ALKALI FLUSHING

OBJECTIVE

To remove dust, rust, grease, slag of
weld aments etc otherwise this presence
will contaminate the system
ALKALI FLUSHING
Line capacity of regenerative system
including DEA - 300 T

Employed only for condensate & feed
system piping only ( excluding Heaters )


Commissioning of regenerative
system includes

Main condensate system
Eqpts: CEP, EJECTORS, GSC, DRAIN
COOLERS, LPHs, DEA
Lines: CEP R/C line,LP B/P spray line,
Excess condensate to surge
tank,Condensate lines and its B/P lines
Feed system

Equipments: BFPs ,HPHs

Lines : Suction line,warm-up line, R/C lines,
feed discharge lines, GPV U loop,
HPHs B/P lines
Drain condensate system


Heaters to next heaters drain condensate line

Heaters to FB line
Condensate & Feed lines alkaline flushing
will be carried out

For other lines only hydro test will be carried out
after erection work is over to check the weld joint

Before erection individual pipe is cleaned and
hydraulically tested
PRE COMMISSIONING
CHECKS
Standard check lists to be prepared for all
items listed in the inventory ( i.e ) heaters
and motor foundations ,pumps,deaerator,
heaters, filters, valves, cabling, orifice plates,
instruments,platforms etc.
Where temporary items have been welded to
the parent metal ,surfaces must be made good
and area must be checked by means of crack
detection techniques
Internals of deaerator ,Hp , Lp heaters must
be inspected and cleaned by wire brush or
hand

Nozzles in the dea tray will be removed and
put back after flushing
Deaerator is the largest vessel in the LP feed
system and final inspection includes check
for removal of temporary stiffness and also
that wedges, clamps etc are removed
After the erection of dea , a hydraulic test will
be carried out as part of the erection activity
to check feed storage tank leak due to
welding works


Hydro test of pipes which was welded at site
and check for passing of valves
REQUIREMENTS
Trisodium phosphate - 2000 kg (approx)
( Na
3
Po
4
)
Sodium hydroxide - 1200 kg
( NaoH )
Lissopal D 300 - 200 kg
( Teepol )

Filtered water - 2500 t ( app)
DM water - 2000 t
Thermometer - 0 200
o
C( 2 Nos)
Sampling bottle - 12 Nos

Lab Equipments - To test alkalinity,
ph , conductivity,
temporary piping ,
flanged dummies
as per site
conditions
Alkali flushing pump 200 t/hr- 2 Nos ( OR )

- 150 t/hr- 3 Nos

Delivery Head - 120 MWC

Mixing tank capacity - 50 T 1 No

TRISODIUM PHOSPHATE
Hard scale forming substances will be
converted into soft sludge

SODIUM HYDROXIDE
Strong base To maintain ph If it falls to
acidic iron materials will be eaten away
LISSOPAL D 300

Acts as a wetting agent

Loosen the debris
PRECAUTIONS
All NRVs ,Orifices to be removed

Necessary lines to be dummied & looped

BFPs &Booster pumps will be bypassed

Heaters will be bypassed
PROCEDURE
MASS FLUSHING - Cold water
- Hot water

ALKALINE FLUSHING

RINSING - First rinsing (once
through )
- Second rinsing
- Final flushing with DM
water ( HOT )


BASIC TECHNIQUES
To create a fluid velocity greater than when
the system is in service

To disturb debris and carry the particles along its
flow so that it can be trapped or discharged from the
system
TO ACHIEVE HIGHER
VELOCITIES

By employing high pr & flow pumps
( Normally 300 to 400 t/hr flow is to be
established for effective flushing )

Sectionalizing the system so that higher velocities
are created by less number of flow paths
Reducing the system resistance by removal of
components which restricts flow such as
orifice plates, filter internals ,NRVs & valves
Heating the flushing medium

Using a medium less viscous than the working
fluid
To disturb debris
Hammering the pipe To dislodge internal
scale and disturb debris

Thermal cycling Used primarily to remove
scale and other flaky particles from internal
surfaces
Sudden changes in the velocity of flushing
medium

By creating turbulence By introducing air
into the flushing medium
PRECAUTIONS
At any stage all pumps should not be in
stopped condition when alkaline flushing is
taking place

If one pump trips start the other pump
COLD WATER FLUSHING
Scheme is made ready in such a way that initially
all equipments in the condensate system were
excluded for flushing

After flushing the lines equipments included one
by one for 20 minutes

All flushed water will be drained to atmosphere
FLOW PATH
When R/C line closed

Alkaline tank- spray LP B/P valve- CEP
dis.header- Ejector- GSC- HW control
station- DC- LPH 1,2,3- Dea B/P valve-
return header


When LP B/P injection closed

Alkaline tank- R/C line- HW control
station- DC- LPH 1,2,3- Dea B/P valve-
return header



Shortest route to Dea

From tank R/C line- HW control station
Excess condensate to surge tank- Surge tank
to dea ( through temporary B/P line )
During flushing check

Ammeter reading & dis pr

Amps & dis pr will be more if there is line
choke
PROCEDURE
Start the pump

Flow circuit pump discharge-CEP R/C-LPHs B/P-
DEA B/P return header- drained to atmosphere
(LP B/P spray valve closed) duration 45min to 1hr

Pump discharge - LP B/P spray valve 1&2-Ejector
B/P GSC-LPH B/P DEA B/P- return header-drain
15 min R/C line closed

Ejector A included- B/P of ME closed (15 -
30 min )
Ejector B included- Ejector A I/L closed (15 -
30 min )
GSC included
LP B/P spray valve 3&4 included & 1&2
isolated


Drain cooler & LPH 1 taken (45 min)

LPH 2 taken for flushing (30 min )

LPH 3 taken for flushing (30 min )

Dea B/P closed Dea filling started ( through
shortest route )

Dea filled completely & feed system charged

BFP A,B,C suction line flushed ( BFPs &BP
will be bypassed )


CEP Excess condensate to surge tank flushed

All BFPs R/C line & warm-up lines flushed
(warm up lines dummied at flash box and
looped together near FB box)

GPV U loop flushed
HPH 5&6 B/P flushed

HPH 5&6 flushed on tube side

Cold water flushing completed

Stop the pump

HOT WATER FLUSHING (DM WATER)
Start the pump

Charge the system & kept under circulation

Admit steam in the tank

When the return header temperature reaches
around 80
o
C flushing activity started by
including the equipments one by one and by
closing its bypass valves and samples were
taken for every one hour

Hot water flushing is said to be completed
when conductivity at both I/L & O/L are same
SAMPLE RESULTS
Time Temp Conductivity in s/cm
I/L O/L I/L O/L
14:00 87 78 7.9 8
15:00 85 80 11.8 13.1
.. .. .. .. ..
.. .. .. .. ..
21:00 87 80 14.8 15.5
High conductivity means ions because of
more impurities

After flushing stop the pumps and open all the
drains
Alkaline flushing
Heaters ( tube side ) will not be flushed

Only lines will be flushed during alkaline
flushing
8:00 Fill the tank with filtered water and raise
it
,
s temp to 50
o
C by admitting steam
Start the pump

Fill the system completely and kept under
circulation for 15-20 minutes
Add chemical reagents slowly
10:00 Add Na
3
Po
4
10 bags
Caustic soda flakes - 5 bags
11:00 Add Na
3
Po
4
20 bags
Caustic soda flakes - 10 bags
12:00 Add Na
3
Po
4
20 bags
Caustic soda flakes - 10 bags
Teepol B 300 - ( 3 can )
Na
3
Po
4
35 bags - 35*50 kg

Caustic soda flakes 20bags - 20*50 kg

Teepol B 300 - ( 3 can )
- 0.2 kg / ton of water

Mix the chemicals thoroughly
Raise the temp to 80
0
C & maintain it
throughout the process
Circulate the solution through the system for
10 hrs
Check the concentration

Add more chemicals to the solution if necessary
If more dust is there then more chemicals are
needed
Samples to be taken at I/L &O/L for one hour
Analyse ph & iron content
Process is said to be complete when values are same
at I/L &O/L
CIRCUIT
14:00 Alkali flushing started . 4 nos LP B/P
spray valves opened & CEP R/C closed
14:40 CEP R/C opened and one pair of LP
spray valve closed
15:15 Other pair of LP B/P spray valve taken
15:15/ CEP excess condensate to surge tank
15:30 taken
15:30
to All LP B/P spray valves &CEP R/C
15:40 valves
15:30
to BFP A suction line
15:45
15:45
to BFP B suction line
16:15
16:15
to BFP C suction line
16:45

16:45
to All R/C line & warm up line
17:00
17:00
to GPV U loop
17:30
17:30
to HPH 5&6 B/P line
18:00

Entire system kept under recirculation
Time Alk ph PO
4
Alk ph PO
4

I/L O/L
14:00 4240 12.37 3040 4160 12.35 3000
15:00 4320 12.5 3200 4240 12.5 3120
.. .. .. .. .. .. ..
.. .. .. .. .. .. ..
21:00 4000 12.42 3120 4000 12.42 3120
21:30 Steam valve closed

21:45 Alkali flushing completed . Drain valve
near neutralising pit opened and draining
started to pit
FIRST RINSING
(ONCE THROUGH )
Mixing tank was filled with water and drained
to trench three times to clear off the alkalinity
from the tank
Main condensate gate valve to dea was
closed. Temporary B/P valve was opened.Dea
drain was closed
00:00 Pumps started and once through
to flushing through LP B/P spray valves,
3:00 CEP R/C line , all equipments B/P
line to pit to wash out the alkalinity
3:15 Dea was filled partly and drained to
clear off alkanity. Dea filling started
after closing its drain valve


After filling the dea charge the feed system .
Water returned to the flushing tank will be
diverted to neutralising pit
Pumps stopped
Tank was drained to the trench
SECOND RINSING
13:30 Mixing tank was filled with water
To Start the pump & charge the system
17:30 Condensate system was flushed and
diverted to neutralising pit
17:45 Close the drain to neutralising pit
Open the return drain to tank and
kept under recirculation
Rinse BFP suc.lines ,warm-up line, r/c line
one by one
Rinse GPV U loop , HPH 5&6 B/P line one
by one
System will be under recirculation
Take the sample at I/L & O/L

Time Alk ph PO
4
cond Alk ph PO
4
cond
I/L O/L
18:30 16 10.09 10.4 58.2 15.2 10.05 10 55

20:15 14 10 10.4 49.8 13.8 9.96 10.2 48.2

21.30 Second rinsing completed
Pumps stopped
Draining started
All lower most point drains near heaters,
warm-up line drain , suction filter drain
opened
MASS FLUSHING
Mixing tank was filled with water
Start the pump
1:00 Charge the condensate system and
to kept under Recirculation ( by passing
4:00 all heaters ).Feed system was charged
and kept under recirculation ( by passing
HP heaters ).
4:00 rinsing of ejectors ,GSC, LPHs ,HPHs
to carried out though their coils , closing the
6:00 bypass one by one, making all the flow
through the equipments .

Purpose : To clean any left out alkaline
solutions inside the tubes due to
passing of valves
5:30 First sample was taken and taken for
every one hour
10:30 Steam was admitted in the tank
12:45 Temp reached to 80
0
C. Samples
collected & analyzed.
When the results were satisfactory ,clear up mass
flushing


Time Alk ph PO
4
cond Alk ph PO
4
cond
I/L O/L
5:30 12 8.8 10 15.3 12 9 10 19.3

6:30 11.2 9.07 10 14.9 11.2 9.07 10 18.8

7:30 10.4 9.05 10 29.2 10.4 9.06 10 31.6
Time Alk ph PO
4
cond Alk ph PO
4
cond
I/L O/L
10:30 10.8 9.45 12 30.5 10.8 9.45 12 25.7

12.30 10.4 9.1 12 39.5 10.4 9.1 12 26.4

15:00 Pumps were stopped after cutting out
steam
15:10 Draining started .All drains were
opened. Dea vent was opened.
SAFETY PRECAUTIONS
Alkali solution may cause skin burning.

It
,
s fumes to eyes are injurious. Hence
operators must use gloves, eyes protecting
glasses ,masks, gum boots etc.
While tightening the flanges of temporary
joints care must be taken so that they do not
leak when the pump is in service

Ensure the availability of first aid kit, cotton
roll , eye drops etc.
HPH FLUSHING
HPH
5
DEA
FB
Charge the system
through shell drain
HPH6 Dip to dea-Dea
to HPH5- HPH5 to FB-
Atmosphere
HPH6 to HPH5-HPH5
to FB- Atmosphere
HPH 6 to FB-
Atmosphere
Temporary line
HPH
6
Hydro test the pipes which are welded ( Drain
Condensate lines )

Cold flushing
Start the pump- charge the system( shell side)
Though shell drain
Circuit
HPH 6 Drip to dea Dea to HPH 5- HPH 5
To FB - Atm
HPH 6 to HPH 5 HPH 5 to FB Atm
HPH 6 to FB - Atm
HOT WATER FLUSHING
Start the pump charge the system kept in
Recirculation- Admit steam Take sample
When return water temp reaches 75
0
C.
Flushing is said to be complete when
Conductivity at both I/L &O/L same.

LP HEATER FLUSHING
LPH
3
LPH
2
LPH
1

FB
DC
FB
Temporary
line
RETURN HEADER
TEMPORARY
OBJECTIVE
Check the internals and free from waste,debris
and clean the internals
Hydro test the lines which are welded
COLD FLUSHING
Pump stated .
LP heater shell side charged through shell
drain
Circuit - LPH3 - LPH 3 to FB to LPH 2
LPH 2- LPH 1 LPH 1 to DC DC to FB
FB to atm
LPH 3 to LPH 2 LPH 2 to LPH 1

LPH 1 to DC DC to FB - atm
HOT WATER FLUSHING
Start the pump charge the system kept in
Recirculation- Admit steam Take sample
When return water temp reaches 75
0
C to 80
0
C
Flushing is said to be complete when
Conductivity at both I/L &O/L same.
Flow circuit will be same as cold water flushing


LOGICS CHECKING
MOV Checking

Air valves air line blow out & checking

Flushing of level transmitters & lines

Logic checking of switches
HYDRO TEST OF BFP SUCTION LINE

TEST PR 19.2 K.SC DURATION- 30 mts PR AFTER TEST - 18.7 k.sc
DROP IN PR 0.5 k.sc
DEA
BP
BFP
D
D
PI
0 60
KSC
AST TO SEALS HYDRO TEST




AST HEADER
PI
TO TURBINE
GLAND
SEALING
NRV FLAP
REMOVED
EX 15
CLOSED
AS 10
NRV FLAP
REMOVED
CONNECTION FOR
PRESSURISING PUMP
MAW 10
0-60 ksc
MAW 10 bef gate valve closed
AS 10 open
Test Pr - 50 ksc
Time 30 mts
STEAM BLOW OUT OF CRH TO DEA
CRH to Dea was warmed up slowly by
opening main valve few turns
Keep the drain and air vents opened for a few
minutes

CRH TO DEA SCHEME
MOV
B/P
B/P
TO DEA
PCV
FROM CRH
LINE
CRH TO DEA MAIN LINE
Blow out was carried out for 15 minutes at a
Pr of 14 ksc &temp 320
o
C
Condition before blow out
Bef & after pr control valve was in closed
Condition
Both B/P valve of pr control valve was in closed
Condition

CONDITION DURING BLOW OUT
Bef valve of pr control valve and its B/P in
Open condition
All drains & vents in close condition
CRH TO DEA B/P LINE
Condition before blow out
Bef iso valve ( MOV ) of pr control valve
was in close condition

CONDITION DURING BLOW
OUT
After isolating valve of pr control valve was
Opened
B/P valve ( western side ) of pr control valve
was opened
B/P valve ( eastern side ) of pr control valve
was opened

COMMISSIONING OF BFP
LUB OIL CICUIT
A temporary heating source and centrifuge is
desirable
Centrifuge to remove dirts & heat the oil
NRV S & Orifices to be removed
Inspection filters will be provided at the return oil
line
Brgs will be removed and lub oil line will be
suitably bypassed
General condition of the lub oil system should
be inspected and the system must be cleaned
manually bef being charged with oil
ALOP s will be started
Collection at inspection filters will be seen
periodically
After oil flushing inspection filters will be
removed
Brgs will be placed in position
Supply to brgs made though
FUNCTIONAL CHECKS
Required condition
Breaker will be in test position
Pumps charged condition
ALOP running
All switches & indicators made through
PERMISSIVES
Suction valve open & dis valve closed
Lub oil pr adequate ( > 2 ksc )
Working oil temp < 110
o
C
R/C valve open
Top & bottom casing difference <15
o
C
Dea level adequate
Scoop minimum contact
PROTECTIONS
Working oil temp V.high > 130
o
C
Local latch
Suction & discharge T > 10
o
C
Lub oil pr low (1.2 ksc)
Suction pr V.low ( main pump < 9 ksc )
Dea level V.low ( 180 mm of wcl )
Suction strainer P high ( 0.5 ksc )
ANNUNCIATIONS
Brg temp high
Oil tank level low
Lub oil temp O/L of oil cooler high
Working oil temp high
Strainer P high
Suction pr low
Dea level low
Reserve starting
Reserve starting must be proven for both
buses
OPERATION & PERFOMANCE
Ensure lub oil supply
Motor in decoupled condition
Check DOR
Run the motor
Check winding temp, Brg temp rise
Movement of the shaft must be within limits
If it is more it will touch thrust pads
Couple the motor
Ensure cooling water for coolers, seals
Scoop tube operation tube to be checked
All valves checking ( R/C,MOV,Pneumatic )
Fill the dea and charge the system
Start the pump with dis valve in closed
Condition & R/C open & min scoop condition
Record starting & steady state current
Check for vibrations ,oil flow through brgs,
suction &dis pr ,leak off pr, oil pr to brgs,
lub oil temp,working oil temp, brg temp flow
at frequent intervals
Speed will be measured through tacho meter

Speed may be increased slowly and readings
may be taken
All personnel near the pump are protected
from noise
After running of 8 hrs stop the pump
Pump performance characteristics should be
checked against the supplier
,
s curve
DEA SAFETY VALVE FLOATING
Required conditions
Fill dea up to normal working level
Ensure AST is charged
Preheat water to 75
o
C
ACTIVITIES TO BE CARRIED OUT
Close R/C gate valves of all BFPs at dea level
Close BFP suction valves & isolate power
Supply
Close main condensate line valve at dea
Close O/F valve DR 33 bef & after gate valve
CRH to dea ext valve EX001 & it
,
s b/p valve
Close DM 20 & it
,
s bef gate valve
Close operating vents of HPH 5&6 at dea
level
Close HPH 5&6 drain condensate to dea
iso.valves
Isolate dea level column
Close SM 20 & check its operation
PROCEDURE
Gag all line and dome safety valves except
The one to be floated
Open gradually AST to dea B/P and slowly
raise dea pr
Ensure the opening of concerned safety valve at
the set pr other wise reduce dea pr and adjust
the spring tension
Again raise the dea pr and ensure blowing of
Safety valve at the set pr
Once safety valve is lifted,close the pegging
B/P valve and open immediately SM 20
Repeat the same procedure one by one for the
remaining safety valves