JPL RAIGARH

(4X250 MW)

BHEL Ref No. PW / TSX /JPL /

BLR -CS/0/REV00

Page 1 of 11

Plant area: BOILER & TURBINE

PROCEDURE FOR DETERGENT FLUSHING OF PRE BOILER SYSTEM

CONTENTS
1.

GENERAL

2.

PREPARATION

3.

PROCEDURE

4.

SEQUENCE AND CIRCUITARY OF DETERGENT FLUSHING

5.

POST FLUSHING OPERATION

6.

SAFTY AND PRECAUTIONS

7.

COMPLITION CRITERIA

8.

ANNEXURE-A (MATERIAL REQUIRMENT)

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JPL

BHEL

JPL RAIGARH
(4X250 MW)

BHEL Ref No. PW / TSX /JPL /

BLR -CS/0/REV00

Page 2 of 11

Plant area: BOILER & TURBINE

PROCEDURE FOR DETERGENT FLUSHING OF PRE BOILER SYSTEM

1.0.0.

GENERAL
In order to achieve trouble free, continuous operation of the power
plant and also to maintain the water quality during the initial operation
of the plant, it is very important that all the systems carrying DM
water from condenser to boiler drum, must be cleaned thoroughly to
remove dirt, oil, grease etc. or else presence of these undesirable
matter will contaminate the system. For achieving the cleanliness, the
detergent flushing by using the chemical EXTRAN MA01 is carried
out in the pre boiler system consisting of Feed water system,
Condensate system and the Heaters drip system.

2.0.0.

PREPARATIONS
Prier to starting the detergent cleaning, the pre-boiler system , i.e.
feed water system, condensate system and drip system is prepared
for its completeness and temporary lines/looping connections etc. as
described in the following manner;

2.1.0.

All the systems should be complete in all respects. Erection of all

pipelines (including valves)- feed water lines up to economizer,
condensate lines and heaters drip lines, HP, LP heaters, deaerator
should be complete along with their fittings such as stand pipes,
gauge glasses etc. However, these fittings are to be isolated during
the flushing.

2.2.0.

Drain cooler vents to flash tank should be isolated.

2

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JPL

BHEL

JPL RAIGARH
(4X250 MW)

BHEL Ref No. PW / TSX /JPL /

BLR -CS/0/REV00

Page 3 of 11

Plant area: BOILER & TURBINE

PROCEDURE FOR DETERGENT FLUSHING OF PRE BOILER SYSTEM

2.3.0.

Remove all safety valves and provide blanks on the stubs on the
following;

2.3.1.
2.3.2.

HP heaters shell side and water side.

LP heaters shell side and water side.

2.3.3.

Deaerator.

2.4.0.

Hydro test of the entire system to be flushed should be completed.

2.5.0.

Complete the temporary pipe line connection as shown (dotted lines)

In the enclosed scheme for the detergent flushing. The drains and
vents at the proper locations are to be provided. Wherever possible,
the drains/vents are to be connected to the system drain.

2.6.0.

Ensure the readiness of mixing tank (including tank drain and

overflow lines up to neutralization pit ), its approach, platform,
detergent filling arrangements, level indications etc.

2.7.0.

Ensure the readiness of mixing pumps, motors, LT supply and motor

starters. Motor trial run should be carried out.

2.8.0.

Close tight all the gate valves of the steam extraction lines to heaters.
Ensure that all the NRVs in these lines are also closed. Open the
drains before these NRVs in atmosphere and observe for any
passing (during flushing operation ) . it should be ensured that
detergent solution does not enter the turbine, condenser, heaters,
3

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JPL

BHEL

JPL RAIGARH
(4X250 MW)

BHEL Ref No. PW / TSX /JPL /

BLR -CS/0/REV00

Page 4 of 11

Plant area: BOILER & TURBINE

PROCEDURE FOR DETERGENT FLUSHING OF PRE BOILER SYSTEM

gland steam condenser and drain cooler by any chance. Blank

suction and discharge ends of BFPs and CEPs to prevent the entry of
the flushing fluid into the pumps. Close all the valves in the steam
lines to and from deaerator.
2.9.0.

Complete all the instrumentation in the system;

2.9.1
2.9.2
2.9.3
2.9.4

Discharge pressure gauges of temporary mixing pumps.

Pressure gauges after the system inlet valve.
Pressure gauges before the system return valve.
Sampling points at system inlet and system outlet

2.10.0

Make sure that all the chemicals and laboratory reagents and
apparatus for testing the samples, are available.

2.11.0

Ensure that the required quantity of DM water and raw water is

available for the process.

2.12.0

BFP suction strainer elements are to be removed before flushing.

2.13.0

Ensure the completion of all instrumentation tapping points of the

complete system, up to isolating root valves, before commencing the
flushing. The instruments are however, to be isolated before the
flushing. The temperature stub points are to be blanked.

2.14.0

Ensure that no cutting /welding work is carried out on any

equipment after the flushing is completed.
4

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JPL

BHEL

JPL RAIGARH
(4X250 MW)

BHEL Ref No. PW / TSX /JPL /

BLR -CS/0/REV00

Page 5 of 11

Plant area: BOILER & TURBINE

PROCEDURE FOR DETERGENT FLUSHING OF PRE BOILER SYSTEM

2.15.0

Deaerator should be cleaned manually and boxed up. Deaerator

nozzles and trays are not to be removed.

2.16.0

Remove all the orifices/flow nozzles and control valves in the

system before flushing and put spool pieces instead. Remove NRV
internals in all the lines.

2.17.0

Ensure that permanent hangers and supports, restraints are provided

for all the pipelines and equipments, before starting the flushing.

2.18.0

Lighting arrangements at all the locations of the system and around

the mixing tank is to be ensured.

2.19.0

Safety precautions, such as aprons, hand gloves, eye protection

goggles, first aid boxes are to be ensured . Disposal of drained
detergent to storm water drain ststem to ensured.

3.0.0.

PROCEDURE

3.1.0.

The flushing of the system is done in following sequence;

1. Mass flushing of the system.
2. Detergent Flushing by using the alkaline detergent EXTRAN
MA 01 OF 0.5 % concentration.
3. Rinsing operation.

Signatures
JPL

BHEL

JPL RAIGARH
(4X250 MW)

BHEL Ref No. PW / TSX /JPL /

BLR -CS/0/REV00

Page 6 of 11

Plant area: BOILER & TURBINE

PROCEDURE FOR DETERGENT FLUSHING OF PRE BOILER SYSTEM

3.2.0.

MASS FLUSHING.

3.2.1.

Mass flushing of the system is carried out with DM water. However,

the first filling of the system may be done with raw water but, the
subsequent fillings must be done with DM water only. The mixing
tank is filled with raw water and the mixing pump is started. The
system is completely filled with raw water and then drained
completely.

3.2.2.

Again fill the system with DM water and establish the circulation.
Samples at inlet & outlet may be taken and compared visually and
analyzed. The process of mass flushing is deemed to be complete
when the turbidity and conductivity of water at system inlet and
system return are same. Drain the complete system.

3.3.0.

DETERGENT FLUSHING:

3.3.1 Fill the system completely with DM water. Keep the system on
circulation and add the alkaline detergent (EXTRAN MA 01) to
obtain the concentration of 0.5%. Circulation is continued and all the
loops are included in the circulation one by one suitably operating
the respective valves. During the process, the samples may be
analyzed for oil content and pH only which should get stabilized at
system inlet and system outlet by the time detergent flushing is
declared completed. The detergent flushing is, in fact, time bound
process. The duration of circulation in each circuit can be from half
to one and half hours depending upon the length of the circuit. After
the detergent flushing is completed, drain the system completely. For
6

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JPL

BHEL

JPL RAIGARH
(4X250 MW)

BHEL Ref No. PW / TSX /JPL /

BLR -CS/0/REV00

Page 7 of 11

Plant area: BOILER & TURBINE

PROCEDURE FOR DETERGENT FLUSHING OF PRE BOILER SYSTEM

the disposal of the detergent, only the dilution with water is required.
As such, the detergent is bio-degradable.
3.4.0.

RINSING OPERATION
Fill the mixing tank with DM water. Start the flushing pumps and fill
the system, keep the loop on circulation for 15 to 20 min. Then open
the drain by a little amount. Make up the level in the mixing tank by
DM water. Try to drain max. Qty. of water from the system
continuously throughout the operation. The samples are taken at
outlet and inlet at the interval of hour, and analyzed for pH. The
rinsing process is deemed to be complete when the pH values are
same at outlet and at the inlet. Drain the complete system.

3.5.0 All the drain valves in the system stand pipes etc should be opened for a
while during and after each flushing to ensure removal of any
blockage.
3.5.1.

While carrying out the flushing of shell side of HP and LP heaters,

care is to be taken for properly venting the heaters for proper filling.
All the systems are also to be properly vented during flushing.

3.5.2.

Mounting of level switches to be done later.

4.0.0.

SEQUENCE AND CIRCUITARY OF DETERGENT FLUSHING

10.1.0.

Make temporary connections as per scheme. The suction and

discharge
flanges of BFPs are to be blanked. Please note that
7

Signatures
JPL

BHEL

JPL RAIGARH
(4X250 MW)

BHEL Ref No. PW / TSX /JPL /

BLR -CS/0/REV00

Page 8 of 11

Plant area: BOILER & TURBINE

PROCEDURE FOR DETERGENT FLUSHING OF PRE BOILER SYSTEM

suction and discharge of only one BFP is looped whereas suction of

the second BFP is used as the return to mixing tank.
4.2.0. The circuitry of mass flushing /detergent flushing and the rinsing
operation shall be as follows:
4.2.1.

Mixing tank, mixing pump-point near Eco NRV- feed control station
(one
line at a time) bypass of HP heater 6-bypass of HP heater
5 BFP discharge line, suction line- booster pump, suction line-FST,
second BFPSuction line through its BP suction line. Back to mixing tank.
Afterwards through recirculation and through HP heater coil side to
be included.

4.2.2.

Mixing tank mixing pumps CEP discharge header-Gland steam

condenser bypass/ through, deaerator control station-drain cooler,
LPH 1 bypass, LPH2 bypass, LPH3 bypass up to a point before
deaerator mixing tank. Afterwards LP Heaters coil side, excess
return line and condensate recirculation line mixing tank to be
included.

4.2.3.

Mixing tank LPH3 drain LPH2 drain-drain cooler-before LP flash

tank.-back to mixing tank. Afterwards alternate drains from LPH3
and LPH2 to LP flash tank and back to mixing tank.

4.2.4.

Minxing tank to HPH 6 drip- HPH5 drip to deaerator Before

deaerator to mixing tank. Afterwards drip of HPH6 to deaerator &
8

Signatures
JPL

BHEL

JPL RAIGARH
(4X250 MW)

BHEL Ref No. PW / TSX /JPL /

BLR -CS/0/REV00

Page 9 of 11

Plant area: BOILER & TURBINE

PROCEDURE FOR DETERGENT FLUSHING OF PRE BOILER SYSTEM

alternate drain from HPH6 and HPH5 &before HP flash tank to

mixing tank.
5.0.0.

POST FLUSHING OPERATIONS

5.1.0.

Remove all the temporary lines/ looping in the system.

5.2.0.

Remove the temporary lines of the system with the mixing tank and
mixing pumps.

5.3.0.

Make and check that all the pipelines and connections are normalized
as per the final scheme of the normal operation.

5.4.0.

Open the manhole of deaerator / FST and inspect it from inside for
foreign substance and clean thoroughly. Box up after inspection.

6.0.0.

SAFETY PRECAUTIONS

6.1.0.

Ensure that the safety procedures for Alkaline flushing of the Preboiler System are followed.

6.2.0.

Due precautions must be taken while tightening the flanges of

temporary pipe joints of the loop so that they do not leak when the
pump is started and thereby a spray of water /detergent leaks through
these joints.

Signatures
JPL

BHEL

JPL RAIGARH
(4X250 MW)

BHEL Ref No. PW / TSX /JPL /

BLR -CS/0/REV00

Page 10 of 11

Plant area: BOILER & TURBINE

PROCEDURE FOR DETERGENT FLUSHING OF PRE BOILER SYSTEM

6.3.0.

Before a person enters the deaerator for inspection, manhole may be

kept opened for 8-10 hours and air may be forced in the deaerator
during that period. 24 V lamps to be used inside any vessel.

6.4.0.

No drilling, welding or cutting operations are allowed during the

process.

7.0.0.

COMPLITION CRITERIA

7.1.0.

Samples at inlet & outlet are compared visually before declaring the
Mass flushing complete. Turbidity of the samples should be the
same.

7.2.0.

Detergent flushing is declared complete when oil content & pH

values of water at inlet & outlet are same.

7.3.0.

Rinsing operation is declared completed when conductivity & pH

values of water at inlet & outlet are same.

10

Signatures
JPL

BHEL

JPL RAIGARH
(4X250 MW)

BHEL Ref No. PW / TSX /JPL /

BLR -CS/0/REV00

Page 11 of 11

Plant area: BOILER & TURBINE

PROCEDURE FOR DETERGENT FLUSHING OF PRE BOILER SYSTEM

8.0.0.

REQUREMENTS OF MATERIALS
1.

D. M. Water

3000 MT

2.

Detergent EXTRAN MA 01

2000 Lits

3.

Laboratory equipments & reagents

For testing pH value, oil content
Conductivity meter, Turbidity meter

4.

Thermometer (0-200 deg C)

2 Nos.

5.

Pressure Gauges (0-20 Kg/cm2)

7 Nos.

6.

Sampling Bottles

12 Nos.

7.

Mixing Tank

20 T capacity.

8.

Temporary Pipes, Flanged dummy

dummy ends, valves etc.

As per schematic
requirement.

11

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JPL

BHEL