LVMs outputs.

b) Normal running :
COPYRIGHT AND CONFIDENTIAL

During normal running of pump set, the lube oil will be supplied by the Main oil pump
(MOP) in the hydraulic coupling. If due to excessive leakage or any other reasons, the
lube oil pressure drops down to 1.0 Kg./Cm², the AOP shall be started with an impulse
from pressure transmitters tag nos. LAV13CP001 & LAV13CP002 with 1/2 out of the
LVMs outputs. When the pressure increased to 2.9 Kg./Cm², the AOP may be
automatically cut off. This support from AOP does not amount to normal working
condition and hence the operator has to investigate the fault and rectify the same. If the
pressure falls to 1.1 Kg./Cm², an optical and accoustic signal for low pressure alarm shall
be initiated in tag nos. LAV13CP001 & LAV13CP002 with 1/2 out of the LVMs
outputs. In case the lube oil pressure further falls down to 0.5 Kg./Cm², the BFP motor
shall be immediately tripped by the 1/2 out of the LVMs outputs in pressure transmitters
tag nos. LAV13CP001 & LAV13CP002.

c) Tripping and run down of BFP :

Whenever the BFP motor HM is tripped, the AOP shall be automatically switched ON to
supply lube oil during the running down of the BFP set including hydraulic coupling
and shall be kept running for the specified period. The AOP may be manually stopped
after the bearing temperatures come down to normal values.

The AOP and MOP are gear type pumps. An adjustable relief valve is provided in the
common discharge line. By adjusting the relief valve, the lube oil pressure at the
discharge of AOP/MOP is normally set to about 3.0 Kg./Cm².

The pressure setting values given above for pressure transmitters in lube oil header after
lube oil cooler and filter are tentative values. These settings may be adjusted as required
at the time of commissioning at site depending on site requirement.
Ref. Doc
 PRODUCT STANDARD Doc. No. HY-DC-4-18000-51345

Rev No. 5
TD-106-2

Form No.
PUMPS Rev No. 00
HYDERABAD PAGE 4 of 7

2. WORKING OIL SYSTEM OF HYDRAULIC COUPLING :

Working oil system is part of Hydraulic Coupling which is involved in giving variable
output speed. This system comprises filling pump, primary wheel, secondary wheel, scoop tube
and working oil cooler. Scoop tube is positioned by the actuator which shall receive the signal
as per the load requirement. While torque transmission takes place between primary and
secondary wheels, working oil temperature rises. Temperature of working oil at inlet to cooler is
monitored with duplex RTDs which are interlocked to trip the main motor at high-high
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED .

temperature.
It must not be used directly or indirectly in any way detrimental to the interest of the company.

B) Conditions to be ensured manually for the Pump chosen for operation on

manual or auto start (For operating personnel):

1. Booster pump suction valve shall be opened fully.

2. BFP discharge valve shall be fully closed (for manual start only)
3. BFP recirculation control valve shall be fully opened.
4. AOP shall be kept running.
COPYRIGHT AND CONFIDENTIAL

5. Cooling water shall be ensured for lube oil coolers, BFP mechanical seal cooler, BFP
stuffing box and Booster Pump stuffing box.
6. Hydraulic Coupling scoop tube shall be in minimum position (for manual start only).

C) Conditions to be ensured through C&I interlocks for the BFP chosen for
operation on manual or auto start :

1.0 Following start per missives shall be satisfied for starting of BFP motor manually or
on auto.

1.1 Booster pump suction valve is fully open through limit switch on the valve.
1.2 Deaerator water level is ‘normal' through level transmitters (LAA10 CL001, 002 & 003
1.3 on deaerator.
1.3 Lube oil header pressure is minimum 0.8 kg/cm2 through pressure transmitters KKS tag
nos. LAV13 CP001 & 002 (1 out of 2 LOGIC).
1.4 Discharge valve closed (For manual start only).
1.5 Recirculation valve open (For Manual start only).

2.0 Following conditions shall be ensured through C&I interlocks when a BFP is kept
on ‘Auto stand by’.

2.1 AOP shall start.

2.2 Discharge valve shall be in open position (Permissive with ‘Discharge valve closed’
condition shall be by-passed).
2.3 R C Valve shall close.
2.4 Scoop tube actuator shall continuously receive the same signal (signal from position Feed
back transmitter LAV13 CG001) as that of running pumps to position the scoop tube
same as that of running pumps.
Ref. Doc
 PRODUCT STANDARD Doc. No. HY-DC-4-18000-51345

Rev No. 5
TD-106-2

Form No.
PUMPS Rev No. 00
HYDERABAD PAGE 5 of 7

D) Conditions to ensure tripping of BFP motor through C&I interlocks

Operating pump shall be tripped whenever the following conditions occur.

1. Deaerator level Low-Low through Level transmitters LAA10 CL001, 002 & 003 (2/3
LOGIC), on Deaerator.
2. Suction pressure of BFP Low-Low at 13.0 kg/cm2 through Pressure Transmitter LAB10
CP022 & CP023 (1 out of 2 LOGIC).
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED .

3. Lube oil header pressure Low-Low at 0.5 kg/cm2 through Pressure Transmitters KKS tag
It must not be used directly or indirectly in any way detrimental to the interest of the company.

nos. LAV13 CP001 & 002 (1 out of 2 LOGIC).

4. Differential temperature feed water across BFP suction and discharge ‘High-High’ at
+15 C, DCS contact, LAB10 CT020/CT022 &CT021/CT023 (1 OUT OF 2 LOGIC) and
suction flow less than 120 t/hr from Flow Nozzle LAB10 CF100.
5. Working oil temperature at inlet to working oil coolers High-high at 130C through
temperature RTD KKS tag nos LAV13 CT009 and CT010 (1 OUT OF 2 LOGIC).
6. Booster pump suction valve not open through “open position” limit switch on the
COPYRIGHT AND CONFIDENTIAL

valve
7. BP & BFP Thrust Bearing Temp very high 100C through LAV11 CT005 to CT008 &
LAV10 CT005 to CT008

E) SUMMARY CONDITIONS FOR BFP AUXILIARIES:

1.0 Auxiliary Oil Pump (AOP) motor shall always be kept on ‘Auto’ mode except when BFP
is not chosen for operation either for maintenance or for other reason. When AOP is kept
on auto, it shall start under following conditions through C&I interlock.
1.1 AOP shall start when BFP is kept on ‘Auto stand by’.
1.2 L.O. Pressure Header alarm low shall be initiated when pressure falls to 1.1 kg/cm2 (g)
(LAV10 CP001 & 002, 1 OUT OF 2 LOGIC). AOP shall start when the lube oil header
pressure falls to 1.0 kg/cm2 (g) (Pressure transmitters KKS tag nos. LAV13 CP001 & 002,
1 out of 2 LOGIC).
1.3 AOP shall stop when the lube oil header pressure reaches 2.9-kg/cm2 (g) due to combined
running of AOP and MOP (Pressure transmitters KKS tag nos. LAV13 CP001 & 002,
1 out of 2 LOGIC).
Note for operating personnel : AOP shall never be stopped within 15 minutes of BFP
motor stopping / tripping.
1.4 AOP will start when BFP will be made off or trip.
1.5 When Rev. rotation switch is actuated, AOP shall be started.

2.0 COOLING WATER VALVE ( MOTOR OPERATED):

This is in common cooling water inlet of BFP motor cooler and working oil cooler. This
shall always be kept in auto-mode except when the valve or cooler is under maintenance.
When on auto mode it shall open/ close through C&I interlocks under following
conditions:

1.1 Cooling water valve shall open when BFP motor starts either on manual or an auto.
2.2 Cooling water valve shall close when BFP motor is stopped/ tripped.
Ref. Doc
 PRODUCT STANDARD Doc. No. HY-DC-4-18000-51345

Rev No. 5
TD-106-2

Form No.
PUMPS Rev No. 00
HYDERABAD PAGE 6 of 7

3.0 DISCHARGE VALVE (MOTOR OPERATED) :

This valve shall always be kept on auto mode except when BFP motor is on manual mode
or when valve is under maintenance. When kept on auto, discharge valve shall open/
close through C&I interlocks under the following conditions:
3.1 Discharge valve shall open when BFP is kept on “Auto stand by”.
3.2 Discharge valve shall be closed during “Manual Start”.
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED .

3.3 During Manual start DV shall be opened when discharge pressure is more than 70kg/cm2
It must not be used directly or indirectly in any way detrimental to the interest of the company.

set in PT LAB10 CP024.

3.4 When BFP DV is closed, BFP rev rotation switch LAV13 CS201 is actuated.

4.0 RECIRCULATION CONTROL VALVE :

This valve shall always be kept on auto mode except when the valve is under
maintenance. When kept on auto, R.C valve shall open/ close through C&I interlocks
under the following conditions.
COPYRIGHT AND CONFIDENTIAL

4.1 R.C valve of a running pump shall open when the suction flow drops to 120 t/hr.
4.2 R.C valve of a running pump shall close when the suction flow reaches 240 t/hr.
4.3 R.C valve of a running pump shall open when differential temperature of feed water
across BFP discharge and suction reaches +10 C, DCS contact (LAB10 CT020/CT022,
LAB10 CT021/CTO23) (1 OUT OF 2 LOGIC).
4.4 R.C valve shall close when BFP is on “ auto stand by ”. When standby BFP gets started
and minimum flow of 120 t/hr is not established with in 25 seconds of starting, RC valve
shall open.

5.0 CIRCULATION CONTROL VALVE :

Through the oil circulation valve the oil flows into the coupling working chamber and, due
to centrifugal force, forms a rotating oil ring in the scoop chamber. The scoop tube
position determines the thickness of oil ring in the scoop chamber and thus also the filling
in the working chamber. The scoop tube scoop up the warmed up working oil in the
working chamber and directs it to the working oil cooler, where it is cooled down and
supplied through the oil circulation valve back into the coupling. This completes the cycle.
The oil circulation valve controls the working oil flow rate dependent on the accumulated
power losses. Any excessive oil in the circuit is re-turned through the pressure relief valve
into the oil tank.

F) LIST OF RECOMMENDED ANNUNCIATIONS /TRIPS:

1. All trip conditions : Clause (D) above
2. BP bearing drain oil temp high : LAV11 CT001 to CT002, 75 C

3. Motor bearing drain oil temp high : LAV12 CT001 to CT002, 75 C

4. BFP bearing drain oil temp high : LAV10 CT001 to CT002, 75 C

5. BP journal bearing temp high : LAV11 CT003 to CT004, 80 C

Ref. Doc

6. BP thrust bearing temp high : LAV11 CT005 to CT008, 90 C

7. BFP journal bearing temp high : LAV10 CT003 to CT004, 90 C
 PRODUCT STANDARD Doc. No. HY-DC-4-18000-51345

Rev No. 5
TD-106-2

Form No.
PUMPS Rev No. 00
HYDERABAD PAGE 7 of 7

8. BFP thrust bearing temp high : LAV10 CT005 to CT008, 90 C

9. Hydraulic Coupling bearing temp high : LAV13 CT001 to CT008, 90 C

10. Lube oil header pressure low : LAV13 CP001&002

1.1/0.5kg /cm2(g) (1 outof 2 logic)
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED .

11. Working oil cooler oil inlet temp high : LAV13 CT009 & CT010, 110 °C
It must not be used directly or indirectly in any way detrimental to the interest of the company.

(1 out of 2 LOGIC)

12. Working oil cooler oil outlet temp high : LAV13 CT011 & CT012, 70°C
(1 out of 2 LOGIC)

13. Lube oil cooler oil inlet temp high : LAV13 CT013 & CT014, 70 °C
(1 out of 2 LOGIC)
14. Lube oil cooler oil outlet temp high : LAV13 CT015 & CT016, 70 °C
COPYRIGHT AND CONFIDENTIAL

(1 out of 2 LOGIC)
15. Hydraulic coupling oil tank level high/low: LAV13 CL100, 60/50 mm

16. Diff. Pressure across oil filter high : LAV13 CP003, 0.6 Kg/cm2 (g)

17. Diff. Pressure across Booster pump : LAB10 CP020, 0.2 Kg/cm2 (g)
Suction strainer high
18. BP suction pressure low : LAB10 CP021, 5.0 kg/cm2 (g)

19. BFP suction pressure low / low low : LAB10 CP022 / LAB10 CP023,
13.0 kg/cm2 (g) / 12.0 kg/cm2 (g)
time delay 5 Secs. (1 out of 2 logic)

20. Balance leak off pressure high : LAC10 CP100,set at 20 kg/cm2 (g)

21. Differential temp across BFP suction : DCS Contact (LAB10 CT020/CT022
and discharge high / high high LAB10 CT021/CT023)
(1 OUT OF 2 LOGIC) +10°C/15°C

22. BFP Mechanical Seal water outlet : LAC11 CT001 to CT002, 100 C
temperature high

23. Deaerator level low : Set in Deaerator level transmitters

24. BFP Vibration (DE/NDE) high / high high: LAV10 CY201 & LAV10 CY202
15.0 mm/sec / 25.0 mm/sec

25. BFP Discharge pressure low : LAB10 CP024, 30.0 kg/cm2 (g)
time delay 15 Secs, at Min Speed.
NOTE :
1. Motor protections are not included in the write-up. They shall be as per motor
Ref. Doc

manufacturer’s recommendations.
2. KKS Tag Nos. indicated are for BFP-A. For KKS Tag Nos. of BFP-B, refer
Instrument Schedule of BFP set, HY-SC-4-18000-51344.