Jindal Power Limited

O.P.J.S.T.P.P, Tamnar, Raigarh

Commissioning Department

Project OPJSTPP (4X600 MW), Tamnar

Procedure MDBFP Lube oil system flushing
Purpose of Document For Execution/Information
Document No. JPL Reference No: Turbine/Comm./021

Prepared By - Reviewed By -
Rev No. 00
Dtd: Commissioning Commissioning Project

Name

Sign

Approved By :
HEAD – Steering Committee

Copy No:

Issued To:
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of 3
Stage II: (4X600 MW) Turbine/Comm./021

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. EMERGENCY PROCEDURES
7. STATE OF THE PLANT
8. METHOD
9. COMPLETION CRITERIA
10. APPENDICES

a. DRAWINGS

b. LOG SHEETS

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of 3
Stage II: (4X600 MW) Turbine/Comm./021

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, Lube-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 lube oil system by removing dirt and other foreign
materials before pressing the lube oil system in regular service and to
ensure that no debris enters the tank of Hydraulic coupling during oil
flushing.

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of 3
Stage II: (4X600 MW) Turbine/Comm./021

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. Hydrochloric Acid 30% Min IS : 265 : 1993

b. Rodine 213 SPL

c. Sodium Nitrite

d. 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

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of 3
Stage II: (4X600 MW) Turbine/Comm./021

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 STATUS
of Moisture & Mechanical impurities in oil

Availability of adequate lighting and telephone facility in lube 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 ammonium
hydroxide, 50% sodium bicarbonate solution, Eye lotion Bandage,
Tincture Iodine, Cotton, Burnol etc.

5.2 Ensure availability of Gum boots - 3 Pairs

Rubber Glove - 5 Pairs

Apron - 3 Nos.

Transparent Face Mask - 3 Nos.

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

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of 3
Stage II: (4X600 MW) Turbine/Comm./021

Plant Area: Turbine

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

EMERGENCY PROCEDURES STATUS

6.0

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

6.1
in case of accident involving injury to personnel.

The team conducting the flushing activity should be aware of the operating
6.2
procedure of fire extinguisher to be used for quenching fires.

7.0 STATE OF THE PLANT

7.1 ACID CLEANING

7.1.1 Lube 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.

Oil lines are then dismantled and one end of each pipe is blocked by a
7.1.3
wooden plug. Tight fitting of the wooden plug is ensured so that no leakage
of chemical solution occurs during acid cleaning process.

7.2 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

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of 3
Stage II: (4X600 MW) Turbine/Comm./021

Plant Area: Turbine

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

7.2.5 Temporary line filters (Stainless Steel Mesh) are provided in the return STATUS
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 80oC

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.

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of 3
Stage II: (4X600 MW) Turbine/Comm./021

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, 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.

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 lube-
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

JPL BHEL
 Station: JPL, Tamnar JPL Reference no:
Sheet 1 of 3
Stage II: (4X600 MW) Turbine/Comm./021

Plant Area: Turbine

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

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

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

grouping Two to Three bearings. (to be decided at site) by
suitable isolation of lube oil supply lines to various bearings, to
8.2.1.8 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 tests 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 The temporary bypass loop connection / Blanks / Dummies are to
be removed and the pipeline connections with the bearing are
normalized.
8.2.2
Stage II
8.2.2.1
Start and continue the lube 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 lube oil. Run the Lube 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

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of 3
Stage II: (4X600 MW) Turbine/Comm./021

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 stabilizes 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 Lube
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

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of 3
Stage II: (4X600 MW) Turbine/Comm./021

Plant Area: Turbine

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

LOG SHEET
(To be suitably modified to as per oil System)

Project : Date:

Unit :

Activity : Lube - Oil Flushing Motor Driven Boiler Feed Pump:

RECOMMENDED LUB OIL:

Sl. Time Pump Oil Pressure DP of Tank Oil No. of

Discharge after Duplex Duplex Oil Temperature Thermal
No. Pressure Filter Filter Level Shock

Signatures

JPL BHEL
Station: JPL, Tamnar JPL Reference no:
Sheet 1 of 3
Stage II: (4X600 MW) Turbine/Comm./021

Plant Area: Turbine

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

PROCEDURE FOR OIL FLUSHING OF LUBE OIL SYSTEM

OF MOTOR DRIVEN BOILER FEED PUMP
PROJECT: JPL, 4X600MW

Signatures

JPL BHEL