1

RECOMMENDED PROCEDURE
FOR TREATED WATER FLUSHING OF
CONDENSATE, FEED WATER & DRIP LINES

PROJECT

RELIANCE, 7X90MW

PROCEDURE

PROCEDURE FOR TREATED WATER FLUSHING OF CONDENSATE,

FEED WATER & DRIP LINES

PURPOSE
DOCUMENT

FOR EXECUTION / INFORMATION

DOCUMENT

BHEL Ref No. : PW/TSX/RUPPL/Tur/CP/04/00

Issued by:
Issued to : CM,BHEL Site Office,Reliance ( Hazira & Dahej)

Sr Manager/TSX
00
Rev. No.

AGM/TX

V K Jhade

S.Mandal

Prepared by

Reviewed by

HEAD TSX
B.Swain
Approved by

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR WESTERN REGION
Shree Mohini Complex,345 Kingsway
Nagpur 440 001

30/04/2015
Date

Station: RUPPL
( 7X90MW)

BHEL Ref No.

PW / TSX / RUPPL/TUR/CP/04/00

Page 2 of 15

Plant area: BOILER

PROCEDURE FOR PREBOILER SYSTEM & DRIP LINES

LIST OF CONTENTS
1. PLANT DETAILS
2. OBJECTIVE
3. PROPOSAL
4. SERVICES REQUIRED
5. SAFETY PERECAUTIONS
6. EMERGENCY PROCEDURE
7. STATE OF THE PLANT
8. METHOD
9. COMPLETION CRITERIA
10. LOG SHEET

Signatures
RUPPL

BHEL

Station: RUPPL
( 7X90MW)

BHEL Ref No.

PW / TSX / RUPPL/TUR/CP/04/00

Page 3 of 15

Plant area: BOILER

PROCEDURE FOR PREBOILER SYSTEM & DRIP LINES
1. PLANT DETAILS:
The preboiler system comprises of :

Condensate system One of the Two 100% duty condensate extraction pumps /unit
extracts condensate from condenser hotwell and pumps to Condensate Forwarding tank.
From Condensate Forwarding Tank the condensate water is again pumped to FST via
GSC, LPH 1,2 &3 and Deaerator by 2 of 3 Condensate Forwarding pump.
Feed water system- Any one of four 100% duty Boiler Feed Pump (BFP) will take
suction from FST and pumps the feed water to boiler feed water common header via HP
Heaters 1&2 From the common header, hot feed water can be fed to any one of the
running boiler.

Drip lines

Heater (LP & HP) drip lines All upper heaters drip lines are cascaded to downstream
heater to have maximum heat gain from the regenerative system.

2. OBJECTIVE:

The objective of this procedure is to remove scales, loose material, dirt etc, that might
have been pipeline, during manufacture, storage, erection at site. Failure to remove the
debris may result in damage pumps and contaminate feed water to boiler.

3. PROPOSAL:

The objectives are achieved by carrying out the following proposals.

Mechanical cleaning of Condenser, Condensate forwarding tank & CEP suction lines
from respective condenser before erection and DM water flushing up to suction nozzle of
the pump.

CEP recirculation line will be connected with temporary pipe to CFT.

Mechanical cleaning of Condensate Forwarding tank and DM water flushing of

Condensate Forwarding Pump (CFP) suction line upto suction nozzle with suction
strainer in position.
3
Signatures
RUPPL

BHEL

Station: RUPPL
( 7X90MW)

BHEL Ref No.

PW / TSX / RUPPL/TUR/CP/04/00

Page 4 of 15

Plant area: BOILER

PROCEDURE FOR PREBOILER SYSTEM & DRIP LINES

Mechanical cleaning of FST followed by treated water flushing of the BFP suction,
discharge upto boiler inlet bypassing the HP heaters. BFP recirculation lines will be
included in this circuit for treated water flushing.

Treated DM water flushing will be done for condensate, feed water & heater drip lines
bypassing the heater shell.

The effects of flushing are evaluated and concluded as per the completion criteria given
in section 9.0

4. SERVICES REQUIRED:

Condensate forwarding tank will be used as mixing tank and condensate forwarding
pump as circulating pump.

Availability of approximately of 1500 ton DM water per unit for the entire operation.
Actual quantity will be arrived at site after ensuring the location of CFT area

Availability of chemicals:

Availability of following chemicals :

Liquor Ammonia (minimum 25% concentration)
Hydrazine Hydrate ( 80% concentration) or Carbohydrazide

Availability of all three condensate forwarding pumps.

Availability of condensate forwarding tank.

Availability of access and lighting in required floors.

Availability of Instrument / Service Air

Availability of laboratory facility for analysis of flushing water etc.

Availability of portable fire extinguishers at selected locations.

4

Signatures
RUPPL

BHEL

Station: RUPPL
( 7X90MW)

BHEL Ref No.

PW / TSX / RUPPL/TUR/CP/04/00

Page 5 of 15

Plant area: BOILER

PROCEDURE FOR PREBOILER SYSTEM & DRIP LINES

Availability of required concerned commissioning manpower.

Availability of DM water

Availability of Ambulance / Fire tender in the Power station premises.

5. SAFETY PRECAUTIONS:

Required quantities of safety gears such as helmets, Asbestos hand gloves, Ear Mufflers
etc are available.

First aid kit box available in control room.

Service water shall be made available near the activity area.

Required stair cases or platform or approaches etc with hand rails to electrical operated
quick opening temporary valves are made available.

Required barricades to be made to prevent personal from coming into contact with treated
water

Required number of sign boards to be put into position at selected locations to indicate
the ongoing process of flushing.

6. EMERGENCY PROCEDURES:

The group consisting of Reliance and BHEL, which is carrying out flushing, should be
aware of procedures to be followed in case of accidents involving injury to personnel.

The group should be aware of operating procedures of portable fire extinguishers to be

used for quenching minor fires.

The group should be aware that if any abnormality is observed in the permanent and
temporary system during the process.

7. STATE OF THE PLANT:

5

Signatures
RUPPL

BHEL

Station: RUPPL
( 7X90MW)

BHEL Ref No.

PW / TSX / RUPPL/TUR/CP/04/00

Page 6 of 15

Plant area: BOILER

PROCEDURE FOR PREBOILER SYSTEM & DRIP LINES

Leak check of the entire system to be flushed is complete.

The suction strainers of CFT pumps are to be kept in service during operation

All the regenerative equipment are installed in position and temporary pipe line
connections as per schemes are complete.

BFPs, their booster pumps and CEPs are bypassed suitably with temporary piping.

Suction and discharge ends of BFPs and CEPs are capped to prevent entry of flushing
fluid into the pump.

BFP suction strainer elements are removed before flushing.

All the valves in the steam lines to and from Dearator are closed.

Installation connected temporary piping along with pressure gauges is complete.

All the cutting and welding work on instrument tapping points is complete up to isolating
root valves.

All the orifices, flow nozzles, control valves and NRVs flap in reverse flow path are
removed and a check list is prepared. Spool pieces are provided wherever required.

All the instruments except those required during flushing are isolated.

Hangers and supports are complete for the system to be flushed.

Signatures
RUPPL

BHEL

Station: RUPPL
( 7X90MW)

BHEL Ref No.

PW / TSX / RUPPL/TUR/CP/04/00

Page 7 of 15

Plant area: BOILER

PROCEDURE FOR PREBOILER SYSTEM & DRIP LINES
8. METHOD:

Flushing is carried out in three stages as detailed in proposal.

The stage to be flushed is lined up.

FLUSHING CIRCUIT
CONDENSATE CIRCUIT
CRCUIT 1- Condensate forwarding tank (CFT) - CFT Pump suction line pump
discharge- Drain cooler bypass-LP Heater1,2,3 bypass- Dearator -FST-FST DrainTemporary pipe to CFT.
CRCUIT 2 CFT Pump recirculation line common header (temporary) connect to CEP
Discharge near to CFT Tank-CEP Discharge & CEP r/c - temporary pipe to CFT Tank.

FEED LINE CIRCUIT

CRCUIT 3- Condensate forwarding tank (CFT) - CFT Pump suction line pump
discharge- Drain cooler bypass-LP Heater1,2,3 bypass- Dearator - Temporary pipe
connect to BFP Suction at dearator floor-BFP Suction Booster pump bypass- Main
pump suction- BFP discharge- HP Heater 1&2 bypass-Eco inlet- back to CFT Through
temporary line.

FEED PUMP R/C LINE & FST

CRCUIT 3- Condensate forwarding tank (CFT) - CFT Pump suction line pump
discharge- Drain cooler bypass-LP Heater1,2,3 bypass- Dearator - Temporary pipe
connect to BFP Suction at dearator floor-BFP Suction Booster pump bypass- Main
pump suction- BFP discharge- BFP R/C lines FST- FST drain and over flow -CFT.

Signatures
RUPPL

BHEL

Station: RUPPL
( 7X90MW)

BHEL Ref No.

PW / TSX / RUPPL/TUR/CP/04/00

Page 8 of 15

Plant area: BOILER

PROCEDURE FOR PREBOILER SYSTEM & DRIP LINES

DRIP LINE CIRCUIT

CIRCUIT 4- CFT to FST bypass- BFP Suction-BP Bypass- main pump suction-BFP
discharge-BFP Recirculation- all three RC line common headers at Dearator level- Drain
to CFT through temporary pipe.
CIRCUIT 5-CFT Discharge to Dearator inlet- connect HPH 2drip to dearator drip line
HPH2 TO HPH1 drip line- HPH1bypass- HPH 1
CIRCUIT 6 -CFT Discharge to LPH 3 inlet- connect LPH 3 drip to LPH 2 & 1 drip line
as shown in scheme temporary line to CFT

The system is filled with DM water by running Condensate Forwarding pump circulation
pumps and circulation is established.

Open circuit flushing with cold DM water is carried out for each circuit till the effluent
becomes visibly clear.

Closed circuit flushing with cold DM water is started and continued for one hour through
each circuit. The system is then drained using substitution method till the effluent
becomes visibly clear and till turbidity in the sample collected from return line is less
than 10-15 NTU.

System is again filled with Hydrazine Hydrate 100-150 ppm and Ammonia to maintain
pH 9 to 9.5.

The solution is circulated in each circuit for duration of two to three hours depending
upon circuit length.

The system is then drained completely.

9. COMPLETION CRITERIA:

Rinsing after cold flushing is declared complete when turbidity in the sample collected
from return line is less than 10-15 NTU.
8

Signatures
RUPPL

BHEL

Station: RUPPL
( 7X90MW)

BHEL Ref No.

PW / TSX / RUPPL/TUR/CP/04/00

Page 9 of 15

Plant area: BOILER

PROCEDURE FOR PREBOILER SYSTEM & DRIP LINES

DM Treated water flushing is considered completed after three hour circulation of each
circuit and system inlet and return sample of Hydrazine hydrate or carbohydrazide and
pH value stabilized.

10.0

Date

LOG SHEET

Sample
no

Turbidity
( NTU)
Inlet
outlet

pH
Inlet

Outlet

Crbohydrazide
Inlet

Remarks

Outlet

Signatures
RUPPL

BHEL

10

TO CFT

11

Booster Pump
Suction

CEP disch
after GSC

12

From CFP disch

TO BOILER

13

TO COND FORD TANK

14

FROM CONDENSATE
FORWARDING PUMP
DISCH TO D/A INLET

CON FORD TANK

15

FROM COND FORD

TANK DISCH AFT
LPH 3 INLET
ISOLATING VALVE

COND FORD TANK