Initial Cleanup Procedure

Customer:
Maharashtra State Power Generation Co. Ltd.
Document Generating Agency:

L&T Power - Commissioning Capability Center
Project:
Koradi TPS Expansion Project – 3 x 660 MW
Document Number:
LTPCCC-KOR-0-GNR-CPR-0007
Document Title:
INITIAL
CLEAN UP PROCEDURE
R0 17-03-2012 Revised as per comments NK/AC HH/SD KSN

P0 07-02-2012 Preliminary Release GS/AC HH/SD KSN
Revision
Date Description Author Reviewed By Approved By
No.
DOC NO. : LTPCCC-
UNIT NO. CUSTOMER
KOR-0-GNR-CPR-0007
8/9/10 MAHAGENCO
Rev. No : R0
PROJECT: PAGE : Page 1 of 41
INITIAL CLEAN UP PROCEDURE
BTG
Prepared By: GSG/AC/NK Checked By : HH/SD Approved By: KSN
Abbreviations and Full Form
Abbreviations Full form

BMCR Boiler Maximum Continuous Rating
BCP Boiler Circulation Pump
BFP Boiler Feed Pump
CCR Central control room
CEP Condensate Extraction Pump
CPU Condensate Polishing Unit
CWT Combined Water Treatment
DCS Distributed Control System
ECC Erection Completion Certificate
GA General Arrangement
HP High Pressure
LC Level Control
LP Low Pressure
MCR Maximum Continues rating
MDBFP Motor Driven Boiler Feed Pump
MOV Motor operated valve
MSDS Material Safety Data Sheet
NWL Normal Water Level
O&M Operation and Maintenance
OEM Original Equipment Manufacture
PLC Programmable Logic Controller
SWAS Steam Water Analysis System
TDBFP Turbine Driven Boiler Feed Pump
DOC NO. : LTPCCC-
UNIT NO. CUSTOMER
KOR-0-GNR-CPR-0007
8/9/10 MAHAGENCO
Rev. No : R0
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CONTENTS
1. Aim ....................................................................................................................... 3
2. Objective .............................................................................................................. 3
3. Pre- Requisites ..................................................................................................... 4
4. Preparation Works ............................................................................................... 4
5. Precautions and Notes ......................................................................................... 5
6. Commissioning Flow - .......................................................................................... 6
7. Cleaning Procedure .............................................................................................. 7
8. List of Exhibits................................................................................................... 22
DOC NO. : LTPCCC-
UNIT NO. CUSTOMER
KOR-0-GNR-CPR-0007
8/9/10 MAHAGENCO
Rev. No : R0
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1. Aim
The purpose of this procedure is to establish the method to perform the activity for the
Initial Clean Up for Pre Boiler System and Boiler.
2. Objective
The procedure enlists the steps to be followed during the Initial Clean up of Pre-
Boiler & Boiler which includes condenser, LP heater lines, HP heater lines, heater
drains. It also enlists the Pre-requisites, precautions to be taken, Acceptance Criteria,
etc. associated with the system.
The systems includes:-
 Hotwell
 Condensate System
 LP heaters
 Deaerator
 Feedwater System
 HP heaters lines
 HP & LP heater drain clean up

DOC NO. : LTPCCC-
UNIT NO. CUSTOMER
KOR-0-GNR-CPR-0007
8/9/10 MAHAGENCO
Rev. No : R0
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3. Pre- Requisites
Sr. No. Job Description Records Remarks
1. CEP is ready to operate.
MD BFP and MD BFP Booster pump is ready to
2.
operate.
3. Condenser vacuum pump is ready to operate.
The required instruments properly installed and
4.
functional for clean-up operation.
Sufficient amount of make-up water can be
5.
provided for clean-up operation
6. Availability of power supply.
7. Condensate Polishing Unit is ready to in service.
8. Availability of Commissioning Spares.
9. Availability of Auxiliary Steam.
10. Chemical Dosing System readiness.
4. Preparation Works
After completion of erection in the corresponding areas, equipment test (including
pre-operation test and motor test), shall be performed. Prior to the each test, conform
that ECC issued and there are no major outstanding items that will prevent the test.
DOC NO. : LTPCCC-
UNIT NO. CUSTOMER
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8/9/10 MAHAGENCO
Rev. No : R0
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5. Precautions and Notes
Sr. No. Precautions Yes/No

Area under cleaning should be completely tagged and barricaded
1. and only authorized persons should be permitted to enter in this
area.
To protect personnel and the equipment, barriers, danger signs,
2. safety tags, area restrictions, etc. should be displayed. A safety
check shall be carried out before cleaning activity.
3. Proper access to be ensured before proceeding for checks.
The equipment should be stopped if unusual sound or excessive
4.
vibration is observed.
Proper communication should be established between each area
5.
and the control room.
Prior to the commencement of the start up cleaning, equipment’s
6. and the operational area should be thoroughly cleaned (free of
debris).
Lineup of equipment /system ( interconnected ) & settings are
checked before any trial run/charging to avoid potential safety /fire
7. hazards/accident to equipment and /or human being arising out of
open connections / blanks, leaks, grounding , inadvertent charging
etc.
8. Applicable MSDS should be displayed nearby the equipment.
Based on the site conditions, minor changes to the procedure may
9. be incorporated at site. OEM’s Instructions/Guidelines shall be
followed.
DOC NO. : LTPCCC-
UNIT NO. CUSTOMER
KOR-0-GNR-CPR-0007
8/9/10 MAHAGENCO
Rev. No : R0
BTG
Prepared By: SG/AC/NK Checked By : HH/SD Approved By: KSN
6. Commissioning Flow - Initial Clean-up
Commissioning Capability Center, L&T Power

DOC NO. : LTPCCC-
UNIT NO. CUSTOMER
KOR-0-GNR-CPR-0007
8/9/10 MAHAGENCO
Rev. No : R0
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7. Cleaning Procedure
The Initial Clean Up procedure will be carried out in following step.
Pre-Boiler cleanup is divided to 9 steps.
Step 1 - Condenser bottom blow. (Exhibit C)

Step 2 - Condensate clean-up blow. (Exhibit D)
Step 3 - Condensate clean-up bypass blow. (Exhibit E)
Step 4 - Condensate clean-up recirculation. (Exhibit F)
Step 5 - LP heater line clean-up blow (Exhibit G 1~2)
Step 6 - LP heater line clean-up recirculation. (Exhibit H)
Step 7 - LP heater line clean-up recirculation. (Exhibit I)
Step 8 - HP heater Line clean-up blow (Exhibit J)
Step 9 - HP heater line clean up recirculation. (Exhibit K)
Boiler cleanup is divided to 4 steps.
Step 10 & Step 11 – Boiler cold clean up blow (at boiler cold start up)
(Exhibit L&M)
Step 12 - Boiler cold clean up recirculation. (Exhibit N)
Step 13 – Boiler Hot clean up recirculation. (Exhibit O)
HP Heater clean Up is divided into 3 steps and LP Heater drain Clean Up is divided
into 2 steps.
Step 14 - LP Heater drain Clean up (Exhibit P 1~2)

Step 15 - HP Heater drain Clean up (Exhibit Q 1~3)

DOC NO. : LTPCCC-
UNIT NO. CUSTOMER
KOR-0-GNR-CPR-0007
8/9/10 MAHAGENCO
Rev. No : R0
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Step 1 - Condenser Bottom Blow
1. Clean the inner surface of Condenser hotwell. Especially, deposits such as mud at
the bottom shall be well removed.
2. Check condensate storage tank level not low.
3. Fill the demineralized water to Condenser by Boiler Fill Pump through Condenser
Quick fill valve (08GHC27-AA085). Hotwell Overflow to CST Control Valve
(08LAC13-AA085) shall remain closed.
4. Open Condenser blow valves (08LCA13-AA481/482/483) and blow the stored
water.
5. Repeat fill & blow (item 4 & 5), until blow water quality satisfy the below condition.
6. Re-fill demineralized water to Condenser up to normal water level.
Chemical
――
Injection
Clean up Used ・Boiler Fill Pump
Flow Rate ―― Equipment
EC*1 CC*2 DO Fe SiO2
Water Sampling point pH Turbidity Remark
(mS/m) (mS/m) (μg/l) (μg/l) (μg/l)
Quality
Monitoring Condenser
Items blow o
end
Condenser Grab
Judgment of
blow ≤3
Completion
end Sampling
*1 Specific Conductivity
Remarks
*2 Cation Conductivity
Note: Refer Exhibit C

DOC NO. : LTPCCC-
UNIT NO. CUSTOMER
KOR-0-GNR-CPR-0007
8/9/10 MAHAGENCO
Rev. No : R0
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Step 2- Condensate Clean up Blow
1. Check Boiler Fill Pump (00GHC27-AP005/006) is running.

2. Fill condensate system through Boiler Fill Pump (00GHC27-AP005/006)
3. Check CPU Inlet/Outlet and bypass motor valve (08LDF28AA-052A/052B/052C
& 08LDF28AA-054A/054B/054C) and CPU bypass motor operated valve
(08LDF28-AA081) are closed.
4. Close Condensate clean up blow motor valve (08LCA13-AA060).
5. Start one CEP (08LCA13-AP006/007/008) and blow-out water. Monitor the
running CEP suction pressure DP
6. Open Condensate clean up blow motor valve (08LCA13-AA060).
7. When water quality at CEP outlet reaches the following value, step-2 is
completed.
8. Monitor the condenser water level and make up flow from Condensate storage
tank through boiler fill pump or cycle makeup pump
Chemical
------
Injection
Blow： 538t/h
Clean up (BMCR2152t/h×0.25 Used ・Boiler Fill Pump
Flow Rate ＝ 538 t/h) Equipment ・CEP

Sampling point pH Turbidity Remark
CEP outlet o
Water
Quality
Monitoring
Items
Judgment of
CEP outlet ≤ 500*3
Completion
Remarks *2 Cation Conductivity
*3 Analyzed by membrane filter
Note: Refer Exhibit D

DOC NO. : LTPCCC-
UNIT NO. CUSTOMER
KOR-0-GNR-CPR-0007
8/9/10 MAHAGENCO
Rev. No : R0
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Step 3 - Condensate Clean up Bypass Blow

1. Check CPU Inlet/Outlet valve (08LDF28AA-052A/052B/052C & 08LDF28AA-
054A/054B/054C) are closed.
2. Check No.1 LP Heater 1B/2B Inlet motor valve (08LCA13-AA036), LP Heater
1A/2A Inlet motor valve (08LCA13-AA015) and bypass motor valve (08LCA13-
AA038,08LCAA13-AA019) are closed, and recirculation control valve
(08LCA13-AA090) is opened.
3. Check Boiler Fill Pump (00GHC27-AP005/006) is running.
4. Check Condensate Cleanup blow motor valve (08LCA13-AA060) is open.
5. CPU bypass motor valve (08LDF28-AA081) is opened
6. Change the driving of CEP．
7. When water quality at CEP outlet reaches the following value, step-3 is
completed.
8. Monitor the condenser water level and make up flow from Condensate storage
tank through boiler fill pump or cycle makeup pump.
Chemical
------
Injection
Blow： 538t/h
Clean up Used ・Boiler Fill Pump
(BMCR2152t/h×0.25
Flow Rate ＝ 538 t/h) Equipment ・CEP
EC*1 CC*2 DO Fe SiO2 Turbi
Sampling point pH
(mS/m) (mS/m) (μg/l) (μg/l) (μg/l) dity
Remark
CEP outlet o
Water
Quality
Monitoring
Items
Judgment
of CEP outlet ≤ 500*3
Completion
・CEP A/B/C shall be switched at intervals.
Remarks
Note: Refer Exhibit E

DOC NO. : LTPCCC-
UNIT NO. CUSTOMER
KOR-0-GNR-CPR-0007
8/9/10 MAHAGENCO
Rev. No : R0
BTG
Step 4 - Condensate Clean up Recirculation
1. Close Condensate Cleanup blow motor valve (08LCA13-AA060) Start Chemical

Dosing System (Refer System Description of Chemical Feed System – Vendor
Document).
2. Start Vacuum System.
3. When water quality at CEP outlet reaches to the following value, open CPU
inlet/outlet valve valve (08LDF28AA-052A/052B/052C & 08LDF28AA-
054A/054B/054C) and close its bypass motor valve (08LDF28-AA081).
Fe ≤ 300 μg/l (Analyzed by membrane filter)
4. When water quality at CEP outlet and CPU outlet reach to the below value, step-4
is completed.
Chemical
Injection pH＝9.3～9.7 (9.4) at Deaerator inlet.
Recirculation flow
1. CEP
Clean up rate：538 t/h Used
2. Condenser Vacuum Pump
Flow Rate (BMCR2152 t/h×0.25 Equipment
3. Chemical Dosing System
＝ 538 t/h)
Sampling point pH (mS/m) (mS/m) (μg/l) (μg/l) (μg/l) Remark
Water
CEP outlet o o o o
Quality
Monitoring CPU outlet o
Items
Water
Quality 9.3~9.7 0.54~1.37
CEP outlet
Standard (9.4) (0.68)
Values
CEP outlet ≤ 0.1

Judgment
of
Completion CPU outlet ≤ 100
･ ( ) shows target value

･ CPU Resin shall be switched at intervals.
Remarks *1 Specific Conductivity

Note: Refer Exhibit F

DOC NO. : LTPCCC-
UNIT NO. CUSTOMER
KOR-0-GNR-CPR-0007
8/9/10 MAHAGENCO
Rev. No : R0
BTG
Step 5 - LP Heater line Clean up Blow (1 / 2), (2 / 2)
1. Close LP Heater 1A/2A, 1B/2B outlet motor valve (08LCA13-AA040, 08LCA13-AA017)

2. Close No.3 LP Heater inlet and outlet motor valve (08LCA13-AA021, 08LCA13-AA023) and No.4
LP Heater inlet and outlet motor valve (08LCA13-AA027, 08LCA-AA029).
3. Close BFP discharge motor valve (08LAB14-AA001, 08LAB14-AA004, and 08LAB-AA007).
4. Close LP-HP clean up recirculation valve (08LAB14-AA038) and open LP Heater No.1A/2A,1B/2B
bypass motor valve (08LCA13-AA019, 08LCA13-AA038).
5. Open No.3/4 LP Heater bypass motor valve (08LCA13-AA025, 08LCA13-AA031).
6. Open the Deaerator vent valve to vacuum up the Deaerator. Check the Deaerator level (NWL) before
opening the Deaerator vent valve for Deaerator vacuum up (fill water if required).
7. Close HP heater clean up isolation motor valve(08LAB14-AA035,08LAB14-AA036)
8. Fill up water to Deaerator storage tank up to N.W.L.
9. Open LP clean up blow motor valve (08LAB14-AA037).
10.After arranged time is passed, open No.1A/2A, 1B/2B, LP Heater inlet/outlet motor valve
(08LCA13-AA036, 08LCA13-AA015), and close its bypass motor valve (08LCA13-AA038,
08LCA13-AA019).
11.Open No.3/4 LP Heater inlet/outlet motor valves (08LCA13-AA021, 08LCA13-AA023, 08LCA13-
AA027 and 08LCA13-AA029) and close its bypass motor valve (08LCA13-AA025, 08LCA13-
AA031).
12.When water quality at LP Heater line clean up line reaches to the below value, go on to the next step.
13.Monitor the condenser water level and make up flow from Condensate storage tank through boiler
fill pump or cycle makeup pump
Chemical
pH＝9.3～9.7 (9.4) at Deaerator inlet.
Injection
Blow： 538t/h 1. Boiler Fill Pump
Clean up (BMCR2152t/h×0.25 Used 2. CEP
Flow Rate ＝ 538 t/h) Equipment 3. Condenser Vacuum Pump
4. Chemical Dosing System
Water EC*1 CC*2 DO Fe SiO2
Sampling point pH Remark
Quality (mS/m) (mS/m) (μg/l) (μg/l) (μg/l)
Monitoring LP Heater line
o
Items clean up line
Judgment of LP Heater line
≤ 500*3
Completion clean up line
･ Deaerator to be well cleaned before clean up.
Remarks
Note: Refer Exhibit G 1~2

DOC NO. : LTPCCC-
UNIT NO. CUSTOMER
KOR-0-GNR-CPR-0007
8/9/10 MAHAGENCO
Rev. No : R0
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Step 6 - LP Heater line Clean up Recirculation (1/2).
1. Open Aux. Steam control valve (08LBD11-AA082). Start Deaerator heating using Aux.
Steam and vent to Condenser (08LCM16-AA002).
2. Open LP clean up recirculation motor valve (08LAB14-AA038) and close LP clean up blow
motor valve (08LAB14-AA037).
3. When water quality at CEP outlet, Deaerator storage tank and LP Heater line clean up line
reach to the below value, complete this step.
Chemical
Injection
Recirculation flow
Clean up rate：538 t/h Used 1. CEP
Flow Rate (BMCR2152 t/h×0.25 Equipment 2. Condenser Vacuum Pump
＝ 538 t/h)
Water CEP outlet o
Quality
Monitoring Deaerator storage
Items o
tank
LP Heater line
o o o
clean up line
Water
Quality LP Heater line 9.3~9.7 0.54~1.37
Standard clean up line ( 9.4) (0.68)
Values
CEP outlet ≤ 0.1
Judgment
Deaerator storage ≤ 50
of
tank (10)
Completion
LP Heater line
≤ 100
clean up line
・ ( ) shows target value.
・ Deaerator tank Storage Water Temperature ≧50℃.

Note: Refer Exhibit H

DOC NO. : LTPCCC-
UNIT NO. CUSTOMER
KOR-0-GNR-CPR-0007
8/9/10 MAHAGENCO
Rev. No : R0
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Step 7 - LP Heater line Clean up Recirculation (2/2)
1. Start MD-BFP (08LAC14-AP082) through minimum recirculation flow line(08LAB14-

AA085).
2. When water quality at CEP outlet, Deaerator storage tank and LP Heater line clean up line
reaches to the below value.
3. Put the condensate spill over control valve (08LCA13-AA085) to auto, this step is complete.
Chemical
Injection
Recirculation flow 1. CEP
rate：538 t/h 2. Condenser Vacuum Pump
Clean up Used
(BMCR2152 t/h×0.25 3. Chemical Dosing System
Flow Rate Equipment
＝ 538 t/h) 4. MD-BFP

Water CEP outlet o
Quality
Monitoring Deaerator storage
o
Items tank
LP Heater line
o o o
clean up line
Water
Quality LP Heater line 9.3~9.7 0.54~1.37
Standard clean up line ( 9.4) (0.68)
Values
CEP outlet ≤ 0.1

Judgment Deaerator storage ≤ 50
of tank (10)
Completion
LP Heater line
≤ 100
clean up line
・ ( ) shows target value.
・ Deaerator tank Storage Water Temperature ≧-------------
・
Note: Refer Exhibit I

DOC NO. : LTPCCC-
UNIT NO. CUSTOMER
KOR-0-GNR-CPR-0007
8/9/10 MAHAGENCO
Rev. No : R0
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Step 8 - HP Heater Line Clean up Blow
1. Three Way Valve (08LAB14-AA058, 08LAB14-AA060) at upstream is kept open

towards heater train side by manual operation and three way valve(08LAB14-
AA057,08LAB14-AA059) at downstream is kept closed towards heater train side to
take Heater’s in Service. LP-HP clean up recirculation motor valve (08LAB14-
AA038) is closed.
2. Open LP-HP Clean up Blow MOV (08LAB14-AA037).

3. Open HP Heater clean up isolation valve (08LAB14-AA035, 08LAB14-AA036)
4. Open MD BFP Discharge Valve (08LAB14-AA007).Regulate the flow through feed
control station.
5. When water quality at HP heater line clean up line reaches to the below value, go on
to the next step.
Chemical
Injection
Blow：538 t/h 1. Boiler Fill Pump
(BMCR2152 t/h×0.25 2. CEP
Clean up Used 3. Condenser Vacuum Pump
Flow Rate ＝ 538 t/h) Equipment 4. Chemical Dosing System
5. MD-BFP
Water EC*1 CC*2 DO Fe SiO2 N2H4
Quality (mS/m) (mS/m) (μg/l) (μg/l) (μg/l) (μg/l)
Monitoring HP Heater line
Items o
clean up line
Judgment
HP Heater line
of ≤ 500*3
clean up line
Completion
・ HP Heater stream A/B shall be switched at intervals.
・
Note: Refer Exhibit J

DOC NO. : LTPCCC-
UNIT NO. CUSTOMER
KOR-0-GNR-CPR-0007
8/9/10 MAHAGENCO
Rev. No : R0
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Step 9 - HP Heater line clean up recirculation

1. Open LP-HP clean up recirculation motor valve (08LAB14-AA038) and close LP-HP clean
up blow motor valve(08LAB14-AA037)
2. When water quality at condensate pump and HP heater clean up line reaches to the below
value.
3. Close HP heater clean up isolation valve (08LAB14-AA035, 08LAB14-AA036) and LP-HP
clean up recirculation motor valve (08LAB14-AA038), complete this step.
Chemical pH＝9.3～9.7 (9.4) at Deaerator inlet.

Injection
Clean up rate：538 t/h Used 2. Condenser Vacuum Pump
Flow Rate (BMCR2152 t/h×0.25 Equipment 3. Chemical Dosing System
＝ 538 t/h) 4. MD-BFP

Water (mS/m) (mS/m) (μg/l) (μg/l) (μg/l)
Quality
Monitoring CEP outlet o
Items
HP Heater line
o o o o o
Clean up line
Water
Quality HP Heater line 9.3~9.7 0.54~1.37
≤ 10
Standard Clean up line ( 9.4) (0.68)
Values
CEP outlet ≤ 0.1

Judgment of
Completion HP Heater line
≤ 100 ≤ 30
Clean up line

Note: Refer Exhibit K

DOC NO. : LTPCCC-
UNIT NO. CUSTOMER
KOR-0-GNR-CPR-0007
8/9/10 MAHAGENCO
Rev. No : R0
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Step 10,11 – Boiler cold clean up blow (at Boiler Cold Start Up)
1. Close vent valve and drain valve attached to a boiler.
2. Carry out flow swing in each step to achieve increased effectiveness of clean up.*1
3. Close BCP BR valve (08HAG03-AA700)
4. Close WDC outlet motor valve (08HAG03-AA001, 08HAG03-AA002) and open WDC
outlet blow motor valve (08HAG03-AA904).
5. Close MD-BFP Discharge Valve (08LAB14-AA007).
6. Three Way Valve (08LAB14-AA058, 08LAB14-AA060) at upstream is kept closed towards
heater train side by manual operation and three way valve (08LAB14-AA057, 08LAB14-
AA059) at downstream is kept closed towards heater train side to bypass heaters.
7. Close HP heater clean up isolation valve (08LAB14-AA035, 08LAB14-AA036).
8. Open MD-BFP Discharge Valve (08LAB14-AA007) and fill the water to boiler and BCP by
MD-BFP&BP.
9. Start a blow while controlling water level of W/S drain tank by WDC valve.
10. When water quality at W/S drain tank outlet line reaches to the below value, take HP heaters
into service.
11. When water quality at W/S drain tank outlet line reaches to the below value, complete this
Step.
Chemical
Injection
Blow：538 t/h 1. Boiler Fill Pump
(BMCR2152 t/h×0.25 2. CEP
Clean up Used 3. Condenser Vacuum Pump
Flow Rate ＝ 538 t/h) Equipment 4. Chemical Dosing System
5. MD-BFP
Quality Water Separator
o
Monitoring drain tank line
Items
Judgment
Water Separator
of ≤ 500*3
drain tank line
Completion
・ .
Remarks
Note: Refer Exhibit L & M

DOC NO. : LTPCCC-
UNIT NO. CUSTOMER
KOR-0-GNR-CPR-0007
8/9/10 MAHAGENCO
Rev. No : R0
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Step 12 –Boiler Cold Clean Up Recirculation ( at Boiler Cold Start up)

1. Open WDC outlet motor valve (08HAG03-AA001, 08HAG03-AA002 )
2. Close WDC outlet blow motor valve (08HAG03-AA904).
3. Start BCP and open BR valve (08HAG03-AA700).
4. Start a recirculation while controlling water level of W/S drain tank by WDC valve.
5. Carry out the flow swing adequately. (Change it by the situation in flow rate and time.）
6. When water quality at W/S drain tank outlet line reaches to the below value, complete this
step.
Chemical pH＝9.3～9.7 (9.4) at Deaerator inlet.

Injection
Clean up Used
(BMCR2152 t/h×0.25 3. Chemical Dosing System
Flow Rate Equipment
＝ 538 t/h) 4. MD-BFP
5. BCP
Water
Deareator
Quality o
Storage tank
Monitoring
Items Economizer inlet o o o o o o
W/S drain tank
o
outlet line
Water
Quality Deareator
≤ 10
Standard Storage tank
Values
9.3~9.7 0.54~1.37
Economizer inlet ≤ 0.1 ≤ 10 ≤ 100 ≤ 30
( 9.4) (0.68)
Judgment of
Completion W/S drain tank ≤ 300*3
outlet line
*3Analyzed by membrane filter and it shall be based on criteria of CPS.
Note: Refer Exhibit N

DOC NO. : LTPCCC-
UNIT NO. CUSTOMER
KOR-0-GNR-CPR-0007
8/9/10 MAHAGENCO
Rev. No : R0
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Step 13 – Boiler HOT Clean up Recirculation
1. Start MD-BFP.
2. Open MD-BFP discharge motor valve (08LAB14-AA007).
3. Start a recirculation while controlling water level of W/S drain tank by WDC valve.
(Recirculation flow rate : 25%BMCR = 673 t/h)
4. Ignite boiler.
5. Keep w/w outlet temperature to about 150 degree Celsius.
6. When water quality at W/S drain tank outlet line reaches to the below valve, complete this
step.
Chemical
Injection
Recirculation flow 1. Condensate Pump
Clean up (BMCR2152 t/h×0.25 Used 3. Chemical Injection Pump
Flow Rate ＝ 538 t/h) Equipment 4. M-BFP BP
5. M-BFP
6. BCP

Quality
Monitoring Economizer inlet o o o o o o
Items
W/S drain tank
o o
Outlet line
Water
Quality 9.3~9.7 0.54~1.37
Economizer inlet ≤ 0.1 ≤ 10 ≤ 50 ≤ 30
Standard ( 9.4) (0.68)
Values
Judgment of W/S drain tank
≤ 100 ≤ 30
Completion Outlet line
Remarks
Note: Refer Exhibit O

DOC NO. : LTPCCC-
UNIT NO. CUSTOMER
KOR-0-GNR-CPR-0007
8/9/10 MAHAGENCO
Rev. No : R0
BTG
Step 14 - LP Heater drain Clean up (for Heater Steam Side）
1. Check LP heater drain LC valve outlet valve (08LCJ15-AA127 and 08LCJ15-AA128) and
LP heater emergency drain level control valve (08LCJ15-AA096 and 08LCJ15-AA097) are
closed.
2. Open vacuum drain tank inlet motor valve (08LCJ15-AA024, 08LCH15-AA025).
3. Start LP extraction steam In-service.
4. Close vacuum drain tank level control valve (1LCM55-AA081) at load 15% and start
vacuum drain pump after vacuum drain tank level reaches NWL.
5. Open vacuum drain tank level control valve (1LCM55-AA081)
6. When water quality vacuum drain blow line reaches to the below value, close vacuum drain
tank level control valve (1LCM55-AA081) and vacuum drain tank inlet motor valve
(08LCJ15-AA024, 08LCH15-AA025).Open LP heater drain LC valve outlet valve
(08LCJ15-AA127 and 8LCJ15-AA128),complete this step.
Chemical
Injection
Clean up Used
1.Vaccum drain blow pump
Flow Rate Equipment
Monitoring LP Heater drain
Items o
blow line
Judgment of LP Heater drain *3
≤ 300
Completion blow line
*3 Analysed by membrane filter and it shall be based on criteria of CPS.
Note: Refer Exhibit P 1~2

DOC NO. : LTPCCC-
UNIT NO. CUSTOMER
KOR-0-GNR-CPR-0007
8/9/10 MAHAGENCO
Rev. No : R0
BTG
STEP 15 - HP Heater drain Clean up (for Heater Steam Side）
1. After taking HP heater No.6 and No.7, 8.in-service.

2. Check HP Heater emergency drain level control valve (08LCH15-AA091 and 08LCH15-
AA092) and HP Heater Normal drain LC valve outlet motor valve to dearator (08LCH15-
AA015, 08LCH15-AA017) are closed.
3. Open HP Heater drain blow motor valve (KKS tagging-Later &08LCH15-AA028).
4. When water quality at HP Heater drain line reaches to the below value① , open HP Heater
emergency drain LC valve (08LCH15-AA091 and 08LCH15-AA092) and close HP Heater
drain blow motor valve (Later/08LCH15-AA028).
5. When more than load 30% and water quality at HP Heater drain line reaches to the following
value②, open HP Heater drain LC valve motor valve (08LCH15-AA015,08LCH15-AA017)
and close HP Heater emergency drain level control valve (08LCH15-AA091 and 08LCH15-
AA092).
Chemical
Injection
Clean up Used
Flow Rate Equipment

Monitoring
HP Heater drain
Items o
line
≤ 300①*3
Judgment of HP Heater drain
Completion blow line
≤ 50②
Remarks
Note: Refer Exhibit Q 1~3

DOC NO. : LTPCCC-
UNIT NO. CUSTOMER
KOR-0-GNR-CPR-0007
8/9/10 MAHAGENCO
Rev. No : R0
BTG
8. List of Exhibits
Drawing /Documents Drawing No. and Revision
Exhibit C 1st step procedure and Flow diagram
Exhibit D 2nd step procedure and Flow diagram
Exhibit E 3rd step procedure and Flow diagram
Exhibit F 4th step procedure and Flow diagram
Exhibit G 1~2 5th step procedure and Flow diagram
Exhibit H 6th Step procedure and Flow diagram
Exhibit I 7th step procedure and Flow diagram
Exhibit J 8th step procedure and Flow diagram
Exhibit K 9th step procedure and Flow diagram
Exhibit L 10th step procedure and Flow diagram
Exhibit M 11th step procedure and Flow diagram
Exhibit N 12th step procedure and Flow diagram
Exhibit O 13th step procedure and Flow diagram
Exhibit P 1~2 14th step procedure and Flow diagram
Exhibit Q 1~3 15th step procedure and Flow diagram
NOTE: The Highlighted part in the Exhibits is Flow path of the Cleanup

Exhibit - C

Exhibit - D

Exhibit - E

Exhibit - F

Exhibit – G-1

Exhibit – G-2

Exhibit – H

Exhibit – I

Exhibit – J

Exhibit – K

Exhibit – L

Exhibit – M

Exhibit – N

Exhibit – O

Exhibit – P - 1

Exhibit – P - 2

Exhibit – Q - 1
T O A T M O S P H E R E
EXT FROM EXT FROM EXT FROM

HP 7th HP 10th
VENT DEAERATOR
IP 4th
FROM
HPH
HPH HPH HPH

TO ECON 7 6
8
M
BFP
VENT TO COND
DRAIN TO DEAERATOR
M
EMERGANCY DRAIN TO HP FLASH TANK
DRAIN TO ATM FLASH TANK

CONDENSOR
HP HEATER STEAM SIDE BLOW OUT(1/3)

Exhibit – Q - 2

HP 7th HP 10th IP 4th
VENT DEAERATOR
FROM
HPH
HPH HPH HPH

TO ECON 7 6
8
M
BFP
VENT TO COND
DRAIN TO DEAERATOR
M

CONDENSOR
HP HEATER STEAM SIDE BLOW OUT-CIRCULATION TO

CONDENSER(2/3)

Exhibit – Q - 3

HP 7th HP 10th IP 4th
VENT DEAERATOR
FROM
HPH
HPH HPH HPH

TO ECON 7 6
8
M
BFP
VENT TO COND
DRAIN TO DEAERATOR
M

CONDENSOR
HP HEATER STEAM SIDE BLOW OUT-CIRCULATION

TO DEARATOR(3/3)

Initial Cleanup Procedure

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Initial Cleanup Procedure

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Customer:

Maharashtra State Power Generation Co. Ltd.

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R0 17-03-2012 Revised as per comments NK/AC HH/SD KSN

Abbreviations and Full Form

Abbreviations Full form

3. Pre- Requisites ..................................................................................................... 4

4. Preparation Works ............................................................................................... 4

5. Precautions and Notes ......................................................................................... 5

6. Commissioning Flow - .......................................................................................... 6

7. Cleaning Procedure .............................................................................................. 7

The systems includes:-

 HP & LP heater drain clean up

5. Precautions and Notes

Sr. No. Precautions Yes/No

6. Commissioning Flow - Initial Clean-up

Commissioning Capability Center, L&T Power

Pre-Boiler cleanup is divided to 9 steps.

Step 1 - Condenser bottom blow. (Exhibit C)

Boiler cleanup is divided to 4 steps.

Step 14 - LP Heater drain Clean up (Exhibit P 1~2)

Commissioning Capability Center, L&T Power

Step 1 - Condenser Bottom Blow

Note: Refer Exhibit C

Commissioning Capability Center, L&T Power

Step 2- Condensate Clean up Blow

1. Check Boiler Fill Pump (00GHC27-AP005/006) is running.

EC*1 CC*2 DO Fe SiO2

Note: Refer Exhibit D

Commissioning Capability Center, L&T Power

Step 3 - Condensate Clean up Bypass Blow

Note: Refer Exhibit E

Step 4 - Condensate Clean up Recirculation

1. Close Condensate Cleanup blow motor valve (08LCA13-AA060) Start Chemical

CEP outlet ≤ 0.1

･ ( ) shows target value

Remarks *1 Specific Conductivity

Note: Refer Exhibit F

Commissioning Capability Center, L&T Power

Step 5 - LP Heater line Clean up Blow (1 / 2), (2 / 2)

1. Close LP Heater 1A/2A, 1B/2B outlet motor valve (08LCA13-AA040, 08LCA13-AA017)

Note: Refer Exhibit G 1~2

Step 6 - LP Heater line Clean up Recirculation (1/2).

Remarks *1 Specific Conductivity

Note: Refer Exhibit H

Commissioning Capability Center, L&T Power

Step 7 - LP Heater line Clean up Recirculation (2/2)

1. Start MD-BFP (08LAC14-AP082) through minimum recirculation flow line(08LAB14-

EC*1 CC*2 DO Fe SiO2

CEP outlet ≤ 0.1

Note: Refer Exhibit I

Commissioning Capability Center, L&T Power

Step 8 - HP Heater Line Clean up Blow

1. Three Way Valve (08LAB14-AA058, 08LAB14-AA060) at upstream is kept open

2. Open LP-HP Clean up Blow MOV (08LAB14-AA037).

Note: Refer Exhibit J

Commissioning Capability Center, L&T Power

Step 9 - HP Heater line clean up recirculation

Chemical pH＝9.3～9.7 (9.4) at Deaerator inlet.

EC1 CC2 DO Fe SiO2

EC1 CC2 DO Fe SiO2

EC1 CC2 DO Fe SiO2

EC1 CC2 DO Fe SiO2

Water EC1 CC2 DO Fe SiO2