8/28/2021 STEAM INJECTION SYSTEM FOR GAS TURBINES

STANDARD
PROCEDURE FOR REGENERATIVE SYSTEM � CHEMICAL CLEANING

210
MW

INTRODUCTION

It
is important that entire feed, condensate drip and regenerative system in the
system are thoroughly
cleaned to remove the dirt, rust, oil grease, weld slag,
loose materials from inside the pipes. Presence of
any undesirable material in
the system contaminates the feed/condensate system and adversely affects
commissioning and operation of the power plant. The various valves in the system
also pose problems like
passing and seat damage due to entrapment of foreign
material on the valve seats. Cleaning of the
system is considered adequate by
alkali flushing and subsequent rinsing and DM water flushing through
the system
and no acid cleaning of piping after alkali flushing will be carried out.

PREPARATION
AND PRECAUTIONS TO BE TAKEN:

�       
Ensure that the system is erected
fully and hydro test of the system is complete.

�       
Ensure that proper supports,
preferably permanent are installed.

�       
Ensure that Mixing tank as per
specification is installed.

�       
Ensure that circulating pumps as per
specification are available for operation and the temporary
connections are made
as per scheme.

�       
Ensure that required chemicals,
laboratory reagents and apparatus are available.

�       
All cutting and welding works on
heaters for gauge glass and level switches etc. are to be
completed.

�       
Deaerator and condenser are to be
mechanically cleaned to the extent possible.

�       
All orifices and flow nozzles are to
be removed and replaced with spool pieces.

�       
Regulating valves are to be mounted
only after completion of chemical cleaning and spool pieces
are to be mounted in
place of the valves.

�       
All the instrument tapings in the
system are to be completed and instruments are to be isolated
before the
flushing process.

�       
All check valves falling in flow
circuit should be installed after flushing. Otherwise their flaps/discs
to be
kept removed.

�       
All the NRVs in extraction lines are
to be erected in position.

�       
All gate valves in turbine extraction
lines are to be tightly closed.

�       
Ensure that suction and discharge end
of BFPs are blanked off.

�       
RH spray, SH spray, HP Bypass spray
and LP Bypass spray lines, TAS/BAS spray lines should be
included in flushing
operation to the extent possible.

�       
Alkali should be passed through tube
of heat exchangers.

�       
It should be ensured that alkali
solution does not enter turbine, condenser, heaters, main ejectors,
BFP, CEP
etc. For this, isolation valves for equipments should be judged properly for any
passing and
accordingly suitable corrective action to be taken either by
attending the valve or by putting dummy
plate.

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�       
Booster pumps should be taken out and
spool piece to be used.

�       
Booster pump suction strainer elements
to be removed.

�       
Flow disperser and the built in
orifice in BFP recirculation lines to be welded only after flushing
completion.

�       
Final connection of BFP discharge
lines and recirculation line to be made after flushing completion.

�       
BFP suction pipe to be slightly titled
form its counter flange at BFP for connecting temporary line
for alkali entry.
BFP suction flange to be kept protected against any foreign material entry.

�       
Portion of pipe lines which are not
covered under flushing operation shall be mechanically cleaned.

�       
Depending upon local conditions and
facilities, minor modification in the scheme can always be
done at site. The
left over spray lines should be water flushed after running of BFP.

INPUTS
REQUIRED

BHEL

�       
Mixing tank as per specification � 1
No.

�       
Temporary drain line from mixing tank
to neutralizing pit.

�       
Chemical circulating pumps: 3 Nos.
(150 T/hr. 12 Kg/sq. cm) minimum

�       
Temporary pipes, flanges, dummies etc.

�       
Pressure gauges 5 Nos. (0-25 kg/sq.
cm)

�       
Thermometers 4 Nos. (0-200 Deg.C.)

�       
Steam source 8 to 10 kg/sq. cm
(150-200 Deg C)

�       
Sampling water � 12 Nos.

�       
Chemicals

TPS
               
1500 kg

NAOH            
1000 kg

LISSOPL        
60 Lt.

CUSTOMER

�       
5 fills of each 250 T of DM water
(feed line)

�       
500 T clarified / filtered water
(condensate & drip lines)

�       
500 T clarified / filtered water for
mass flushing

�       
Neutralizing pit.

�       
Lab equipment for testing PH valve,
alkalinity.

SAFETY
AND PRE-CAUTIONS

Alkaline
solution may cause skin burning and as its fumes are injurious to eyes, all
safety precautions
must be taken during alkaline flushing.

1.     
The operators and workers must use rubber gloves, eye protecting glasses,
Aprons, Gum boots,
Masks etc. while flushing is going on and they are working on
the job.

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2.     
Due precautions must be taken while tightening the flanges of temporary
pipe joints of the loops so
that they do not leak when the pump is started and
thereby a spray of alkali leaks through these
joints.

3.     
Ensure the handy availability of first aid boxes, eye drops, neutralizing
bottles, cotton rolls etc.

4.     
Before a person enters the deaerator for inspection, its manhole may be
kept opened for 8-10 hours
and air may be forced in the deaerator during period
of working.

PROCEDURE:

The
flushing of the system can be carried out in the following steps:

1.     
Mass flushing

2.     
Alkali flushing

3.     
Rinsing

4.     
Final flushing

1.     
MASS FLUSHING

a.      
With Cold Water

Firstly
mass flushing is done with cold filtered water. The mixing tank is to be cleaned
properly and
filled with filtered water and then the system is to be completely
filled be running circulating pump.
The system is thereafter kept on circulation
for about 45 min and the entire water is then drained.
This filling and draining
should be continued till the effluent is clear. Samples at inlet and outlet
should be taken and compared before declaring completion of mass flushing.

b.     
With Hot Water

The
system should be filled up with filtered water and kept on circulation for 8
hrs. Maintaining
water temperature at about 80 Deg. C. The process is declared
completed when turbidity and
conductivity of water at inlet and outlet are same.

2.     
ALKALI FLUSHING:

Mixing
tank is filled with DM water and steam is admitted to raise the temperature at
50 Deg. C. The
system is filled up and kept on circulation till the temperature
of water in the entire system comes to
50 Deg. C. Chemicals are then added in
the mixing tank in the following quantities:

a)
Tri sodium phosphate        
5 kg/Ton of water i.e. 5000 ppm.

b)  
Sodium hydroxide         3 kg/Ton of water i.e. 3000 ppm.

c)
Lissopal D              
      0.2
/kg/Ton of water

Lissopal
�D should be added carefully so as to avoid excess foaming. After achieving
the required
concentration of chemicals, the temperature of the solution is
raised to 80 Deg. C. and the system is
kept on circulation for 6-8 hours for
each loop. Samples are to be taken from inlet and outlet ends of
the loop hourly
and analyzed for mechanical impurities, iron content, and PH value. The process
is
declared complete when the inlet and outlet sample values are identical. The
entire system is to be
drained completely.

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3.     
RINSING:

Immediately
after completion of the alkaline flushing operation, the system is rinsed with
DM water to
remove the alkalinity left over on surfaces.

Fill
the tank with DM water and run the pump for 30 minutes through system. Then open
the make up and
drain in controlled way keeping the level constant. Try to drain
maximum quantity of water from the
system continuously throughout the operation.
Hourly samples are taken and analyzed for phosphate,
alkaline content and
conductivity. The conductivity and PH value of DM water used is to be measured.
Rinsing operation is cleared completed when conductivity and PH value are same
at inlet and outlet. The
system is then drained completely.

4.     
FINAL FLUSHING WITH DM WATER

After
rinsing operation, final mass flushing is to be done with cold DM water and DM
water at a
temperature of 80 Deg. C. The system is kept on circulation for some
time and drained completely.

All
drain lines in the circuitry should be charged to ensure thoroughness. Any line
found cold should be
attended.

STAGE-I
(FEED LINES):

Temporary
connections are made as per the scheme shown in sketch. The Booster pump is to
be replaced
with a spool piece and filter elements of booster pump suction
strainers is to be taken out. Mass flushing
is carried out.

After
mass flushing, alkaline flushing is to be done. No alkaline flushing is to be
done through the tubes of
the heaters. Rinsing and final mass flushing
operations are to be done.

STAGE-II
(CONDENSATE LINES):

Temporary
connections are made as per scheme in the sketch. Mass flushing with cold and
hot water is to
be carried out.

After
flushing alkaline flushing is to be carried out. No alkaline flushing is to be
done through the tubes.
After alkaline flushing, Rinsing operation is to be
carried out. Final DM water flushing is to be done after
this.

STAGE-III
(DRIP LINES):

Temporary
connections are to be made as per scheme

Mass
flushing with cold and hot water is to be done.

Final
Dm water flushing is to be done if filtered water is used during mass flushing.

Criteria
for completion of flushing activity

1.     
Mass Flushing

a)     
Turbidity

b)     
Conductivity

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Process
is declared complete when both turbidity and conductivity of water at inlet and
outlet is approx.
same

2.     
Alkali Flushing

a)     
Conductivity

b)     
PH value

c)     
Phosphate

d)     
Mechanical impurity

Samples
are taken at every hours and the analyzed for the above and process declared
completed when
the inlet and outlet sample values approx same.

3.     
Rinsing

Process
is declared competed when conductivity is approx. same at inlet and outlet.

POST
FLUSHING OPERATION:

A.    
Following temporary lines are to be removed.

1.     
All temporary lines of the loop

2.     
Temporary lines from the system to Mixing Tank.

3.     
Temporary line from Alkaline Pump discharge to system.

B.    
Blanks provided in the system are to be removed

C.    
Stubs used for Alkali Flushing are to be normalized.

D.    
Any choked drain line, as identified during flushing operation, should be
attended either by opening
the valve bonnet or by cutting the line.

E.     
After draining the deaerator, it should be thoroughly inspected from
inside and cleaned properly
(The Deaerator manhole doors should be kept open for
8-10 hours prior to entry for expelling chemical
gasses).

F.     
Install the control valves, flow nozzles, orifices in the system
permanently after taking due care so
that no foreign matter enters the system
again.

G.    
In case of BFP suction flow nozzles after it�s welding it is always
advisable to flush the line again
before entering water to the pump. Suction
pipe at BFP flange may be lifted slightly and some sheet
may be kept at pump
flange for this purpose.

PREBOILER
ALKALI FLUSHING / HOT WATER FLUSHING OF DRIP LINES 210 MW

Sr.
No. List
of Valves    

1 PUMP
SUCTION VALVES Nb
200 3
NOS.

2 PUMP
DISCHARGE NRVs Nb
100/150 3
NOS.

3 PUMP
DISCH. VALVES Nb
100/150 3
NOS.
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4 MIXING
TANK DRAIN V/v Nb
200 1
NO.

5 SYSTEM
INLET/OUTLET V/vs Nb
250 7
NOS.

Nb
200 1
NO.

Nb
150 2
NOS.

Nb
100 1
NO.

6 DRAIN
TO NEUTRALIZING PIT Nb
250 1
NO.

7 PUMP
RC VALVE Nb
150 1
NO.

8 ROOT
VALVES Nb
25 8
NOS.

9 SAMPLE
VALVES Nb
40 4
NOS.

10 LINE
DRAINS Nb
80 3
NOS.

11 DMW
& STM V/v Nb
40 5
NOS.

Nb
150 2
NOS.

12 FLOW
METER IN SYSTEM INLET (0-600 T/Hr)    

PIPING:

1 DIA
323.9 X 7.5 MM - 15
MTRS

2 DIA
273 X 7.5 MM - 200
MTRS

3 DIA
219 X 6.3 MM - 110
MTRS

4 DIA
159 X 6.3 MM - 80
MTRS

5 DIA
133 X 4.0 MM - 60
MTRS

6 DIA
44.5 X 2.5 MM - 50
MTRS

7 DIA
21.3 X 2.6 MM - 50
MTRS

BENDS

1  
DIA 273 X 7.5 CS 90 DEG           
=           
15 NOS.

2  
DIA 219 X 6.3 CS 90 DEG.           
=           
5 NOS.

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8/28/2021 STEAM INJECTION SYSTEM FOR GAS TURBINES

3  
DIA 199 X 6.3 CS 90 DEG.           
=           
5 NOS

4  
DIA 133 X 6.5 CS 90 DEG           
=           
10 NOS.

5  
DIA 108 X 4.5 CS 90 DEG.           
=           
12 NOS.

REDUCESS

1  
300-250 MM CS                              
=           
2 NOS.

2   
250-200 MM CS                              
=           
2 NOS.

3   
200-150 MM CS                              
=           
4 NOS.

4   
250-150 MM CS                              
=           
8 NOS.

5   
150-100 MM CS                              
=           
4 NOS.

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