Detergent Flushing

Station: NTPC-
VINDHYACHAL-ST-III
BHEL Ref No: PW/TSX/VIN/TUR-CS/001/REV00
NTPC Ref No:
Plant area:
TURBINE & AUXILARIES

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COMMISSIONING SCHEDULE
COMMISSIONING SCHEDULE FOR
DETERGENT FLUSHING OF PREBOILER AND CONDENSATE SYSTEM

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1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0

LIST OF CONTENTS

PLANT DETAILS

OBJECTIVE

PROPOSAL

SERVICES REQUIRED

SAFETY PRECAUTIONS

EMERGENCY PROCEDURES

STATE OF THE PLANT

METHOD

COMPLETION CRITERIA

APPENDICES

DRAWINGS

LOG SHEETS

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1.0

1.1

1.2

1.3

1.4

2.0

3.0

3.1
PLANT DETAILS

The Pre-Boiler system consists of Condensate system, Drip
system, Feed water system and Extraction steam lines to
Regenerative Heaters.

Condensate system comprises 3 nos. of Condensate
Extraction Pumps, Low Pressure Heaters, Gland steam cooler,
Drain cooler, Deaerator, connecting pipelines including excess
condensate line upto condensate storage Tank.

Feed water system comprises 1 no. Motor driven and 2 Nos.
Turbo driven Boiler Feed Pumps, their Booster pumps and
recirculation lines, High Pressure Heaters, their connecting
pipelines upto Economizer inlet. RH & SH spray lines are also
included for the purpose of flushing.

Drip system comprises the shell side of all LP and HP Heaters
and the Drip lines.

OBJECTIVE

To remove dirt, oil, grease etc., from the Condensate, Feed
water, Drip and Extraction steam lines of HP & LP Heaters,
using a non-ionic detergent, prior to putting these systems in
regular service. This is to ensure flow of clean condensate
and feed water to the Boiler.

PROPOSAL

Temporary Circulation Pumps (4 nos) each having a capacity

STATUS
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3.2

3.3

3.4

3.4.1
of 200 T/hr at 20 Kg/sq cm shall be used in this activity.
Drawings at pages 13, 14 & 15 provide the layout of
connections between temporary and permanent systems.

Flushing shall be carried out in four separate stages using
fresh detergent in each stage.

The four stages are:

Stage-I: Feed lines
Stage-II: Condensate lines & Drip lines of HP Heaters 5A
& 5B
Stage-III: Extraction steam lines and Drip lines of HP
Heaters
Stage-IV: Extraction steam lines and Drip lines of LP
Heaters
Each system shall be suitably sub-divided into various sub
circuits to cover all the lines and components.

STAGE - I

Sub Stage IA
Mixing Tank - Circulation Pumps - BFP suction lines (of one
BFP at a time) - Booster Pump suction line - Feed Storage
Tank - Recirculation lines - Temporary line - Mixing Tank

Sub Stage IB
Mixing Tank - Circulation Pumps - discharge line of BFP -
Bypass lines of HP Heaters - Feed control station - point near
economizer inlet valve - Mixing Tank

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3.4.2

3.4.3

Sub Stage IC
Mixing Tank - Circulation Pumps - SH Spray & RH Spray lines
- Attemperation station - Mixing Tank

STAGE - II

Sub Stage IIA
Mixing Tank - Circulation Pumps - Condensate discharge line
- Gland Steam Condenser bypass - CPU bypass - Deaerator
level control station - Drain Cooler & LP Heater 1 bypass - LP
Heater 2 bypass - LP Heater 3 bypass upto a point before
Deaerator - Drip line of HP Heater 5A to Deaerator - HP
Heater 5A shell - Alternate drain of HP Heater 5A - Mixing
Tank

Loop from Gland Steam Condenser - excess condensate
return - Mixing Tank is also to be included

Sub Stage IIB
Mixing Tank - Circulation Pumps - condensate discharge line
- Gland Steam Condenser - CPU bypass - Deaerator level
control station - Drain Cooler - LP Heater 1 bypass - LPH 2
bypass - LPH 3 bypass upto a point before Deaerator - Drip
line of HP Heater 5B to Deaerator - HP Heater 5B shell -
Alternate drain of HP Heater 5B - Mixing Tank

STAGE - III

STATUS
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Sub Stage IIIA
Mixing Tank - Circulation Pumps - Extraction line of HP
Heater 5B - HP Heater 5B shell - alternate drip line of HP
Heater 5B - Mixing Tank

Sub Stage IIIB
Heater 5B - HP Heater 5B shell - Drip line between HP
Heaters 5B & 6B - HP Heater 6B shell - Alternate drip line of
HP Heater 6B - Mixing Tank

Sub Stage IIIC
Heater 6B - HP Heater 6B shell - alternate drip line of HP
Heater 6B - Mixing Tank

Sub Stage IIID
Heater 5A - HP Heater 5A shell - alternate drip line of HP
Heater 5A - Mixing Tank
Sub Stage IIIE
Heater 5A - HP Heater 5A shell - Drip line between HP
Heaters 5A & 6A - HP Heater 6A shell - alternate drip line of
HP Heater 6A - Mixing Tank

Sub Stage IIIF
Heater 6A - HP Heater 6A shell - alternate drip line of HP
Heater 6A - Mixing Tank

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3.4.4

3.5

3.5.1

STAGE IV

Sub Stage IVA
Mixing Tank - Circulation Pump - Extraction line of LP Heater
3 - LP Heater 3 shell - alternate drain line of LP Heater 3 -
Mixing Tank

Sub Stage IVB
2 - LP Heater 2 shell - alternate drain line of LP Heater 2 -
Mixing Tank

Sub Stage IVC
3 - LP Heater 3 shell - drain line between LPH 3 and LP
Heater 2 - LP Heater 2 shell - alternate drain line of LP Heater
2 - Mixing Tank

Sub Stage IVD
2 - LP Heater 2 shell - drip line between LP Heater 2 and LP
Heater 1 - LP Heater 1 shell - drip line between LP Heater 1
and Drain Cooler - drip line between Drain cooler and Flash
Tank - Mixing Tank.

In each stage the following activities shall be carried out:

Open circuit Mass Flushing of each sub stage with cold water
for 1 hour or till the effluent is visibly clear, whichever is
later.
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3.5.2

3.5.3

3.5.4

3.5.5

Closed circuit Mass Flushing of each sub stage with cold
water for 1 hour and draining. If the effluent is not visibly
clear this shall be repeated once more.

Closed circuit Mass Flushing of each sub stage with hot water
for 2 hours and draining. If the effluent is not visibly clear
this shall be repeated once more.

Closed circuit Detergent Flushing of each sub stage for 4
hours.
Rinsing of the entire system. Rinsing shall be declared
complete based on analytical results as detailed in the
completion criteria.

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3.5.6

3.6

Passivation of individual circuit for 8 hours.
After successful completion of Detergent flushing the
permanent system shall be isolated from the temporary
system and released for normalization.

STATUS
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4.0

4.1

4.2

4.3

4.4

4.5

4.6

4.7

4.8

SERVICES REQUIRED

Availability of approximately 5000 Tons of DM water for the
entire operation.

Availability of nonionic detergent:

Rinopol - Jet 100% OR Sumisol - N 100%
Estimated quantity - 1000 Litres
Required concentration - 0.05%
Availability of following chemicals for Passivation:

i) Hydrazene Hydrate (minimum 80% concentration) - 800
Kg
(IS: 12086 / 1991)
ii) Liquor Ammonia (minimum 25% concentration) - 400 Kg
(IS: 799 / 1985)

Availability of 4 Nos. of temporary circulation pumps having
200 T/Hr capacity at 20 Kg/sq cm. (Motor rating - 180 KW)

Availability of Temporary Tank of 40m
3
capacity.

Availability of power supply to temporary circulation pumps.

Availability of adequate lighting in all workings areas.

Availability of reliable communication system such as walkie-
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4.9

4.10
talkie sets, telephones etc.

Availability of laboratory facility for analysis of flushing water
etc.

Availability of required manpower.

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5.0

5.1

5.2

5.3

5.4

6.0

6.1

6.2

6.3

SAFETY PRECAUTIONS

Readiness of staircases, platforms, hand-rails, approaches etc
as decided jointly in advance by BHEL and NTPC at site
should be ensured.

First aid kit should be available during the process.

Safety and protection equipments like hand gloves, eye
protection equipments, helmets etc should be available
during the process.

Service water should be made available near the activity
area.

EMERGENCY PROCEDURES

The testing team should be aware of the procedures to be
followed in case of accident involving injury to personnel.

The team conducting the flushing activity should be aware of
the operating procedures of fire extinguishers for quenching
minor fires.

An operator should be posted in the pump area and
instructed that he should trip the circulation pumps in the
event of emergency being notified to him by observers.

STATUS
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7.0

7.1

7.2

7.3

7.4

7.5

7.6

7.7

7.8

7.9
STATE OF THE PLANT

Hydrotest of the entire system to be flushed is declared
complete.

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

Installation of circulation pumps, mixing tank and connected
temporary piping along with pressure gauges is complete.

All HP Heaters safety valves are removed and blanks are
provided with a inch valve for air venting. Temperature
stubs in extraction steam lines for LP Heaters may be used
for venting of LP Heaters. While carrying out the flushing of
shell sides of HP and LP Heaters, care is to be taken for
proper venting of heaters for proper filling.

Safety valves of LP heaters are erected in position. This is
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7.10

7.11

7.12

7.13

7.14

7.15

required to release the pressure in the system, in case the
pressure exceeds the set value during the operation due to
any unforeseen reasons.

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

All the orifices, flow nozzles, control valves and NRV internals
are removed and a check list is prepared. Spool pieces are
provided wherever required.

All the instruments except those required during flushing are
isolated.

All permanent supports are provided for all the pipelines
before starting the flushing.

Temporary Mixing Tank is provided with 2 nos of Level
Indicators.

The bore of the temporary pipelines should preferably be the
same as that used in the permanent system.

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8.0

8.1

8.2

8.3

8.4

8.5

8.6

8.7

8.8

METHOD

Flushing shall be carried out in four stages as detailed in
proposal.

The stage to be flushed is lined up.

The system is filled with DM water by running temporary
circulation pumps and circulation is established.

Cold DM water is circulated in all the sub loops. Continuous
filling, circulation and draining is continued through each sub
stage for one hour or till the effluent becomes visibly clear. .

Closed circuit mass flushing with cold DM water is started and
continued for one hour through each sub stage. The system is
then drained. If the effluent is not visibly clear then this
process is repeated once more.

Steam is admitted into the mixing tank and water
temperature is raised to 60
0
C. Closed circuit hot DM water
circulation is done through each sub stage for two hours and
the system is drained. If the effluent is not visibly clear then
this process is repeated once more.

System is refilled with DM water by running circulation pumps
and circulation is established.

Steam is admitted into the mixing tank and water
temperature is raised to 60
0
C. Rinopol - Jet 100% or Sumisol
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8.9

8.10

8.11

8.12

8.13

8.14

8.15

8.16

8.17
- N 100% is added in mixing tank to achieve the solution
concentration of 0.05%.

The solution is circulated in each of the loops for a minimum
duration of four hours. During circulation make up is given as
per the system requirement and the solution temperature is
kept at 60
0
C.

On completion of detergent circulation in all the loops
continuous make up and draining is carried out in all the
loops one by one for a duration of Fifteen minutes in each
loop.
The system is drained completely and filled again with DM
water.

DM water is circulated in each loop for half an hour once
again.

The system is drained completely.

The system is rinsed with DM water by continuous filling and
draining till the conductivity and oil parameters meet the
values specified in completion criteria.

The system is drained completely.

The system is filled with DM water and circulation is
established. Water temperature is raised to 60
0
C by
admitting steam in the mixing tank.

Hydrazine and Ammonia are added to get 200 ppm Hydrazine
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8.18

8.19

8.19.1

8.19.2

8.19.3

8.19.4

and pH of water between 9.5 and 10.0. Temperature of the
solution is raised to 80
0
C by steam admission in mixing tank.
Circulation is maintained for Eight hours through each sub
stage at this temperature.

The system is completely hot drained. All vent valves and
Feed Storage Tank manholes are opened to aerate the
system.

POST FLUSHING OPERATION

All the temporary connections are removed from the
permanent scheme.

It is checked that all the pipelines and connections are as per
the final scheme.

Deaerator is drained, jointly inspected and cleaned
thoroughly.

After welding of flow nozzles in BFP suction lines, the suction
lines are flushed by draining water from Deaerator for half an
hour through each line. For this purpose temporary pipe
connections are made from suction of each BFP to drain pit.

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9.0

10.0

COMPLETION CRITERIA

DM water rinsing after chemical flushing is considered
complete when conductivity of drained water is less than 10
micro mhos / cm and oil content is NIL.

APPENDICES

LOG SHEET # 1
LOG SHEET # 2
LOG SHEET # 3
LOG SHEET # 4
LOG SHEET # 5

STATU
S

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LOG SHEET # 1
Unit :
Activity: Detergent Flushing of Stage I

S
No.
Activity
Duration
Start
Date /
Time
Finish
Date /
Time
Remarks
1. Open circuit flushing
of sub stage IA with
cold water
1 Hr Flushing is continued
for 1 hour OR till the
effluent is visibly clear
of sub stage IB with
cold water
1 Hr -do-
of sub stage IC with
cold water
1 Hr -do-
4. Closed circuit flushing
cold water
1 Hr -do-
cold water
1 Hr -do-
cold water
1 Hr -do-
7. Complete draining of
the system

8. Refilling of the
System and
establishing

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circulation
9. Raising the water
temperature to 60
0
C

hot water
2 Hrs Flushing is continued
for 2 hours OR till the
hot water
2 Hrs -do-
hot water
2 Hrs -do-
the system

14. Refilling of the
System and
establishing
circulation

temperature to 60
0
C
and addition of
detergent

16. Circulation of
detergent solution in
sub stage IA
4 Hrs
17. Circulation of
sub stage IB
4 Hrs
18. Circulation of
sub stage IC
4 Hrs
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19. Continuous make up
& draining of sub
stage IA
15 min
& draining of sub
stage IB
15 min
& draining of sub
stage IC
15 min
22. Draining the
complete system &
refilling with DM
water

23. Circulation of DM
water in sub stage
IA
1 Hr
water in sub stage
IB
1 Hr
water in sub stage
IC
1 Hr
26. Draining the system
completely

System and
establishing
circulation

28. Rinsing of sub stage
IA with DM water by
continuous filling &
Rinsing is considered
complete when water
conductivity is less
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draining than 10 micro mhos /
cm and oil content is
nil.
IB with DM water by
draining
-do-
IC with DM water by
draining
-do-
31. Draining of the
system

system and
establishing
circulation

33. Raising of water
temp to 60
0
C and
adding Hydrazene &
Ammonia
Hydrazene content
should be 200 ppm
and ammonia is added
to get pH of 9.5 to 10
34. Raising of the
solution temp to
80
0
C and passivation
of sub stage IA
8 Hrs
35. Passivation of sub
stage IB
8 Hrs
stage IC
8 Hrs
37. Hot draining of the
system

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LOG SHEET # 2
Unit :
Activity: Detergent Flushing of Stage II

S
No.
Activity Duration Start
Date /
Time
Finish
Date /
Time
Remarks
of sub stage IIA with
cold water
for 1 hour OR till
effluent is visibly
clear
of sub stage IIB with
cold water
1 Hr -do-
3. Closed circuit
flushing of sub stage
IIA with cold water
1 Hr -do-
4. Closed circuit
IIB with cold water
1 Hr -do-
the system

6. Refilling of the
System and
establishing
circulation

temperature to 60
0
C

8. Closed circuit 2 Hrs Flushing is continued
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IIA with hot water
for 2 hours OR till
effluent is visibly
clear
9. Closed circuit
IIB with hot water
2 Hrs -do-
the system

system and
establishing
circulation

12. Raising water temp
to 60
0
C and addition
of detergent

13. Circulation of
sub stage IIA
4 Hrs
14. Circulation of
sub stage IIB
4 Hrs
& draining of sub
stage IIA
15 min
& draining of sub
stage IIB
15 min
17. Draining of the
complete system &
refilling with DM
water

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water in sub stage
IIA
1 Hr
water in sub stage
IIB
1 Hr
system

System and
establishing
circulation

IIA with DM water by
draining
complete when
water conductivity is
less than 10 micro
mhos / cm and oil
content is nil
IIB with DM water by
draining
-do-
24. Draining of the
system

system and
establishing
circulation

temp to 60
0
C and
addition of
Hydrazene content
should be 200 ppm
and ammonia is
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Hydrazene &
Ammonia
added to get pH of
9.5 to 10
27. Raising the solution
temp to 80
0
C and
passivation of sub
stage IIA
8 Hrs
stage IIB
8 Hrs
system

LOG SHEET # 3
Unit :
Activity: Detergent Flushing of Stage III

S
No.
Activity Durat
ion
Star
t
Dat
e /
Tim
e
Finish
Date /
Time
Remarks
1. Open circuit flushing of
sub stage IIIA with cold
water
sub stage IIIB with cold
water
1 Hr -do-
sub stage IIIC with cold
water
1 Hr -do-
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sub stage IIID with cold
water
1 Hr -do-
sub stage IIIE with cold
water
1 Hr -do-
sub stage IIIF with cold
water
1 Hr -do-
7. Closed circuit flushing of
sub stage IIIA with cold
water
sub stage IIIB with cold
water
1 Hr -do-
sub stage IIIC with cold
water
1 Hr -do-
sub stage IIID with cold
water
1 Hr -do-
sub stage IIIE with cold
water
1 Hr -do-
sub stage IIIF with cold
water
1 Hr -do-
13. Complete draining of the
system

14. Refilling of the System
and establishing

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circulation
temperature to 60
0
C

sub stage IIIA with hot
water
sub stage IIIB with hot
water
2 Hrs -do-
sub stage IIIC with hot
water
2 Hrs -do-
sub stage IIID with hot
water
2 Hrs -do-
sub stage IIIE with hot
water
2 Hrs -do-
sub stage IIIF with hot
water
2 Hrs -do-
22. Complete draining of the
system

23. Refilling of the System
and establishing
circulation

temperature to 60
0
C and
addition of detergent

25. Circulation of detergent
solution in sub stage IIIA
4 Hrs
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solution in sub stage IIIB
4 Hrs
solution in sub stage IIIC
4 Hrs
solution in sub stage IIID
4 Hrs
solution in sub stage IIIE
4 Hrs
solution in sub stage IIIF
4 Hrs
31. Continuous make up &
draining of sub stage
IIIA
15
min

IIIB
15
min

IIIC
15
min

IIID
15
min

IIIE
15
min

draining of sub stage IIIF
15
min

37. Draining of complete
system & refilling with
DM water

38. Circulation of DM water 1 Hr
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in sub stage IIIA
39. Circulation of DM water
in sub stage IIIB
1 Hr
in sub stage IIIC
1 Hr
in sub stage IIID
1 Hr
in sub stage IIIE
1 Hr
in sub stage IIIF
1 Hr
system

45. Refilling of the system
and establishing
circulation

IIIA with DM water by
draining
complete when
than 10 micro mho/
nil
IIIB with DM water by
draining
-do-
IIIC with DM water by
draining
-do-
49. Rinsing of sub stage -do-
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IIID with DM water by
draining
50. Rinsing of sub stage IIIE
with DM water by
draining
-do-
51. Rinsing of sub stage IIIF
with DM water by
draining
-do-
52. Draining of the system
53. Refilling the system and
establishing circulation

54. Raising of water temp to
60
0
C and adding
Hydrazene & Ammonia
Hydrazene content
should be 200 ppm
and ammonia is
added to get pH of
9.5 to 10
55. Raising of solution
temp to 80
0
C and
passivation of sub
stage IIIA
8 Hrs
stage IIIB
8 Hrs
stage IIIC
8 Hrs
stage IIID
8 Hrs
stage IIIE
8 Hrs
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Page 31of 35
stage IIIF
8 Hrs
system

LOG SHEET # 4

Unit :
Activity: Detergent Flushing of Stage IV

S
No.
Activity Duration Start
Date /
Time
Finish
Date /
Time
Remarks
of sub stage IVA
with cold water
of sub stage IVB
with cold water
1 Hr -do-
of sub stage IVC
with cold water
1 Hr -do-
of sub stage IVD
with cold water
1 Hr -do-
5. Closed circuit
IVA with cold water
6. Closed circuit
IVB with cold water
1 Hr -do-
Station: NTPC-
VINDHYACHAL-ST-III
NTPC Ref No:
Plant area:

Document- Type

Signatures

BHEL

NTPC

Page 32of 35
7. Closed circuit
IVC with cold water
1 Hr -do-
8. Closed circuit
IVD with cold water
1 Hr -do-
the system

System and
establishing
circulation

temperature to 60
0
C

12. Closed circuit
IVA with hot water
13. Closed circuit
IVB with hot water
2 Hrs -do-
14. Closed circuit
IVC with hot water
2 Hrs -do-
15. Closed circuit
IVD with hot water
2 Hrs -do-
the system

system and
establishing

Station: NTPC-
VINDHYACHAL-ST-III
NTPC Ref No:
Plant area:

Document- Type

Signatures

BHEL

NTPC

Page 33of 35
circulation
temp to 60
0
C and
addition of detergent

19. Circulation of the
sub stage IVA
4 Hrs
20. Circulation the
sub stage IVB
4 Hrs
21. Circulation the
sub stage IVC
4 Hrs
22. Circulation the
sub stage IVD
4 Hrs
& draining of sub
stage IVA
15 min
& draining of sub
stage IVB
15 min
& draining of sub
stage IVC
15 min
& draining of sub
stage IVD
15 min
27. Draining of the
complete system &
refilling with DM

Station: NTPC-
VINDHYACHAL-ST-III
NTPC Ref No:
Plant area:

Document- Type

Signatures

BHEL

NTPC

Page 34of 35
water
water in sub stage
IVA
1 Hr
water in sub stage
IVB
1 Hr
water in sub stage
IVC
1 Hr
water in sub stage
IVD
1 Hr
the system

IVA with DM water
by continuous filling
& draining
complete when water
than 10 micro mhos /
nil
IVB with DM water
& draining
-do-
IVC with DM water
& draining
-do-
IVD with DM water
-do-
Station: NTPC-
VINDHYACHAL-ST-III
NTPC Ref No:
Plant area:

Document- Type

Signatures

BHEL

NTPC

Page 35of 35
& draining
37. Draining of the
system

38. Refilling the system
with DM water and
establishing
circulation

temp to 60
0
C and
addition of
Hydrazene &
Ammonia
Hydrazene content
should be 200 ppm
and ammonia is
added to get pH of
9.5 to 10
40. Raising the solution
temp to 80
0
C and
passivation of sub
stage IVA
8 Hrs
stage IVB
8 Hrs
stage IVC
8 Hrs
stage IVD
8 Hrs
system

LOG SHEET # 5

Station: NTPC-
VINDHYACHAL-ST-III
NTPC Ref No:
Plant area:

Document- Type

Signatures

BHEL

NTPC

Page 36of 35
Details of Chemicals used during the process

Unit :

S
No.
System Activity Name of
Chemical
used
Quantity
1. Feed water

2. Condensate

3. Ex steam lines & Drip
lines of HP Heaters

4. Ex steam lines & Drip
lines of LP Heaters

Remarks:

Detergent Flushing

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Detergent Flushing

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Station: NTPC-

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