Station: NTPC- BHEL Ref No.

PS-DC-202-500-0004A
Ramagund NTPC Ref no. COS-COMM-R-Commg-PRO/012
Sheet 1 of 14
am
Plant area: TURBINE
PROCEDURE FOR FLUSHING OF TG CONTROL OIL SYSTEM (FRF FLUSHING)
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

10.0

APPENDICES
DRAWING
LOG SHEET

Station: NTPC- BHEL Ref No. PS-DC-202-500-0004A

Ramagund NTPC Ref no. COS-COMM-R-Commg-PRO/012
Sheet 2 of 14
am
Plant area: TURBINE
PROCEDURE FOR FLUSHING OF TG CONTROL OIL SYSTEM (FRF FLUSHING)
1.0

PLANT DETAILS

STATUS

In 500 MW Units Fire Resistant Fluid (FRF) is used for the control system
and LP Bypass system mainly to avoid fire accidents in case of leakage of
working fluid over parts at high temperatures. This system consists of the
following:
1.0.1

Control Fluid Tank (CFT)

The Tank contains the FRF and the pumps are mounted inside the tank.

1.0.2

Pumps
These are meant to circulate the fluid through the system at required pressure
and flow.

1.0.3

Vapour Fans
These are used to exhaust the vapour from the system.

1.0.4

Filters
Filters are used to arrest the solid particles entering into the system. One of
the filters is kept in since while the other is standby.

1.0.5

Fire Resistant Fluid Coolers

These are meant for maintaining the temperature of FRF.

1.1

The fluid circulated in the system is divided for different purposes such as
Control fluid, Secondary fluid, Trip fluid and Start up fluid.

1.2

Check valves such as extraction valve and CRH swing check valves are
operated by FRF.

Signatures
NTPC

BHEL

Station: NTPCBHEL Ref No. PS-DC-202-500-0004A

Ramagunda NTPC Ref no. COS-COMM-R-Commg-PRO/012
Sheet 3 of 14
m
Plant area: TURBINE
PROCEDURE FOR FLUSHING OF TG CONTROL OIL SYSTEM (FRF FLUSHING)
2.0

OBJECTIVE
To flush the Control Fluid system to remove mechanical impurities from the
system.

3.0

PROPOSAL

3.1

Flushing shall be carried out using the normal operating Fire Resistant Fluid
recommended in the O & M manual. The quantity of FRF required for
flushing shall be 15 KL which is approximately 50% of the normal quantity.

3.2

Thermal shocks shall be given to the system by making sudden changes in

the fluid temperature from 70 - 75 0C to 35 - 40 0C to make the flushing
effective. Rapping of the fluid lines shall be carried out during thermal
shocks specially at weld joints.

3.3

No additional heating arrangement shall be required as the fire resistant fluid

gets heated up during running of the control fluid pump itself and by keeping
the tank heaters ON.

3.4

Governing rack, Stop and Control valves, Extraction valves, CRH check
valves, slide, spool and pilot valves etc. shall not be included in the flushing
process and will be kept bypassed by suitable temporary lines.

3.5

Sufficient number of thermal shocks shall be given before declaring

completion of flushing. Completion shall be based on completion criteria.

3.6

Hydrotest of the lines shall be done after completion of flushing.

3.7

Hydrotest of the HP system shall be done using a separate pressurizing

pump.

Signatures

STATUS

NTPC
BHEL
Station: NTPCBHEL Ref No. PS-DC-202-500-0004A
Ramagunda NTPC Ref no. COS-COMM-R-Commg-PRO/012
Sheet 4 of 14
m
Plant area: TURBINE
PROCEDURE FOR FLUSHING OF TG CONTROL OIL SYSTEM (FRF FLUSHING)
STATUS
4.0
SERVICES REQUIRED
4.1

Availability of required quantity of FRF.

4.2

Availability of sufficient skilled manpower for supervision / execution of the

process.

4.3

Availability of laboratory facilities for analysis of FRF samples.

4.4

Availability of service air for filter cleaning.

4.5

Availability of proper lighting arrangement.

4.6

Availability of communication facility.

4.7

Availability of portable fire extinguishers.

4.8

Availability of pressurizing pump.

5.0

SAFETY PRECAUTIONS

5.1

First aid kit should be readily available.

5.2

Adequate lighting should be available near CFT and in flushing area.

5.3

Fire fighting equipment / systems should be ready for use.

5.4

Area of flushing should have easy and free access.

5.5

Spillage, leakage and contamination of FRF should be avoided.

5.6

Welding / gas cutting should not be carried out in flushing area.

5.7

Load on fluid pumps should not exceed full load current of the motor.

Signatures

NTPC
BHEL
Station: NTPC- BHEL Ref No. PS-DC-202-500-0004A
Ramagund NTPC Ref no. COS-COMM-R-Commg-PRO/012
Sheet 5 of 14
am
Plant area: TURBINE
PROCEDURE FOR FLUSHING OF TG CONTROL OIL SYSTEM (FRF FLUSHING)
STATUS
5.8
Provision for emergency stopping of oil pumps from local / UCB should be
made.
5.9

As FRF is harmful to the skin & eyes, any part of the body exposed to FRF
should be immediately washed with soap and rinsed with water.

5.10

Sufficient quantity of safety appliances such as Helmets, Hand gloves, Gum

boots, Aprons, Nose breather etc should be available for use at site.

6.0

EMERGENCY PROCEDURE

6.1

The team members should be aware of the procedure to be followed in case

of accident involving injury to personnel.

6.2

An operator should be posted near the pump area and instructed to trip the
pumps in the event of emergency being notified to him by the team
members.

7.0

STATE OF THE PLANT

7.1

Fabrication and erection of the system is complete as per approved drawing.

7.2

The temporary pipes are of the same size as that of the main pipes and are
separately cleaned mechanically before their installations.

7.3

Control Fluid Tank is clean.

7.4

Cooling water to FRF cooler is available for thermal shock operation during
FRF flushing.

7.5

Temperature indicators before and after the coolers are available for FRF as
well as cooling water.

7.6

Calibration of FRF tank level indicators, level switches etc. is complete

before FRF filling.

Signatures
NTPC

BHEL

Station: NTPCBHEL Ref No. PS-DC-202-500-0004A

Ramagunda NTPC Ref no. COS-COMM-R-Commg-PRO/012
Sheet 6 of 14
m
Plant area: TURBINE
PROCEDURE FOR FLUSHING OF TG CONTROL OIL SYSTEM (FRF FLUSHING)
STATUS
7.7
Vapour extraction system along with vapour extraction fans is available for
operation.
7.8

All the filter elements in the system other than the tank filters are removed
before initial flushing.

7.9

Necessary bypassing as per scheme has been carried out and the correctness
of loopings checked.

7.10

The equipment room, the valve room and the oil channels are painted with
special paint as per suppliers recommendations.

7.11

All the drain valves of the system are closed.

8.0

METHOD

8.1

FRF Filling

8.1.1

FRF is filled in the CFT (Controlled Fluid Tank) preferably through the
Regenerative pumps. Filling can also be done from the CFT top through tank
filters.

8.1.2

The operation of fluid tank level indicator is checked during fluid filling.
Level is closely monitored to avoid any overflow.

8.1.3

Regenerative system of FRF is run continuously with tank heaters ON. Its
mechanical filters are cleaned intermittently to remove the sludge collected.

8.1.4

CFT filters are cleaned as and when required.

8.1.5

All the safety precautions of FRF are strictly followed during filling,
flushing and handling of FRF.

Signatures

NTPC

BHEL

Station: NTPCBHEL Ref No. PS-DC-202-500-0004A

Ramagunda NTPC Ref no. COS-COMM-R-Commg-PRO/012
Sheet 7 of 14
m
Plant area: TURBINE
PROCEDURE FOR FLUSHING OF TG CONTROL OIL SYSTEM (FRF FLUSHING)
STATUS
8.2
FRF Flushing
8.2.1

System is lined up for flushing as per scheme.

8.2.2

The LP (8 bar) and HP (32 bar) control fluid systems are flushed together.

8.2.3

Direction of rotation of both FRF pumps is checked with short start / stop
command. The trial run of the pumps is taken up along with flushing
process.

8.2.4

Flushing is started by running FRF pumps for short duration and system is
checked for leakages and attended.

8.2.5

FRF pumps are taken in service for further flushing after attending all the
leakages. Regenerative pumps are run continuously with tank heaters ON to
maintain quality of FRF during flushing process.

8.2.6

Care is taken that FRF pump load is limited to full load current of the motor.
If required both pumps are run.

8.2.7

Flushing of control fluid system is carried out by dividing the system in 4 to

5 circuits to achieve maximum velocity through the pipelines. This also
limits fluid pump motor current. This is suitably decided at site.

8.2.9

Initially Control fluid Tank filters are inspected once every 8 hours and
cleaned. Thereafter frequency is gradually changed to once a day depending
upon the filter condition.

8.2.10

The temperature of control fluid after heating should be between 70 to 75 0C.

After flushing for 2-3 hours at this temperature, the temperature is reduced to
minimum possible by opening the water outlet. This process of thermal
shock is repeated several times. Rapping of fluid lines is carried out during
thermal shocks.

Signatures
NTPC

BHEL

Station: NTPC- BHEL Ref No. PS-DC-202-500-0004A

Ramagund NTPC Ref no. COS-COMM-R-Commg-PRO/012
Sheet 8 of 14
am
Plant area: TURBINE
PROCEDURE FOR FLUSHING OF TG CONTROL OIL SYSTEM (FRF FLUSHING)
STATUS
8.2.11 After all the circuits have been flushed and fluid tank strainer remains clean
for 24 Hours, all the filter elements in the system removed before initial
flushing are put back for final flushing.
8.2.12

During flushing one sample a day must be analysed.

8.2.13

Flushing is declared completed as per completion criteria.

8.3
8.3.1
8.3.1.1

Hydraulic Testing of Lines

General
Hydraulic test of various lines shall be carried out as per details given below:
S. No.

8.3.2

System

Standard Pressure

1.

Pressure Fluid

8 bar

2.

HP Control Fluid

32 bar

Test Pressure
20 bar
(without rack)

Duration
10 min

96 bar
10 min
(without filter elements)

Preparation

8.3.2.1

Blank flanges are installed and valves closed wherever the subsystem is
connected to drain as per flushing scheme.

8.3.2.2

Test gauges are provided as per test pressure requirement.

8.3.2.3

Elements not subjected to test are isolated.

8.3.2.4

Valves of all process pressure gauges / transmitters are closed.

Signatures
NTPC
BHEL
Station: NTPC- BHEL Ref No. PS-DC-202-500-0004A
Ramagund NTPC Ref no. COS-COMM-R-Commg-PRO/012
Sheet 9 of 14
am
Plant area: TURBINE
PROCEDURE FOR FLUSHING OF TG CONTROL OIL SYSTEM (FRF FLUSHING)
STATUS
8.3.2.5 Venting arrangements provided at blind ends with valves. Location of vent
valves is decided at site as per site lay out.
8.3.2.6

8 bar system is pressurised by feeding 32 bar fluid through a temporary

connection provided for this purpose.

8.3.2.7

AII duplex filter elements are removed before hydraulic testing.

8.3.2.8

32 bar system is tested by installing a separate pressurising pump.

8.3.3

Test Procedure

8.3.3.1

Control fluid pump is run and system filled.

8.3.3.2

Venting of total system is carried out.

8.3.3.3

Pressure of 8 bar system is raised to 20 bar by feeding 32 bar fluid through

the temporary connection provided. System is checked for leakages for 10
minutes.

8.3.3.4

Control fluid pump is stopped.

8.3.3.5

8 bar pressure fluid system is isolated. Pressure is raised to 96 bar in 32 HP

control fluid system and is held for 10 minutes. System is checked for
leakages.

8.3.3.6

If leakages are observed system is depressurized, leakages attended and

hydraulic test is repeated.

Signatures
NTPC

BHEL

Station: NTPC- BHEL Ref No. PS-DC-202-500-0004A

Ramagund NTPC Ref no. COS-COMM-R-Commg-PRO/012
Sheet 10 of 14
am
Plant area: TURBINE
PROCEDURE FOR FLUSHING OF TG CONTROL OIL SYSTEM (FRF FLUSHING)
STATUS
8.4
Normalisation
8.4.1

Control fluid is drained from the total system is drained in Barrels.

8.4.2

Control fluid tank is cleaned and inspected.

8.4.3

Control fluid coolers are cleaned and inspected.

8.4.4

All the provisional arrangements made in the system for flushing &
hydraulic testing are removed and system normalised.

8.4.5

The drained control fluid is refilled after the tank is absolutely clean. Fluid is
filled through the regenerative system only.

8.4.6

Required quantity of Control fluid is kept filled in the tank and level
measured and recorded.

9.0

COMPLETION CRITERIA

9.1

FRF samples are collected at Regenerative pumps inlet (with Pump in

operation) and analysed at regular interval, preferably once a day, for
Mechanical impurities, Water content & Acid content.
a. Mechanical impurities
b. Water content
c. Acid content

Less than 0.05% by weight

Less than 0.1% by weight
Less than 0.1 mg KOH/gm

9.2

Control fluid Tank filter remains clean after 24 hours of flushing.

9.3

All duplex filters remain clean after 12 hours of flushing.

9.4

If the above are met then the sample is sent to R & D lab at NOIDA or any
other approved lab for further analysis.

Signatures
NTPC

BHEL

Station: NTPCBHEL Ref No. PS-DC-202-500-0004A

Ramagunda NTPC Ref no. COS-COMM-R-Commg-PRO/012
Sheet 11 of 14
m
Plant area: TURBINE
PROCEDURE FOR FLUSHING OF TG CONTROL OIL SYSTEM (FRF FLUSHING)
STATUS
9.5
Control system flushing is declared complete based on the following:
a. Particle count in the fluid sample should be as per NAS 1638, Class 7
b. Sediments should not be more than 5 mg / 100 ml of fluid.
c. Specific resistance, checked as per IEC method, should not be less than
5x109 ohm-cm.

Signatures
NTPC

BHEL

Station: NTPC- BHEL Ref No. PS-DC-202-500-0004A

Ramagund NTPC Ref no. COS-COMM-R-Commg-PRO/012
Sheet 14 of 14
am
Plant area: TURBINE
PROCEDURE FOR FLUSHING OF TG CONTROL OIL SYSTEM (FRF FLUSHING)
LOG SHEET
S. No.

Pump
in
service

Pump
Control fluid
Discharge
temperature
pressure Before After
cooler cooler

S. No. of
thermal
shock

Remarks

Signatures
NTPC

BHEL