Station: NTPCBHEL Ref No.

PS-DC-202-500-0004A
Sheet 1 of 16
Ramagundam
NTPC Ref no RGM/1/TS/2/003
Plant area: TURBINE
PROCEDURE FOR FRF FLUSHING (TG CONTROL OIL SYSTEM)
SLNO
1.0

PLANT DETAILS

2.0

OBJECTIVE

3.0

PROPOSAL

4.0

SERVICES REQUIRED

5.0

SAFETY PERECAUTIONS

6.0

EMERGENCY PROCEDURE

7.0

STAE OF THE PLANT

8.0

TEST METHOD

9.0

COMPLETION CRITERIA

10.0

APPENDICES
a. TECHNICAL SPECIFICATION
b. DRAWING
c. LOG SHEET

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

Sheet 2 of 16
Ramagundam
NTPC Ref no RGM/1/TS/2/003
Plant area: TURBINE
PROCEDURE FOR FRF FLUSHING (TG CONTROL OIL SYSTEM)
STATUS
SLNO
1.0

PLANT DETAILS:
In 500 MW Units, fire Resistant Fluid (FRF) used for the control
systems and LP Bypass system mainly to avoid fire accident in
case of leakage of working fluid over high temperature parts of
turbine. This system consists of following.

1.1

a) Oil Tank: It is to contain the FRF and pumps are mounted inside the tank.
b) Oil Pumps: These are meant to circulate the fluid through the system at
required pressure and flow.
c) Oil Vapour Fans: To exhaust the vapour from the system.
d) Filters:To retain the solid particles entering into the system. One is kept
in since while the other is standby.
e) Fire Resistant Fluid Coolers:
These are meant for maintaining the temperature of FRF.

1.2

The fluid circulated in the system is divided for different purposes.

Such as control fluid, secondary fluid, Trip fluid and startup fluid.

Signatures
NTPC

BHEL

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

Sheet 3 of 16
Ramagundam
NTPC Ref no RGM/1/TS/2/003
Plant area: TURBINE
PROCEDURE FOR FRF FLUSHING (TG CONTROL OIL SYSTEM)
STATUS
1.3
The quantity of FRF fluid required for flushing will be
approximately 50% of normal quantity. ie. 15KL.
1.4

Operation of check valves such as extraction valve and CRH

swing - check valves are done by the fluid.

1.5

The signed copy of safety rules clearance certificate to be

attached.

1.6

Plant item completion list for areas such as mechanical, electrical

and C & I are to be prepared at site prior to commencement of
the achivity.

1.7

The schematic diagram of FRF flushing is given in section 10.0

Signatures
NTPC

BHEL

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

Sheet 4 of 16
Ramagundam
NTPC Ref no RGM/1/TS/2/003
Plant area: TURBINE
PROCEDURE FOR FRF FLUSHING (TG CONTROL OIL SYSTEM)
STATUS
SLNO
2.0

OBJECTIVE:

2.1

After erection completion, complete fire resistant fluid system

shall be flushed with fire resistant fluid to remove mechanical
impurities from the system, by creating condition similar to the
m/c in operation.

Signatures
NTPC

BHEL

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

Sheet 5 of 16
Ramagundam
NTPC Ref no RGM/1/TS/2/003
Plant area: TURBINE
PROCEDURE FOR FRF FLUSHING (TG CONTROL OIL SYSTEM)
STATUS
SLNO
3.0

PROPOSAL:

3.1

Keeping the fluid in circulation throught the system. Thermal

shocks shall be given to the system by sudden changes in fluid
temperature from 60-65 deg C to 35-40 deg C to make the
flushing effective. No heating arrangement will be required as the
fire resistant fluid gets heated up during running of the control
fluid pump itself and by keeping tank heaters ON. Rapping of the
fluid lines shall be carried out during thermal shocks.

3.2

Fluid flushing shall be carried out using the normal operating fire
resistent fluid as recommended in O & M manual. The quantity of
FRF required for flushing will be approx. 50% of the normal
quantity, i.i. 15 KL.

3.3

Governing rack. Control and stop valves. Extraction valves CRH

check valves and slide, spool and pilot valves etc. will not be
included in the flushing process and will be by passed, by
suitable temporary lines.

Signatures
NTPC

BHEL

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

Sheet 6 of 16
Ramagundam
NTPC Ref no RGM/1/TS/2/003
Plant area: TURBINE
PROCEDURE FOR FRF FLUSHING (TG CONTROL OIL SYSTEM)
STATUS
SLNO
4.0

SERVICES REQUIRED:

4.1

Availability of laboratory facilities for analysis of FRF samples.

4.2

Availability of sufficient skilled manpower for supervision /

execution of the process.

4.3

Availability of service Air for filter cleaning.

4.4

Availability of Proper lighting arrangement at flushing area.

4.5

Availability of Communication facility at flushing area.

4.6

Availability of required quantity of FRF.

4.7

Availability of portable fire extinguishers at oil flushing area.

Signatures
NTPC

BHEL

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

Sheet 7 of 16
Ramagundam
NTPC Ref no RGM/1/TS/2/003
Plant area: TURBINE
PROCEDURE FOR FRF FLUSHING (TG CONTROL OIL SYSTEM)
STATUS
SLNO
5.0

SAFETY PRECAUTIONS:

5.1

First aid kit is available near Test area.

5.2

Adequate lighting shall be available near CFT and flushing area.

5.3

Fire fighting equipment/systems should be ready for use.

5.4

Area of flushing shall have free access.

5.5

Efforts shall be made to avoid spillage / leakage and

contamination of FRF.

5.6

Welding / cutting shall not be carried out in flushing area.

5.7

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

5.8

Provision for emergency stopping of oil pumps from local / UCB

has to 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. Soap

5.10

Sufficient quantity of safety appliances such as helmets, face

mark, hand gloves, Crum boots, Apron, nose breather are made
available for use at site.

Signatures
NTPC

BHEL

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

Sheet 8 of 16
Ramagundam
NTPC Ref no RGM/1/TS/2/003
Plant area: TURBINE
PROCEDURE FOR FRF FLUSHING (TG CONTROL OIL SYSTEM)
STATUS
SLNO
6.0

EMERGENCY PROCEDURE:

6.1

The team for this operation shall be aware of this procedure for
oil flushing and shall act at the time of any emergency.

6.2

The team should be aware of operating procedures of fire

extinguisher to be used for quenching minor oil fires.

6.3

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

accident involving injury to personnel.

6.4

An operator to be posted near the pump area and instructed that

he should trip the pumps in the event of emergency being notified
to him by the team / observers.

6.5

The team should be aware of reestablishing the operation in case

of system stoppage due to failure of power supply.

Signatures
NTPC

BHEL

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

Ramagundam
NTPC Ref no RGM/1/TS/2/003
Plant area: TURBINE
Testing / Commissioning Schedule: TURBINE OIL FLUSHING
SLNO

Sheet 9 of 16

STATUS

7.0

STATE OF THE PLANT:

7.1

The temporary pipes which are included in the process are of

same size as main pipes and are separately cleaned
mechanically before their installations.

7.2

Fabrication and erection of the system completed as per drawing.

7.3

Cooling water to FRF cooler available for thermal shock operation

during FRF flushing.

7.4

FRF coolers inspected through fluid line connection and, if

required, the same shall be cleaned before start of flushing.

7.5

Temperature indicator before and after fluid cooler are made

available for FRF as well as cooling water.

7.6

Before filling the control fluid in control fluid tank (CFT) the fire
resistant fluid tank cleaned carefully.

7.7

All C & I installation and calibration of FRF tank level indicators,

level switches etc. completed before FRF filling.

7.8

Visual inspection carried out to check cleanliness of the interior of

the fire resistant fluid tank.

7.9

Vapour extraction system with vapour extraction fan available for

operation.

7.10

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

7.11

The necessary by pass work as per scheme enclosed carried out

and the correctness of looping checked.

Signatures
NTPC

BHEL

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

Sheet 10 of 16
Ramagundam
NTPC Ref no RGM/1/TS/2/003
Plant area: TURBINE
PROCEDURE FOR FRF FLUSHING (TG CONTROL OIL SYSTEM)
STATUS
SLNO
7.12

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

7.13

Insulation of Turbine & piping shall be completed and TG floor,

Fluid Tank & flushing area completely cleaned.

Signatures
NTPC

BHEL

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

Sheet 11 of 16
Ramagundam
NTPC Ref no RGM/1/TS/2/003
Plant area: TURBINE
PROCEDURE FOR FRF FLUSHING (TG CONTROL OIL SYSTEM)
STATUS
SLNO
8.0

METHOD:

8.1

FRF Filling:

8.1.1

Required quantity of FRF shall be made available.

8.1.2

The filling of FRF will be carried out in the FRF tank, after
completion of Turbine / Piping Insulation.

8.1.3

FRF shall be filled in the CFT preferably through the

Regenerative pumps. Filling can also be done from the CFT top
through tank filters. The procedure of filling will be decided at site.

8.1.4

Care shall be taken that all the drains of the system are closed
and no FRF leakage occur during filling.

8.1.5

The operation of fluid tank level indicator shall be checked during

fluid filling. Level will be closely monitored to avoid any overflow.

8.1.6

Regenerative system of FRF to be run continously with tank

heaters ON. Its mechanical filters will be cleaned intermittently to
remove sludge collected.

8.1.7

CFT filters should be cleaned as and when required.

8.1.8

All the safety precaution of FRF have to be strictly followed during

filling, flushing and handling of FRF.

8.2

FRF Flushing:

8.2.1

System shall be lined up for flushing as per scheme.

8.2.2

The LP (8 bar) and HP (32 bar) control fluid systems shall be

flushed together.

Signatures
NTPC

BHEL

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

Sheet 12 of 16
Ramagundam
NTPC Ref no RGM/1/TS/2/003
Plant area: TURBINE
PROCEDURE FOR FRF FLUSHING (TG CONTROL OIL SYSTEM)
STATUS
SLNO
8.2.3
Direction of rotation of both FRF pumps shall be checked with
short start/stop command. The trial run of the pumps is to be
taken up along with flushing process.
8.2.4

Flushing shall be started by running FRF pumps for short

duration and system shall be checked for leakages and attended.

8.2.5

FRF pumps shall be taken in service, for further flushing after

attending all the leakages. Regenerative pumps to be run
continously with tank heaters ON to maintain quality of FRF
during flushing process.

8.2.6

Care shall be taken that FRF pump load is limited to full load
current of the motor. If reqd., both pumps shall be run.

8.2.7

Flushing of control fluid system shall be carried out by dividing it

into 4 to 5 groups and circulation of fluid shall be rotated in these
groups to achieve maximum velocity through the pipelines. This
will also limit fluid pump motor current. This grouping to be
suitably decided at site.

8.2.8

Initially Control fluid tank filters shall be inspected once in every 8

hours and cleaned as and when required. Thereafter frequency
shall be gradually changed to once a day depending upon the
filter condition.

8.2.9

The temperature of control fluid after heating should be between

65 to 70 deg C. After flushing for labour 2-3 hrs. at this temp., the
temp. will be reduced to minimum possible by opening the water
outlet. This process of thermal shock will be repeated several
times. Rapping of fluid lines shall be carried out during thermal
shocks.

8.2.10

After all the circuits have been taken for flushing and fluid tank
strainer remains clean for 24 Hrs., all the filter elements in the
system, removed before initial flushing shall be put back for final
flushing.

Signatures
NTPC

BHEL

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

Sheet 13 of 16
Ramagundam
NTPC Ref no RGM/1/TS/2/003
Plant area: TURBINE
PROCEDURE FOR FRF FLUSHING (TG CONTROL OIL SYSTEM)
STATUS
SLNO
8.2.11

During flushing; regular samples once in a day must be analysed

for entrained water, foreign matter content and acid value.

8.2.12

Flushing shall be declared completed as per completion criteria.

8.3.0

HYDRAULIC TESTING OF LINES:

8.3.1

General:

8.3.1.1

Hydraulic test of various lines shall be carried out as per chart

given below.
S.No.

8.3.2

System

Std. Pr.

Test Pr.

Duration

1.

Pressure Fluid

8 bar

20 bar
(without rack)

10 min

2.

HP Control Fluid

32 bar

96 bar
(without filter)
elements.

10 min

Preperation:

8.3.2.1

Blank flanges shall be installed and valves shall be closed

wherever the subsystem is connected to drain as per flushing
scheme.

8.3.2.2

Test gauges shall be provided as per test pressure requirement.

8.3.2.3

Isolation of equipment not subjected to test shall be done.

8.3.2.4

Valves of all process pr. gauges / transmitters shall be closed.

Signatures
NTPC

BHEL

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

Sheet 14 of 16
Ramagundam
NTPC Ref no RGM/1/TS/2/003
Plant area: TURBINE
PROCEDURE FOR FRF FLUSHING (TG CONTROL OIL SYSTEM)
STATUS
SLNO
8.3.2.5

Venting arrangements shall be provided at blind ends with valve.

Location of vent valves will be decided at site as per site lay out.

8.3.2.6

8 bar system shall be pressarised by feeding 32 bar fluid through

a temporary connection which will be provided for this purpose.

8.3.2.7

AII duplex filter elements shall be removed before hydraulic

testing.

8.3.2.8

32 bar system shall be tested by installing a separate

pressurising pump.

8.3.3

TEST PROCEDURE:

8.3.3.1

Control fluid pump shall be run and system filled.

8.3.3.2

Venting of total system shall be carried out.

8.3.3.3

Pressure of 8 bar system shall be raised to 20 bar by feeding 32

bar fluid through the temp. connection provided. System will be
checked for leakages for 10 mts.

8.3.3.4

Control fluid pump shall be stopped.

8.3.3.5

8 bar pressure fluid system shall be isolated. Pressure shall be

raised to 96 bar in 32 HP control fluid system and it will be held
for 10 mts. System shall be checked for leakages.

8.3.3.6

If leakages are observed, system shall be depressurised,

leakages attended and hydraulic test shall be repeated.

8.3.3.7

Minor leakages in temporary system shall be ignored.

Signatures
NTPC

BHEL

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

Sheet 15 of 16
Ramagundam
NTPC Ref no RGM/1/TS/2/003
Plant area: TURBINE
PROCEDURE FOR FRF FLUSHING (TG CONTROL OIL SYSTEM)
STATUS
SLNO
8.4

NORMALISATION:

8.4.1

Control fluid shall be drained from the total system.

8.4.2

Control fluid tank shall be cleaned and inspected.

8.4.3

Control fluid coolers shall be cleaned and inspected.

8.4.4

All the provisional arrangements made in the system for flushing

& hydraulic testing shall be removed and system normalised.

8.4.5

The drained control fluid shall be refilled after the tank is

absolutely clean. Fluid shall be filled through the regenerative
system only.

8.4.6

Control fluid quantity refilled will be measured and recorded.

Signatures
NTPC

BHEL

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

Sheet 16 of 16
Ramagundam
NTPC Ref no RGM/1/TS/2/003
Plant area: TURBINE
PROCEDURE FOR FRF FLUSHING (TG CONTROL OIL SYSTEM)
STATUS
SLNO
9.0

COMPLETION CRITERIA:

9.1

FRF samples at Regenerative pumps inlet (when in operation)

shall be analysed at regular intervals (once a day) for the
following : a. Mechanical impurities
b. Water content
c. Acid content

9.2

Less than 0.05% by wt.

Less than 0.01% by wt.
Less than 0.1 mg KOH/gm.

FRF System flushing shall be declared complete based on the

followings:

Partical count in the oil sample should be as per NAS 1638,

Class 7
Sediments should not be more than 5 mg/ 100 ml of oil.
Acid content should not be more than 0.1 mg KOH/gm of oil.
Moisture should not be more than 1000 ppm.
Specific resistance, checked as per IEC method, should not
be less than 5X 109 ohm cm.

9.3

Control fluid Tank filter should remain clean after 24 Hrs. of

flushing.

9.4

All duplex filters should remain clean after 12 hours of flushing.

Signatures
NTPC

BHEL

ANNEXURE

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

Sheet 1 of 5
Ramagundam
NTPC Ref no RGM/1/TS/2/003
Plant area: TURBINE
PROCEDURE FOR FRF FLUSHING (TG CONTROL OIL SYSTEM)
STATUS
SLNO
10.a

TECHNICAL SPECIFICATION:
Numerical value
Air release

at 50 deg C

max.

Unit

min.

Neutralization number

max.

0.1

mgKOH/g

Water content

max.

0.1

% by weight

Foam characteristics at 25 deg C

Foaming
max.
Foam stability 0 cm3 after
max.

100
450

cm3
s

Kinematic viscosity at 40 deg C max.

Max.

41.4
50.6

mm2 /s
(cSt)

Density

1.25

g/cm3

at 15 deg C max.

Content of solid
Particles

max.

0.05

Flash point (Cleveland

Open cup)

min.

235

Ignition temperature

min.

550

deg C

Chlorine content

max.

50

mg/kg

Electrical resistance

min.

0.5x10 9

ohm Cm

Pour point

min.

18

deg C

Particle distribution

min.

17/14

Code

% by weight
deg C

Signatures
NTPC

BHEL

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

Sheet 2 of 5
Ramagundam
NTPC Ref no RGM/1/TS/2/003
Plant area: TURBINE
PROCEDURE FOR FRF FLUSHING (TG CONTROL OIL SYSTEM)
STATUS
SLNO
Oxidation stability

max.

2.0

mg KHO/g

Hydrolytic stability after

Treatment with Fullers earth
Change of neutralization number max.

2.0

mg KHO/g

Radiation resistance
First molecule splitting

min.

5 x 10

Burning behaviour
Burning period

max.

J/ kg
s

Signatures
NTPC

BHEL

SHEET 3 OF 5
10. C

LOG SHEET
FRF PUMP NO.1 / 2

Date /
Time

Pump
Discharge
Pressure

FRF Temperature
Before
Cooler

After
Cooler

No. of
Thermal
Shocks

Remarks

Signatures
NTPC

BHEL

PROCEDURE FOR FRF FLUSHING

(TG CONTROL OIL SYSTEM)
FOR NTPC RAMAGUNDAM, UNIT 7 500 MW

PS:TSX:177:00:03

PROJECT : RAMAGUNDAM 500 MW

BHARAT HEAVY ELECTRICALS LIMITED

TECHNICAL SERVICES DEPARTMENT
POWER SECTOR SOUTHERN REGION
CHENNAI 600 035.

PROJECT

RAMAGUNDAM 500MW, UNIT-7

PROCEDURE

PROCEDURE FOR FRF FLUSHING (TG CONTROL OIL

SYSTEM)

PURPOSE OF
DOCUMET

FOR EXECUTION / INFORMATION

DOCUMENT

PS:TSX:177:00:03

Copy No:
Issued to :

00

K.J

M.K.S

K.B

28.08.03

Rev.No.

Prepared by

Reviewed by

Approved by

Date

BHARAT HEAVY ELECTRICALS LIMITED

PSSR/TECHNICAL SERVICES
474, Anna Salai, Nandanam,
Chennai 600 035.

RAMAGUNDAM 500 MW UNIT 7

SCHEME FOR FRF FLUSHING

DRG.NO.4:PS:TSX:0149: 00
DRAWN

CHECKED

APPROVED

DATED

KJ

MKS

KB

28.08.03