Station: NTPC

BHEL Ref No. PS - DC - 202 - 500 - 13 A

Sheet 1 of 10
Ramagundam
NTPC Ref No. COS-COMM -R-Commg-PRO/002
Plant Area: BOILER
OIL FLUSHING & HYDROTEST OF LUB OIL SYSTEM OF ROTATING EQUIPMENT
LIST OF CONTENTS
1.0

PLANT DETAILS

2.0

OBJECTIVE

3.0

PROPOSALS

4.0

SERVICES REQUIRED

5.0

SAFETY PRECAUTIONS

6.0

EMERGENCY PROCEDURES

7.0

STATE OF THE PLANT

8.0

METHOD

9.0

COMPLETION CRITERIA

10.0

APPENDICES
Lub Oil Specifications
Drawing
Log sheet

Signatures
NTPC

BHEL

Station: NTPC
BHEL Ref No. PS - DC - 202 - 500 - 13 A
Sheet 2 of 10
Ramagundam
NTPC Ref No. COS-COMM -R-Commg-PRO/002
Plant Area: BOILER
OIL FLUSHING & HYDROTEST OF LUB OIL SYSTEM OF ROTATING EQUIPMENT
STATUS
1.0
PLANT DETAILS
All rotating equipment like Fans, Air preheaters etc are provided with
external lub oil system for supplying necessary lubrication to the bearings.
This lub oil also serves as a coolant for equipment bearings.
The external lubricating oil system generally consists of the lub oil tank,
lub oil pumps, suction strainers, duplex filters, oil coolers, connecting
pipelines from lub oil tank to bearings through oil pumps and back to tank.
This system also consists of local gauges and switches. This plant is
located near the main equipment.
2.0

OBJECTIVE
To thoroughly clean the lub oil system by removing dirt and other foreign
materials before pressing the lub oil system in regular service so that dirt
and foreign material do not enter the bearings.

3.0

PROPOSALS

3.1

The pipelines shall be dissembled from flange joints.

3.2

Each pipeline piece shall be acid cleaned by soaking method.

3.3

After neutralization and passivation of each pipeline the pipelines shall be

reassembled for oil flushing.

3.4

Oil flushing shall be done in two stages.

3.4.1

Stage I - Bearings shall be kept bypassed by interconnecting the inlet and

outlet lines using temporary loop.

3.4.2

Stage II Bearings shall also be included in the flushing circuit.

3.4.3

In case of AP fans, for flushing of servomotor oil lines, oil supply line shall
be looped with return line and then with leak off line using temporary hose.

Signatures
NTPC

BHEL

Station: NTPC
BHEL Ref No. PS - DC - 202 - 500 - 13 A
Sheet 3 of 10
Ramagundam
NTPC Ref No. COS-COMM -R-Commg-PRO/002
Plant Area: BOILER
OIL FLUSHING & HYDROTEST OF LUB OIL SYSTEM OF ROTATING EQUIPMENT
STATUS
Note : For lub oil system of equipment such as Air Preheater where use of
high viscosity oil is recommended for regular operation, low viscosity oil
may be used for carrying out oil flushing. Flushing shall be declared
complete based on the completion criteria. After completion of oil flushing
the oil shall be drained. Recommended oil shall then be filled in the system
and flushing done for 3-4 hours covering all the components and bearings.
Oil shall be drained again and recommended oil filled in the system for
regular operation.
4.0

SERVICES REQUIRED

4.1

Availability of DM water and service water.

4.2

Availability of following chemicals for each lub oil system

i.
ii.
iii.
iv.
v.

Hydrochloric acid 30 %
Rodine 213 SPL
Sodium Nitrite
Liqour Ammonia 25%
Lime powder

IS : 265 - 1993
IS : 799 1990
IS : 1540 1990 (part-II)

Note : Quantities of the above chemicals are to be worked out at site.

4.3

Availability of required number of wooden plugs.

4.4

Availability of service air.

4.5

Availability of required grade and quantity of lub oil and flushing oil.

4.6

Availability of LT power supply.

4.7

Availability of Laboratory service for conducting efficiency test and for

testing oil for mechanical impurities and moisture content.

4.8

Availability of adequate lighting and telephone facility in lub oil flushing

area.

Signatures
NTPC

BHEL

Station: NTPC
BHEL Ref No. PS - DC - 202 - 500 - 13 A
Sheet 4 of 10
Ramagundam
NTPC Ref No. COS-COMM -R-Commg-PRO/002
Plant Area: BOILER
OIL FLUSHING & HYDROTEST OF LUB OIL SYSTEM OF ROTATING EQUIPMENT
STATUS
4.9
Availability of adequate manpower with tools and consumables like cloth,
kerosene etc.
4.10

Availability of calibrated pressure gauges and DP gauges.

5.0

SAFETY PRECAUTIONS

5.1

Availability of First Aid Box containing dilute Ammonium Hydroxide,

50% Sodium Bicarbonate solution, Eye lotion, Bandage, Tincture iodine,
Cotton, Burnol etc should be ensured.

5.2

Availability of portable fire extinguishers should be ensured.

5.3

Availability of the following should be ensured:

i. Gum Boots
3 pairs
ii. Rubber gloves
5 pairs
iii. Apron
3 nos
iv. Transparent face Mask
3 nos

5.4

Availability of running service water near the activity area is ensured.

5.5

Suitable and safe place for draining and neutralization of used chemicals
should be kept identified.

6.0

EMERGENCY PROCEDURES

6.1

The team members should be aware of the procedures to be followed in

case of accidents causing injury to personnel.

6.2

The team members should be aware of the Fire extinguishers operating

procedures.

7.0

STATE OF THE PLANT

7.1

ACID CLEANING

7.1.1
Signatures
NTPC

Lub oil system and its oil lines are erected fully as per approved drawing.

BHEL
Station: NTPC
BHEL Ref No. PS DC 202 500 13 A
Sheet 5 of 10
Ramagundam
NTPC Ref No. COS-COMM R-Commg-PRO/002
Plant Area: BOILER
OIL FLUSHING & HYDROTEST OF LUB OIL SYSTEM OF ROTATING EQUIPMENT
STATUS
7.1.2
Hydraulic test of oil coolers is successfully completed at a pressure 1.5
times the designed pressure.
7.1.3

7.2

Lub oil lines are then dismantled and one end of each pipe is blocked by
wooden plug. Tight fitting of the wooden plug is ensured so that no
leakage of chemicals occurs during acid cleaning process.
OIL FLUSHING

7.2.1

Oil pipelines are assembled after acid cleaning is over.

7.2.2

Oil tank and oil filters are clean.

7.2.3

Oil pipelines are disconnected from the bearings. The bearings are
bypassed by temporarily interconnecting inlet and outlet lines of bearings.

7.2.4

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

7.2.5

In case of AP Fans supply and return lines are temporarily connected

using servomotor hoses.

7.2.6

After declaration of completion of flushing through the servomotor supply

and return line based on the completion criteria stated in clause 9.0, the
supply line is connected to leak off line through temporary hose for
further flushing.

8.0

METHOD

8.1

ACID CLEANING

8.1.1

The dissembled pipeline pieces are filled with DM water and flushed few
times. It is ensured that there is no leakage through the wooden plug
provided at one end of the pipe.

Signatures
NTPC

BHEL

Station: NTPC
BHEL Ref No. PS - DC - 202 - 500 - 13 A
Sheet 6 of 10
Ramagundam
NTPC Ref No. COS-COMM -R-Commg-PRO/002
Plant Area: BOILER
OIL FLUSHING & HYDROTEST OF LUB OIL SYSTEM OF ROTATING EQUIPMENT
STATUS
8.1.2
5% Hydrochloric acid with 0.2% inhibitor (Rodine 213 SPL) is filled in
the pipes. Efficiency test of the inhibitor is done prior to its use as per
NACE procedure.
8.1.3

The solution is allowed to soak in the pipes for 4 (four) hours and then
drained in a safe place and neutralized. This is then disposed of with
plenty of service water.

8.1.4

The pipes are flushed with DM water for 5 to 10 minutes.

8.1.5

The pipes are again filled with 2.0% Sodium Nitrite 5.0% liquor ammonia
solution. The solution is allowed to soak for 30 minutes and then drained.

8.1.6

The pipe is rinsed with DM water till pH is 7.5 (approximately).

8.1.7

The internal surface of the pipes is dried with dry compressed air.

8.1.8

The lines are filled with lub oil and uniform oil film is achieved through
out the internal surface of the pipe.

8.2
8.2.1

OIL FLUSHING
Stage I

8.2.1.1

The oil tank is filled with recommended oil (or flushing oil).

8.2.1.2

Direction of rotation of both lub oil pumps is checked.

8.2.1.3

After ensuring correct direction of rotation for both the pumps, one of the
pumps is kept in service with recirculation valve in open condition.

8.2.1.4

An oil pressure of 6-8 kg/cm2 is maintained in servomotor supply line.

8.2.1.5

Pressure in the lub oil lines is brought to 1.0 to 1.5 kg/cm 2 by throttling
the recirculation valve.

Signatures
NTPC

BHEL

Station: NTPC
BHEL Ref No. PS - DC - 202 - 500 - 13 A
Sheet 7 of 10
Ramagundam
NTPC Ref No. COS-COMM -R-Commg-PRO/002
Plant Area: BOILER
OIL FLUSHING & HYDROTEST OF LUB OIL SYSTEM OF ROTATING EQUIPMENT
STATUS
8.2.1.6 The system is checked for any leakage of oil.
8.2.1.7

Both main and standby lub oil pumps are run alternately.

8.2.1.8

The oil filters are inspected periodically and cleaned whenever these get
choked which is indicated by the increase in differential pressure across
the filter. Periodicity of filter inspection is decided mutually between
NTPC & BHEL at site.

8.2.1.9

Oil flushing of the circuit involving servomotor supply and return lines
apart from the lub oil lines is declared complete as per the completion
criteria stated in clause 9.0.

8.2.1.10

Temporary hose interconnecting the servomotor supply line with return

line is then removed and connected with leak off line and flushing is
continued till completion criteria stated in clause 9.0.

8.2.1.11

The hydraulic test of the lub oil system is carried out at a pressure 1.5
times the design pressure. There should not be any leakage / seepage.
(External hand pump or the oil pump itself can be used for carrying out
the hydrotest).

8.2.2

Stage II

8.2.2.1

Temporary bypass loop connections are removed and the pipeline

connections with the bearings are normalized.

8.2.2.2

Lub oil flushing is again started with the bearings included in the circuit.

8.2.2.3

Stage-II oil flushing is declared complete as per the completion criteria

stated in clause 9.0.

8.2.2.4

The oil used in flushing is drained and kept in safe custody for flushing in
other units, if found suitable. While using this used oil for flushing in
other unit, filling is to be through centrifuge.

Signatures
NTPC

BHEL

Station: NTPC
BHEL Ref No. PS - DC - 202 - 500 - 13 A
Sheet 8 of 10
Ramagundam
NTPC Ref No. COS-COMM -R-Commg-PRO/002
Plant Area: BOILER
OIL FLUSHING & HYDROTEST OF LUB OIL SYSTEM OF ROTATING EQUIPMENT
STATUS
8.2.2.5 Fresh oil of recommended grade is filled in the tank. Flow through the
bearings is adjusted and relief valves are set. Envisaged interlocks,
protections, alarms, annunciation and measurements are checked and auto
change over schemes are proved.
8.2.2.6

A joint protocol between NTPC & BHEL is signed after completion of oil
flushing.

9.0

COMPLETION CRITERIA

9.1

The pipelines are considered clean when DP across the filter stabilizes and
does not increase beyond 0.1 to 0.2 kg/cm 2 over the normal value after 8
(eight) hours of flushing operation. Also there should be NO hard particles
deposition in lub oil filters.

9.2

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

the samples collected from flushing oil should be each less than 100 ppm
(by weight) in three consecutive samples taken at interval of 4 (four) hours.

10.0

Lub Oil specifications

Equipment
FD Fan
ID Fan
PA Fan
Air Preheater
Bowl Mill

Recommended oil
Servoprime-68 of IOC
Turbinol-68 of BPCL
Bharat Turbol-68 of BPCL
-do-doServocyl C-680 of IOC
Cyndol TC-680 of HPCL
Bharat Engol J-680 of BPCL
Servomesh SP-320 of IOC
Parthan EP-320 of HPCL
Amocam Oil-320 of BPCL

Quantity
800 lit / Fill / Fan
600 lit / Fill / Fan
600 lit / Fill / Fan
130 lit (Support Brg)
30 lit (Guide Brg)
2690 lit / Fill / Mill

Signatures
NTPC

BHEL

Station: NTPC
BHEL Ref No. PS - DC - 202 - 500 - 13 A
Sheet 10 of 10
Ramagundam
NTPC Ref No. COS-COMM -R-Commg-PRO/002
Plant Area: BOILER
OIL FLUSHING & HYDROTEST OF LUB OIL SYSTEM OF ROTATING EQUIPMENT
LOG SHEET
PROJECT

UNIT

DATE :

EQUIPMENT :
ACTIVITY

: LUB OIL FLUSHING OF ..

RECOMMENDED LUB OIL:

S.
No.

Time

Pump in
Pump
Duplex Filter Oil Pressure DP across
Tank Oil
service Discharge in service after Duplex Duplex Filter
Level
Pressure
Filter

Signatures
NTPC

BHEL

Remarks