Detergent - Preboiler& Condsys. (Rama)

Station: NTPCBHEL Ref No.
PS-DC-202-500-0001
Sheet 1 of 25
Ramagundam
NTPC Ref no RGM /1/TS/2/002
Plant area: TURBINE
DETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM
SLNO
LIST OF CONTENTS
1.0
PLANT DETAILS
2.0
OBJECTIVE
3.0
PROPOSAL
4.0
SERVICES REQUIRED
5.0
SAFETY PRECAUTIONS
6.0
EMERGENCY PROCEDURES
7.0
STATE OF THE PLANT
8.0
METHOD
9.0
COMPLETION CRITERIA
10.0
APPENDICES
a) DRAWINGS
b) LOG SHEETS.
Station: NTPCBHEL Ref No.PS-DC-202-500-0001

Sheet 2 of 25
Ramagundam
Plant area: TURBINE
STATUS
SLNO
1.0
PLANT DETAILS:
The Pre Boiler system consists of Condensate system, Drip
system and Feed water system.
The plant under this Pre boiler system mainly consists of
following equipments and pressure vessels.
1) Condensate system comprises 3 nos. Condensate Extraction
Pumps, Low Pressure Heaters, Gland steam cooler, Drain
cooler, Deaerator, connecting pipelines including excess
condensate line upto condensate storage Tank.
2) Feed water system comprises 1 No. of H.T. motor driven and
2 Nos Turbo driven Boiler Feed Pumps, their Booster pumps
and recirculation lines, High Pressure Heaters, their
connecting pipelines upto Economiser inlet. RH & SH spray
lines are also included for the purpose of flushing.
3) Drip system comprises the shell side of all LP and HP Heaters
and the Drip lines.
4) Temporary circulation pumps (4 nos) each having a capacity
of 200 T/hr at 20 Kg/sq cm will be used in this activity.
Drawings enclosed in section 10.0 e) provide the layout of
connections between temporary and permanent systems.
5) Extraction lines of LP & HP Heaters.
2.0
OBJECTIVE:
To remove dirt, oil, grease etc., from the Condensate, Feed water
and Drip system, using a non-ionic detergent, prior to putting
these systems in regular service. This ensures flow of clean
condensate and feed water to the boiler.
Signatures
NTPC
BHEL

Sheet 3 of 25
Ramagundam
Plant area: TURBINE
STATUS
SLNO
3.0
PROPOSAL:
3.1
Each of the Condensate, Feed water and Drip system shall be

flushed separately using fresh detergent.
3.2
The three stages are:

Stage I : Feed lines of Regenerative System
Stage II : Condensate lines of Regenerative System
Stage III: Drip lines of Regenerative System
Stage IV : Detergent flushing of Extraction lines of LP & HP
Heaters.
3.3
Each system shall be suitably sub-divided into various sub

circuits to cover all the lines and components.
3.3.1
STAGE 1 (Feed Lines Of Regenerative System)

This stage is divided into sub- stages 1A, 1B & 1C
3.3.1.1
Stage 1 A
Mixing Tank Circulating pumps BFP suction lines (one line at
a time) booster pump suction line feed storage tank
recirculation lines Mixing Tank.
3.3.1.2
Stage 1 B
Mixing Tank Circulating pumps discharge line of BFP by-pass
of HP Heaters 5A & 5B and HP Heaters 6A & 6B-feed control
station point near economizer inlet valve Mixing Tank.
3.3.1.3
Stage 1C
Mixing tank Circulation pumps S. H. Spray & R.H. Spray lines
feed control station Point near Economiser inlet valve Mixing
Tank.
Signatures
NTPC
BHEL

Sheet 4 of 25
Ramagundam
Plant area: TURBINE
STATUS
SLNO
3.3.2.0
STAGE II
(Condensate lines of Regenerative System)
3.3.2.1
A
Mixing Tank - Circulation pumps condensate discharge
line by pass Gland steam condenser- by pass of CPU- bypass
of drain cooler & LP heater 1 - bypass LPH 2 - bypass LPH 3 upto a point before deaerator Mixing Tank. Loop from GSCExcess condensate Return Mixing Tank is also to be included.
3.3.2.2
B Mixing tank circulation pumps Condensate discharge line

then through gland steam condenser bypass of CPU Drain
cooler Bypass of LPH 1 LPH 2 LPH 3 upto deaerator Mixing tank.
STAGE: III (Drip lines of Regenerative System)
3.3.3.0
HP HEATER DRIP LINES:
3.3.3.1
a) Mixing Tank-circulation Pumps alternate drip line to HPH 6

A to HP flash tank HPH 6 A shell HPH 5 A shell HPH 5A
drip line to Deararator Mixing Tank.
3.3.3.2
b) Mixing Tank circulation Pumps HPH 6 B alternate drip line

to HP flash tank HPH 6 B shell HPH 5 B shell HPH 5 B
drip line to Deararator Mixing Tank.
3.3.3.3
c) Mixing tank Circulation pumps alternate drip line to HPH 5

A HP flash tank HPH 5 A drip line to deaerator Mixing
Tank.
3.3.3.4
d) Mixing tank circulation pumps alternate drip line of HPH 5

B HP flash tank HPH 5 B drip line to deaerator Mixing
Tank.
NOTE: In the above, a) , b) and c), d) to be combined.
Signatures
NTPC
BHEL

Sheet 5 of 25
Ramagundam
Plant area: TURBINE
STATUS
SLNO
LP HEATER DRIP LINES:
e) Mixing Tank Circulation Pump alternate drain line from LPH
3 to LP flash tank LPH 3 shell Drip line from LPH 3 to LPH
2 LPH 2 shell Alternate drain from LPH 2 to LPFT Mixing
Tank.
f)
Mixing Tank Circulation Pump Alternate drain line from LPH

3 to LPFT Drip from LPH 3 to LPH 2 -LPH 2 shell Drip
from LPH 2 to LPH 1 Drip line from LPH 1 to drain Cooler
Drip line from the cooler to LP Flash Tank - Mixing Tank.
In each stage the following activities shall be carried out :i.
Open circuit Mass flushing in each individual sub circuit

with cold water till the effluent is visibly clean.
ii.
Mass flushing in closed circuit with cold water in individual
sub circuits is to be done for one hour and sample analysed
for turbidity and drained. This process of filling, circulation
and draining is to be continued till the turbidity of discharge
water is same as that of DM water being used.
iii.
Mass flushing in closed circuit with hot water, at a
temperature of 600 C, in individual sub circuits is to be done
for two hours and sample analysed for turbidity and drained.
This process of filling, circulation and drained. This process
of filling, circulation and draining is to be continued till the
turbidity of discharge water is same as that of DM water
being used.
iv.
Detergent Flushing for 4 hours each in individual sub circuit.
v.
Rinsing operation of the entire system as per completion
criteria.
vi.
Passivation of individual circuit for 8 hours.
vii.
Manual removal of debris from FST and other accessible
pipelines.
After successful completion of Detergent flushing of Pre-Boiler
system, the permanent system is isolated from the temporary
system and released for normalisation.
3.4
Signatures
NTPC
BHEL

Sheet 6 of 25
Ramagundam
Plant area: TURBINE
STATUS
SLNO
4.0
SERVICES REQUIRED:
4.1
Availability of approximatilly 5000 Tons of DM water for the entire

operation.
4.2
Availability of nonionic detergent viz

Rinopol Jet 100%
OR
Sumisol N 100
Estimated quantity and required concentration is 1000 Litres and
0.05% V/V respectively.
4.3
Availability of chemicals for passivation viz.,

i.
ii.
4.4
Hydrazine Hydrate (min. 80% concentration); 800 KG

(IS: 12086 / 1991).
(Liquor Amomonia) (Min 25% concentration) 400 KG
(IS: 799 / 1985)
Availability of 4 Nos. of temporary circulation pumps having

capacity 200 T/Hr and dischage pressure of 20 Kg/sq.cm.
Availability of temporary tank of capacity of 40 cu.metre.
Availability of power supply to temporary circulation pumps.
4.5
Availability of adequate lighting in all workings areas.
4.6
Availability of reliable communication system such as walkie

talkie sets, telephones etc.
4.7
4.8
Availability of laboratory facility for analysis of samples of the

detergent flushing process.
Availability of workmen with supervisor for round the clock operation

with required tools.
4.9
Signatures
NTPC
BHEL

Sheet 7 of 25
Ramagundam
Plant area: TURBINE
STATUS
SLNO
4.10
Availability of workmen with supervisor for round the clock
operation with required tools.
5.0
SAFETY PRECAUTIONS:
5.1
Readinees of Staircases, platforms, hand rails, approaches etc

as decided jointly by BHEL and NTPC at site, should be ensured.
5.2
Ensure the availability of First aid facilites during the process.
5.3
Ensure the availability Safety and protection equipments like

Hand gloves, eye protection equipments, Helmets etc during the
process.
5.4
Ensure the availability of Service water near the activity area.
6.0
EMERGENCY PROCEDURES:
6.1
The testing 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 procedures of fire entinguishers to be used for
quenching minor fires.
6.3
An operator, posted at the pump area, should be instructed to

stop the circulation pumps and properly isolate the system in the
event of emergency. Emergency operating instructions, in this
regards, should be prepared at site.
Signatures
NTPC
BHEL

Sheet 8 of 25
Ramagundam
Plant area: TURBINE
STATUS
SL.NO
7.0
STATE OF THE PLANT:
7.1
Hydraulic test of the entire system to be flushed should be

complete.
7.2
All the regenerative equipments are installed in position and

temporary pipe line connections as shown in the enclosed schemes
are completed.
7.3
All the isolating valves of the steam extraction lines to heaters are
tightly closed. Ensure that all the NRVS in these lines are also
closed.
7.4
BFPs, their booster pumps and CEPs are bypassed suitably with
temporary piping.
7.5
Suction and discharge ends of BFPs and CEPs are capped to

prevent the entry of flushing fluid in to the pump.
7.6
BFP suction strainer elements are removed before flushing.
7.7
All the valves in the steam lines to and from deaerator are closed.
7.8
Installation of circulation pumps, mixing tank and connected

temporary piping along with pressure gauges is complete.
7.9
All H.P. heaters safety valves are removed and blanks are provided
with a 1 / 2 valve for air venting. Temperature stubs in extraction
steam lines for L.P heaters may be used for venting of LP heaters.
Care is to taken for venting and proper filling of the heaters. While
carrying out the flushing of shell side of HP and LP heaters,
7.10
Safety valves of L.P. heaters are erected in position. This is required

to release the pressure in the system, incase, the pressure exceeds
the set value during the operation due to any unforeseen reasons.
Signatures
NTPC
BHEL

Sheet 9 of 25
Ramagundam
Plant area: TURBINE
STATUS
SL.NO
7.11
All the cutting and welding work on instrument tapping points are
complete upto isolating root valves.
7.12
No cutting/welding work is permitted to be carried out on any

equipment after the flushing is completed.
7.13
Deaerator and Hotwell are manually cleaned and inspected

jointly.
7.14
All the orifices, flow nozzles, control valves and NRVs are
removed and spool pieces are to be provided wherever required.
A check list we prepared, this would avoid the error during
normalization of the system.
7.15
All the instruments of the system other then the required ones
shall be kept isolated during flushing activity.
7.16
All permanent supports are provided for all the pipelines before
starting the flushing.
7.17
The flushing shall be done as per the schemes attached

herewith. Sec. 10.0) e).
7.18
The bore of temporary pipe lines should be preferably same as

that used in permanent system.
7.19
Temporary Mixing tank is provided with 2 Nos of level Indicators.
7.20
Temperature gauges with the discharge header of circulation

pumps and in the return line to mixing tank provided for
monitoring the temperature during the process.
Signatures
NTPC
BHEL

Sheet 10 of 25
Ramagundam
Plant area: TURBINE
STATUS
SL.NO
8.0
METHOD:
8.1
Flushing of Regenerative system shall be carried out in three
stages as depicted in section 3.0.
8.2
Line up the stage to be flushed. Carry out the open circuit

flushing of individual sub- stage with cold DM water
8.3
Fill the total system with DM water by running Circulation pumps
and establish flow of around 100-250 TPH through the
circuits/Sub-circuits by operating one pump/Two pumps/Three
pumps as per requirement. This is to be suitably decided at site.
8.4
Carryout DM water circulation in all the sub loops with cold water
as detailed in section 3.3.1, 3.3.2 & 3.3.3 for one hour each to
carry out Cold Water Mass Flushing.
8.5
Admit steam into the mixing tank and raise the water temperature
to 60oC and continue the DM water circulation in all the sub loops
as detailed in section 3.3.1, 3.3.2 & 3.3.3 for two hours each to
carry out hot Water Mass Flushing.
8.6
Stop the pumps and drain the system.
8.7
Refill the total system with DM water by running circulation

pumps and establish circulation.
8.8
Admit steam into the mixing tank and raise the water temperature
to 60 deg C Add Rinopol JET 100% OR SUMISOL N 100 in
mixing tank to achieve the solution concentration of 0.05% V/V.
8.9
Circulate the solution in each of the loops as per section 3.3.1,

3.3.2 & 3.3.3 for a minimum duration of four hours. During
circulation make up shall be made as per the system requirement
keeping the solution temperature at 60oC.
8.10
On completion of flushing of all the loops, carry out continuous

make up and draining in all the loops one by one for duration of
15 minutes each.
Signatures
NTPC
BHEL

Sheet 11 of 25
Ramagundam
Plant area: TURBINE
STATUS
SLNO
8.11
Drain the system completely and again fill it with DM water.
8.12
DM water shall be circulated in each loop for half an hour once

again.
8.13
Drain the system completely.
8.14
Rinse the system with DM water by continuous filling and draining

while keeping the pumps running till effluent is visibly clean and
the conductivity and oil parameters meet the values specified in
completion criteria.
8.15
Stop the pump and drain the whole system.
8.16
Fill the system with DM water and establish the circulation. Raise
the system temp to 60 deg. C by admitting steam in the mixing
tank.
8.17
Obtain Hydrazine content of 200 PPM and add Ammonia to get

pH value of the solution of the order of 9.5 to 10.0. Raise the
temp of the solution to 80 deg. C by steam admission in mixing
tank. Maintain the Circulation for 8 Hrs. at this temp. The system
is completely drained hot. All air vent valves and feed storage
tank manholes are opened to aerate the system.
Signatures
NTPC
BHEL

Sheet 12 of 25
Ramagundam
Plant area: TURBINE
STATUS
SL.NO
POST FLUSHING OPERATION:
8.18
Remove all the temporary connections from the permanent

scheme.
8.19
Check that all the pipelines and connections are as per the final
scheme.
8.20
After draining the deaerator, make internal inspection for foreign

material, if any, and clean thoroughly.
8.21
After welding of flow nozzle in BFP suction line flush the suction
line by draining water from Deaerator for half an hour through
each line. For this purpose, temporary pipe connections from
suction of each BFP, near the pump, to drain pit is to be made.
8.22
After synchronization of the Unit, Drips of LP & HP Heaters are to

be taken in the system after checking the quality of drip. (Silica
should be less than 20ppb)
9.0
COMPLETION CRITERIA:
DM water mixing after chemical flushing shall be considered
complete once drained water conductivity is less than 10 micro
mhos / cm, and oil content is NIL.
10.0
APPENDICES:
Signatures
NTPC
BHEL

Sheet 16 of 25
Ramagundam
Plant area: TURBINE
LOG SHEET # 1
PROJECT:
UNIT :
ACTIVITY: DETERGENT FLUSHING OF FEED WATER SYSTEM
SN
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14
Activity
Open circuit flushing of sub
stage 1A
stage 1B
stage 1C
Closed circuit flushing with cold
water of sub stage 1 A
water of sub stage 1 B
water of sub stage 1 C
Closed circuit flushing with hot
water of sub stage 1 A
water of sub stage 1 B
water of sub stage 1 C
Complete draining of the
system.
Refilling of the System and
establish circulation
Raising the water temp. to 60
deg C. and addition of detergent
Circulation of detergent solution
in sub stages 1A + 1B
Circulation of detergent solution.
In sub stage 1C
Dura
Start
Finish
tion time/date time/date
Remarks
Flushing to continue till
effluent is visibly clear
1 hr
1 hr
1 hr
2 hr
2 hr
2 hr
4 hr
4 hr
Signatures
NTPC
BHEL

Sheet 17 of 25
Ramagundam
Plant area: TURBINE
SN
15.
16.
17.
18.
19.
20.
21.
Activity
Continuous make up & draining
of sub stages 1 A + 1B
of sub stage 1C
Drain the complete system & refill with DM water
Circulate DM water in sub stage
1A + 1B
1C
Drain the system completely
Rinse sub stage 1A + 1B with
DM water by continuous filling &
draining
22.
Rinse sub stage 1C with DM

water by continuous filling &
draining
23.
Draining of the system
24.
Refill the System and establish

circulation
Raise the water temp. to 60 deg
C and add Hydrazene &
Ammonia to required
concentration
Raise the solution temp. to 80
deg C and passivate of the
system
Drain the system hot
25.
26.
27.
Dura
Start
Finish
15
min
15
min
Remarks
1 hr
30
min
Rinsing is considered
complete, when water
conductivity is less than
10 micro mhos / cm and
oil content is nil.
oil content is nil.
8
hrs
Hydrazene content
should be 200 ppm and
add Ammonia to get pH
9.5 to 10
8
hrs
Signatures
NTPC
Station: NTPC-
BHEL Ref No.PS-DC-202-500-0001
BHEL
Sheet 18 of 25
Ramagundam
Plant area: TURBINE
LOG SHEET # 2
PROJECT:
UNIT :
ACTIVITY: DETERGENT FLUSHING OF CONDENSATE SYSTEM
SN
Dura
Start
Finish
Activity
1.

stage II A
2.
stage II B
3.
water of sub stage II A
4.
water of sub stage II B
5.
water of sub stage II A
6.
water of sub stage II B
7.
Complete draining of the
system.
8.
Refill of the System and
9.
C. and addition of detergent
10.
in sub stages II A
11.
Circulation of detergent solution.
In sub stage II B
12.
of sub stages II A
13.
of sub stage II B
14.
Drain the complete system & refill with DM water
15.
IIA
Signatures
NTPC
Station: NTPC-
Remarks
1hr
1hr
2
hrs
2
hrs
4
hrs
4
hrs
15
min.
15
min.
1 hr
BHEL Ref No.PS-DC-202-500-0001
BHEL
Sheet 19 of 25
Ramagundam
Plant area: TURBINE
SN
16.
17.
18.
Activity
II b
Rinse sub stage II A with DM
draining
19.
Rinse sub stage II B with DM

draining
20.
Draining of the system
21.

Ammonia to required
concentration
deg C and passivate sub stage
II A
II B
22.
23.
24
25.
Dura
Start
Finish
1 hr
Remarks
oil content is nil .
oil content is nil.
8
hrs
8
hrs
Signatures
NTPC
BHEL

Sheet 20 of 25
Ramagundam
Plant area: TURBINE
LOG SHEET #3
PROJECT :
UNIT :
ACTIVITY :
SN
1.
2.
3.
4.
5.
6.
7.
8.
9.
10
11.
12.
13.
14.
15.
DETERGENT FLUSHING OF HP HEATERS DRIP SYSTEM

Activity
Open circuit flushing of sub stage

III A
IIIB
IIIC
IIID
water of sub stage IIIA
water of sub stage IIIB
water of sub stage IIIC
water of sub stage IIID
water of sub stage IIIA
water of sub stage IIIB
water of sub stage IIIC
Closed circuit flushing with
hotwater of sub stage IIID
Complete draining of the system
Raising the water temp. to 60 deg
C. and addition of detergent
Dur
a
tion
Start
Time /
date
Finish
time /
date
Remarks
1hr.
1hr.
1hr.
1hr.
2hr.
2hr.
2hr.
2hr.

Sheet 21 of 25
Ramagundam
Plant area: TURBINE
SN
16.
17.
18.
19.
20.
21.
22.
23.
24
25.
26.
27.
28.
29.
30.
31.
Activity
in sub stages IIIA
in sub stages IIIB
in sub stages IIIC
in sub stages IIID
of sub stages IIIA
of sub stages IIIB
of sub stages IIIC
of sub stages IIID
Drain the complete system &
refill with DM water
IIIA
IIIB
IIIC
IIID
Rinse sub stage IIIA with DM
draining.
Rinse sub stage IIIB with DM
draining.
Dura
Start
Finish
4hr.
Remarks
4hr.
4hr.
4hr.
15
min
15
min
15
min
15
min
1hr.
1hr.
1hr.
1hr.
Rinising is considered
oil content is nil
oil content is nil

Sheet 22 of 25
Ramagundam
Plant area: TURBINE
SN
32.
Activity
oil content is nil
Rinse sub stage IIIDwith DM

draining.
oil content is nil
Drain the system
34.
Refill the system and establish

circulation
Ammonia
36.
37.
38.
39.
40.
Remarks
Rinse sub stage IIIC with DM

draining.
33.
35.
Dura
Start
Finish

IIIA
IIIB
IIIC
IIID
Drain the system
Hydrazene content should

be 200 ppm and add
Ammonia to get pH 9.5 to
10
8
hrs.
8
hrs.
8
hrs.
8
hrs.
Signatures
NTPC
BHEL

Sheet 23 of 25
Ramagundam
Plant area: TURBINE
LOG SHEET #4
PROJECT :
UNIT :
ACTIVITY : DETERGENT FLUSHING OF LP HEATERS DRIP SYSTEM
SN
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Activity
stage IIIE
stage IIIF
water of sub stage IIIE
water of sub stage IIIF
water of sub stage IIIE
water of sub stage IIIF
Complete draining of the system
circulation
Raise the water temp. to 60
degC. And add detergent
Circulate the detergent solution
in sub stage IIIE
Circulate the detergent solution
in sub stage IIIF
of sub stage IIIE
of sub stage IIIF
Drain the complete system &refill
with DM water
Dura
Start
Finish
Remarks
1hr.
1hr.
2hrs.
2hrs.
4hrs.
4hrs.
15
min
15
min

Sheet 24 of 25
Ramagundam
Plant area: TURBINE
SN
15.
16.
17.
Activity
IIIE
IIIE
18.
Rinsing of sub stage IIIE with DM

draining
19.
Rinsing of sub stage IIIFwith DM

draining
20.
21.
Drain the system

circulation
Ammonia
22.
23.
24.
25.

deg C and passivate of the sub
stage IIIE
deg C and passivate of the sub
stage IIIF
Dura
Start
Finish
1hr.
Remarks
1hr.
oil content is nil
oil content is nil
Hydrazene content should

be 200 ppm and add
Ammonia to get pH 9.5 to
10
8hrs
8 hrs
Signatures
NTPC
BHEL
SHEET 25 OF25
DETAILS OF CHEMICALS USED DURING THE PROCESS
SN SYSTEM
ACTIVITY
NAME OF
CHEMICALS ADDED
QUANTITY
FEED WATER
CONDENSATE
DRIP (HP HEATERS)
DRIP (LP HEATERS)
REMARKS :
Signatures
NTPC
BHEL
DETERGENT FLUSHING OF PREBOILER

AND CONDENSATE SYSTEM
PS:TSX:159:00:03
PROJECT : RAMAGUNDAM 500 MW
TECHNICAL SERVICES DEPARTMENT
BHARAT HEAVY ELECTRICALS LIMITED

(A Government of India Undertaking)
Power Sector Southern Region
474, Anna Salai, Nandanam, Chennai 600 035.
PROJECT
RAMAGUNDAM 500MW
PROCEDURE
DETERGENT FLUSHING OF PREBOILER AND

CONDENSATE SYSTEM
PURPOSE OF
DOCUMENT
FOR EXECUTION / INFORMATION
DOCUMENT NO.
PS:TSX:159:01:03
COPY NO:
ISSUED TO:
00
Rev. No.
K.J
K.R
K.B
18-08-03
Prepared by
Reviewed by
Approved by
Date
TECHNICAL SERVICES DEPARTMENT
BHARAT HEAVY ELECTRICALS LIMITED

(A Government of India Undertaking)
Power Sector Southern Region
474, Anna Salai, Nandanam, Chennai 600 035.
DETERGENT FLUSING OF PRE-BOILER & CONDENSATE SYS

RAMAGUNDAM 500 MW UNIT-7 DRG:NO:4 : PS : TSX : 00134:01
DRAWN
CHECKED
APPROVED
DATE
KJ
K.R
K.B
18-08-03

RAMAGUNDAM 500 MW UNIT-7 DRG:NO:4 : PS : TSX : 00135 :01
DRAWN
CHECKED
APPROVED
DATE
KJ
K.R
K.B
18-08-03

RAMAGUNDAM 500 MW UNIT-7 DRG:NO:4 : PS : TSX : 00136 :01
DRAWN
CHECKED
APPROVED
DATE
KJ
K.R
K.B
18-08-03
DETERGENT FLUSHING OF PRE-BOILER AND CONDENSATE SYSTEM, RAMAGUNDAM 500MW

FEED WATER LINES

CONDENSATE SYSTEM

HEATERS AND DRIP SYSTEM

Detergent - Preboiler& Condsys. (Rama)

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Detergent - Preboiler& Condsys. (Rama)

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Station: NTPCBHEL Ref No.

STATE OF THE PLANT

Station: NTPCBHEL Ref No.PS-DC-202-500-0001

Station: NTPCBHEL Ref No.PS-DC-202-500-0001

Each of the Condensate, Feed water and Drip system shall be

The three stages are:

Each system shall be suitably sub-divided into various sub

STAGE 1 (Feed Lines Of Regenerative System)

Station: NTPCBHEL Ref No.PS-DC-202-500-0001

(Condensate lines of Regenerative System)

B Mixing tank circulation pumps Condensate discharge line

HP HEATER DRIP LINES:

a) Mixing Tank-circulation Pumps alternate drip line to HPH 6

b) Mixing Tank circulation Pumps HPH 6 B alternate drip line

c) Mixing tank Circulation pumps alternate drip line to HPH 5

d) Mixing tank circulation pumps alternate drip line of HPH 5

Station: NTPCBHEL Ref No.PS-DC-202-500-0001

Mixing Tank Circulation Pump Alternate drain line from LPH

In each stage the following activities shall be carried out :i.

Open circuit Mass flushing in each individual sub circuit

Station: NTPCBHEL Ref No.PS-DC-202-500-0001

Availability of approximatilly 5000 Tons of DM water for the entire

Availability of nonionic detergent viz

Availability of chemicals for passivation viz.,

Hydrazine Hydrate (min. 80% concentration); 800 KG

Availability of 4 Nos. of temporary circulation pumps having

Availability of adequate lighting in all workings areas.

Availability of reliable communication system such as walkie

Availability of laboratory facility for analysis of samples of the

Availability of workmen with supervisor for round the clock operation

Station: NTPCBHEL Ref No.PS-DC-202-500-0001

Readinees of Staircases, platforms, hand rails, approaches etc

Ensure the availability of First aid facilites during the process.

Ensure the availability Safety and protection equipments like

Ensure the availability of Service water near the activity area.

The testing team should be aware of the procedures to be

The team conducting the flushing activity should be aware of the

An operator, posted at the pump area, should be instructed to

Station: NTPCBHEL Ref No.PS-DC-202-500-0001

Hydraulic test of the entire system to be flushed should be

All the regenerative equipments are installed in position and

Suction and discharge ends of BFPs and CEPs are capped to

BFP suction strainer elements are removed before flushing.

Installation of circulation pumps, mixing tank and connected

Safety valves of L.P. heaters are erected in position. This is required

Station: NTPCBHEL Ref No.PS-DC-202-500-0001

No cutting/welding work is permitted to be carried out on any

Deaerator and Hotwell are manually cleaned and inspected

The flushing shall be done as per the schemes attached

The bore of temporary pipe lines should be preferably same as

Temporary Mixing tank is provided with 2 Nos of level Indicators.

Temperature gauges with the discharge header of circulation

Station: NTPCBHEL Ref No.PS-DC-202-500-0001

Line up the stage to be flushed. Carry out the open circuit

Stop the pumps and drain the system.

Refill the total system with DM water by running circulation

Circulate the solution in each of the loops as per section 3.3.1,

On completion of flushing of all the loops, carry out continuous

Station: NTPCBHEL Ref No.PS-DC-202-500-0001

Drain the system completely and again fill it with DM water.

DM water shall be circulated in each loop for half an hour once

Drain the system completely.

Rinse the system with DM water by continuous filling and draining