COMMISSIONING PROCEDURE

FOR STEAM BLOWING AND

OIL FLUSHING OF
FUEL OIL LINES
(APPROVED)

Station: NTPCBHEL Ref No.PS-DC-202-500-0008

Sheet 1 of 7
Ramagundam
NTPC Ref no COS -COMM-R-Commg-PRO / 007
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING AND OIL FLUSHING OF FUEL OIL LINES
LIST OF CONTENTS
1.0

PLANT DETAILS

2.0

OBJECTIVE

3.0

PROPOSAL

4.0

SERVICES REQUIRED

5.0

SAFETY PRECAUTIONS

6.0

EMERGENCY PROCEDURE

7.0

STATE OF THE PLANT

8.0

METHOD

9.0

COMPLETION CRITERIA

Signatures
NTPC

BHEL

Station: NTPCBHEL Ref No.PS-DC-202-500-0008

Sheet 2 of 7
Ramagundam
NTPC Ref no COS -COMM-R-Commg-PRO / 007
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING AND OIL FLUSHING OF FUEL OIL LINES
STATUS
1.0
PLANT DETAILS
1.1

The Fuel oil plant consists of facilities for Unloading, Storage and Supply of
LDO and HFO.

1.2

Fuel Oil Pump House is located close to Fuel Storage Yard. The Pump house
houses:
a.

LDO Pumps for Main Boiler

b.

HFO Pumps for Main Boiler

c.

HFO Heaters

d.

HFO cooler in the return line

e.

Drain Oil Tank & Drain Pump

f.

Electrical & control Panels for F.O. Pump House auxiliaries

1.3

Fuel Oil lines from Fuel Oil Pump House to Main Boiler are routed through
trestles with supports given suitably for thermal expansion. Steam tracing
lines run along the entire length of HFO lines and are inside the same
insulatio n.

2.0

OBJECTIVE
To remove debris, scales and weld splatters and clean the internal surface of
oil lines in the LDO / HFO system including atomising steam lines and steam
tracing lines.

Signatures
NTPC

BHEL

Station: NTPCBHEL Ref No.PS-DC-202-500-0008

Sheet 3 of 7
Ramagundam
NTPC Ref no COS -COMM-R-Commg-PRO / 007
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING AND OIL FLUSHING OF FUEL OIL LINES
STATUS
3.0
PROPOSAL
3.1

All the lines shall be steam blown in suitable sections to have effective
cleaning.

3.2

Steam blowing shall be done by continuous blowing method.

3.3

Oil flushing of oil lines shall be taken up after completion of steam blowing.

3.4

Since LDO system does not have provision of return line from Boilers
suitable temporary connections shall be made at Boiler end and in storage
tank area for oil flushing of LDO lines so that closed loop flushing be carried
out from LDO tank to Main Boiler & back to LDO tank using HFO return
line.

3.5

A temporary strainer shall be put in the return line near the LDO Storage
Tank. The mesh size of the strainer shall be same as that envisaged for the
suction strainers of the Pressurising Pumps.

3.6

Flushing of HFO lines shall be done using HFO.

4.0

SERVICES REQUIRED

4.1

Steam Blowing

4.1.1

Availability of Auxiliary Steam at required pressure and temperature.

4.1.2

Availability of Permanent fire fighting system and sufficient number of

portable fire extinguishers at identified locations.

4.1.3

Availability of adequate manpower and communication facility.

4.1.4

Availability of Public address system or siren to communicate the

commencement of steam blowing.

4.1.5

Availability of compressed air for drying the pipelines after steam blowing.

Signatures
NTPC

BHEL

Station: NTPCBHEL Ref No.PS-DC-202-500-0008

Sheet 4 of 7
Ramagundam
NTPC Ref no COS -COMM-R-Commg-PRO / 007
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING AND OIL FLUSHING OF FUEL OIL LINES
STATUS
4.2
Oil flushing
4.2.1

Availability of LT power supply for LDO / HFO Pumps.

4.2.2

Availability of sufficient quantity of LDO / HFO.

5.0

SAFETY PRECAUTIONS

5.1

First aid kit should be available in the test area.

5.2

Sufficient number of safety gears such as helmets, asbestos hand gloves, ear
mufflers etc should be available.

5.3

Service water should be available near the activity area.

5.4

The blowing area should be barricaded.

5.5

Required number of sign boards should be put at selected places to indicate the
ongoing process of steam blowing

5.6

All permanent HFO & Steam lines should be insulated prior to the
commencement of steam blowing.

5.7

All temporary lines and permanent LDO lines which may come in contact with
personnel should be suitably insulated before steam blowing.

5.8

All the pipelines should have provision for free expansion.

5.9

Availability of Ambulance and Fire Tender in the Power Plant premises.

6.0

EMERGENCY PROCEDURES

6.1

The persons involved in carrying out the cleaning activity should be aware of
the actions to be taken in the event of injury to personnel.

6.2

The group members should be aware of operating instructions of portable fire

extinguishers.

Signatures
NTPC

BHEL

Station: NTPCBHEL Ref No.PS-DC-202-500-0008

Sheet 5 of 7
Ramagundam
NTPC Ref no COS -COMM-R-Commg-PRO / 007
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING AND OIL FLUSHING OF FUEL OIL LINES
STATUS
7.0
STATE OF THE PLANT
7.1

Steam Blowing

7.1.1

Suitable spool pieces are erected in places of Trip valves, control valves and
flow measuring elements.

7.1.2

Filter elements and NRV internals are removed wherever required. A checklist
is to be prepared which shall be used during restoration.

7.1.3

All vents and drains are properly routed and supported.

7.2

Oil Flushing

7.2.1

Steam blowing of the concerned lines is over.

7.2.2

LDO / HFO pumps are commissioned on recirculation.

7.2.3

Temporary lines (for LDO lines flushing) are suitably connected at Boiler as
well as storage tank ends.

7.2.4

A temporary strainer is provided in the return line before entry to the Storage
Tank. The mesh size of the strainer should be same as that envisaged for the
suction strainers of the Pressurising Pumps.

8.0

METHOD

8.1

Steam Blowing

8.1.1

The line to be blown is charged slowly with auxiliary steam and warmed up
keeping the drains open.

8.1.2

After proper charging blow is given for 20-30 minutes.

8.1.3

Steam at a pressure of 10-12 Kg/cm2 and having a superheat of at least 500 C at

source is used for blowing.

8.1.4

The line is allowed to cool for two hours and then again blown.

Signatures
NTPC

BHEL

Station: NTPCBHEL Ref No.PS-DC-202-500-0008

Sheet 6 of 7
Ramagundam
NTPC Ref no COS -COMM-R-Commg-PRO / 007
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING AND OIL FLUSHING OF FUEL OIL LINES
STATUS
8.1.2 Steam blowing is declared complete based on Completion criteria.
8.1.3

Blowing of drains, vents and instrument tapping points is done at 5 Kg/cm2

for 10 minutes each.

8.1.4

Blowing of LDO lines, Steam tracing lines and condensate lines is done at 6
Kg/cm2 for 20-30 minute each.

8.1.5

Drains / vents of F.O. lines are kept open as required during steam blowing
and thereafter for draining of condensate.

8.1.6

After sufficient cooling the pipings are dried with compressed air.

8.1.7

After completion of steam blowing, all spool pieces are removed and Trip
valves, control valves, flow elements, filter elements and NRV internals are
restored / normalized. Pipe connections to LDO / HFO pumps are normalized
and pumps are commissioned.
NOTE: During the cooling period of one section of pipeline other section, as
per convenience, can be steam blown.

8.2

Oil Flushing of LDO Lines

8.2.1

LDO lines are lined up for flushing with LDO through HFO return line from
Boiler.

8.2.2

LDO Pump is started and the line flushed for minimum 24 hours. Temporary
filter in the return line and Pump suction filters are taken out and cleaned as
and when required. Frequency of strainer cleaning is to be decided jointly by
NTPC & BHEL at site.

8.2.3

Flushing is declared complete based on completion criteria.

8.2.4

LDO lines are subsequently normalized and released for regular operation.

Signatures
NTPC

BHEL

Station: NTPCBHEL Ref No.PS-DC-202-500-0008

Sheet 7 of 7
Ramagundam
NTPC Ref no COS -COMM-R-Commg-PRO / 007
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING AND OIL FLUSHING OF FUEL OIL LINES
STATUS
8.3
Oil flushing of HFO Lines
8.3.1

HFO lines are lined up for flushing with HFO through normal HFO return
line from Boiler.

8.3.2

Steam tracing line is kept charged.

8.3.3

HFO Pump is started and the line flushed for minimum 24 hours. Pump
suction and discharge filters (installed at outlet of heaters) are taken out and
cleaned as and when required. Frequency of strainer cleaning is to be decided
jointly by NTPC & BHEL at site.

8.3.4

Flushing is declared complete based on completion criteria.

9.0

COMPLETION CRITERIA

9.1

Steam Blowing

9.1.1

Steam blowing of the section of LDO / HFO lines is declared complete after
minimum five blows each having a blow duration of 20-30 minutes.

9.1.2

Blowing medium at exit of the pipe should be visually clean.

9.2

Oil Flushing

9.2.1

LDO flushing is declared complete after minimum 24 hours of flushing and

the filters remaining clean for 8 hours of continuous flushing.

9.2.2

HFO flushing is declared complete after minimum 24 hrs of flushing and the
filters remaining clean for 8 hours of continuous flushing.

Signatures
NTPC

BHEL