Fuel Oil, Auxiliary Steam & Condensate Return System Piping Flushing Procedure

MINISTRY OF ENERGY
IRAN POWER DEVELOPMENT COMPANY
I.P.D.C
PROJECT:
SHIRVAN GAS TURBINE POWER PLANT (BOP2 PORTION)
FUEL OIL, AUXILIARY STEAM & CONDENSATE RETURN SYSTEM PIPING FLUSHING PROCEDURE
MAPNA
Co.
(PRIVATE JOINT STOCK) IRAN POWER PLANT PROJECTS MANAGEMENT Co.
IN-HOUSE REVISIONS
DOCUMENT REVISIONS
FOR APPROVAL
A.M
Oct.05
A.S.M
Oct.05
E.A.
Oct.05
FOR APPROVAL
A.M
Oct.05
A.S.M
Oct.05
E.A.
Oct.05
Doc. No.: MP-SVG-18ME-10-FG0-001

Contract No.: SV-0602-HA/TL
Rev. : 0 File No.:

FLUSHING PROCEDURE
Kherad Water Treatment CO.
SE Code:
MF Code:9007
Page 1 of 17
MINISTRY OF ENERGY
I.P.D.C
PROJECT:
REV.
DESCRIPTION
DESG. DATE
CHK.
DATE
APP.
DATE
REV.
DESCRIPTION
DESG.
Date
CHK.
Date
APP.
Date
MAPNA
Co.

Rev. : 0 File No.:

FLUSHING PROCEDURE
SE Code:
MF Code:9007
Page 2 of 17
MINISTRY OF ENERGY
I.P.D.C
PROJECT:
PAGE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 REVISION 0 X X X X X X X X X X X X X X X X X A B C D E F G

REMARKS PAGE 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 REVISION 0 A B C D E F G REMARKS
MAPNA
Co.

Rev. : 0 File No.:

FLUSHING PROCEDURE
SE Code:
MF Code:9007
Page 3 of 17
MINISTRY OF ENERGY
I.P.D.C
PROJECT:
Content
1. Reference drawing 2. Description 3. Pre-cautions 4. Flushing 4.1. Flushing of gas oil line from unloading bay up to unloading pump house. 4.2. Flushing of the pipes from unloading pump house to tank yard. 4.3. Flushing from tank yard up to the forwarding pumps. 4.4. Flushing from forwarding pumps up to the end of pipe racks. 4.5. Flushing of the steam heater of the gas oil storage tank.
MAPNA
Co.

Rev. : 0 File No.:

FLUSHING PROCEDURE
SE Code:
MF Code:9007
Page 4 of 17
MINISTRY OF ENERGY
I.P.D.C
PROJECT:
1. Reference Drawing Gas oil unloading & forwarding system description (MP-SVG-18IE-04-FG0-001) Steam & condensate return system description (MP-SVG-22IE-04-SBO-002) Gas oil P&ID diagram unloading system (MP-SVG-18IE-02-FG0-001) Gas oil P&ID diagram forwarding system (MP-SVG-18ID-02-FG0-001) Fuel oil,Aux.steam&cond.return system Piping Hydrotest(MP-SVG-18ME-10-FG0-003) 2. Description For flushing of gas oil, steam & condensate Pipes of Shirvan gas turbine power plant, five main loops should be considered. 3. Pre-Cautions All equipments like duplex filters, pumps & etc, are being flushed and cleaned in Producer Company. For preventing from damaging the mentioned equipment during flushing, they will be by passed. They will be flushed in commissioning operation. Before start of flushing, following consideration should be considered: 3.1. All duplex filters, pumps & accumulators of gas oil system should be out of service.(By closing up & down stream valves) 3.2. All expansion joints and flexible tubes should be out of flushing loop. 3.3. All steam traps should be out of service. 3.4. All steam traps panels & steam feed panels should be out of service. (By closing the isolating valve on the steam or condensate branch to steam or condensate header) 3.5. Personnel should be trained for safety and should avoid closing the water flushing MAPNA
Co. valves or pipes.
3.6. Necessary temporary spools to be ready.

Rev. : 0 File No.:

FLUSHING PROCEDURE
SE Code:
MF Code:9007
Page 5 of 17
MINISTRY OF ENERGY
I.P.D.C
PROJECT:
4. Flushing As described before, Flushing is carried out in five main loops from processing viewpoint: Flushing of gas oil, steam & condensate lines from unloading area up to the unloading pump house. Flushing of gas oil, steam & condensate lines from unloading pump house up to the storage tank. Flushing of gas oil, steam & Condensate lines from tank yard up to the forwarding pumps. Flushing of gas oil, steam & Condensate lines from forwarding pumps up to the end of pipe rack. Flushing of steam heater coil of gas oil storage tank. 4.1 Flushing of gas oil line from unloading bay up to unloading pump house. The 12" gas oil line from unloading bay to 80m3 unloading tank should be flushed. After finishing the water flushing all the drain valves to be opened to dry the pipes soon. 4.2 Flushing of the pipes from unloading pump house to tank yard. This step is carried out in 3 steps: - Steam line - Condensate line - Gas oil line First the steam line to be flushed by removing the isolating 1'' valves (50LBG04MAPNA AA252) branched from the 5'' line.
Co.
The condensate line to be flushed by removing the isolating valve of steam trap panel in unloading area bedside the unloading pump house wall.
Rev. : 0 File No.:

FLUSHING PROCEDURE
SE Code:
MF Code:9007
Page 6 of 17
MINISTRY OF ENERGY
I.P.D.C
PROJECT:
For flushing, the expansion joint besides gas oil storage tank should be by passed into the 4 m3 drainage tank.
For flushing the gas oil line, the unloading pumps and the duplex filter in the unloading pump house should be isolated by using temporary by pass lines.
When the flushing of the unloading area is finished, all the drain valves should be opened to dry the pipes soon.
UNLOADING PUMP HOUSE
PORTA BLE PU M P
12"
60EGA 07 A A 001 12"
60E GA08,09 A P001 STORAG E TA NK
60EGA 08,09 AA 001
60EGA 08,09 AA002
MAPNA
Co.
FIGURE NO. 1

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FLUSHING PROCEDURE
SE Code:
MF Code:9007
Page 7 of 17
MINISTRY OF ENERGY
I.P.D.C
PROJECT:
4.3 Flushing from tank yard up to the forwarding pumps. This stage is carried out from 16" pipe header up to each suction-isolating valve of forwarding pumps in 6 lines. It is strongly recommended to flush the lines one by one. For each branch the relevant isolation valve should be considered. For Flushing the gas oil line of unit 1, all the isolation valves of other units should be closed. The expansion joint on 16" line beside gas oil storage tank should be removed and its down stream valve beside the tank should be opened.(acc. To fig No. 8) One portable pump will be connected to the beginning of 16" pipe. The suction isolating valve of forwarding pumps will be removed to drain the flushed water. By opening the temporary valves and start the pump, the line is to be flushed. The process should be continued until all foreign material and particles to be discharged. Flushing water can be drained or should be gathered in one empty tank or tanker. valve on the start of pipe trench. By removing the steam valve in auxiliary boiler building the flushing water should be discharged. The condensate line from tank yard pipe to condensate pump should be cleaned in the same manner. In this stage the condensate recovery pumps should be by passed. In this stage for Flushing the lines the condensate recovery tank should be used for drain. The process should be continued until all foreign material and particles are discharged. MAPNA
Co.
The steam line to auxiliary boiler building should be flushed by opening the isolating

Rev. : 0 File No.:

FLUSHING PROCEDURE
SE Code:
MF Code:9007
Page 8 of 17
MINISTRY OF ENERGY
I.P.D.C
PROJECT:
GAS OIL STORAGE TANK (TANK YARD)
PORTABLE PUMP 16"
16"x12"
12"x10"
10"x8"
6"
6"
6"
6"
6"
6"
21/2"
DRAIN
FIGURE NO. 2 4.4 Flushing from forwarding pumps up to the end of pipe racks: It is strongly recommended the lines to be flushed one by one. For cleaning the lines, the gas oil pumps, duplex filters and accumulator of each unit should be bypassed by temporary spool during the Flushing. Beginning and end of each line should be free in order to be connected to the portable pump, and be able to discharge the polluted water. Also following considerations should be done: For Flushing the gas oil line of unit 1, all the isolation valves of other units should be closed. Co.
MAPNA
Flushing should be continued until clean water is discharged. All other lines at the rack and in the pipe trench should be cleaned in the same
Rev. : 0 File No.:

FLUSHING PROCEDURE
SE Code:
MF Code:9007
Page 9 of 17
MINISTRY OF ENERGY
I.P.D.C
PROJECT:
manner. The steam line to auxiliary boiler building should be flushed by opening the isolation valve. By removing the steam valve in auxiliary boiler building the flushing water should be discharged. The condensate line from forwarding pump house to condensate pump should be cleaned in the same manner. The condensate recovery pumps should be by passed. In this stage for Flushing the lines the condensate recovery tank should be used for drain. For each branch the relevant isolating valve should be considered. The expansion joints should not be installed in this stage.
MAPNA
Co.

Rev. : 0 File No.:

FLUSHING PROCEDURE
SE Code:
MF Code:9007
Page 10 of 17
MINISTRY OF ENERGY
I.P.D.C
PROJECT:
FORWARDING PUMP HOUSE
POR TABLE PUMP
61EGD 02 A A001
62EGD 02 A A001
63EGD02 A A001
64EGD 02 A A001
65EGD02 AA001
66EGD 02 A A001
60EGD 02 A A001
61EGD 03 B B001
61EGR 01 A T001
61EGC 02,03 A P001 D RAIN
Note : The inter connection piping between duplex filter pump & accumulator, will be flushed by removing the equipment and drain the polluted water.
FIGURE NO. 3 4.5 To flush the steam heater of the gas oil storage tank: The bottom heater of gas oil storage tank is being flushed by feeding water through 5''steam by pass line. Flushed water will go out through the 5'' condensate lines and 2 1/2" header line. (acc. To fig No. 4)
MAPNA
Co.

Rev. : 0 File No.:

FLUSHING PROCEDURE
SE Code:
MF Code:9007
Page 11 of 17
MINISTRY OF ENERGY
I.P.D.C
PROJECT:
FIGURE NO. 4 LOOP DESCRIPTION: (PIPING FLUSHING PROCEDURE) LOOP 1- UNLOADING AREA TO 80 m3 UNDERGROUND GAS OIL UNLOADING TANK . LOOP 2- UNLOADING PUMP HOUSE TO 20000 m3. FUEL OIL STORAGE TANK AND RETURN TO UNLOADING PUMP HOUSE. LOOP 3- 6 GT UNITS 16" & 4" RETURN LINES TO 20000 m3 FUEL OIL STORAGE TANK .
MAPNA
LOOP 4- 16" Co. LINE FROM 20000 m3 FUEL OIL STORAGE TANK TO FORWARDING PUMP HOUSE AND 6 GT UNITS 16" RETURN LINE TO 20000 m3 FUEL OIL STORAGE TANK .
Rev. : 0 File No.:

FLUSHING PROCEDURE
SE Code:
MF Code:9007
Page 12 of 17
MINISTRY OF ENERGY
I.P.D.C
PROJECT:
LOOP 5,6,7- 16" LINE FROM FUEL OIL STORAGE TANK TO FORWARDING PUMP HOUSE & 16" RETURN LINE FROM 6GT UNITS TO 2000 m3 FUEL OIL STORAGE TANK . LIST OF EQUIPMENT FOR PIPING FLUSHING PROCEDURE. 1) PUMP (Q=50 m3/h) 2) ORTABLE STORAGE TANK (V=4 m3) 3) BAR SCREEN (2-3 mm) 4) TEMPORARY FLEXIBLE HOUSE (2 1/2")
MAPNA
Co.

Rev. : 0 File No.:

FLUSHING PROCEDURE
SE Code:
MF Code:9007
Page 13 of 17

Fuel Oil, Auxiliary Steam & Condensate Return System Piping Flushing Procedure

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MINISTRY OF ENERGY

IRAN POWER DEVELOPMENT COMPANY

SHIRVAN GAS TURBINE POWER PLANT (BOP2 PORTION)

Doc. No.: MP-SVG-18ME-10-FG0-001

Rev. : 0 File No.:

Kherad Water Treatment CO.

SHIRVAN GAS TURBINE POWER PLANT (BOP2 PORTION)

Doc. No.: MP-SVG-18ME-10-FG0-001

Rev. : 0 File No.:

Kherad Water Treatment CO.

SHIRVAN GAS TURBINE POWER PLANT (BOP2 PORTION)

(PRIVATE JOINT STOCK) IRAN POWER PLANT PROJECTS MANAGEMENT Co.

Doc. No.: MP-SVG-18ME-10-FG0-001

Rev. : 0 File No.:

Kherad Water Treatment CO.

SHIRVAN GAS TURBINE POWER PLANT (BOP2 PORTION)

Doc. No.: MP-SVG-18ME-10-FG0-001

Rev. : 0 File No.:

Kherad Water Treatment CO.

SHIRVAN GAS TURBINE POWER PLANT (BOP2 PORTION)

Co. valves or pipes.

3.6. Necessary temporary spools to be ready.

Doc. No.: MP-SVG-18ME-10-FG0-001

Rev. : 0 File No.:

Kherad Water Treatment CO.

SHIRVAN GAS TURBINE POWER PLANT (BOP2 PORTION)

Rev. : 0 File No.:

Kherad Water Treatment CO.

SHIRVAN GAS TURBINE POWER PLANT (BOP2 PORTION)

UNLOADING PUMP HOUSE

60EGA 07 A A 001 12"

60E GA08,09 A P001 STORAG E TA NK

60EGA 08,09 AA 001

60EGA 08,09 AA002

Doc. No.: MP-SVG-18ME-10-FG0-001

Rev. : 0 File No.:

Kherad Water Treatment CO.

SHIRVAN GAS TURBINE POWER PLANT (BOP2 PORTION)

Doc. No.: MP-SVG-18ME-10-FG0-001

Rev. : 0 File No.:

Kherad Water Treatment CO.

SHIRVAN GAS TURBINE POWER PLANT (BOP2 PORTION)

GAS OIL STORAGE TANK (TANK YARD)

PORTABLE PUMP 16"

Rev. : 0 File No.:

Kherad Water Treatment CO.

SHIRVAN GAS TURBINE POWER PLANT (BOP2 PORTION)

Doc. No.: MP-SVG-18ME-10-FG0-001

Rev. : 0 File No.:

Kherad Water Treatment CO.

SHIRVAN GAS TURBINE POWER PLANT (BOP2 PORTION)

FORWARDING PUMP HOUSE

POR TABLE PUMP

61EGC 02,03 A P001 D RAIN

Doc. No.: MP-SVG-18ME-10-FG0-001

Rev. : 0 File No.:

Kherad Water Treatment CO.

SHIRVAN GAS TURBINE POWER PLANT (BOP2 PORTION)

Rev. : 0 File No.:

Kherad Water Treatment CO.

SHIRVAN GAS TURBINE POWER PLANT (BOP2 PORTION)

Doc. No.: MP-SVG-18ME-10-FG0-001