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$eet # of #4
P%ant a&ea: T'RB(NEPR CED'RE ) R )L'SH(N* ) T* C NTR L (L S+STE! ,)R) )L'SH(N*
#.0
2.0
.0
4.0
5.0
/.0
.0
1.0
.0
#0.0
PLANT DETA(LS
B3ECT( E
PR P SAL
SER (CES RE '(RED
SA)ET+ PRECA'T( NS
E!ER*ENC+ PR CED'RE
STATE ) THE PLANT
!ETH D
C !PLET( N CR(TER(A
APPEND(CES
DRA6(N*
L * SHEET
8/18/2019 FRF Flushing
2/13
Station: NTPC-Ramagundam
BHEL Ref No. PS-DC-202-500-0004ANTPC Ref no. C S-C !!-R-Commg-PR "0#2 S$eet 2 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*
#.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$erated y FRF.
STAT'S
Signatu&e9
NTPC BHEL
8/18/2019 FRF Flushing
3/13
Station: NTPC-Ramagundam
BHEL Ref No. PS-DC-202-500-0004ANTPC Ref no. C S-C !!-R-Commg-PR "0#2 S$eet of #4
P%ant a&ea: T'RB(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
8/18/2019 FRF Flushing
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 $s should not e,ceed full load current of the otor.
STAT'S
Signatu&e9
8/18/2019 FRF Flushing
5/13
8/18/2019 FRF Flushing
6/13
Station: NTPC-Ramagundam
BHEL Ref No. PS-DC-202-500-0004ANTPC Ref no. C S-C !!-R-Commg-PR "0#2 S$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*
.
.>
.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
8/18/2019 FRF Flushing
7/13
NTPC BHEL
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*
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
8/18/2019 FRF Flushing
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
P%ant a&ea: T'RB(NEPR CED'RE ) R )L'SH(N* ) T* C NTR L (L S+STE! ,)R) )L'SH(N*
>.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 $ressure re+uire ent.
8/18/2019 FRF Flushing
9/13
Signatu&e9
NTPC BHELStation: NTPC-
Ramagund
am
BHEL Ref No. PS-DC-202-500-0004ANTPC Ref no. C S-C !!-R-Commg-PR "0#2 S$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*
>.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$$ed.
> ar $ressure fluid syste is isolated. "ressure is raised to A ar in 32 "control fluid syste and is held for 10 inutes. yste is chec&ed for lea&a'es.
If lea&a'es are o ser%ed syste is de$ressuri=ed lea&a'es attended andhydraulic test is re$eated.
STAT'S
8/18/2019 FRF Flushing
10/13
Signatu&e9
NTPC BHEL
Station: NTPC-
Ramagundam
BHEL Ref No. PS-DC-202-500-0004A
NTPC Ref no. C S-C !!-R-Commg-PR "0#2 S$eet #0 of #4
P%ant a&ea: T'RB(NEPR CED'RE ) R )L'SH(N* ) T* C NTR L (L S+STE! ,)R) )L'SH(N*
1.4
>.4.1
>.4.2
>.4.3
>.4.4
>.4.5
>.4.
.0A.1
A.2
A.3
A.4
No&ma%i9ation
/ontrol fluid is drained fro the total syste is drained in #arrels.
/ontrol fluid tan& is cleaned and ins$ected.
/ontrol fluid coolers are cleaned and ins$ected.
?ll the $ro%isional arran'e ents ade in the syste for flushin' hydraulic testin' are re o%ed and syste nor alised.
he drained control fluid is refilled after the tan& is a solutely clean. Fluid isfilled throu'h the re'enerati%e syste only.
Re+uired +uantity of /ontrol fluid is &e$t filled in the tan& and le%eleasured and recorded.
C !PLET( N CR(TER(AFRF sa $les are collected at Re'enerati%e $u $s inlet ( ith "u $ ino$eration) and analysed at re'ular inter%al $refera ly once a day for Mechanical i $urities Water content ?cid content.
a. Mechanical i $urities !ess than 0.057 y ei'ht . Water content !ess than 0.17 y ei'htc. ?cid content !ess than 0.1 ' 6- @'
/ontrol fluid an& filter re ains clean after 24 hours of flushin'.
?ll du$le, filters re ain clean after 12 hours of flushin'.
If the a o%e are et then the sa $le is sent to R C la at :-IC? or anyother a$$ro%ed la for further analysis.
STAT'S
8/18/2019 FRF Flushing
11/13
Signatu&e9
NTPC BHEL
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*
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 $er I
8/18/2019 FRF Flushing
12/13
Signatu&e9
NTPC BHEL
Station: NTPC-Ramagundam
BHEL Ref No. PS-DC-202-500-0004ANTPC Ref no. C S-C !!-R-Commg-PR "0#2 S$eet #4 of #4
P%ant a&ea: T'RB(NEPR CED'RE ) R )L'SH(N* ) T* C NTR L (L S+STE! ,)R) )L'SH(N*
L * SHEET
. :o. "u $in
ser%ice
"u $Cischar'e $ressure
/ontrol fluidte $erature
. :o. of ther alshoc&
Re ar&s
#eforecooler
?ftercooler
8/18/2019 FRF Flushing
13/13
Signatu&e9
NTPC BHEL