1

RECOMMENDED PROCEDURE
FOR OIL FLUSHING OF LUB OIL
AND JACKING OIL SYSTEM

PROJECT

RELIANCE, 7X90MW

PROCEDURE

OIL FLUHSING OF LUB OIL & JACKING OIL SYSTEM

PURPOSE
DOCUMENT

FOR EXECUTION / INFORMATION

DOCUMENT

BHEL Ref No. : PW/TSX/RUPPL/Tur/CP/05/00

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

Sr. Mgr/TSX

Rev.No.

AGM/TSX

V.K.Jhade

S.Mandal

Prepared by

Reviewed by

Head/TSX

30.5.15

B.Swain
Approved by

BHARAT HEAVY ELECTRICALS LIMITED

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

Date

Station: RUPPL
( 7X90MW)

BHEL Ref No.

PW / TSX / RUPPL/TUR/CP/05/00

Page 2 of 15

Plant area: BOILER

PROCEDURE FOR OIL FLUSHING OF LUB OIL & JACKING OIL SYSTEM

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/05/00

Page 3 of 15

Plant area: BOILER

PROCEDURE FOR OIL FLUSHING OF LUB OIL & JACKING OIL SYSTEM
1. PLANT DETAILS:
Turbine Lub oil

Turbine lub oil system consists of two nos of AC lub oil pumps, one DC EOP , lub oil
cooler ( 2X100%) & duplex filter (2x100%) and associated oil supply and drain
pipelines. Two nos ( 2x100%) of oil Vapour extractors are mounted on MOT for
extracting oil Vapour during operation.

Jacking oil system

Two nos of JOP (one DC and one AC) are there with suction filter and pressure regulating
valves in the discharge pipe to lift the turbine and generator rotor system for barring gear
operation. Barring gear is done with the help of one hydromotor mounted outside the
front bearing pedestal and coupled with the rotor system with overrun clutch.

Oil purification system

There in one centrifuge which runs parallel with oil system to keep the oil clean from dirt
and moisture during operation.

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 turbine & generator bearings.

Oil centrifuge will be running preferably in clarifier mode to remove dirt during oil
flushing.

3. PROPOSAL:

To establish oil flow in lub oil & Jack Oil system & continue flushing at flow &
temperatures which are above normal working parameters

Both the AC lub oil pumps will be put into operation for achieving high flow condition.
Oil centrifuge will be used for heating oil up to 60 deg C

Signatures
RUPPL

BHEL

Station: RUPPL
( 7X90MW)

BHEL Ref No.

PW / TSX / RUPPL/TUR/CP/05/00

Page 4 of 15

Plant area: BOILER

PROCEDURE FOR OIL FLUSHING OF LUB OIL & JACKING OIL SYSTEM

Hammering will be done with the help of wooden hammer all along the supply and drain
lines to dislodge the internal dirt during oil flushing.

4. SERVICES REQUIRED:

Manpower with required tools for attending to any leak, cleaning the oil filter and
hammering of pipe lines

Operating personnel to co-ordinate the activities.

LT Power supply for the pumps and oil vapour extractors and oil centrifuge

Lighting arrangement and approach in MOT,oil tank and other operating floors.

Portable fire fighting equipments in all the floors.

Centrifuge for cleaning the oil.

Flushing oil quantity (estimated) = 36 Cu.M.(tentative, actual quantity will be estimated

at site) Properties of oil should be compatible with regular operation oil.

Availability of laboratory facilities for analysis of Oil samples.

Availability of service Air for filters cleaning.

Availability of Communication facility at flushing area.

Availability of laboratory facility for analysis of flushing oil for MI and moisture

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

Signatures
RUPPL

BHEL

Station: RUPPL
( 7X90MW)

BHEL Ref No.

PW / TSX / RUPPL/TUR/CP/05/00

Page 5 of 15

Plant area: BOILER

PROCEDURE FOR OIL FLUSHING OF LUB OIL & JACKING OIL SYSTEM

5. SAFETY PRECAUTIONS:

Display of Board No cutting / welding at all floors and near Oil Tank, Oil Coolers etc.
Debris in all the floors shall be removed. Debris in and around oil systems and MOT
(Main Oil Tank) floor to be removed.

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 cutting , welding near flushing area.

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

6. EMERGENCY PROCEDURES:

The group consisting of Reliance and BHEL, which is carrying out steam Blowing,
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 steam blowing operation, the operation should be
immediately terminated and appropriate action taken to address the emergency.

7. STATE OF THE PLANT:

Lub oil and Jacking oil lines are erected as per PID with all instrument points.
5

Signatures
RUPPL

BHEL

Station: RUPPL
( 7X90MW)

BHEL Ref No.

PW / TSX / RUPPL/TUR/CP/05/00

Page 6 of 15

Plant area: BOILER

PROCEDURE FOR OIL FLUSHING OF LUB OIL & JACKING OIL SYSTEM

Hydraulic test of oil lines completed and leakages attended. All permanent piping &
temporary piping erected and supports/hangers are released with cold setting.

Adequate communication between MOT room, Turbine floor and control room area
ensured.

Temporary lines are erected as per scheme and routed to safe direction so as to avoid
damage to men and material.

Strainer elements removed from strainer body. Control valves wherever applicable are
not erected before oil flushing and suitable spool pieces are erected.

No loose debris / extraneous materials are left inside the permanent / temporary piping

All drains to be kept closed.

Central lub oil system is erected in all respect to drain oil after flushing.

Installation of oil pumps, oil level gauge and connected temporary piping along with
pressure gauges is complete

Required quantity flushing oil is available

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

Oil coolers inspected through oil line connection .Temperature indicators before and after
oil cooler are made available for Oil as well as cooling water.

Before filling the oil in Main oil tank (MOT), the tank is cleaned carefully. All C&I
installation and calibration of Oil tank level indicators, level switches etc. completed
before Oil filling.Visual inspection carried out to check cleanliness of the interior of the
fire resistant oil tank. Ensure the suction belmouth at the suction of all oil pumps.

Vapour extraction system with vapour extraction fan is available for operation.
6

Signatures
RUPPL

BHEL

Station: RUPPL
( 7X90MW)

BHEL Ref No.

PW / TSX / RUPPL/TUR/CP/05/00

Page 7 of 15

Plant area: BOILER

PROCEDURE FOR OIL FLUSHING OF LUB OIL & JACKING OIL SYSTEM

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

The necessary by pass work as per scheme enclosed carried out and the correctness of
looping checked.

Insulation of Turbine & piping nearby pedestals shall be completed and TG floor, Oil
Tank & flushing area completely cleaned

All pumps (AOPs & JOPs) shall be available. Oil in the tank is filled to the required
level. All bearings are Boxed up with bypass device

Provision for emergency stopping of oil pumps from Local / Main Control Room has to
be made.

8. METHOD:

After completion of the oil lines with all instrumentation tapping as shown in the PID,
card board bursting is done including the drain lines up to MOT with air pressure of 4-6
kg/cm2. Oil throttle internals in oil supply line to bearings are to be removed and are
provided dummy plates on top of the throttle body.

Oil throttle before oil coolers need not to be removed, also provide a spool pipeline
between inlet and outlet of the cooler.

Duplex filter elements provided in the supply line to thrust bearing are to be removed.
These elements are to be put back in position during the final stage of flushing.

Signatures
RUPPL

BHEL

Station: RUPPL
( 7X90MW)

BHEL Ref No.

PW / TSX / RUPPL/TUR/CP/05/00

Page 8 of 15

Plant area: BOILER

PROCEDURE FOR OIL FLUSHING OF LUB OIL & JACKING OIL SYSTEM

The regular adaptors in the bearing pedestals for supply are replaced with flushing device
so that oil is deflected to bearing-to-bearing pedestal instead of going to the bearings.

The jacking oil pumps are disconnected at the discharge flanges of the pumps and rotates
as required and oil supply pipe to be connected through a temporary valve (of high
pressure duty) to the dummy flange in the AOP discharge header.

The header of the jacking oil supply line has a dummy flange at the exciter side. From
this a temporary connection is run to the oil return pipe blank flanges of flushing, with an
isolating valve.

Pressure regulating valve of JOP (Jacking Oil Pump) discharge line to be removed and
spool piece to be erected for connecting JOP discharge header and relief drains is to be
blanked.

The hose connections of JOP lines inside the bearing pedestals are removed at the bearing
end and left in the pedestals it.

The internals of non-return valves provided in individuals jacking oil line of the bearings
may be removed. Internals of combined discharge and non-return valve in the JOP
discharge line is to be removed.

Remove the turning solenoid box and provide a flushing device in its place before boxing
up the pedestal.

Signatures
RUPPL

BHEL

Station: RUPPL
( 7X90MW)

BHEL Ref No.

PW / TSX / RUPPL/TUR/CP/05/00

Page 9 of 15

Plant area: BOILER

PROCEDURE FOR OIL FLUSHING OF LUB OIL & JACKING OIL SYSTEM

The necessary temporary arrangement for oil filling has to be made at site. Appox 150180 barrels of oil (SERVO PRIME 46) will be required for flushing.

Permanent dirty oil drain and clean oil tank must be made available for accepting the full
charge of oil.

Arrangement for analysis of oil sample after the flushing must be made. The sample may
be taken for checking mechanical impulses.

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

First charging of oil system is to be done preferably by running the EOP in order to avoid
any excessive oil spillage during first charging as discharge pressure of EOP is lower than
that of AOP. Ensure proper venting from all available vents in the system. If EOP is not
available, start AOP for small interval (5-10 sec) keeping all vent open till the system is
filled up.
For initial oil flushing the Lub oil cooler is to be bypassed by suitable looping. This will
prevent the dirt of lines from entering in the cooler. The duration of oil flushing can be
decided observing, the main oil tank filter. Normally 2-3 days flushing should be
sufficient, after these connections to be normalized.
Once oil system in completely filled up and all leakages are attended, AOP is to be run
for further flushing operations
During flushing operations ensure the followings:

Thermal shocks as described below are given regularly. During the process of thermal
shocks, oil temperature is increased to 60-65 C. (oil temperature after coolers) by
9

Signatures
RUPPL

BHEL

Station: RUPPL
( 7X90MW)

BHEL Ref No.

PW / TSX / RUPPL/TUR/CP/05/00

Page 10 of 15

Plant area: BOILER

PROCEDURE FOR OIL FLUSHING OF LUB OIL & JACKING OIL SYSTEM
churning & centrifuge heater. After that heating is to be stopped and oil cooled by
opening the cooling water to the coolers till the oil temperature goes down to minimum
possible (oil temperature before coolers). Ensure that oil temperature does not exceed
70C. During heating process. As soon as oil temperature drops to the minimum possible
(40-45 0C) again start heating up and raise temperature.

Manual tapping / hammering of oil lines to be done continuously during the heating /
cooling periods. Hammering to be done on the complete length of the pipes.

Filters in MOT are to be cleaned regularly, during the oil flushing. Oil purification Unit is
to be run continuously.

Both AOPs are to be kept in service during flushing.

After initial cleaning of oil lines, throttles in the oil supply line to bearings are to be put in
position. Oil flushing should then be continued for some bearing at a time (keeping the
throttles full open condition and closing the throttles of the remaining bearings),
therefore, ensuring flushing with maximum possible flow in the oil return lines.

The flushing operation is to be continued by undertaking the above exercise in rotation so

that bearing oil supply lines are thoroughly flushed

Jacking Oil Lines Flushing:

Initially the jacking oil header is to be flushed by using the connection i.e. from header
dead end to drain header.

After using above circuit for about 3-4 days the above connection is to be closed and then
the lines to the individual bearing are to be flushed, say 2 or 3 lines at a time for effective
flushing
10

Signatures
RUPPL

BHEL

Station: RUPPL
( 7X90MW)

BHEL Ref No.

PW / TSX / RUPPL/TUR/CP/05/00

Page 11 of 15

Plant area: BOILER

PROCEDURE FOR OIL FLUSHING OF LUB OIL & JACKING OIL SYSTEM
Flushing of Jacking oil lines at higher pressure ( 20 kg/cm2) by running JOP is taken up
only after

Completion of lub oil lines as per criteria 9.0

Fresh oil is filled in the system and filtration of new oil has been done to ensure NAS 8
quality.

Turning gear line is to be flushed by opening the gate-gearing valve in such a way that
JOP motor does not get overloaded. This should be done daily once for hour with
thermal shock.
Each line is to be flushed for at least 2 -3 hrs at pressure more than 20 kg/cm2 by running
JOP. Before connecting JOP hose line is to be flushed for five min just before connecting
to bearing.

9. COMPLETION CRITERIA:

The oil analysis of sample drawn from oil purifier inlet should not have any mechanical
impurities and moisture. Main oil tank bucket filter should be in clean condition over a
period of 24 hours.

Duplex filter element should be free from impurities such that no chocking of filter
should be experienced in duration of 24 hours.

Bearing Line filters are to be installed and flushing carried out for 8 hours after ensuring
the duplex filter no choking criteria and no accumulation of dirt in the line filters should
be observed.

All criteria are to be met for declaring the oil flushing completion.
11

Signatures
RUPPL

BHEL

Station: RUPPL
( 7X90MW)

BHEL Ref No.

PW / TSX / RUPPL/TUR/CP/05/00

Page 12 of 15

Plant area: BOILER

PROCEDURE FOR OIL FLUSHING OF LUB OIL & JACKING OIL SYSTEM
After completion of flushing hydraulic test of lub oil and jacking oil lines is to be done as per the
following procedure.

10.0

LOG SHEET

12

Signatures
RUPPL

BHEL

13

SPOOL PIECES IN PLACE OF

CONTROL VALVES

TEMPORARY PIPE FROM

DICH NRV OF DC EOP TO
MOT

14

OVER HEAD
TANK

LUB OIL SUPPLY FROM

AOP DISCH

SUPPLY TO DRAIN
TEMPORARY LINE
THROTTLE

HYDRO
MOTOR

TO MOT DRAIN

TURBINE

GENERATOR

EXCITER

15

ALL NRV INTERNALS ARE TO KEPT REMOVED. CONNECTING HOSE PIPES IN THE BEARING
PEDESTAL ARE TO BE REMOVED FROM BEARINGS AND LEFT OPEN & SUPPORTED INSIDE
PEDESTAL DURING FLUSHING.

BYPASS LOOPS
FOR SOLENOID
VALVE AND
HYDROMOTOR
TEMPORARY
CONNECTION
FROM AOP
DISCHARGE
FOR INITIAL
FLUSHING

AFTER INITIAL FLUSHING FINAL FLUAHING WITH FRSH OIL WILL

BE DONE BY USING FRESH OIL AT PRESSURE 15-20 KG/CM2.

TEMPORARY CONNECTION TO MOT