Bis Bfp Oil Flushing

MDBFP OIL FLUSHING

INDIABULLS POWER LTDAMARAVATI PHASE-I(5×270)

Testing Procedure MECHANICAL

STATION: AMARAVATI Commissioning Procedure PLANT ITEM: MDBFP UNIT:

Location:REF: NO.

Supplier:Manufacture: Type: Serials No:Range: Input: Output:Power Supplies: Volts: Amps: Hz:Plant System: Sub Location:Tag No: Duty: Unit:

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

SL.NO. LIST OF CONTENTS

1. PLANT DETAILS

OBJECTIVES

PROPOSALS

SERVICES REQUIRED

SAFETY PRECAUTIONS

EMERGENCY PROCEDURES

STATE OF THE PLANT

METHOD

COMPLETION CRITERIA

APPENDICES

a. DRAWINGS

b. LOG SHEET

2.

3.

4.

5.

6.

7.

8.

9.

10.

INDIABULLS

NAME SIGNATURE DATEMECH.ERECTELECT.ERECTC&I ERECT.COMMNG.



Location:REF: NO.



1.0 PLANT DETAILS

STATUS

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.

INDIABULLS




Location:REF: NO.



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

4.1

SERVICES REQUIRED

Availability of DM Water and Service Water

Availability of following chemicals

a. Hydrochloric Acid 30% Min IS : 265 : 1993

INDIABULLS




Location:REF: NO.


b. Rodine 213 SPLc. Sodium Nitrited. 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

Availability of Lab Service for efficiency test of inhibitor and for testing of Moisture & Mechanical impurities in oil

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)

INDIABULLS




Location:REF: NO.


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 PairsRubber Gloves - 5 PairsApron

- 3 Nos.Transparent Face Mask - 3 Nos.

5.3 Ensure the availability of service water near the activity area.

INDIABULLS




Location:REF: NO.



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

7.1.1

ACID CLEANING

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 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.

INDIABULLS




Location:REF: NO.


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

7.2.4

7.2.5

7.2.6

7.2.6

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

INDIABULLS




Location:REF: NO.


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 65-750 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).

7.2.10 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.

INDIABULLS




Location:REF: NO.


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.

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.

INDIABULLS




Location:REF: NO.


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

8.2.1.7

8.2.1.8

8.2.1.9

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.

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

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.

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

INDIABULLS




Location:REF: NO.


8.2.1.10 8.2.1.11

8.2.1.11

8.2.2

8.2.2.18.2.2.2

8.2.2.3

8.2.2.4

8.2.2.5

pressure across the filter. (> 0.7KSC) Periodicity of oil sampling and filters inspection to be mutually decided by NTPC and BHEL at site.

Declare the completion of oil flushing as per completion criteria at 9.0

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.

The temporary bypass loop conneciton / Blanks / Dummies are to be removed and the pipeline connections with the bearing are normalised.

Stage II

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

Declare the completion of oil flushing as per completion criteria at.9.0

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.

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

INDIABULLS




Location:REF: NO.



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.

INDIABULLS




Location:REF: NO.


Sheet 11 of 11

LOG SHEET

(To be suitably modified to as per oil System)

Project : Date : Unit : 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

INDIABULLS




Location:REF: NO.


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

PROJECT : Amravati 5X270 MW

INDIABULLS




Location:REF: NO.


PROJECT Amravati 5X270MW

PROCEDURE MOTOR DRIVEN BFP OIL FLUSHING

PURPOSE OF DOCUMET FOR EXECUTION / INFORMATION

DOCUMENT

INDIABULLS




Location:REF: NO.


Copy No:

Issued to :

Rev.No. Prepared by Reviewed by Approved by Date

INDIABULLS


Bis Bfp Oil Flushing

Documents

Transcript of Bis Bfp Oil Flushing