COMMISSIONING GROUP

WELCOME TO THE PRESENTATION ON

DETERGENT FLUSHING OF PRE BOILER SYSTEM

PRESENTED BY:C. DEWANGAN

COMMISSIONING GROUP

DETERGENT FLUSHING OF PRE-BOILER SYSTEM

PRE-BOILER SYSTEM CONSISTS OF CONDENSATE SYSTEM DRIP SYSTEM FEED WATER SYSTEM EXTRACTION STEAM LINES TO REGENERATIVE HEATERS CONDENSATE SYSTEM: COMPRISES OF 3 NOS OF CEPS, L.P.HEATERS, G.S.C, DRAIN COOLER, DEAERATOR, CONNECTING PIPELINES INCLUING EXCESS CONDENSATE LINE UPTO C.S.T. FEED WATER SYSTEM: COMPRISES OF 1 NO. MDBFP AND 2Nos. TDBFPS, THEIR BOOSTER PUMPS AND RECIRCULATION LINES , H.P HEATERS, THEIR CONNECTING PIPE LINES UPTO ECONOMISER INLET. RH & SH SRRAY LINES ARE ALSO INCLUDED FOR THE PURPOSE OF FLUSHING. DRIP SYSTEM: COMPRISES THE SHELL SIDE OF ALL LP &HP HEATERS & THE DRIP LINES. EXTRACTION SYSTEM: INCLUDES ALL EXTRACTION LINES TO LP & HP HEATERS

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OBJECTIVE:

TO REMOVE DIRT, OIL, GREASE etc., FROM THE CONDENSATE , FEED WATER, DRIP & EXTRACTION STEAM LINES OF HP & LP HEATERS, USING A NON-IONIC DETERGENT ,PRIOR TO PUTTING THESE SYSTEMS IN REGULAR SERVICE. THIS ENSURES FLOW OF CLEAN CONDENSATE & FEED WATER TO BOILER THE FOUR STAGES OF DETERGENT FLUSHING ARE: STAGE-I: FEED LINES STAGE-II: CONDENSATE LINES & DRIP LINES OF HPH-5A & 5B STAGE-III: EXTRACTION STEAM LINES AND DRIP LINES OF HPHs STAGE-IV: EXTRACTION STEAM LINES AND DRIP LINES OF LPHs NOTE: EACH SYSTEM SHALL BE SUITABLY SUBDIVIDED INTO VARIOUS SUB CIRCUITS TO COVER ALL THE LINES AND COMPONENTS

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1)

DETERGENT FLUSHING REQUIREMENTS

CHEMICALS &WATER a) DM WATER : 5000T b) NON-IONIC DETERGENT RINOPOL-JET 100% 1000 LITRES (OR SUMISOL-N 100% )

@0.05%CONCENTRATION

c) FOR PASSIVATION HYDRAZINE HYDRATE -800KG @ 80% CONCENTRATION (IS:12086/1991) LIQUOR AMMONIA------ 400KG @ 25% CONCENTRATION (IS:799/1985)

2)

PUMPS AND VALVES: a) TEMPORARY CIRCULATION PUMPS ( 4Nos) CAPACITY : 200T/hr Head: 20 KG/CM2 MOTOR : 180 KW b) TEMPORARY MIXING TANK CAPACITY 40 M3 . c) VALVES & INSTRUMENTS a) b) c) d) e) f) g) STEAM SUPPLY LINE V/V (1No.) DM WATER SUPPLY LINE V/V (1No.) MIXING TANK DRAIN TO NEUTRALISATION PIT V/V (1No.) PUMP DISCHARGE SAMLE LINE V/V (1No.) DETERGENT RETURN SAMPLE LINE V/V (1No.) PUMP DISCHARGE LINE DRAIN V/V (1No.) DETERGENT RETURN LINE DRAIN V/V (1No.) 3'' 4'' 4'' 1'' 1'' 1'' 10'

COMMISSIONING GROUP

DETERGENT FLUSHING REQUIREMENTS

h) i) j) k) l) m) n)

TEMPORARY P/P SUCTION LINE V/Vs (4Nos) TEMPORARY P/P DISCHARGE LINE V/Vs (4Nos) PUMPS RECIRCULATION V/V (1No.) PUMPS COMMON DISCHARGE LINE V/V (1No.) PRESSURE GAUGES (0-40Ksc) (2Nos) TEMPERATURE GAUGES (0-1500C) (2Nos) LEVEL INDICATOR FOR MIXING TANK (2Nos)

3)

OTHER REQUIREMENTS a) POWER SUPPLY TO TEMPORARY CIRCULATION PUMPS(415V) b) ADEQUATE LIGHTING IN ALL WORKING AREAS c) LABORATORY FACILITY FOR ANALYSIS OF FLUSHING WATER d) SERVICE WATER e) FIRE EXTINGUISHERS f) ADEQUATE TEMPORARY PIPING & SUPPORTS

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METHOD

LINE UP THE STAGE TO BE FLUSHED FILL THE SYSTEM WITH DM WATER BY CIRCULATION PUMPS CARRY OUT COLD WATER MASS FLUSHING IN ALL THE SUB LOOPS FOR 1 HOUR, THEN CONTINUOUS RINSING TILL EFFLUENT VISIBLY CLEAR. ADMIT STEAM INTO MIXING TANK & RAISE THE DM WATER TEMP. UP TO 600C AND CARRY OUT HOT WATER MASS FLUSHING IN ALL THE SUB LOOPS FOR 2 HOUR CONT. RINSING & DRAINING OF THE < 5NTU REFILL TOTAL CIRCULATION SYSTEM WITH SYSTEM TILL TURBIDITY & ESTABLISH

DM WATER

ADMIT STEAM INTO MIXING TANK, RAISE THE WATER TEMP. TO 600C ADD RINOPOL-JET 100% OR SUMISOL-N 100% TO ACHIEVE SOLUTION CONCENTRATION OF 0.05% CIRCULATE THE SOLUTION IN EACH OF THE LOOPS FOR A MIN. DURATION OF 4 HOURS. DURING CIRCULATION GIVE MAKE UP STEAM / WATER KEEPING THE SOLUTION TEMP.AT 600C

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METHOD

DRAIN THE SYSTEM COMPLETELY & FILL IT AGAIN WITH DM WATER CIRCULATE DM WATER IN EACH LOOP FOR HOUR ONCE AGAIN DRAIN THE SYSTEM COMPLETELY RINSE THE SYSTEM WITH DM WATER BY CONTINUOUS FILLING & DRAINING TO MEET COMPLETION CRITERIA STOP THE PUMPS & DRAIN THE WHOLE SYSTEM FILL THE SYSTEM WITH DM WATER & RAISE THE TEMP. TO 600C FOR PASSIVATION ADD HYDRAZINE & AMMONIA TO GET 210PPM HYDRAZINE& PH OF WATER TO 9.5 TO 10.0. RAISE THE TEMP. TO 800C & MAINTAIN CIRCULATION FOR 8 HOURS THEN DRAIN OUT THE SYSTEM & ALL AIR VENTS & FEED STORAGE TANK MAN HOLES ARE OPENED TO AERATE THE SYSTEM MAKE INTERNAL INSPECTION OF D/A FOR FOREIGN MATERIAL, IF ANY, AND CLEAN THORUOGHLY

COMPLETION CRITERIA:DM WATER RINSING AFTER CHEMICAL FLUSHING SHALL BE CONSIDERED COMPLETE ONCE CONDUCTIVITY OF DRAINED WATER IS LESS THAN 10MICRO

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FEED CONTROL STN FEED STORAGE SH AND RH SPRAY TANK R / C LINE

POINT NEAR ECO I/L

PI TI STEAM SUPPLY DM WATER SUPPLY SAMPLE DRAIN TEMP TANK P/Ps R/C HPH-6B HPH-5B SAMPLE PI TI OPEN DRAIN

BP SUCTION

DRAIN

HPH-6A BP BFP HPH-5A

BFP SUCTION

BFP DISCHARGE

TEMPORARY PIPING BLANK / FLANGE

STAGE-1A

HPH BYPASS

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FEED CONTROL STN FEED STORAGE SH AND RH SPRAY TANK

POINT NEAR ECO I/L

PI TI STEAM SUPPLY DM WATER SUPPLY SAMPLE DRAIN TEMP TANK P/Ps R/C HPH-6B HPH-5B SAMPLE PI TI OPEN DRAIN

BP SUCTION

R / C LINE

DRAIN

HPH-6A BP BFP HPH-5A

BFP SUCTION

BFP DISCHARGE

TEMPORARY PIPING BLANK / FLANGE

STAGE-1B

HPH BYPASS

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POINT NEAR ECO I/L

SPREAY CONTROL STN

FEED CONTROL STN FEED STORAGE SH AND RH SPRAY TANK STEAM SUPPLY DM WATER SUPPLY R / C LINE TEMP TANK

PI TI SAMPLE DRAIN P/Ps R/C SAMPLE

BP SUCTION

DRAIN

HPH-6A BP BFP HPH-5A

HPH BYPASS

HPH-6B HPH-5B

BFP SUCTION

BFP DISCHARGE

PI

TI

TEMPORARY PIPING BLANK / FLANGE

STAGE-1C

OPEN DRAIN

LPH-3 BYPASS

COMMISSIONING GROUP

POINT NEAR D/A

HPH-5A DRIP TO D/A

DEAERATOR

PI TI STEAM SUPPLY SAMPLE DRAIN TEMP TANK DRAIN P/Ps

LPH-2 BYPASS

LPH-3

HPH-5A

DM WATER SUPPLY

LPH-2

LPH-1 B.P

HPH-5A ALT. DRIP

LPH-1 CONDENSER. CONTROL STATION D/A LEVEL

R/C

DRAIN CLR.

CONDENSATE EXCESS RETURN SUC. STRAINER CEPS

SAMPLE TI

PI CPU TEMPORARY PIPING

GSC.

BLANK / FLANGE

STAGE-2A

OPEN DRAIN

LPH-3 BYPASS

COMMISSIONING GROUP

POINT NEAR D/A

HPH-5A DRIP TO D/A

DEAERATOR

PI TI STEAM SUPPLY SAMPLE DRAIN TEMP TANK DRAIN P/Ps

LPH-2 BYPASS

LPH-3

HPH-5B

DM WATER SUPPLY

LPH-2

LPH-1 B.P

HPH-5B ALT. DRIP

LPH-1 CONDENSER. CONTROL STATION D/A LEVEL

R/C

DRAIN CLR.

CONDENSATE EXCESS RETURN SUC. STRAINER CEPS

SAMPLE TI

PI CPU TEMPORARY PIPING

GSC.

BLANK / FLANGE

STAGE-2B

OPEN DRAIN

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DEAERATOR

TEMPORARY LINE TO MIXING TANK

5A DRIP TO D/A

FEED STORAGE TANK

EXT TO 6A EXT TO 5A 6A DRIP TO 5A

STEAM SUPPLY

SAMPLE DRAIN

HPH-6A

HPH-5A

TEMP TANK DRAIN

HP FT

HPH ALT. DRIPS TO F.T

P/Ps
EXT TO 6B EXT TO 5B 6B DRIP TO 5B

R/C

HPH-6B

HPH-5B
5B DRIP TO D/A

SAMPLE

PI

TI

BLANK / FLANGE

TEMPORARY PIPING

STAGE-3A

OPEN DRAIN

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DEAERATOR

TEMPORARY LINE TO MIXING TANK

5A DRIP TO D/A

FEED STORAGE TANK

EXT TO 6A EXT TO 5A 6A DRIP TO 5A

STEAM SUPPLY

SAMPLE DRAIN

HPH-6A

HPH-5A

TEMP TANK DRAIN

HP FT

HPH ALT. DRIPS TO F.T

P/Ps
EXT TO 6B EXT TO 5B 6B DRIP TO 5B

R/C

HPH-6B

HPH-5B
5B DRIP TO D/A

SAMPLE

PI

TI

BLANK / FLANGE

TEMPORARY PIPING

STAGE-3B

OPEN DRAIN

COMMISSIONING GROUP
DEAERATOR

TEMPORARY LINE TO MIXING TANK

5A DRIP TO D/A

FEED STORAGE TANK

STEAM SUPPLY

SAMPLE DRAIN

6A DRIP TO 5A

HPH-6A

HPH-5A

TEMP TANK DRAIN

HP FT

HPH ALT. DRIPS TO F.T

P/Ps R/C

6B DRIP TO 5B

HPH-6B

HPH-5B
5B DRIP TO D/A

SAMPLE

PI

TI

BLANK / FLANGE

TEMPORARY PIPING

STAGE-3C

OPEN DRAIN

COMMISSIONING GROUP
DEAERATOR

TEMPORARY LINE TO MIXING TANK

5A DRIP TO D/A

FEED STORAGE TANK

EXT TO 6A EXT TO 5A 6A DRIP TO 5A

STEAM SUPPLY

SAMPLE DRAIN

HPH-6A

HPH-5A

TEMP TANK DRAIN

HP FT

HPH ALT. DRIPS TO F.T

P/Ps
EXT TO 6B EXT TO 5B 6B DRIP TO 5B

R/C

HPH-6B

HPH-5B
5B DRIP TO D/A

SAMPLE

PI BLANK / FLANGE TEMPORARY PIPING

TI

STAGE-3D

OPEN DRAIN

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DEAERATOR

TEMPORARY LINE TO MIXING TANK

5A DRIP TO D/A

FEED STORAGE TANK

EXT TO 6A EXT TO 5A 6A DRIP TO 5A

STEAM SUPPLY

SAMPLE DRAIN

HPH-6A

HPH-5A

TEMP TANK DRAIN

HP FT

HPH ALT. DRIPS TO F.T

P/Ps
EXT TO 6B EXT TO 5B 6B DRIP TO 5B

R/C

HPH-6B

HPH-5B
5B DRIP TO D/A

SAMPLE

PI BLANK / FLANGE TEMPORARY PIPING

TI

STAGE-3E

OPEN DRAIN

COMMISSIONING GROUP
DEAERATOR

TEMPORARY LINE TO MIXING TANK

5A DRIP TO D/A

FEED STORAGE TANK

EXT TO 6A EXT TO 5A 6A DRIP TO 5A

STEAM SUPPLY

SAMPLE DRAIN

HPH-6A

HPH-5A

TEMP TANK DRAIN

HP FT

HPH ALT. DRIPS TO F.T

P/Ps
EXT TO 6B EXT TO 5B 6B DRIP TO 5B

R/C

HPH-6B

HPH-5B
5B DRIP TO D/A

SAMPLE

PI BLANK / FLANGE TEMPORARY PIPING

TI

STAGE-3F

OPEN DRAIN

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TEMPORARY LINE TO MIXING TANK

EXT-2 EXT-3 LPH-3

LP3 DRIP TO LP2

STEAM SUPPLY LPH-2

TEMP
LP2 DRIP TO LP1

TANK

LPH ALT. DRIPS TO LP F.T

LP FT
LPH-1

P/Ps

CONDENSER. DRAIN CLR.

SAMPLE

PI

TI

BLANK / FLANGE

TEMPORARY PIPING

STAGE-4A

OPEN DRAIN

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TEMPORARY LINE TO MIXING TANK

EXT-2 EXT-3 LPH-3

LP3 DRIP TO LP2

STEAM SUPPLY LPH-2

TEMP
LP2 DRIP TO LP1

TANK

LPH ALT. DRIPS TO LP F.T

LP FT
LPH-1

P/Ps

CONDENSER. DRAIN CLR. DRIP FROM D/C TO LPFT

SAMPLE

PI

TI

BLANK / FLANGE

TEMPORARY PIPING

STAGE-4B

OPEN DRAIN

COMMISSIONING GROUP
TEMPORARY LINE TO MIXING TANK

EXT-2 EXT-3 LPH-3

LP3 DRIP TO LP2

STEAM SUPPLY LPH-2

TEMP
LP2 DRIP TO LP1

TANK

LPH ALT. DRIPS TO LP F.T

LP FT
LPH-1

P/Ps

CONDENSER. DRAIN CLR.

SAMPLE

PI

TI

BLANK / FLANGE

TEMPORARY PIPING

STAGE-4C

OPEN DRAIN

COMMISSIONING GROUP
TEMPORARY LINE TO MIXING TANK

EXT-2 EXT-3 LPH-3

LP3 DRIP TO LP2

STEAM SUPPLY LPH-2

TEMP
LP2 DRIP TO LP1

TANK

LPH ALT. DRIPS TO LP F.T

LP FT
LPH-1

P/Ps

CONDENSER. DRAIN CLR. DRIP FROM D/C TO LPFT

SAMPLE

PI

TI

BLANK / FLANGE

TEMPORARY PIPING

STAGE-4D

OPEN DRAIN