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Friday, 17 April 2015

BOILER FEED PUMP ERECTION AND COMMISSIONING PART-V ABC OF THERMAL POWER PLANT

Oil pipelines are reassembled after acid cleaning is over.

Oil tank and duplex filters are clean.

Oil tank is filled to the required level with recommended oil. Oil should be filled through filter

/centrifuge. Oils of different quality / make should never be mixed. Follow OEM

Recommendation.

Oil pipelines are disconnected from the bearings. The bearings are bypassed by temporarily

interconnecting the inlet and outlet lines of bearings using temporary loops.

Oil lines are properly supported and all temporary supports are cut and removed.

Temporary line filter of stainless steel mesh is provided in the return line before entry to the tank to

avoid entry of dirt into MOT of Hydraulic coupling.

Working oil lines to working oil coolers disconnected at hydraulic coupling end and temporary loops

made as shown in the flushing scheme.

Temporary connections, preferably of transparent hose which can withstand temperature as high as

800 C, are made across the bearings.

Portable centrifuge / electrostatic filtration unit is connected to the MOT of the Hydraulic coupling.


Suction of the unit is connected to the drain of MOT of Hydraulic coupling through suitable hose and  the 

discharge is left inside the Hydraulic Coupling tank through inspection cover.

Required instruments such as pressure and temperature gauges are calibrated and mounted in the

system.

Temperature of 65-750C to be reached during oil flushing through centrifuge heaters.

With MOT of Hydraulic tank already filled with recommended oil, AOP is bump started to check the

direction of rotation of the pump.

After ensuring correct direction of rotation the AOP is run continuously and the system is filled

gradually.

Oil level in the tank is watched till oil flow is established throughout the system. Oil is topped up, if

required.

The system is checked for oil leakages and the leakages, if any, are attended.

Temperature of oil is raised to 65-70 deg Celsius by using the heaters of centrifuge or by external

heaters.

After attaining the elevated oil temperature, heater is switched off and cooling water is admitted in

the cooler to suddenly bring down the oil temperature to get an effect of thermal shock. Oil pipelines

are also tapped with wooden hammers during the period of thermal shock.

Oil temperature is again raised and thermal shock is given. Thermal shocks are repeated till oil

flushing is declared complete as per completion criteria.

The working oil and lub oil circuits are flushed separately by making suitable temporary connections.

Flushing of lub oil circuit is done in sub stages by grouping lines of two to three bearings ( to be

decided at site ) by suitable isolation of lub oil supply lines to other bearings to have adequate

velocity in the pipelines for effective flushing .

The filters are cleaned whenever there is an increase in differential pressure across the filter beyond

0.5 kg/cm2 over the normal value. 

Periodicity of oil sampling and filter inspection is mutually decided at site.

Oil flushing of oil lines bypassing the bearings is declared complete based on completion criteria.

Hydraulic test of the pipelines is carried out at a pressure 1.5 times the working pressure with the

help of an external pump or the AOP itself. There should be NO leakage.

Temporary bypass connections / blanks / dummies / are removed and the pipeline connections with

the bearings are normalized.

Flushing of lub oil circuit with bearings included in the flushing circuit is started.

Flushing through bearings is declared complete based on completion criteria.

The oil used for flushing is drained and kept in safe custody. This oil can be used for flushing in

other units if the oil quality is found suitable. While using this used oil for flushing in other units,

filling should be done through centrifuge.

All the bearings are inspected and cleaned.

Fresh oil is filled in the system. Oil pump is run, flow through each bearing adjusted and flow of

return oil through each bearing ensured.

COMPLETION CRITERIA

The flushed components are considered clean when the DP across the filter stabilizes and does

not rise more than 0.2 to 0.3 ksc over the normal value after eight hours of continuous flushing.

Also there should be NO deposition of hard particles in oil filters.

Mechanical impurities ( through 0.45 micron filter ) and moisture content in the sample collected

from flushing oil should be each less than 100 ppm in three consecutive samples taken at

intervals of four hours.

Continued to last part BFP commissioning



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