MDBFP OIL FLUSHING
INDIABULLS POWER LTD
AMARAVATI PHASE-I(5270)
Testing Procedure MECHANICAL
STATION: AMARAVATI Commissioning Procedure
PLANT ITEM: MDBFP UNIT:
Location:
REF: NO.
Supplier:
Mnu!cture: T"pe: Serils No:
Rnge: Input: Output:
Po#er Supplies: $olts: Amps: H%:
Plnt S"stem: Su& Loction:
Tg No: 'ut": (nit:
OIL FLUSHING OF LUB OIL SYSTEM OF MOTOR DRIVEN BOILER FEED
PUMP
SL.NO. LIST OF CONTENTS
1. PLANT DETAILS
OBJECTIVES
PROPOSALS
SERVICES REUIRED
SAFETY PRECAUTIONS
EMERGENCY PROCEDURES
STATE OF THE PLANT
METHOD
COMPLETION CRITERIA
APPENDICES
a. DRA!INGS
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1*.
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COMMN*.
Testing Procedure MECHANICAL
STATION: AMARAVATI Commissioning Procedure
PLANT ITEM: MDBFP UNIT:
Location:
REF: NO.
Supplier:
Mnu!cture: T"pe: Serils No:
Rnge: Input: Output:
Po#er Supplies: $olts: Amps: H%:
Plnt S"stem: Su& Loction:
Tg No: 'ut": (nit:
+. LOG SHEET
OIL FLUSHING OF LUB OIL SYSTEM OF MOTOR DRIVEN BOILER FEED PUMP
1.* PLANT DETAILS
STATUS
,., )oiler Feed Pump is pro-ided #it. n integrl lu&ricting oil
s"stem #.ic. ser-es t#o purposes. T.e Oil S"stem supplies
lu&ricting oil to t.e &erings/ #.ic. in turn ser-es lso s
coolnt !or e0uipment &erings. T.e Oil S"stem lso supplies oil
to t.e #or1ing oil circuit #.ic. controls t.e scoop opertion o!
t.e H"drulic coupling.
,.2 T.e lu&ricting s"stem generll" consists o! Min oil tn1 o!
H"drulic coupling/ Au3ilir" Oil Pump 4AOP5/ min Oil Pump
4MOP5/ 'uple3 Filter/ #or1ing Oil Cooler/ Lu&6Oil coolers nd
ssocited pipelines. T.is s"stem lso consists o! locl guges
nd control s#itc.es !or locl o&ser-tion nd remote opertion.
T.is plnt is locted ner t.e min e0uipments.
".* OBJECTIVE
To t.oroug.l" clen t.e lu& oil s"stem &" remo-ing dirt nd
ot.er !oreign mterils &e!ore pressing t.e lu& oil s"stem in
regulr ser-ice nd to ensure t.t no de&ris enters t.e tn1 o!
H"drulic coupling during oil !lus.ing.
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Testing Procedure MECHANICAL
STATION: AMARAVATI Commissioning Procedure
PLANT ITEM: MDBFP UNIT:
Location:
REF: NO.
Supplier:
Mnu!cture: T"pe: Serils No:
Rnge: Input: Output:
Po#er Supplies: $olts: Amps: H%:
Plnt S"stem: Su& Loction:
Tg No: 'ut": (nit:
OIL FLUSHING OF LUB OIL SYSTEM OF MOTOR DRIVEN BOILER FEED
PUMP
#.* PROPOSAL STATUS
7., T.e pipelines s.ll &e disssem&led !rom !lnge 8oints.
7.2
Ec. pipelines s.ll &e cid clened &" so1ing met.od.
7.7
A!ter neutrli%tion nd pssi-tion o! ec. pipeline t.e
pipelines s.ll &e ressem&led !or oil !lus.ing.
7.9 Oil !lus.ing !or #or1ing oil nd lu& oil circuits s.ll &e done
seprtel". Necessr" temporr" connections s.ll &e done
!or t.is purpose.
7.: 'uring oil !lus.ing o! lu& oil circuit &erings s.ll &e initill"
1ept &"pssed using temporr" loops. Su&se0uentl"
&erings s.ll lso &e included in t.e !lus.ing circuit.
$.*
9.,
SERVICES REUIRED
A-il&ilit" o! 'M ;ter nd Ser-ice ;ter
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Testing Procedure MECHANICAL
STATION: AMARAVATI Commissioning Procedure
PLANT ITEM: MDBFP UNIT:
Location:
REF: NO.
Supplier:
Mnu!cture: T"pe: Serils No:
Rnge: Input: Output:
Po#er Supplies: $olts: Amps: H%:
Plnt S"stem: Su& Loction:
Tg No: 'ut": (nit:
A-il&ilit" o! !ollo#ing c.emicls
. H"droc.loric Acid 7<= Min IS : 2>: : ,??7
&. Rodine 2,7 SPL
c. Sodium Nitrite
d. Li0uor Ammoni 2:= IS : @?? 6 ,??<
e. Lime Po#der IS : ,:9< : ,??< 4Prt II5
Note : Auntit" o! &o-e c.emicl re to &e #or1ed out t
site
A-il&ilit" o! de0ute num&er o! #ooden plugs
A-il&ilit" o! Ser-ice Air
A-il&ilit" o! re0uired grde nd 0untit" o! lu& oil
A-il&ilit" o! L.T Po#er Suppl"
A-il&ilit" o! L& Ser-ice !or e!!icienc" test o! in.i&itor nd
!or testing o! Moisture + Mec.nicl impurities in oil
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Testing Procedure MECHANICAL
STATION: AMARAVATI Commissioning Procedure
PLANT ITEM: MDBFP UNIT:
Location:
REF: NO.
Supplier:
Mnu!cture: T"pe: Serils No:
Rnge: Input: Output:
Po#er Supplies: $olts: Amps: H%:
Plnt S"stem: Su& Loction:
Tg No: 'ut": (nit:
A-il&ilit" o! de0ute lig.ting nd telep.one !cilit" in lu&
oil !lus.ing re
A-il&ilit" o! Port&le !ire tender
A-il&ilit" o! mnpo#er #it. tools nd consum&les li1e
clot./ 1erosene etc.
A-il&ilit" o! Port&le Centri!uge.
A-il&ilit" o! Cooling #ter to oil cooler 4!or T.erml
S.oc1s5
%.* SAFETY PRECAUTION
:., Ensure t.e -il&ilit" o! First id &o3 contining dilute
mmounium ."dro3ide/ :<= sodium &icr&onte solution/
E"e lotion )ndge/ Tincture Iodine/ Cotton/ )urnol etc.
:.2 Ensure -il&ilit" o!
*um &oots 6 7
Pirs
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Testing Procedure MECHANICAL
STATION: AMARAVATI Commissioning Procedure
PLANT ITEM: MDBFP UNIT:
Location:
REF: NO.
Supplier:
Mnu!cture: T"pe: Serils No:
Rnge: Input: Output:
Po#er Supplies: $olts: Amps: H%:
Plnt S"stem: Su& Loction:
Tg No: 'ut": (nit:
Ru&&er *lo-es
6 : Pirs
Apron
6 7 Nos.
Trnsprent Fce
Ms1 6 7 Nos.
:.7 Ensure t.e -il&ilit" o! ser-ice #ter ner t.e cti-it"
re.
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Testing Procedure MECHANICAL
STATION: AMARAVATI Commissioning Procedure
PLANT ITEM: MDBFP UNIT:
Location:
REF: NO.
Supplier:
Mnu!cture: T"pe: Serils No:
Rnge: Input: Output:
Po#er Supplies: $olts: Amps: H%:
Plnt S"stem: Su& Loction:
Tg No: 'ut": (nit:
OIL FLUSHING OF LUB OIL SYSTEM OF MOTOR DRIVEN BOILER FEED PUMP
&.*
EMERGENCY PROCEDURES STATUS
>.,
T.e mem&ers o! t.e tem s.ould &e #re o! t.e procedures to
&e !ollo#ed in cse o! ccident in-ol-ing in8ur" to personnel.
>.2
T.e tem conducting t.e !lus.ing cti-it" s.ould &e #re o! t.e
operting procedure o! !ire entinguis.er to &e used !or 0uenc.ing
!ires.
'.* STATE OF THE PLANT
'.1
@.,.,
ACID CLEANING
Lu& oil s"stem nd its oil lines re erected !ull" s per ppro-ed
dr#ing.
@.,.2
H"drulic test o! t.e coolers is success!ull" completed t
pressure ,.: times t.e design pressure.
@.,.7
Oil lines re t.en dismntled nd one end o! ec. pipe is &loc1ed
&" #ooden plug. Tig.t !itting o! t.e #ooden plug is ensured so
t.t no le1ge o! c.emicl solution occurs during cid clening
process.
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Testing Procedure MECHANICAL
STATION: AMARAVATI Commissioning Procedure
PLANT ITEM: MDBFP UNIT:
Location:
REF: NO.
Supplier:
Mnu!cture: T"pe: Serils No:
Rnge: Input: Output:
Po#er Supplies: $olts: Amps: H%:
Plnt S"stem: Su& Loction:
Tg No: 'ut": (nit:
@.2
@.2.,
@.2.2
OIL FLUSHING
Oil pipelines re ressem&led !ter cid clening is o-er.
Oil Tn1 nd 'uple3 !ilters re clen. Oil tn1 is !illed to t.e
re0uired le-el #it. recommended oil. Oil o! di!!erent 0ulit" B
m1e s.ould ne-er &e mi3ed. Oil s.ould &e !illed t.roug. !ilters.
@.2.7
@.2.9
@.2.:
@.2.>
@.2.>
Oil pipelines re disconnected !rom t.e &erings. T.e &erings re
&"pssed &" temporril" inter6connecting inlet nd outlet lines o!
&erings using temporr" loops.
Oil lines re properl" supported nd ll temporr" supports re cut
nd remo-ed.
Temporr" line !ilter 4Stinless Steel Mes.5 re pro-ided in t.e
return line &e!ore entering t.e tn1 to -oid entr" o! dirt into MOT
o! H"drulic Coupling
'ummies re pro-ided t t#o loctions s s.o#n in t.e dr#ing.
Temporr" connections re mde cross t.e &erings pre!er&l"
o! trnsprent P$C Hose to #it.stnd temperture s .ig. s
C<
<
C
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Testing Procedure MECHANICAL
STATION: AMARAVATI Commissioning Procedure
PLANT ITEM: MDBFP UNIT:
Location:
REF: NO.
Supplier:
Mnu!cture: T"pe: Serils No:
Rnge: Input: Output:
Po#er Supplies: $olts: Amps: H%:
Plnt S"stem: Su& Loction:
Tg No: 'ut": (nit:
@.2.C Suit&le connections re mde &et#een port&le centri!uge nd
MOT o! H"drulic Coupling. Suction is t1en !rom H"drulic
Coupling Tn1 &ottom drin nd disc.rge is le!t inside t.e HC
t.roug. t.e inspection co-er. Centri!uge #ill &e run during oil
!lus.ing.
@.2.? Temperture o! round >:6@:
*
C to &e rec.ed during oil !lus.ing
t.roug. centri!uge .eters 4i! re0uired dditionl .eters re to &e
pro-ided t suit&le loction in t.e oil circuit to ttin t.e re0uired
temperture during oil !lus.ing5.
@.2.,< Re0uired instruments suc. s pressure nd temperture guges
re cli&rted nd mounted in t.e s"stem.
(.* METHOD
C., Aci, C-.anin/ 0Soa1in/ M.t2o,3
C.,., Fill t.e lines #it. 'M #ter nd !lus. it !e# times. Also ensure t.t
no le1ge t1es plce t.roug. t.e #ooden plug pro-ided t one
end o! t.e pipe line.
C.,.2 Fill := concentrtion ."droc.loric cid #it. <.2= in.i&itor 4Rodine
2,7 Specil5 in t.e pipes. E!!icienc" test o! in.i&itor is to done
prior to its use s per NACE stndrd.
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Testing Procedure MECHANICAL
STATION: AMARAVATI Commissioning Procedure
PLANT ITEM: MDBFP UNIT:
Location:
REF: NO.
Supplier:
Mnu!cture: T"pe: Serils No:
Rnge: Input: Output:
Po#er Supplies: $olts: Amps: H%:
Plnt S"stem: Su& Loction:
Tg No: 'ut": (nit:
C.,.7 Pour nd llo# t.is cid solution to so1 !or 9 .ours in t.e pipeline
nd t.en drin t.e cid mi3ture in s!e plce/ neutrli%e dispose
it o!! #it. plent" o! ser-ice #ter.
C.,.9 Flus. t.e pipeline #it. t.e 'M #ter !or : 6 ,< minutes.
C.,.: Fill t.e pipelines gin #it. sodium nitrite 42=5 nd li0uor
mmoni :=. Allo# t.e solution to so1 !or 7< minutes. 'rin t.e
solution nd rinse #it. 'M #ter till pH o! disc.rged #ter is >.:6
@.:.
C.,.> Fill up t.e lines #it. lu&e oil nd ensure uni!orm oil !ilm is
c.ie-ed t.roug. out t.e internl sur!ce o! t.e pipes. T.e ends o!
t.e pipes re to &e 1ept properl" cpped till t.e pipes re
ressem&led.
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Testing Procedure MECHANICAL
STATION: AMARAVATI Commissioning Procedure
PLANT ITEM: MDBFP UNIT:
Location:
REF: NO.
Supplier:
Mnu!cture: T"pe: Serils No:
Rnge: Input: Output:
Po#er Supplies: $olts: Amps: H%:
Plnt S"stem: Su& Loction:
Tg No: 'ut": (nit:
(."
Oi- F-452in/
Sta/. I
C.2.,., )ump AOP nd c.ec1 t.e direction o! rottion. 4Plese note t.t
Lu& 6 Oil tn1 o! H"drulic coupling is lred" !illed up #it.
recommended oil.
C.2.,.2 A!ter ensuring t.t t.e direction o! rottion is correct/ run t.e AOP
continuousl" nd !ill t.e s"stem grdull".
C.2.,.7 Oil le-el in t.e tn1 is to &e #tc.ed till t.e !lo# is est&lis.ed
t.roug.out t.e s"stems. Oil to &e topped up/ i! re0uired.
C.2.,.9 C.ec1 !or n" oil le1ge nd ttend t.e sme/ i! n".
C.2.,.:
C.2.,.@
Rise oil temperture &" .eters o! centri!uge 4or &" e3ternl
.eters5 to >:6@<
o
C. Stop .eting to &e cut6o!! nd cooling #ter
dmitted to lu&6oil nd #or1ing oil coolers to sls. do#n t.e
temperture !st to gi-e t.e e!!ect o! t.erml s.oc1. Pipe lines re
tpped #it. #ooden .mmer during t.is period o! t.erml s.oc1.
T.e procedure is repeted till t.e oil !lus.ing is declred
completed.
T.e #or1ing oil nd Lu& oil circuits re !lus.ed seprtel" &"
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Testing Procedure MECHANICAL
STATION: AMARAVATI Commissioning Procedure
PLANT ITEM: MDBFP UNIT:
Location:
REF: NO.
Supplier:
Mnu!cture: T"pe: Serils No:
Rnge: Input: Output:
Po#er Supplies: $olts: Amps: H%:
Plnt S"stem: Su& Loction:
Tg No: 'ut": (nit:
C.2.,.C
C.2.,.?
C.2.,.,
<
C.2.,.,
,
C.2.,.,
,
(."."
C.2.2.,
C.2.2.2
C.2.2.7
C.2.2.9
C.2.2.:
m1ing suit&le temporr" connections.
T.e !lus.ing o! lu& oil circuit is to &e done in su&6stges &"
grouping T#o to T.ree &erings. 4to &e decided t site5 &" suit&le
isoltion o! lu& oil suppl" lines to -rious &erings/ to .-e
de0ute -elocit" in t.e pipelines !or e!!ecti-e !lus.ing.
T.e lu&e oil !ilters re inspected periodicll". T.e !ilters re to &e
clened #.ene-er t.e !ilters get c.o1ed #.ic. is indicted &"
increse in di!!erentil pressure cross t.e !ilter. 4D <.@ESC5
Periodicit" o! oil smpling nd !ilters inspection to &e mutull"
decided &" NTPC nd )HEL t site.
'eclre t.e completion o! oil !lus.ing s per completion criteri t
?.<
Crr"out t.e ."drulic test o! t.e pipelines t pressure ,.: times
t.e design pressure &" using e3ternl .nd pump or lu&6oil pump
itsel!. T.ere s.ould &e no
le1ge.
T.e temporr" &"pss loop conneciton B )ln1s B 'ummies re to
&e remo-ed nd t.e pipeline connections #it. t.e &ering re
normlised.
Sta/. II
Strt nd continue t.e lu& oil !lus.ing gin including t.e &ering
in t.e circuit.
'eclre t.e completion o! oil !lus.ing s per completion criteri
t.?.<
T.e oil used !or !lus.ing is to &e drined nd 1ept in s!e custod"
!or !lus.ing o! ot.er units/ i! !ound suit&le. ;.ile using suc. oil
4used oil5 !or !lus.ing in ot.er unit/ it s.ould &e !illed t.roug.
centri!uge.
Fill t.e s"stem #it. !res. lu& oil. Run t.e L.u& oil s"stem d8ust
t.e !lo# t.roug. &erings/ set t.e relie! -l-e. Pro-e en-isged
protection/ interloc1s/ lrms/ nnuncition nd mesurements.
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Testing Procedure MECHANICAL
STATION: AMARAVATI Commissioning Procedure
PLANT ITEM: MDBFP UNIT:
Location:
REF: NO.
Supplier:
Mnu!cture: T"pe: Serils No:
Rnge: Input: Output:
Po#er Supplies: $olts: Amps: H%:
Plnt S"stem: Su& Loction:
Tg No: 'ut": (nit:
A 8oint protocol &" IPL + )HEL is to &e prepred !ter completion
o! oil !lus.ing opertion.
OIL FLUSHING OF LUB OIL SYSTEM OF MOTOR DRIVEN BOILER FEED
PUMP
STATUS
).*
COMPLETION CRITERIA
?., T.e pipelines re to &e considered clen #.en t.e 'P
cross t.e !ilter st&ilises nd does not rise more t.n
<., to <.2 ESC/ o-er t.e norml -lue !ter C .ours o!
!lus.ing opertion. Also/ t.ere s.ould not &e NO .rd
prticles deposition in Lu& oil !ilters.
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Testing Procedure MECHANICAL
STATION: AMARAVATI Commissioning Procedure
PLANT ITEM: MDBFP UNIT:
Location:
REF: NO.
Supplier:
Mnu!cture: T"pe: Serils No:
Rnge: Input: Output:
Po#er Supplies: $olts: Amps: H%:
Plnt S"stem: Su& Loction:
Tg No: 'ut": (nit:
?.2 Mec.nicl impurities 4t.roug. <.9: micron !ilter5 nd
moisture content in t.e smples collected !rom
!lus.ing oil s.ould &e ec. less t.n ,<< ppm in t.ree
consecuti-e smples t1en t inter-l o! 9 .ours.
S2..t 11 o6 11
LOG SHEET
0To +. 54ita+-7 8o,i6i., to a5 9.: oi- S75t.83
Pro8ect : 'te :
(nit :
Acti-it" : Lu& 6 Oil Flus.ing Motor 'ri-en )oiler Feed Pump :
RECOMMENDED LUB OIL :
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Testing Procedure MECHANICAL
STATION: AMARAVATI Commissioning Procedure
PLANT ITEM: MDBFP UNIT:
Location:
REF: NO.
Supplier:
Mnu!cture: T"pe: Serils No:
Rnge: Input: Output:
Po#er Supplies: $olts: Amps: H%:
Plnt S"stem: Su& Loction:
Tg No: 'ut": (nit:
S-.
No.
Ti8. P489
Di5c2a:/.
P:.554:.
Oi-
P:.554:.
a6t.:
D49-.;
Fi-t.:
DP o6
D49-.;
Fi-t.:
Tan1
Oi-
L.<.-
Oi-
T.89.:at4
:.
No. o6
T2.:8a-
S2oc1
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Testing Procedure MECHANICAL
STATION: AMARAVATI Commissioning Procedure
PLANT ITEM: MDBFP UNIT:
Location:
REF: NO.
Supplier:
Mnu!cture: T"pe: Serils No:
Rnge: Input: Output:
Po#er Supplies: $olts: Amps: H%:
Plnt S"stem: Su& Loction:
Tg No: 'ut": (nit:
PROCEDURE FOR OIL FLUSHING OF LUBE OIL SYSTEM OF MOTOR DRIVEN
BOILER FEED PUMP
PROJECT : A8:a<ati %="'* M!
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Testing Procedure MECHANICAL
STATION: AMARAVATI Commissioning Procedure
PLANT ITEM: MDBFP UNIT:
Location:
REF: NO.
Supplier:
Mnu!cture: T"pe: Serils No:
Rnge: Input: Output:
Po#er Supplies: $olts: Amps: H%:
Plnt S"stem: Su& Loction:
Tg No: 'ut": (nit:
PROJECT A8:a<ati %="'*M!
PROCEDURE MOTOR DRIVEN BFP OIL FLUSHING
PURPOSE OF
DOCUMET
FOR E=ECUTION > INFORMATION
DOCUMENT
Co97 No:
I554., to :
R.<.No. P:.9a:., +7 R.<i.?., +7 A99:o<., +7 Dat.
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Testing Procedure MECHANICAL
STATION: AMARAVATI Commissioning Procedure
PLANT ITEM: MDBFP UNIT:
Location:
REF: NO.
Supplier:
Mnu!cture: T"pe: Serils No:
Rnge: Input: Output:
Po#er Supplies: $olts: Amps: H%:
Plnt S"stem: Su& Loction:
Tg No: 'ut": (nit:
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