Station : NTPC

Ramagundam

BHEL Ref No. PS - DC - 202 - 500 - 13 B

NTPC Ref No. COS-RGM-COMM-Commg-PRO/003

Sheet 1 of 11

Plant Area : TURBINE

OIL FLUSHING OF LUB OIL SYSTEM OF MOTOR DRIVEN BOILER FEED PUMP
SL.NO.

LIST OF CONTENTS

1.

PLANT DETAILS

2.

OBJECTIVES

3.

PROPOSALS

4.

SERVICES REQUIRED

5.

SAFETY PRECAUTIONS

6.
7.
8.
9.
10.

EMERGENCY PROCEDURES
STATE OF THE PLANT
METHOD
COMPLETION CRITERIA
APPENDICES
a. DRAWINGS
b. LOG SHEETS

Station : NTPC

BHEL Ref No. PS - DC - 202 - 500 - 13 B

Sheet 2 of 11

NTPC Ref No. COS-RGM-COMM-Commg-PRO/003

Ramagundam

Plant Area : TURBINE

OIL FLUSHING OF LUB OIL SYSTEM OF MOTOR DRIVEN BOILER FEED PUMP
STATUS
1.0

PLANT DETAILS

1.1

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.

1.2

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.

2.0

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.

Signatures
NTPC
Station : NTPC
Ramagundam

BHEL
BHEL Ref No. PS - DC - 202 - 500 - 13 B
NTPC Ref No. COS-RGM-COMM-Commg-PRO/003

Sheet 3 of 11

Plant Area : TURBINE

OIL FLUSHING OF LUB OIL SYSTEM OF MOTOR DRIVEN BOILER FEED PUMP

3.0

PROPOSAL

STATUS

3.1

The pipelines shall be disassembled from flange joints.

3.2

Each pipelines shall be acid cleaned by soaking method.

3.3

After neutralization and passivation of each pipeline the pipelines

shall be reassembled for oil flushing.

3.4

Oil flushing for working oil and lub oil circuits shall be done
separately. Necessary temporary connections shall be done for this
purpose.

3.5

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.

4.0

SERVICES REQUIRED

4.1

Availability of DM Water and Service Water

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

e.

Lime Powder

IS : 1540 : 1990 (Part II)

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
Signatures
NTPC
Station : NTPC
Ramagundam

BHEL Ref No. PS - DC - 202 - 500 - 13 B

NTPC Ref No. COS-RGM-COMM-Commg-PRO/003

BHEL
Sheet 4 of 11

Plant Area : TURBINE

OIL FLUSHING OF LUB OIL SYSTEM OF MOTOR DRIVEN BOILER FEED PUMP

Availability of Lab Service for efficiency test of inhibitor and for

testing of Moisture & Mechanical impurities in oil

STATUS

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

SAFETY PRECAUTION

5.1

Ensure the availability of First aid box containing dilute ammounium

hydroxide, 50% sodium bicarbonate solution, Eye lotion Bandage,
Tincture Iodine, Cotton, Burnol etc.

5.2

Ensure availability of
Gum boots 3 Pairs
Rubber Gloves
- 5 Pairs
Apron
- 3 Nos.
Transparent Face Mask
- 3 Nos.

5.3

Ensure the availability of service water near the activity area.

Signatures
NTPC

BHEL

Station : NTPC
Ramagundam

BHEL Ref No. PS - DC - 202 - 500 - 13 B

NTPC Ref No. COS-RGM-COMM-Commg-PRO/003

Sheet 5 of 11

Plant Area : TURBINE

OIL FLUSHING OF LUB OIL SYSTEM OF MOTOR DRIVEN BOILER FEED PUMP
6.0

EMERGENCY PROCEDURES

STATUS

6.1

The members of the team should be aware of the procedures to be

followed in case of accident involving injury to personnel.

6.2

The team conducting the flushing activity should be aware of the operating
procedure of fire entinguisher to be used for quenching fires.

7.0

STATE OF THE PLANT

7.1

ACID CLEANING

7.1.1

Lub oil system and its oil lines are erected fully as per approved drawing.

7.1.2

Hydraulic test of the coolers is successfully completed at a pressure 1.5

times the design pressure.

7.1.3

7.2

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.
OIL FLUSHING

7.2.1

Oil pipelines are reassembled after acid cleaning is over.

7.2.2

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.

7.2.4

Oil lines are properly supported and all temporary supports are cut and
removed.

Signatures
NTPC
Station : NTPC
Ramagundam

BHEL
BHEL Ref No. PS - DC - 202 - 500 - 13 B
NTPC Ref No. COS-RGM-COMM-Commg-PRO/003

Sheet 6 of 11

Plant Area : TURBINE

OIL FLUSHING OF LUB OIL SYSTEM OF MOTOR DRIVEN BOILER FEED PUMP
7.2.5

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.

7.2.6

Dummies are provided at two locations as shown in the drawing.

7.2.7

Temporary connections are made across the bearings preferably of

transparent PVC Hose to withstand temperature as high as 80 0C

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.

7.2.9

Temperature of around 65-75 0 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).

7.2.10

Required instruments such as pressure and temperature gauges are

calibrated and mounted in the system.

8.0

METHOD

8.1

Acid Cleaning (Soaking Method)

8.1.1

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.

8.1.2

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.

STATUS

Signatures
NTPC
Station : NTPC
Ramagundam

BHEL Ref No. PS - DC - 202 - 500 - 13 B

NTPC Ref No. COS-RGM-COMM-Commg-PRO/003

BHEL

Sheet 7 of 11

Plant Area : TURBINE

OIL FLUSHING OF LUB OIL SYSTEM OF MOTOR DRIVEN BOILER FEED PUMP

STATUS
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, neutralise dispose it off with
plenty of service water.

8.1.4

Flush the pipeline with the DM water for 5 - 10 minutes.

8.1.5

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 6.5-7.5.

8.1.6

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.
Oil Flushing

8.2

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.

Signatures
NTPC
Station : NTPC
Ramagundam

BHEL
BHEL Ref No. PS - DC - 202 - 500 - 13 B
NTPC Ref No. COS-RGM-COMM-Commg-PRO/003

Sheet 8 of 11

Plant Area : TURBINE

OIL FLUSHING OF LUB OIL SYSTEM OF MOTOR DRIVEN BOILER FEED PUMP

8.2.1.7

The working oil and Lub oil circuits are flushed separately by
making suitable temporary connections.

8.2.1.8

The flushing of lub oil circuit is to be done in sub-stages by

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.

8.2.1.9

The lube oil filters are inspected periodically. The filters are to be
cleaned whenever the filters get choked which is indicated by
increase in differential pressure across the filter. (> 0.7KSC)
Periodicity of oil sampling and filters inspection to be mutually
decided by NTPC and BHEL at site.

8.2.1.10 Declare the completion of oil flushing as per completion criteria

at 9.0
8.2.1.11 Carryout the hydraulic test of the pipelines at a pressure 1.5
times the design pressure by using external hand pump or lub-oil
pump itself. There should be no leakage.
8.2.1.11

8.2.2

The temporary bypass loop conneciton / Blanks / Dummies are

to be removed and the pipeline connections with the bearing are
normalised.
Stage II

8.2.2.1

Start and continue the lub oil flushing again including the bearing
in the circuit.

8.2.2.2

Declare the completion of oil flushing as per completion criteria

at.9.0

8.2.2.3

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.

8.2.2.4

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.

8.2.2.5

A joint protocol by NTPC & BHEL is to be prepared after

completion of oil flushing operation.

Signatures
NTPC

Station : NTPC
Ramagundam

BHEL

BHEL Ref No. PS - DC - 202 - 500 - 13 B

NTPC Ref No. COS-RGM-COMM-Commg-PRO/003

Sheet 9 of 11

Plant Area : TURBINE

OIL FLUSHING OF LUB OIL SYSTEM OF MOTOR DRIVEN BOILER FEED PUMP

STATUS
9.0

COMPLETION CRITERIA

9.1

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.

9.2

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.

Signatures
NTPC

BHEL

Sheet 11 of 11
LOG SHEET
(To be suitably modified to as per oil System)
Project :
Unit
:

Date :

Activity :

Lub - Oil Flushing Motor Driven Boiler Feed Pump :

RECOMMENDED LUB OIL :

Sl.
No.

Time

Pump
Discharge
Pressure

Oil Pressure
after Duplex
Filter

DP of
Duplex
Filter

Tank
Oil
Level

Oil
Temperature

No. of
Thermal
Shock

Signatures
NTPC

BHEL

PROCEDURE FOR OIL FLUSHING OF LUBE OIL SYSTEM OF

MOTOR DRIVEN BOILER FEED PUMP

PS:TSX:176:00:03

PROJECT : RAMAGUNDAM 500 MW

BHARAT HEAVY ELECTRICALS LIMITED

TECHNICAL SERVICES DEPARTMENT
POWER SECTOR SOUTHERN REGION
CHENNAI 600 035.

PROJECT

RAMAGUNDAM 500MW, UNIT-7

PROCEDURE
PURPOSE OF
DOCUMET
DOCUMENT

MOTOR DRIVEN BFP OIL FLUSHING

FOR EXECUTION / INFORMATION
PS:TSX:176:00:03

Copy No:
Issued to :

00
Rev.No.

K.J
Prepared by

M.K.S
Reviewed by

K.B
Approved by

28.08.03
Date

BHARAT HEAVY ELECTRICALS LIMITED

PSSR/TECHNICAL SERVICES
474, Anna Salai, Nandanam,
Chennai 600 035.

RAMAGUNDAM500MWUNIT7
MOTORDRIVENBFPOILFLUSHING

DRG.NO.4:PS:TSX:0147:00
DRAWN

CHECKED

APPROVED

DATED

KJ

MKS

KB

28.08.03