PROCEDURE FOR STEAM BLOWING & OIL FLUSHING OF

F.O.SYSTEM

PROJECT:M/s RAMAGUNDAM

UNIT 7 (500 MW )

BHARAT HEAVY ELECTRICALS LIMITED

(A Government of India Undertaking)
Power Sector Southern Region
474, Anna Salai, Nandanam, Chennai 600 035.

PROJECT

M/s. RAMAGUNDAM UNIT 7, 500 MW

PROCEDURE

PROCEDURE FOR STEAM BLOWING & OIL

FLUSHING OF F.O.SYSTEM

PURPOSE OF
DOCUMENT

FOR EXECUTION / INFORMATION

DOCUMENT NO.

PS:TSX:174:00:03

COPY NO:
ISSUED TO:

00
Rev. No.

KJ

KPTM

KB

04.08.2003

Prepared by

Reviewed by

Approved by

Date

BHARAT HEAVY ELECTRICALS LIMITED

(A Government of India Undertaking)
Power Sector Southern Region
474, Anna Salai, Nandanam, Chennai 600 035.

Station: NTPC BHEL Ref No.PS-DC-202-500-0008

Sheet 1 of 7
Ramagundam
NTPC Ref no COS-COMM-RGM-Commg-PRO/008
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING AND OIL FLUSHING OF FUEL OIL SYSTEM
SLNO
LIST OF CONTENTS
1.0

PLANT DETAILS

2.0

OBJECTIVE

3.0

PROPOSAL

4.0

SERVICES REQUIRED

5.0

SAFETY PERECAUTIONS

6.0

EMERGENCY PROCEDURE

7.0

STATE OF THE PLANT

8.0

METHOD

9.0

COMPLETION CRITERIA

10.0

APPENDICES
a) DRAWING

Station: NTPC BHEL Ref No.PS-DC-202-500-0008

Sheet 2 of 7
Ramagundam
NTPC Ref no COS-COMM-RGM-Commg-PRO/008
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING AND OIL FLUSHING OF FUEL OIL SYSTEM
STATUS
SL.NO
1.0
PLANT DETAILS:
1.1

The Fuel oil plant consists of facilities for Unloading, Storage and
Supply of LDO and HFO.
Fuel Oil Pump House is located close to Fuel Storage Yard. The
Pump house houses:
a. LFO 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

1.2

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 insulation.

2.0

OBJECTIVE

2.1

To remove debris, scales and weld splatters and clean the

internal surface of oil lines in the LDO / HFO system including
atomizing steam lines and steam tracing lines.

Signatures
NTPC

BHEL

Station: NTPC BHEL Ref No.PS-DC-202-500-0008

Sheet 3 of 7
Ramagundam
NTPC Ref no COS-COMM-RGM-Commg-PRO/008
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING AND OIL FLUSHING OF FUEL OIL SYSTEM
STATUS
SL.NO
3.0
PROPOSAL:
3.1

All the lines shall be steam blown in sections.

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.
Flushing of HFO lines shall be done using HFO.

3.6
SERVICES REQUIRED
4.0
Steam Blowing
4.1
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.
Availability of adequate manpower and communication facility.

4.1.3
4.1.4
Signatures

Availability of Public address system or siren to communicate the

commencement of steam blowing.

NTPC

BHEL

Station: NTPC BHEL Ref No.PS-DC-202-500-0008

Sheet 4 of 7
Ramagundam
NTPC Ref no COS-COMM-RGM-Commg-PRO/008
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING AND OIL FLUSHING OF FUEL OIL SYSTEM
STATUS
SL.NO
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
5.1

SAFETY PRECAUTIONS
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 lines should be insulated prior to the commencement

of steam blowing.

5.7

All temporary 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.

The group members should be aware of operating instructions of

6.2
portable fire extinguishers.
Signatures
NTPC

BHEL

Station: NTPC BHEL Ref No.PS-DC-202-500-0008

Sheet 5 of 7
Ramagundam
NTPC Ref no COS-COMM-RGM-Commg-PRO/008
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING AND OIL FLUSHING OF FUEL OIL SYSTEM
STATUS
SL.NO
7.0
STATE OF THE PLANT
7.1
7.1.1

Steam Blowing
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
7.2.1

Oil Flushing
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
8.1.1

Steam Blowing
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/cm 2 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: NTPC BHEL Ref No.PS-DC-202-500-0008

Sheet 6 of 7
Ramagundam
NTPC Ref no COS-COMM-RGM-Commg-PRO/008
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING AND OIL FLUSHING OF FUEL OIL SYSTEM
STATUS
SL.NO
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
8.2.1

Oil Flushing of LDO Lines

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: NTPC BHEL Ref No.PS-DC-202-500-0008

Sheet 7 of 7
Ramagundam
NTPC Ref no COS-COMM-RGM-Commg-PRO/008
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING AND OIL FLUSHING OF FUEL OIL SYSTEM
STATUS
SL.NO
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.

8.3.4

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.

8.3.5

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