MDBFP OIL FLUSHING

INDIABULLS POWER LTD AMARAVATI PHASE-I(5270)

Testing Procedure STATION: AMARAVATI PLANT ITEM: MDBFP Supplier: Manufacture: Range: Power Supplies: Plant System: Tag No:

MECHANICAL

Commissioning Procedure UNIT: REF: NO. Location: Type: Input: Volts: Sub Location: Duty: Serials No: Output: Amps: Unit:

Hz:

OIL FLUSHING OF LUB OIL SYSTEM OF MOTOR DRIVEN BOILER FEED PUMP 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. DRAWINGS LIST OF CONTENTS

NAME INDIABULL S MECH.ERECT ELECT.EREC T C&I ERECT. COMMNG.

SIGNATURE

DATE

Testing Procedure STATION: AMARAVATI PLANT ITEM: MDBFP Supplier: Manufacture: Range: Power Supplies: Plant System: Tag No: b. LOG SHEET

MECHANICAL

Commissioning Procedure UNIT: REF: NO. Location: Type: Input: Volts: Sub Location: Duty: Serials No: Output: Amps: Unit:

Hz:

OIL FLUSHING OF LUB OIL SYSTEM OF MOTOR DRIVEN BOILER FEED PUMP STATUS 1.0 1.1 PLANT DETAILS Boiler Feed Pump is provided with an integral lubricating oil system which serves two purposes. The Oil System supplies lubricating oil to the bearings, which in turn serves also as coolant for equipment bearings. The Oil System also supplies oil to the working oil circuit which controls the scoop operation of the Hydraulic coupling. The lubricating system generally consists of Main oil tank of Hydraulic coupling, Auxiliary Oil Pump (AOP), main Oil Pump (MOP), Duplex Filter, working Oil Cooler, Lub-Oil coolers and associated pipelines. This system also consists of local gauges and control switches for local observation and remote operation. This plant is located near the main equipments. OBJECTIVE To thoroughly clean the lub oil system by removing dirt and other foreign materials before pressing the lub oil system in regular service and to ensure that no debris enters the tank of Hydraulic coupling during oil flushing. NAME INDIABULL S MECH.ERECT ELECT.EREC T C&I ERECT. COMMNG. SIGNATURE DATE

1.2

2.0

Testing Procedure STATION: AMARAVATI PLANT ITEM: MDBFP Supplier: Manufacture: Range: Power Supplies: Plant System: Tag No:

MECHANICAL

Commissioning Procedure UNIT: REF: NO. Location: Type: Input: Volts: Sub Location: Duty: Serials No: Output: Amps: Unit:

Hz:

OIL FLUSHING OF LUB OIL SYSTEM OF MOTOR DRIVEN BOILER FEED PUMP 3.0 3.1 3.2 3.3 3.4 PROPOSAL The pipelines shall be disassembled from flange joints. Each pipelines shall be acid cleaned by soaking method. After neutralization and passivation of each pipeline the pipelines shall be reassembled for oil flushing. Oil flushing for working oil and lub oil circuits shall be done separately. Necessary temporary connections shall be done for this purpose. During oil flushing of lub oil circuit bearings shall be initially kept bypassed using temporary loops. Subsequently bearings shall also be included in the flushing circuit. SERVICES REQUIRED Availability of DM Water and Service Water STATUS

3.5

4.0 4.1

NAME INDIABULL S MECH.ERECT ELECT.EREC T C&I ERECT. COMMNG.

SIGNATURE

DATE

Testing Procedure STATION: AMARAVATI PLANT ITEM: MDBFP Supplier: Manufacture: Range: Power Supplies: Plant System: Tag No:

MECHANICAL

Commissioning Procedure UNIT: REF: NO. Location: Type: Input: Volts: Sub Location: Duty: Serials No: Output: Amps: Unit:

Hz:

Availability of following chemicals a. b. c. d. Hydrochloric Acid 30% Min IS : 265 : 1993 Rodine 213 SPL Sodium Nitrite Liquor Ammonia 25% IS : 799 - 1990 IS : 1540 : 1990 (Part II)

e. Lime Powder

Note : Quantity of above chemical are to be worked out at site

Availability of adequate number of wooden plugs Availability of Service Air Availability of required grade and quantity of lub oil Availability of L.T Power Supply Availability of Lab Service for efficiency test of inhibitor and for testing of Moisture & Mechanical impurities in oil

NAME INDIABULL S MECH.ERECT ELECT.EREC T C&I ERECT. COMMNG.

SIGNATURE

DATE

Testing Procedure STATION: AMARAVATI PLANT ITEM: MDBFP Supplier: Manufacture: Range: Power Supplies: Plant System: Tag No:

MECHANICAL

Commissioning Procedure UNIT: REF: NO. Location: Type: Input: Volts: Sub Location: Duty: Serials No: Output: Amps: Unit:

Hz:

Availability of adequate lighting and telephone facility in lub oil flushing area Availability of Portable fire tender Availability of manpower with tools and consumables like cloth, kerosene etc. Availability of Portable Centrifuge. Availability of Cooling water to oil cooler (for Thermal Shocks)

5.0 5.1

SAFETY PRECAUTION Ensure the availability of First aid box containing dilute ammounium hydroxide, 50% sodium bicarbonate solution, Eye lotion Bandage, Tincture Iodine, Cotton, Burnol etc. Ensure availability of Gum boots 3 Pairs SIGNATURE

5.2

NAME INDIABULL S MECH.ERECT ELECT.EREC T C&I ERECT. COMMNG.

DATE

Testing Procedure STATION: AMARAVATI PLANT ITEM: MDBFP Supplier: Manufacture: Range: Power Supplies: Plant System: Tag No:

MECHANICAL

Commissioning Procedure UNIT: REF: NO. Location: Type: Input: Volts: Sub Location: Duty: Serials No: Output: Amps: Unit: Rubber Gloves - 5 Pairs Apron - 3 Nos. Transparent Face Mask - 3 Nos.

Hz:

5.3

Ensure the availability of service water near the activity area.

NAME INDIABULL S MECH.ERECT ELECT.EREC T C&I ERECT. COMMNG.

SIGNATURE

DATE

Testing Procedure STATION: AMARAVATI PLANT ITEM: MDBFP Supplier: Manufacture: Range: Power Supplies: Plant System: Tag No:

MECHANICAL

Commissioning Procedure UNIT: REF: NO. Location: Type: Input: Volts: Sub Location: Duty: Serials No: Output: Amps: Unit:

Hz:

OIL FLUSHING OF LUB OIL SYSTEM OF MOTOR DRIVEN BOILER FEED PUMP 6.0 6.1 EMERGENCY PROCEDURES The members of the team should be aware of the procedures to be followed in case of accident involving injury to personnel. The team conducting the flushing activity should be aware of the operating procedure of fire entinguisher to be used for quenching fires. STATE OF THE PLANT ACID CLEANING Lub oil system and its oil lines are erected fully as per approved drawing. Hydraulic test of the coolers is successfully completed at a pressure 1.5 times the design pressure. Oil lines are then dismantled and one end of each pipe is blocked by a wooden plug. Tight fitting of the wooden plug is ensured so that no leakage of chemical solution occurs during acid cleaning process. STATUS

6.2

7.0 7.1 7.1.1

7.1.2

7.1.3

NAME INDIABULL S MECH.ERECT ELECT.EREC T C&I ERECT. COMMNG.

SIGNATURE

DATE

Testing Procedure STATION: AMARAVATI PLANT ITEM: MDBFP Supplier: Manufacture: Range: Power Supplies: Plant System: Tag No:

MECHANICAL

Commissioning Procedure UNIT: REF: NO. Location: Type: Input: Volts: Sub Location: Duty: Serials No: Output: Amps: Unit:

Hz:

7.2 7.2.1 7.2.2

OIL FLUSHING Oil pipelines are reassembled after acid cleaning is over. Oil Tank and Duplex filters are clean. Oil tank is filled to the required level with recommended oil. Oil of different quality / make should never be mixed. Oil should be filled through filters.

7.2.3

Oil pipelines are disconnected from the bearings. The bearings are bypassed by temporarily inter-connecting inlet and outlet lines of bearings using temporary loops. Oil lines are properly supported and all temporary supports are cut and removed. Temporary line filter (Stainless Steel Mesh) are provided in the return line before entering the tank to avoid entry of dirt into MOT of Hydraulic Coupling Dummies are provided at two locations as shown in the drawing. Temporary connections are made across the bearings preferably of transparent PVC Hose to withstand temperature as high as 800C

7.2.4 7.2.5

7.2.6 7.2.6

NAME INDIABULL S MECH.ERECT ELECT.EREC T C&I ERECT. COMMNG.

SIGNATURE

DATE

Testing Procedure STATION: AMARAVATI PLANT ITEM: MDBFP Supplier: Manufacture: Range: Power Supplies: Plant System: Tag No:

MECHANICAL

Commissioning Procedure UNIT: REF: NO. Location: Type: Input: Volts: Sub Location: Duty: Serials No: Output: Amps: Unit:

Hz:

7.2.8

Suitable connections are made between portable centrifuge and MOT of Hydraulic Coupling. Suction is taken from Hydraulic Coupling Tank bottom drain and discharge is left inside the HC through the inspection cover. Centrifuge will be run during oil flushing. Temperature of around 65-750 C to be reached during oil flushing through centrifuge heaters (if required additional heaters are to be provided at suitable location in the oil circuit to attain the required temperature during oil flushing).

7.2.9

7.2.10 Required instruments such as pressure and temperature gauges are calibrated and mounted in the system. 8.0 8.1 8.1.1 METHOD Acid Cleaning (Soaking Method) Fill the lines with DM water and flush it few times. Also ensure that no leakage takes place through the wooden plug provided at one end of the pipe line. Fill 5% concentration hydrochloric acid with 0.2% inhibitor (Rodine 213 Special) in the pipes. Efficiency test of inhibitor is to done prior to its use as per NACE standard.

8.1.2

NAME INDIABULL S MECH.ERECT ELECT.EREC T C&I ERECT. COMMNG.

SIGNATURE

DATE

Testing Procedure STATION: AMARAVATI PLANT ITEM: MDBFP Supplier: Manufacture: Range: Power Supplies: Plant System: Tag No:

MECHANICAL

Commissioning Procedure UNIT: REF: NO. Location: Type: Input: Volts: Sub Location: Duty: Serials No: Output: Amps: Unit:

Hz:

8.1.3

Pour and allow this acid solution to soak for 4 hours in the pipeline and then drain the acid mixture in a safe place, neutralize dispose it off with plenty of service water. Flush the pipeline with the DM water for 5 - 10 minutes. Fill the pipelines again with sodium nitrite (2%) and liquor ammonia 5%. Allow the solution to soak for 30 minutes. Drain the solution and rinse with DM water till pH of discharged water is 6.57.5. Fill up the lines with lube oil and ensure uniform oil film is achieved through out the internal surface of the pipes. The ends of the pipes are to be kept properly capped till the pipes are reassembled.

8.1.4 8.1.5

8.1.6

NAME INDIABULL S MECH.ERECT ELECT.EREC T C&I ERECT. COMMNG.

SIGNATURE

DATE

Testing Procedure STATION: AMARAVATI PLANT ITEM: MDBFP Supplier: Manufacture: Range: Power Supplies: Plant System: Tag No:

MECHANICAL

Commissioning Procedure UNIT: REF: NO. Location: Type: Input: Volts: Sub Location: Duty: Serials No: Output: Amps: Unit:

Hz:

8.2

Oil Flushing Stage I

8.2.1.1 Bump AOP and check the direction of rotation. (Please note that Lub - Oil tank of Hydraulic coupling is already filled up with recommended oil. 8.2.1.2 After ensuring that the direction of rotation is correct, run the AOP continuously and fill the system gradually. 8.2.1.3 Oil level in the tank is to be watched till the flow is established throughout the systems. Oil to be topped up, if required. 8.2.1.4 Check for any oil leakage and attend the same, if any. 8.2.1.5 Raise oil temperature by heaters of centrifuge (or by external heaters) to 65-70o C. Stop heating to be cut-off and cooling water admitted to lub-oil and working oil coolers to slash down the temperature fast to give the effect of thermal shock. Pipe lines are tapped with wooden hammer during this period of thermal shock. The procedure is repeated till the oil flushing is declared completed. 8.2.1.7 The working oil and Lub oil circuits are flushed separately by NAME INDIABULL S MECH.ERECT ELECT.EREC T C&I ERECT. COMMNG. SIGNATURE DATE

Testing Procedure STATION: AMARAVATI PLANT ITEM: MDBFP Supplier: Manufacture: Range: Power Supplies: Plant System: Tag No:

MECHANICAL

Commissioning Procedure UNIT: REF: NO. Location: Type: Input: Volts: Sub Location: Duty: Serials No: Output: Amps: Unit:

Hz:

8.2.1.8 making suitable temporary connections. The flushing of lub oil circuit is to be done in sub-stages by 8.2.1.9 grouping Two to Three bearings. (to be decided at site) by suitable isolation of lub oil supply lines to various bearings, to have adequate velocity in the pipelines for effective flushing. The lube oil filters are inspected periodically. The filters are to be 8.2.1.1 cleaned whenever the filters get choked which is indicated by 0 increase in differential pressure across the filter. (> 0.7KSC) Periodicity of oil sampling and filters inspection to be mutually 8.2.1.1 decided by NTPC and BHEL at site. 1 Declare the completion of oil flushing as per completion criteria at 9.0 8.2.1.1 Carryout the hydraulic test of the pipelines at a pressure 1.5 times 1 the design pressure by using external hand pump or lub-oil pump itself. There should be no 8.2.2 leakage. 8.2.2.1 The temporary bypass loop conneciton / Blanks / Dummies are to 8.2.2.2 be removed and the pipeline connections with the bearing are normalised. 8.2.2.3 Stage II Start and continue the lub oil flushing again including the bearing 8.2.2.4 in the circuit. Declare the completion of oil flushing as per completion criteria at.9.0 8.2.2.5 The oil used for flushing is to be drained and kept in safe custody for flushing of other units, if found suitable. While using such oil (used oil) for flushing in other unit, it should be filled through centrifuge. Fill the system with fresh lub oil. Run the L.ub oil system adjust the flow through bearings, set the relief valve. Prove envisaged protection, interlocks, alarms, annunciation and measurements. NAME INDIABULL S MECH.ERECT ELECT.EREC T C&I ERECT. COMMNG. SIGNATURE DATE

Testing Procedure STATION: AMARAVATI PLANT ITEM: MDBFP Supplier: Manufacture: Range: Power Supplies: Plant System: Tag No:

MECHANICAL

Commissioning Procedure UNIT: REF: NO. Location: Type: Input: Volts: Sub Location: Duty: Serials No: Output: Amps: Unit:

Hz:

A joint protocol by IPL & BHEL is to be prepared after completion of oil flushing operation.

OIL FLUSHING OF LUB OIL SYSTEM OF MOTOR DRIVEN BOILER FEED PUMP STATUS 9.0 9.1 COMPLETION CRITERIA The pipelines are to be considered clean when the DP across the filter stabilises and does not raise more than 0.1 to 0.2 KSC, over the normal value after 8 hours of flushing operation. Also, there should not be NO hard particles deposition in Lub oil filters.

NAME INDIABULL S MECH.ERECT ELECT.EREC T C&I ERECT. COMMNG.

SIGNATURE

DATE

Testing Procedure STATION: AMARAVATI PLANT ITEM: MDBFP Supplier: Manufacture: Range: Power Supplies: Plant System: Tag No: 9.2

MECHANICAL

Commissioning Procedure UNIT: REF: NO. Location: Type: Input: Volts: Sub Location: Duty: Serials No: Output: Amps: Unit:

Hz:

Mechanical impurities (through 0.45 micron filter) and moisture content in the samples collected from flushing oil should be each less than 100 ppm in three consecutive samples taken at interval of 4 hours.

Sheet 11 of 11 LOG SHEET (To be suitably modified to as per oil System) Project : Unit : Activity Date : : Lub - Oil Flushing Motor Driven Boiler Feed Pump :

RECOMMENDED LUB OIL : NAME INDIABULL S MECH.ERECT ELECT.EREC T C&I ERECT. COMMNG. SIGNATURE DATE

Testing Procedure STATION: AMARAVATI PLANT ITEM: MDBFP Supplier: Manufacture: Range: Power Supplies: Plant System: Tag No:

MECHANICAL

Commissioning Procedure UNIT: REF: NO. Location: Type: Input: Volts: Sub Location: Duty: Serials No: Output: Amps: Unit:

Hz:

Sl. No.

Time

Pump Discharge Pressure

Oil Pressure after Duplex Filter

DP of Duplex Filter

Tank Oil No. of Oil Temperatu Thermal Level re Shock

NAME INDIABULL S MECH.ERECT ELECT.EREC T C&I ERECT. COMMNG.

SIGNATURE

DATE

Testing Procedure STATION: AMARAVATI PLANT ITEM: MDBFP Supplier: Manufacture: Range: Power Supplies: Plant System: Tag No:

MECHANICAL

Commissioning Procedure UNIT: REF: NO. Location: Type: Input: Volts: Sub Location: Duty: Serials No: Output: Amps: Unit:

Hz:

PROCEDURE FOR OIL FLUSHING OF LUBE OIL SYSTEM OF MOTOR DRIVEN BOILER FEED PUMP

PROJECT : Amravati 5X270 MW

NAME INDIABULL S MECH.ERECT ELECT.EREC T C&I ERECT. COMMNG.

SIGNATURE

DATE

Testing Procedure STATION: AMARAVATI PLANT ITEM: MDBFP Supplier: Manufacture: Range: Power Supplies: Plant System: Tag No: PROJECT PROCEDURE PURPOSE OF DOCUMET DOCUMENT

MECHANICAL

Commissioning Procedure UNIT: REF: NO. Location: Type: Input: Volts: Sub Location: Duty: Amravati 5X270MW MOTOR DRIVEN BFP OIL FLUSHING FOR EXECUTION / INFORMATION Serials No: Output: Amps: Unit:

Hz:

Copy No: Issued to :

Rev.No.

Prepared by

Reviewed by

Approved by

Date

NAME INDIABULL S MECH.ERECT ELECT.EREC T C&I ERECT. COMMNG.

SIGNATURE

DATE

Testing Procedure STATION: AMARAVATI PLANT ITEM: MDBFP Supplier: Manufacture: Range: Power Supplies: Plant System: Tag No:

MECHANICAL

Commissioning Procedure UNIT: REF: NO. Location: Type: Input: Volts: Sub Location: Duty: Serials No: Output: Amps: Unit:

Hz:

NAME INDIABULL S MECH.ERECT ELECT.EREC T C&I ERECT. COMMNG.

SIGNATURE

DATE