FRF Flushing

8/18/2019 FRF Flushing

1/13

Station: NTPC-Ramagundam

BHEL Ref No. PS-DC-202-500-0004ANTPC Ref no. C S-C !!-R-Commg-PR "0#2 S$eet # of #4

P%ant a&ea: T'RB(NEPR CED'RE ) R )L'SH(N* ) T* C NTR L (L S+STE! ,)R) )L'SH(N*

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2.0

.0

4.0

5.0

/.0

.0

1.0

.0

#0.0

PLANT DETA(LS

B3ECT( E

PR P SAL

SER (CES RE '(RED

SA)ET+ PRECA'T( NS

E!ER*ENC+ PR CED'RE

STATE ) THE PLANT

!ETH D

C !PLET( N CR(TER(A

APPEND(CES

DRA6(N*

L * SHEET


2/13


BHEL Ref No. PS-DC-202-500-0004ANTPC Ref no. C S-C !!-R-Commg-PR "0#2 S$eet 2 of #4


#.0

1.0.1

1.0.2

1.0.3

1.0.4

1.0.5

1.1

1.2

PLANT DETA(LS

In 500 MW Units Fire Resistant Fluid (FRF) is used for the control systeand !" #y$ass syste ainly to a%oid fire accidents in case of lea&a'e of

or&in' fluid o%er $arts at hi'h te $eratures. his syste consists of thefollo in'*

Cont&o% )%uid Tan7 ,C)T

he an& contains the FRF and the $u $s are ounted inside the tan&.

Pum89

hese are eant to circulate the fluid throu'h the syste at re+uired $ressureand flo .

a8ou& )an9

hese are used to e,haust the %a$our fro the syste .

)i%te&9

Filters are used to arrest the solid $articles enterin' into the syste . -ne of the filters is &e$t in since hile the other is stand y.

)i&e Re9i9tant )%uid Coo%e&9

hese are eant for aintainin' the te $erature of FRF.

he fluid circulated in the syste is di%ided for different $ur$oses such as/ontrol fluid econdary fluid ri$ fluid and tart u$ fluid.

/hec& %al%es such as e,traction %al%e and /R s in' chec& %al%es areo$erated y FRF.

STAT'S

Signatu&e9

NTPC BHEL


3/13


BHEL Ref No. PS-DC-202-500-0004ANTPC Ref no. C S-C !!-R-Commg-PR "0#2 S$eet of #4

P%ant a&ea: T'RB(NE

PR CED'RE ) R )L'SH(N* ) T* C NTR L (L S+STE! ,)R) )L'SH(N*

2.0

.0

3.1

3.2

3.3

3.4

3.5

3.

3.

B3ECT( E

o flush the /ontrol Fluid syste to re o%e echanical i $urities fro thesyste .

PR P SAL

Flushin' shall e carried out usin' the nor al o$eratin' Fire Resistant Fluidreco ended in the - M anual. he +uantity of FRF re+uired for

flushin' shall e 15 6! hich is a$$ro,i ately 507 of the nor al +uantity.her al shoc&s shall e 'i%en to the syste y a&in' sudden chan'es in

the fluid te $erature fro 0 8 5 0/ to 35 8 40 0/ to a&e the flushin'effecti%e. Ra$$in' of the fluid lines shall e carried out durin' ther alshoc&s s$ecially at eld 9oints.

:o additional heatin' arran'e ent shall e re+uired as the fire resistant fluid'ets heated u$ durin' runnin' of the control fluid $u $ itself and y &ee$in'the tan& heaters -:. ;o%ernin' rac& to$ and /ontrol %al%es


4/13

NTPC BHELStation: NTPC-

Ramagundam

BHEL Ref No. PS-DC-202-500-0004ANTPC Ref no. C S-C !!-R-Commg-PR "0#2 S$eet 4 of #4

P%ant a&ea: T'RB(NE

PR CED'RE ) R )L'SH(N* ) T* C NTR L (L S+STE! ,)R) )L'SH(N*

4.0

4.1

4.2

4.3

4.4

4.5

4.

4.

4.>

5.0

5.1

5.2

5.3

5.4

5.5

5.

5.

SER (CES RE '(RED

?%aila ility of re+uired +uantity of FRF.

?%aila ility of sufficient s&illed an$o er for su$er%ision @ e,ecution of the $rocess.

?%aila ility of la oratory facilities for analysis of FRF sa $les.

?%aila ility of ser%ice air for filter cleanin'. ?%aila ility of $ro$er li'htin' arran'e ent.

?%aila ility of co unication facility.

?%aila ility of $orta le fire e,tin'uishers.

?%aila ility of $ressuri=in' $u $.

SA)ET+ PRECA'T( NS

First aid &it should e readily a%aila le.

?de+uate li'htin' should e a%aila le near /F and in flushin' area.

Fire fi'htin' e+ui$ ent @ syste s should e ready for use.

?rea of flushin' should ha%e easy and free access.

$illa'e lea&a'e and conta ination of FRF should e a%oided.

Weldin' @ 'as cuttin' should not e carried out in flushin' area.

!oad on fluid $u $s should not e,ceed full load current of the otor.

STAT'S

Signatu&e9


5/13


6/13


BHEL Ref No. PS-DC-202-500-0004ANTPC Ref no. C S-C !!-R-Commg-PR "0#2 S$eet / of #4


.

.>

.A

.10

.11

1.0

1.#

>.1.1

>.1.2

>.1.3

>.1.4

>.1.5

Ba$our e,traction syste alon' ith %a$our e,traction fans is a%aila le for o$eration.

?ll the filter ele ents in the syste other than the tan& filters are re o%ed efore initial flushin'.

:ecessary y$assin' as $er sche e has een carried out and the correctnessof loo$in's chec&ed.

he e+ui$ ent roo the %al%e roo and the oil channels are $ainted iths$ecial $aint as $er su$$liers reco endations.

?ll the drain %al%es of the syste are closed.

!ETH D

)R) )i%%ing

FRF is filled in the /F (/ontrolled Fluid an&) $refera ly throu'h theRe'enerati%e $u $s. Fillin' can also e done fro the /F to$ throu'h tan& filters.

he o$eration of fluid tan& le%el indicator is chec&ed durin' fluid fillin'.!e%el is closely onitored to a%oid any o%erflo .

Re'enerati%e syste of FRF is run continuously ith tan& heaters -:. Itsechanical filters are cleaned inter ittently to re o%e the slud'e collected.

/F filters are cleaned as and hen re+uired.

?ll the safety $recautions of FRF are strictly follo ed durin' fillin'flushin' and handlin' of FRF.

STAT'S

Signatu&e9


7/13

NTPC BHEL




1.2

>.2.1

>.2.2

>.2.3

>.2.4

>.2.5

>.2.

>.2.

>.2.A

>.2.10

)R) )%u9$ing

yste is lined u$ for flushin' as $er sche e.

he !" (> ar) and " (32 ar) control fluid syste s are flushed to'ether.

Cirection of rotation of oth FRF $u $s is chec&ed ith short start @ sto$co and. he trial run of the $u $s is ta&en u$ alon' ith flushin'

$rocess.

Flushin' is started y runnin' FRF $u $s for short duration and syste ischec&ed for lea&a'es and attended.

FRF $u $s are ta&en in ser%ice for further flushin' after attendin' all thelea&a'es. Re'enerati%e $u $s are run continuously ith tan& heaters -: to

aintain +uality of FRF durin' flushin' $rocess.

/are is ta&en that FRF $u $ load is li ited to full load current of the otor.If re+uired oth $u $s are run.

Flushin' of control fluid syste is carried out y di%idin' the syste in 4 to5 circuits to achie%e a,i u %elocity throu'h the $i$elines. his alsoli its fluid $u $ otor current. his is suita ly decided at site.

Initially /ontrol fluid an& filters are ins$ected once e%ery > hours andcleaned. hereafter fre+uency is 'radually chan'ed to once a day de$endin'u$on the filter condition.

he te $erature of control fluid after heatin' should e et een 0 to 5 0/.?fter flushin' for 283 hours at this te $erature the te $erature is reduced to

ini u $ossi le y o$enin' the ater outlet. his $rocess of ther alshoc& is re$eated se%eral ti es. Ra$$in' of fluid lines is carried out durin'ther al shoc&s.

STAT'S


8/13

Signatu&e9

NTPC BHEL

Station: NTPC-

Ramagundam

BHEL Ref No. PS-DC-202-500-0004A

NTPC Ref no. C S-C !!-R-Commg-PR "0#2 S$eet 1 of #4


>.2.11

>.2.12

>.2.13

1.

>.3.1

>.3.1.1

>.3.2

>.3.2.1

>.3.2.2

>.3.2.3

>.3.2.4

?fter all the circuits ha%e een flushed and fluid tan& strainer re ains cleanfor 24 ours all the filter ele ents in the syste re o%ed efore initialflushin' are $ut ac& for final flushin'.

Curin' flushin' one sa $le a day ust e analysed.

Flushin' is declared co $leted as $er co $letion criteria.

H d&au%i; Te9ting of Line9

*ene&a%

ydraulic test of %arious lines shall e carried out as $er details 'i%en elo *

. :o. yste tandard "ressure est "ressure Curation

1. "ressure Fluid > ar 20 ar 10 in

( ithout rac&)2. " /ontrol Fluid 32 ar A ar 10 in ( ithout filter ele ents) P&e8a&ation

#lan& flan'es are installed and %al%es closed here%er the su syste isconnected to drain as $er flushin' sche e.

est 'au'es are $ro%ided as $er test $ressure re+uire ent.


9/13

Signatu&e9

NTPC BHELStation: NTPC-

Ramagund

am



>.3.2.5

>.3.2.

>.3.2.

>.3.2.>

>.3.3

>.3.3.1

>.3.3.2

>.3.3.3

>.3.3.4

>.3.3.5

>.3.3.

Bentin' arran'e ents $ro%ided at lind ends ith %al%es. !ocation of %ent%al%es is decided at site as $er site lay out.

> ar syste is $ressurised y feedin' 32 ar fluid throu'h a te $oraryconnection $ro%ided for this $ur$ose.

?II du$le, filter ele ents are re o%ed efore hydraulic testin'.

32 ar syste is tested y installin' a se$arate $ressurisin' $u $.

Te9t P&o;edu&e

/ontrol fluid $u $ is run and syste filled.

Bentin' of total syste is carried out.

"ressure of > ar syste is raised to 20 ar y feedin' 32 ar fluid throu'hthe te $orary connection $ro%ided. yste is chec&ed for lea&a'es for 10

inutes.

/ontrol fluid $u $ is sto$$ed.

> ar $ressure fluid syste is isolated. "ressure is raised to A ar in 32 "control fluid syste and is held for 10 inutes. yste is chec&ed for lea&a'es.

If lea&a'es are o ser%ed syste is de$ressuri=ed lea&a'es attended andhydraulic test is re$eated.

STAT'S


10/13

Signatu&e9

NTPC BHEL

Station: NTPC-

Ramagundam

BHEL Ref No. PS-DC-202-500-0004A

NTPC Ref no. C S-C !!-R-Commg-PR "0#2 S$eet #0 of #4


1.4

>.4.1

>.4.2

>.4.3

>.4.4

>.4.5

>.4.

.0A.1

A.2

A.3

A.4

No&ma%i9ation

/ontrol fluid is drained fro the total syste is drained in #arrels.

/ontrol fluid tan& is cleaned and ins$ected.

/ontrol fluid coolers are cleaned and ins$ected.

?ll the $ro%isional arran'e ents ade in the syste for flushin' hydraulic testin' are re o%ed and syste nor alised.

he drained control fluid is refilled after the tan& is a solutely clean. Fluid isfilled throu'h the re'enerati%e syste only.

Re+uired +uantity of /ontrol fluid is &e$t filled in the tan& and le%eleasured and recorded.

C !PLET( N CR(TER(AFRF sa $les are collected at Re'enerati%e $u $s inlet ( ith "u $ ino$eration) and analysed at re'ular inter%al $refera ly once a day for Mechanical i $urities Water content ?cid content.

a. Mechanical i $urities !ess than 0.057 y ei'ht . Water content !ess than 0.17 y ei'htc. ?cid content !ess than 0.1 ' 6- @'

/ontrol fluid an& filter re ains clean after 24 hours of flushin'.

?ll du$le, filters re ain clean after 12 hours of flushin'.

If the a o%e are et then the sa $le is sent to R C la at :-IC? or anyother a$$ro%ed la for further analysis.

STAT'S


11/13

Signatu&e9

NTPC BHEL


BHEL Ref No. PS-DC-202-500-0004ANTPC Ref no. C S-C !!-R-Commg-PR "0#2 S$eet ## of #4


A.5 /ontrol syste flushin' is declared co $lete ased on the follo in'*

a. "article count in the fluid sa $le should e as $er :? 1 3> /lass . edi ents should not e ore than 5 ' @ 100 l of fluid.c. $ecific resistance chec&ed as $er I


12/13

Signatu&e9

NTPC BHEL


BHEL Ref No. PS-DC-202-500-0004ANTPC Ref no. C S-C !!-R-Commg-PR "0#2 S$eet #4 of #4


L * SHEET

. :o. "u $in

ser%ice

"u $Cischar'e $ressure

/ontrol fluidte $erature

. :o. of ther alshoc&

Re ar&s

#eforecooler

?ftercooler


13/13

Signatu&e9

NTPC BHEL

FRF Flushing

Documents

Transcript of FRF Flushing