Documente Academic
Documente Profesional
Documente Cultură
H.J.Hyu
A 05/05/11 First issue SWKang K.T.Son
n
REV. DATE DESCRIPTION DGN CHK REVIEW APPR
NTPC Limited
(A GOVERNMENT OF INDIA ENTERPRISE)
CATEGORY APPROVAL 26 E
Record of Revisions
This Document is the property of Doosan Heavy Industries and Construction Co., Ltd., Chang-won, KOREA,
and is to be used only for the purpose of the agreement with Doosan pursuant to which it is furnished.
STEAM LINE BLOWING
ATTACHMENTS
3
STEAM LINE BLOWING PROCEDURE
1. Introduction
The purpose of steam line blowing is to remove pipe slag, weld bead deposits and other
foreign material from the main and reheat steam systems prior to turbine operation. The
cleaning is accomplished by subjecting the piping systems to heating, blowing steam and
cooling cycles in sufficient number and duration until clean steam is obtained.
Steam line cleanliness is determined by the appearance of polished target plates that are
mounted in the pipe during the final steam blows. The acceptance criteria for maximum
number and size of pits in the target plate are typically specified by the turbine supplier.
The design of the temporary piping and supports is the responsibility of Doosan. This
procedure is a suggested method of steam line blowing and does not attempt to address
all aspects of the blowing operation that will be required. The Commissioning-in-charge
has the ultimate responsibility for the comprehensive steam line blowing procedure or
implementation at the Project Site after due approval of NTPC site. E
3. Precautions
The process of steam line blowing imposes abnormal and severe conditions upon the
unit and steam piping. Large, rapid temperature changes occur during each blowing
cycle, which is far more severe than is incurred in normal operation. Thermal stresses
may be high in the thick walled portions of the unit. It is prudent to consider this fact
when performing this procedure and to limit the number of blowing cycles to the
minimum consistent with cleaning the system.
Since the temporary piping may be designed for a lower pressure than
the steam generator, care must be taken to prevent over-pressurization
during the entire steam blow operation.
The piping system and headers upstream of all SH and RH sections should be drained
and free of condensate at all times during the blowing operation.
The initial blow of each phase should be done at reduced pressure in order to check the
temporary piping anchors and supports.
Steam blowing operation is the first occasion on which the unit is fired at significant rate,
therefore special attention must be paid to the start-up and operation at all times. The
unit must be started much slower the initial time while all equipment is checked for
expansion movement.
BLOWING PROCEDURES
The steam line blowing procedure is divided into two (2) phases. Phase 1 consists of two
(2) pre-step blows, and phase 2 consists of two (2) main-step blows. In each phase,
specific sections of piping will be cleaned.
1. Phase 1: Pre–Step
The steam lines to be cleaned in the pre-step are the main steam line, the HP bypass
lines, and the cold RH lines. These are cleaned first in order to avoid carrying debris into
the RH assemblies and possibly causing tube blockage and subsequent overheating
problems. Since there will be no flow through the RH during this phase, the firing rate
must be limited such that the gas temperature at the furnace outlet does not exceed
537°C. Use the Furnace Gas Temperature Probe (at DDCMIS) to monitor the furnace
outlet temperature.
The unit is started up in accordance with normal start-up procedures. The two (2) martyr
valves located in the temporary piping downstream of the MSV will initially be closed and
the bypass valve is opened. The pressure at the separator outlet will be raised to the
value calculated to produce the desired blowing flow (approximate 40 kg/cm2(g)). E
Elevation AB oil burners will be used for the pressure and temperature raising. When the
required separator pressure is attained and stabilized, the oil burners are shut off and the
BCP will be stopped. Immediately the martyr valves will be opened wide to get the
maximum possible steam blowing flow. When the pressure has reduced to approximately
20 to 40 kg/cm2(g), the martyr valves are reset to the closed position. Oil firing is then re-
started and the process is then repeated until clean white smoke is observed at the
exhaust of tailpipe.
The suggested steam flow path is as follows: The final steam flow paths will be
determined based on discussions and mutual agreement between DOOSAN, NTPC and
Turbine supplier.
(Note: Temporary blanks or valves may be required to establish the suggested flow
path).
Pre-step 1 : Separator SH main steam line MSV temporary pipe martyr valve
tailpipe to atmosphere.
Pre-step 2: Separator SH main steam line HP Bypass Cold RH line backward flush
through drain pot near RH inlet header temporary pipe tailpipe to
atmosphere.
Note: During pre-step 2, the isolators at CRH line are kept open and the isolators at
HRH line are kept in closed position.
The pre-step steam blowing out operation shall be carried out with a Cleaning Force
Ratio below 1.0.
The unit is started up in accordance with normal start-up procedures. The two (2) martyr
valves located in the temporary piping downstream of the MSV will initially be closed and
the bypass valve is open. The pressure at the separator outlet is raised to approximately
80 kg/cm2(g) while firing Light Oil/HFO. Elevation AB and CD oil burners will be used for
the pressure raising. The feed water flow, firing rate, and steam pressure will then be
increased in coordinated fashion until the desired steam production is achieved.
The SH and RH outlet temperatures are controlled by the burner tilts and the respective
de-superheating stations, as required.
NOTE: These operating conditions are estimated only. The actual steam
flow, pressure, and temperature in the steam lines during the steam blow
must be evaluated to determine if the minimum cleaning forces have been
obtained. It may be necessary to adjust these operating conditions as actual
blow conditions dictate.
It is assumed that the feedwater temperature is maintained at 120°C. Variation from this
temperature will have an impact on the firing rate required to generate the target steam
flow.
When the required steam parameters are attained and stabilized, the oil burners are shut
off and the BCP will be stopped. Immediately the martyr valves will be opened wide to
get the maximum possible steam blowing flow. When the pressure has reduced to
approximately to 40 kg/cm2g, the martyr valves are reset to the closed position. Oil firing
is then re-started and the process is then repeated until clean target plate is achieved
and the appearance of the target plate is acceptable to the turbine supplier.
The duration of each main-step blow may be for about three (3) minutes.
The main step steam blowing out operation shall be carried out with a Cleaning Force
Ratio above 1.0.
The suggested steam flow path is as follows: The final steam flow paths will be
determined by the NTPC / Turbine Supplier.
Before taking up the steam blowing operation, the following major equipments / systems
/activities are scheduled to be completed.
E. Main steam, Cold Reheat, Hot Reheat, HP & LP BP, Auxiliary steam & Interconnection
piping and valves
I. Miscellaneous system
1) Equipment for Oxygenation Treatment
2) LP Dosing system
3) Equipment for Cooling Water system
4) Chemical cleaning equipment
5) Lifting device
6) Garbage Chute
The following major activities are scheduled to be completed before commencing steam
blowing operation.
A. Hydraulic Test
B. Readiness of SG C&I for Boiler
C. Boiler Light up & Chemical cleaning
2. Preparing Items
A. Temporary Piping
B. Temporary Motor Operated Valve
C. Blind Plate & Flange
D. Test Piece (Target Plate-Mild Carbon Steel of roughness of surface 0.8 microns &
having mirror like finish)
E. Test Piece and Flange assembly and de-assembly facilities.
F. Tele-communication facility
G. Recording Sheet
H. 415V AC Power Distribution Local Panel
3. Check points
A. Care should be exercised not to over-pressurize the unit during steam blowing
operation since the temporary piping may designed for a lower pressure than boiler.
B. All welded connection should be done 100%RT for safety and confirm the flange
connections.
C. Install steam piping/temporary piping with proper hanger, support and expansion
provisions.
D. Temporary piping will be insulated locally (only insulation without cladding) at
measurement locations & target plate location where personnel movement is
expected.
E. To check the drain valve for main steam line and Hot/Cold reheat line for steam
blowing.
Install the temporary piping at drip pot of main steam line and Hot/Cold reheat line in
order to drain the foreign materials easily.
Confirm that the drain lines for boiler and turbine piping are not blocked due to flange
or intentional blockage.
F. Confirm that well ground test pieces are ready and check the ease of insert and
tacking-off of test piece.
G. Test piece should be installed in the temporary piping with horizontal direction.
H. Check the condition of temporary motor valve and bypass valve of temporary motor
valve.
I. During steam blowing operation period following inter-lock should not be worked in
order to prevent from being broken with frequent start and stop of auxiliary equipment
according to the burner firing and extinguishment.
(1) All BFP stop inter-lock by MFT
(2) MFT inter-lock by feed water flow low//low-low
(3) MFT inter-lock by all burner putting-off
J. Boiler feed water pump with motor operation should be kept operating condition until
ending of steam blowing to hot banking. Boiler feed water pump with motor operation
should be kept operating at minimum feed water supplying condition when boiler does
not need feed water.
K. Check all instruments to be used during steam blowing, its attachment condition and
calibration.
TE LBA12CT001 ~ 002
FT LAE52CF001 ~ 002
FT LAE62CF001 ~ 002
FT LAF52CF001, 002
TE HNA13CT001 ~ 004
TX HBK10CT001 ~ 003
TX HBK20CT001 ~ 003
PT LBA12CP003
PT LBA32CP001
PT LBC12CP001
PT LBB32CP001, 002
O. Keep the safety area around steam blowing outlet and steam blowing facilities. Clear of
all obstructions and personnel.
P. Check other necessary things for steam blowing. If there are any discrepancies /
problems associated with steam blowing procedure/operation, consult DOOSAN site
representative
Hot start-up is performed during steam blowing. Keep the boiler hot during night by boxing
up the unit. The following procedure shall be followed from light-off to raising pressure.
Please refer to the operating manual for details.
(8) Purge
- When the purge ready conditions are satisfied the purge start should be turned on.
- Purge is carried on for 10 minutes and then purge is done, MFT is reset again.
- Auxiliary Air damper is switched to auto. That means the differential pressure
between Windbox and Furnace is changed depending on the load increase.
C. HOT BOXING-UP
During steam blowing, box-up the unit to conserve heat at night, and operate hot
start up in the morning.
For more details, it is recommended to follow Boiler operating manual.
The step to shut down is as follows:
(1) After igniting boiler and increasing boiler pressure as a next step of final steam
blowing on that day, put out the burner and operate purge.
(2) When final oil burner gun scavenge and furnace purge are finished, stop the BCP
after maintaining the UG valve at minimum point.
(3) Stop the BFP-M after closing BFP-M exit flow control valve manually.
(4) Drain valve of main steam system will be closed during boxing- up.
(5) Stop the steam coil air heater.
(6) Stop FDF and IDF, and control the damper of air/gas system to box- up mode.
(1) After igniting Oil Burner and raising boiler pressure, according to the
recommended range for Pre-step and Main Step, steam blowing is operated
following temporary MOV installed in temporary piping Open/Close signal.
(2) To prevent any equipment damage during steam blowing, the steam pressure
shall be maintained as suggested such that-during Pre-step, Cleaning Force
Ratio should be maintained less than 1.0, and during Main Step, Cleaning Force
Ratio should be kept greater than 1.0.
(3) The final evaluation of steam cleaning is decided by inspection of the target plate
installed in temporary pipe for steam blowing
(4) During cold start-up, drain of every piping should be fully operated so that Steam
Hammering phenomenon would not occur.
(5) During steam blowing, feed water is fed to boiler by motor operated BFP. Oil
burner is ignited and boiler pressure raised after securing re-circulation flow.
Burner is extinguished and stopped before starting steam blowing. The steam
blowing operation is repeated till successful completion.
(1) During steam cleaning, the recommended steam pressure to ensure desired
Cleaning Force Ratio at each section is 40 ~ 80 kg/cm2g range of pressure at
Separator outlet.
(2) The steam pressure for initial test blow is approximately 20 Kg/cm2g. For the pre-
step blowing operation, the steam pressure is maintained as 40 Kg/cm2g and for E
the main step blowing, the pressure is maintained approximately 80 Kg/cm2g. The
required Cleaning Force Ratio is calculated during each blowing operation.
(3) Loss of standard pressure for comparison with Cleaning Force Ratio is listed as
below
Item Pressure instrument location Loss of standard
From To pressure
Main steam pipe 10LBA11CP003 10LBA31CP001 7.29kg/cm2
10LBA12CP003 10LBA32CP001
Low-temp reheat 10LBC11CP001, 10LBC31CP001 0.76 kg/cm2
steam pipe 10LBC12CP001 10LBC32CP001
High-temp reheat 10LBB11CP003 10LBB31CP002 0.97 kg/cm2
steam pipe 10LBB12CP003 10LBB32CP002
(4) Steam Pressure & Temperature condition for each process (reference)
E
Process Pressure Temp.(℃) Estimated Blowing Remark
(kg/cm^2g) Discharge Force
rate (ton/h)
Pre- Operating ~40 ~370 ~ 212 <1 Separator
step martyr outlet base
valve
Main Operating ~80 ~ 390 1310~1400 >1 Separator
Step martyr outlet base
valve ~80 ~ 390 1310~1400 > 1 Separator
outlet base
Above Cleaning Force Ratio table is only for reference. Actual operation must be
done after finding the right pressure which satisfies Cleaning Force Ratio of each
sector by gradually increasing pressure for each stage of Steam Blowing.
Sample Calculation for Cleaning Force Ratio:
1. Steam flow at VWO kg/hr : 2160000
2. Specific volume of main steam
at 255 kg/cm2(a) & 540˚C m3/kg : 0.012429
2
3. Estimated Pr. Drop in main steam pipe kg/cm : 7.29
4. Estimated steam flow at 80 kg/cm2(g)
separator outlet pressure kg/hr : 1310000
2
5. Pr. Drop in main steam pipe for (4) kg/cm : (1310000/2160000)² x 7.29
(Value to be read from pr. Transmitters = 2.68
mentioned in table under (3)
C. Cautions
(1) Control room Operators and field personnel must be in close communication.
(2) The First Steam Blowing for each stage of Steam Blowing process must be done
in lower pressure than setting pressure in order to check (protect) Temporary
Piping, Supports, Anchor Bolts.
(3) BFP-M must be operated under curve given by BFP-M manufacture, for the
safety of operation. One must check that motor driven feed water pump trips
when it operates beyond its limit.
D. Pre-step
through Reheater coils. Hence, the firing rate is controlled so that the furnace
outlet temperature is maintained below 538℃. Elevation AB Oil guns are put into
service maintaining approximately 10%TMCR firing. Boiler pressure is slowly
increased till the separator outlet pressure is approximately 40 Kg/cm2g. Oil firing
is put off and BCP is turned off. The temporary MOV is open and flushing the
steam flow path as in Pre-step-1 is carried out for 30 seconds.
For the pre-step steam cleaning, start up & operation of boiler is as per boiler
operation manual and the procedures outlined as above.
E. Main Step
- Main Step 1 : Separator Superheater Main Steam Line Main Stop Valve
Temporary Piping Temporary MOV Non-return Valve Cold
Reheat Line Reheater Hot Reheat Line IPT Stop Valve
Tailpipe to atmosphere
- Main Step 2 : Separator Superheater Main Steam Line Main Stop Valve
Temporary Piping Temporary MOV Non-return Valve Cold
Reheat Line Reheater Hot Reheat Line LP Bypass Valve
Tailpipe to atmosphere
Start-up and blowing process for main step are same as that of pre-step except
that the steam blowing path and steam blowing pressure are different.
Steam blowing is fulfilled with Cleaning Force Ratio above 1.0 and also checking
that the pressure drop in main steam piping is over 7.29 Kg/cm2 at selected
measurement points.
The amount of Pressure drop in Cold Reheat piping and Hot Reheat Piping
should be satisfied over 0.76 Kg/cm2 and 0.97 Kg/cm2 respectively, so that the
Cleaning Force Ratio is over 1.0 in those lines.
It is important to increase pressure step by step to find out proper Cleaning Force
Ratio before steam blowing. It is necessary to check the pipe and equipment after
each steam blowing.
1. Requirements
Each boiler drain line must be blown free of debris with steam water prior to boiler
operation at full pressure. Utilize the following procedure while boiler pressure is between
10 and 20 Kg/cm2g. The best time to perform this procedure is while raising pressure in
preparation for steam line blowing as outlined in the previous procedures. Failure to
adequately blow out the lines will result in debris damage to the seating surfaces on the
drain valves.
2. Procedure
NOTE: Ensure that all drain valves are closed, except for those needed to
correctly fire and raise pressure on the boiler.
1. Walk down the drain line that is to be blown out with steam/water.
Ensure that there are no closed valves, blanks or other obstructions
except the two drain valves located at the header.
2. Open the root or upstream valve (the valve closest to the header) on the drain line to
be blown out.
3. Fully open the second or downstream valve SLOWLY in order to allow the line to
warm up. This should take no more than 2 minutes.
4. Verify that there is flow in the line by checking the temperature of the second or
downstream drain valve. The valve should be noticeably hot. If not then report this to
the Site Representative immediately.
6. Wait 2 minutes and then open the second or downstream drain valve wide open.
11. Ensure that there is no leakage through the two valves when closed. If flow is
suspected, immediately inform the Site Representative.
Move on to the next drain line and repeat steps 1 to 11. Do this for each drain line. Refer
to applicable P&ID's.
OPEN
CLOSED
RSV
NRV
RCV
From
HP Cyl. IP/LP Cyl.
Separator, MSV
Superheater
HP-Bypass
LP-Bypass
CLOSED
OPEN
23
STEAM LINE BLOWING PROCEDURE
Martyr Valve
RSV
HP-Bypass
NRV
CLOSED RCV
From
MSV HP Cyl. IP/LP Cyl.
Separator,
Superheater
CLOSED
HP-Bypass
LP-Bypass
Temporary Pipe
24
STEAM LINE BLOWING PROCEDURE
OPEN
CLOSED
RSV OPEN
NRV Spectacle Flange
RCV
From
MSV HP Cyl. RH IP/LP Cyl.
Separator,
Superheater
OPEN
LP-Bypass
HP-Bypass
CLOSED
OPEN
25
STEAM LINE BLOWING PROCEDURE
OPEN
RSV CLOSED
NRV Spectacle Flange
RCV
From
MSV HP Cyl. RH IP/LP Cyl.
Separator,
Superheater
CLOSED
LP-Bypass
HP-Bypass
OPEN
OPEN
26