Professional Documents
Culture Documents
THERM-SERVICE
fr Kraftwerke und Industrie GmbH
by
Martin Herberg, dipl. eng., Therm Service GmbH, Seevetal, Germany
Dr. Eng. Zoran Micevic, Energoprojekt-Entel, Belgrade, Serbia
Dr. Eng. Slobodan Djekic, Inter Kontakt-Energo d.o.o., Serbia
10.10.2014
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Content
1.
1.1
1.2
1.2.1
1.2.2
1.2.3
1.2.4
Introduction.................................................................................................................................................... 4
Therm Service GmbH ...................................................................................................................................... 5
Kostolac B2 Project Data................................................................................................................................. 5
Boiler design data ......................................................................................................................................... 5
Volumes ........................................................................................................................................................ 5
Key dates acid cleaning ................................................................................................................................ 5
Key dates steam blow................................................................................................................................... 5
2.
2.1
2.1.1
2.1.2
2.1.3
2.1.4
2.2
2.3
3.
3.1
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.5.1
3.2.5.2
3.3
3.3.1
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
4.
4.1
4.2
4.3
4.3.1
4.3.2
4.4
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
4.4.6
4.5
4.6
4.6.1
4.6.2
4.7
5.
5.1
5.2
5.3
5.4
5.4.1
5.4.2
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 2
5.5
5.6
5.7
5.7.1
5.7.2
5.7.3
5.8
5.9
5.10
5.11
5.11.1
5.11.2
6.
6.1
6.2
6.2.1
6.2.2
6.2.3
7.
7.1
7.1.1
7.1.2
7.1.3
7.1.4
7.2
7.2.1
7.2.2
7.2.3
8.
Bibliography................................................................................................................................................. 36
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 3
1.
INTRODUCTION
The main goal of this paper is to show the state of the art of cleaning technology for modernization and
reconstruction/life time extension of large Thermal Power Plants based on the example of TPP
"Kostolac B2".
Thermal Power Plant "Kostolac B2", 348.5 MW, consists of two pressure stage Sulzer type boiler. It was
commissioned in 1992. For this unit a life time extension of about 15 years was decided and therefor a
major modernization and reconstruction was performed in 2012.
Before running again into service, an operational cleaning followed by a steam blow had been
performed. The paper will further indicate the importance of a structured planning, needed to transact
such projects technically and financially effective.
Before it came to the cleaning process itself the most important requirement alongside detailed
knowledge about the plant and chemical processes, was a close cooperation between the owner, the
project leader and the cleaning service company.
Regarding the preparatory work at the plant (e.g. temporary connections, dismantling valve inserts, etc.)
approximately fifty points at water- steam cycle were considered at TPP Kostolac B2. Therefore, placing
the order at the earliest possible moment means time that enables contracting parties to do a proper
engineering, to organize, buy and/or construct material and equipment required for an optimal cleaning
process realization.
The chosen combination of chemical cleaning and steam blowing at TPP Kostolac B2 assured the best
possible cleaning result and an optimal time schedule to the project. Chemical cleaning was dedicated
to remove iron oxides and all mineral deposits up to the metal, including cupper removal. Steam blowing
was dedicated to removal of all remaining after installation and creation of proper conditions for
introduction of steam into turbine without operational risk.
Further advantages of such approach of combining chemical cleaning and Steam blowing were:
Orders integration avoids coordination problems.
Short rebuilding phases between chemical clean and steam blow.
Use of temporary steam blow pipes for execution of chemical cleaning.
Use of same equipment (valves inserts pumps etc) for chemical cleaning and steam blow (saves
critical path time).
Temporary steam blow pipes are already cleaned up to the target.
Because of the detailed preparation the erection of the temporary chemical clean and steam blow
material could start and finish as scheduled.
The chemical cleaning process itself was carried out successfully within 4 days, followed by the steam
blow of HP-, RH-System and common steam lines within 2 days of effective steam blowing.
The process at TPP Kostolac B2 shows generally that the combination of chemical clean and steam
blow is the most effective process to shorten time for commissioning of boiler plants for operational or
pre-operational cleaning.
Additionally it shows that the order shall be placed as early as possible to have sufficient time for
different arrangements to assure a manageable process and finally to avoid unnecessary time losses
and expense.
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 4
1.1
1.2
1.2.1
1.2.2
VOLUMES
Unit sections
Volume HP
Volume IP
Volume total
1.2.3
1,000 t/h
186 bar
540 C
46.3 / 42.9 bar
337.5 / 540 C
416
244
660
m3
m3
m3
1.2.4
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 5
2.
MAIN PART
2.1
2.1.1
OFFER STAGE
First offer based on real plant data was prepared on 02nd February 2010.
2.1.2
CONTRACTING STAGE
Contracts for chemical cleaning and steam blow have been finally signed by the customer on March 30st
2012.
2.1.3
ENGINEERING STAGE
The basic engineering for chemical cleaning and steam blow on May 15th 2012.
The final engineering for chemical cleaning/Steam blowing dated on
September 11th/18th 2012
2.1.4
2.1.4.1
2.1.4.2
Steam Blow
18.11.-23.11.2012
2.2
2.3
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 6
3.
3.1
GENERAL
The purpose of each internal cleaning is to reach steam purity stipulated in VGB-R 450 L as soon as
possible after the start up of the unit.
In principle each internal cleaning is based on two different processes (physical/chemical) independent
of the method used.
Removal of insoluble substances
The insoluble substances in the system to be cleaned like swarf, welding beads, wood and fibre of
insulating sheetsetc will be discharged out of the system by flushing.
Removal of soluble substances
By use of chemicals substances like salts, grease, rust, scaleetc will be dissolved. The dissolution
rate of iron oxides increases proportionally to the acid concentration and exponentially due to
increase in temperature; as a rule, the dissolution rate doubles per 10 K temperature increase.
By combination of these steps it is possible to discharge scales including soluble substances, solved
or dissolved, and the remaining insoluble substances.
3.2
DEFINITION
Pre-operational chemical cleaning
Use of acids in water and steam-wetted plant components for the purpose of creating defined clean
surface conditions so that protective layers can be built-up.
Operational chemical cleaning
Operational cleaning is the removal of deposits accumulated during plant operation.
3.2.1
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 7
3.2.2
PREPARATORY MEASURES
The development of a suitable procedure, comprehensive planning, co-operation of the parties involved,
the determination of responsibilities for personnel as regards the operation of system and temporary
valves, and the permanent monitoring of the cleaning procedure will be decisive for successful cleaning
of the plant. Following need to be considered:
valves not resistant to acid cleaning (e.g. chromium clad and nitrided steels) shall be protected or
otherwise be dismounted.
provision of storage capacity for water and waste water.
procurement of acid-resisting valve trim.
disassembly of check valves, spray water control valves, pumps (circulating pumps), strainers,
distributor nozzles, flow-metering equipment installed (where required), etc.
fabrication of temporary pipework, control of materials for resistance to acid cleaning and of plant
components for possible chemical pre-treatment and/or coatings, the cutting-off of tube samples (dry
saw-cutting) is also of importance prior to the beginning of cleaning operations to ensure that the
cleaning is successful.
orifices to be replaced by adapters or remain in the system. Agreement between the purchaser and
the cleaning firm must be found as early as possible.
The local authorities responsible shall be consulted as early as possible with respect to waste water
treatment and effluent disposal conditions required after such cleaning procedures.
3.2.3
3.2.4
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 8
When disposing off organic acids, the increased COD value of the effluent shall be taken into account.
In most European countries it is not permitted to directly discharge waste water containing EDTA which
shall be disposed off separately.
3.2.5
PROCEDURE
The use of demineralised water for all procedural steps of pre-operational cleaning is the rule.
Principally, distinction is made between the open-circuit (OC) method and the closed circuit (CC) or
circulation method.
PROCEDURAL STEPS
3.3.1
FLUSHING
To remove coarse contaminants or the agents, flushing with demineralised water at a flow rate >0.5 m/s
shall
be
effected
until
a
turbidity
<0.2
has
been
obtained.
In general the higher the velocity the better is the result of the flushing.
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 9
3.3.2
HEATING-UP
Via a temporary pipe system it must be ensured that the whole system to be cleaned can be circulated
during the heating process.
3.3.3
1,2
12
10
0,8
HF inlet
HF outlet
0,6
Iron Fe
0,4
0,2
0
0
10
15
20
25
30
35
Open-circuit method
1,4
40
time [min]
3.3.4
6
]
[% 5
l
C
H
n 4
io
t
a
tr 3
n
e
c
n
o 2
C
6
5 /l]
[g
t
e
t
n
4 n
HCl
o
3 c
Iron
n
o
r
2 I
0
0
0,5
1,5
2,5
3,5
4,5
Time [h]
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 10
3.3.5
3.3.6
PASSIVATION
Alkaline pH adjustment of the system fill water shall then be made with ammonia to obtain a pH value of
10. Where passivation is performed, a 30 to 35 % hydrogen peroxide solution shall additionally be
injected shortly after having started the alkalisation. In the system a concentration of 0.1 to 0.3 % by
volume shall be obtained. The temperature shall not exceed 40 C.
When applying the circulation method the clean surface formed in the acid phase will corrode again
depending on the process and duration of flushing. Citric acid may be used for dissolving initial rust by
complexing the iron.
Where citric acid is used, the high COD content of the solvent effluent should be taken into account.
Sodium nitrite (danger of nitrous fumes formation) and hydrazine should not be used for environmental
protection and safety and health reasons.
4.
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 11
Where copper is found in layer examinations, specific additional copper removal steps shall be taken
since
copper
cannot
be
removed
with
the
standard
cleaning
procedure.
In the case of power plant equipment made of copper-containing materials, often an increased copper
ingress into the boiler system is observed. Copper may partially enrich in the protective layers and lead
to considerable problems during chemical cleaning where necessarily performed. In addition, copper
may be transported via the steam to the high-pressure steam turbine and be deposited on the blades of
the high-pressure steam turbine section thus leading to considerable loss of turbine efficiency.
On evaporator tube samples the amount of deposits on the heat-loaded surface is generally clearly
higher than on the other part of the furnace walls. These examinations result in the choice of the
cleaning chemicals and duration of chemical treatment which, when compared to laboratory studies
made, may lead to deviations due to differing conditions between volume and surface, flow rate and
temperature.
4.1
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 12
ACID CLEANING
In most cases, the acid mixture to be determined by laboratory studies is a mixture of hydrochloric acid
and hydrofluoric acid. This solution should, however, be renewed at a total iron content of approx. 15g/.
Practice has shown that at higher iron contents the inhibitor protective function is not guaranteed
anymore and thus an incalculable risk of corrosion attack up to plant damage exists.
The first use of hydrochloric acid and, in a second stage, of hydrofluoric acid, may also become
necessary.
Hydrochloric acid should not be used for the operational cleaning of austenitic materials as there will be
the risks of chloride-induced stress corrosion cracking and crevice corrosion.
Copper removal methods may be used individually or in combination:
copper removal prior to chemical cleaning,
copper removal during chemical cleaning,
copper removal upon chemical cleaning,
copper removal along with passivation.
For these methods oxidising agents (e.g. hydrogen peroxide, atmospheric oxygen, bromates) and,
where required, additional complexing agents (EDTA, NTA, EDA, thioamines) will be used.
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 13
4.3
PROCEDURE
Principally, distinction is made between the open-circuit and the closed circuit (circulation) method.
4.3.1
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 14
4.3.2
The treatment to the circulation method comprises several procedural steps as follows:
Depending on the measurement for copper the copper removal has to be fixed either/or or even
combined.
Removal of copper (optional)
Pre-flushing, where required
Heating-up
Treatment with inhibited acid/mixture of acids
Removal of copper during chemical cleaning
Displacement of acid
Flushing to low conductivity
Removal of initial rust, if any
Removal of copper, if any
Alkaline treatment with ammonia and, where required, passivation with hydrogen peroxide and
Removal of copper if any
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 15
4.4
PROCEDURAL STEPS
4.4.1
HEATING UP
Via a temporary pipe system it must be ensured that the whole system to be cleaned can be circulated
during the heating process.
4.4.2
14
1,2
12
10
0,8
HF inlet
HF outlet
Iron Fe
0,6
0,4
6
4
0,2
Open-circuit method
1,4
0
5
10
15
20
25
30
35
40
time [min]
4.4.3
]
%
[ 5
l
C
H
n 4
io
t
a
rt
n 3
e
c
n
o 2
C
l]/
g
[
t
4 n
e
t
n
o
3 c
n
ro
2 I
5
HCl
Iron
0
0
0,5
1,5
2,5
3,5
4,5
Time [h]
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 16
4.4.4
4.4.5
PASSIVATION
Alkaline pH adjustment of the system fill water shall then be made with ammonia to obtain a pH value of
10. Where passivation is performed, a 30 to 35 % hydrogen peroxide solution shall additionally be
injected shortly after having started the alkalisation. In the system a concentration of 0.1 to 0.3 % by
volume shall be obtained. The temperature shall not exceed 40 C.
When applying the circulation method the clean surface formed in the acid phase will corrode again
depending on the process and duration of flushing. Citric acid may be used for dissolving initial rust by
complexing the iron. By the alkalisation with ammonia and addition of hydrogen peroxide a thin oxide
layer will be formed to prevent further corrosion of the plant for approx. 4 weeks in dependence of the
degree of dryness of the system. Plants to be started up within a few days need not be passivated.
Here, alkaline flushing with ammonia will generally suffice.
Where citric acid is used, the high COD content of the solvent effluent should be taken into account.
4.4.6
COPPER REMOVAL
In order to be able to perform chemical cleaning in plants showing copper-containing deposits,
extensive examinations and dissolution tests shall be performed on tube samples with deposits. Only by
this way can the chemicals to be used and the most effective procedure be determined.
The following cleaning procedures have proved to be effective in practice:
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 17
4.5
INHIBITORS
To protect materials against acid attacks, corrosion inhibitors are used depending on type of inhibitor
and acid used. The inhibitors shall prevent the acid from attacking the metal without preventing the
removal of deposits. The maximum allowable operating temperature fixed for each inhibitor shall not be
exceeded since otherwise the inhibitor will decompose and become ineffective.
Therefore, heating up of steam boiler plants filled with acid cleaning solution by means of the plant firing
system shall be refused.
4.6
MONITORING
4.6.1
PARAMETERS TO BE MONITORED
The success of pre-operational/operational chemical cleaning largely depends on the careful execution
and monitoring of the process. The parameters to be monitored are:
Parameter
Turbidity
Iron
Copper
Acid concentration
Temperature
Conductivity
pH value
Redox potential
Inhibitor test
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 18
Schematic for monitoring of operational cleaning with e.g. hydrofluoric acid and hydrochloride acid:
Procedural steps
Functional check
Acid treatment
Guide value
Open-circuit method
Condition
Parameter
Operating supplies
Available
Plant components
Leak tightness
Flow rate
< 0.5 m/s
Iron
< 2g/
Temperature
50 - 80 C
Acid
1 10 %
1 10 %
Corrosive attack on
metal
Inhibitor test ok
Inhibitor test ok
Conductivity
difference
< 10 S/cm
< 20 S/cm
Circulation
method
Constant
(< 15 g/)
Flushing to low
conductivity
Removal of initial
rust
Flow rate
> 0.5 m/s
Temperature
< 40 C
Alkalisation
Copper removal
Passivation
Platinum electrode
against silver/silver
chloride or
Indicator sticks
Post-flushing
Iron
< 1 g/
Citric acid
> 0.5 %
No visible sign of
flocculation during
alkalisation
pH value
Copper
> 10
> 9.5
constant
Redox potential
positive
positive
H2O2
Redox potential
verifiable
positive
verifiable
positive
Oxidation means
(preferably H2O2)
verifiable
verifiable
pH value
> 10
> 10
Required
Optional
4.6.2
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 19
On completion of copper dissolution treatments the surfaces shall be clean and free from copper
(visual examination).
A QA plan should be agreed between all parties involved prior to performing the cleaning process.
Visual examinations shall be performed on visually inspectable plant components e.g. drum,
headers, connections for temporary pipework) and on tube specimens. Residual deposits may be
determined analytically on tube specimens.
Parameter
Metal loss
Measurement procedure
Determination of weight loss on the materials used in the system circuit
Residual deposit
The procedure shall not cause damage on the component subjected to cleaning and adjacent plant
parts. It shall be verified that the materials used in the plant circuit are not endangered by the chemical
treatment and the process applied. The corrosive attack on metals shall be determined by the weight
loss method.
Upon operational chemical cleaning the treated surfaces shall be free from deposits and other
contaminants. Residual layers, if any, shall be guaranteed to be less than 20 g/m 2.
As a rule, thin and easy-to-dissolve layers are to be removed during pre-operational cleaning so that the
risk of a great extent of residual layers remaining in the system is relatively low. Since, on the other
hand, welding work is required to determine the amount of residual layers, which may cause danger on
the previously inspected pressurised body, the determination of residual layers can be renounced
during pre-operational cleaning.
The weight loss upon repeated acid treatments shall be determined excluding losses due to corrosive
attack.
The allowable corrosive attack shall be determined using specimens/tube specimens to be installed
externally to the circuit. In addition, further specimens may be taken from the pressurised body;
however, this will mean additional welding work on the pressurised body.
4.6.2.1Pre-operational acid cleaning
The metal loss during pre-operational chemical cleaning depends on the chemicals used. The following
maximum values can be adhered to as experience has shown.
Cleaning agent (inhibited)
Hydrofluoric acid
EDTA
NTA
Hydrochloric acid
Citric acid
Metal loss
20 g/m2
40 g/m2
40 g/m2
20 g/m2
20 g/m2
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 20
4.7
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Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 21
5.
5.1
INTRODUCTION
The purpose of each steam blowing is to protect the downstream steam turbine. This process
requires that the pertinent disturbance factors K are obtained and mechanical steam purity is
proved by means of target plates.
Other processes where disturbance factors are not adhered to and mechanical steam purity is not
verified (by means of target plates), such as blowing-off of steam via start-up lines and other
operational systems, etc. are not considered steam blowing operations for the purpose of VGB
R513 guideline.
PREPARATORY TECHNICAL WORK FOR STEAM BLOWING
Instrumentation and control devices as well as internals such as strainer inserts, orifices, steam
traps and water separators, valves, check valves, or the like which may impair the blowing
through of debris and solid matter, shall also be checked and be dismounted, where required,
prior to steam blowing. For drum type boilers, the separators may remain in the drum during
steam blowing.
SAFETY ASPECTS DURING STEAM BLOWING
Steam blowing of steam generators means working under increased safety risks and high noise
nuisance. It shall also be considered that the plant has not yet proved its effectiveness, space is
restricted (due to erection scaffoldings etc.), and a high number of personnel will be employed to
perform numerous working activities within restricted time schedules.
5.2
5.3
To ensure safe steam blowing operations, the following safety aspects should be
additionally:
steam blowing operations shall be organised and performed by expert personnel.
prior to performing steam blowing operations, a written program and check lists shall be
established and be distributed to the parties involved.
strength analyses shall be made for temporary pipework and equipment.
the erectors and plant users personnel as well as authorities and the public shall be informed
in writing.
during steam blowing operations the steam generator and turbine house shall be evacuated
and be cordoned off by a sufficient number of instructed expert and control personnel.
between the control personnel and the control room permanent and reliable connections (by
radio or cable) should be established.
at suitable locations danger signs shall be installed in sufficient number.
the steam blow exhaust jet should expand safely into a cordoned-off area and not hit any
objects such as buildings, equipment etc.
as a rule, temporary pipework will not be thermally insulated, or where required, will only be
provided with personnel protection insulation.
the area of non-insulated temporary pipework shall be specifically identified (by flutter band,
chains, etc. and signs) so that personnel cannot be injured during the cooling phase of the
pipework.
combustible or other dangerous or sensible materials shall not be stored in the area of
temporary pipework and equipment during steam blowing.
personnel present in the area of increased noise level shall wear suitable ear protection
equipment.
Water quality during steam blowing
The water fed to the water-steam system during steam blowing should have the same make-up
water quality as that used later during operation. Alkalisation of the feed water shall only be
performed with steam-volatile agents such as ammonium, hydrazine or amines, etc. (pH value in
feed water > 9.5, preferred value 9.8).
Due to risk of water droplet carry-over solid conditioning agents such as sodium hydroxide,
trisodium phosphate, shall not be used.
Lecture of operational cleaning and steam blow of large Thermal Power Plant boilers based on Kostolac B2 experience
22
5.4
5.4.1
5.4.2
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 23
The steam blowing operation described lasts approximately two to five hours, including start-up
and shutdown of the steam generating plant. Normally not more than two steam blowing
operations should be effected daily to ensure adequate cooling of the system.
Steam blowing with fully flown-through reheater shall also start during continuous start-up from
cold condition to a given load. The HP steam temperature shall be adjusted by means of the
attemperators to a temperature which shall be adapted to meet the strength requirements for the
cold-leg reheat line. The HP turbine shall be by-passed by means of temporary pipework.
Upon approx. 10 to 20 minutes of effective steam blowing the plant shall be shut down to outage
without interruption so that it can cool down. With the plant having cooled down steam blowing
shall be repeated.
5.4.3
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 24
5.5
Discharge of loose particles such as rust, scale, sand and, to a certain extent, also large foreign
matter. To this end, high steam velocities are required.
Effect 2:
B2 vB
m
K=
;
V2 vV
m
where:
B
m
V
m
vB
vV
=
=
The steam pressure during steam blowing should be selected in dependence of the steam
blowing process, but shall not exceed the maximum allowable working pressure in the other
individual sections.
To avoid erosion damage caused by wet steam, the steam should show minimum superheating
of 15 K during steam blowing, but shall not exceed the maximum operating temperature.
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 25
5.7
TARGET PLATE
5.7.1
A
Section A - A
0.85 x d
40 mm
Flow direction
Plate 6 mm thick
with mirror-finish surface on both sides
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 26
5.7.3
5.8
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 27
5.9
A
100
B
A
A
A A
20
0
5.10
5.11
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 28
5.11.1 SILENCERS
During steam blowing the noise may be reduced by a silencer installed at the outlet of the
temporary blow-through pipework.
Condenser
Since here by-pass operation is concerned and this is a quasi-operating condition, the noise
emitted to the neighbourhood is within routine plant operation so that no further noise reduction
measures are required.
5.11.2 SILENCING THROUGH WATER INJECTION
This process means the injection of water at a suitable location which leads to a reduction of the
exit velocity and of noise development. In industry, this process is known under several
trademarks (e.g. silent steam blowing, dBmin or low-noise blowing).
In sliding-pressure steam blowing operation the noise can be reduced by this method instead of
using a conventional silencer. In this process the velocity of the steam exhausted into the
atmosphere via the temporary steam blow piping is reduced by spray attemperation such that the
use of an additional silencer is not required. Normally, sound pressure levels of less than 90 dBA
at a distance of 10 metres are obtained.
Among others, this process has the following characteristic features:
low steam-blow exhaust pressure and extremely reduced steam temperature in the temporary
pipework downstream of the point of injection.
low steam-blow exhaust pressure ensures a major cleaning effect and a high disturbance
factor K.
extreme reduction of sound pressure level (< 90 dBA at a distance of 10 m)
little reaction forces in the temporary pipework downstream of the point of injection.
higher water consumption.
large nominal size of temporary pipework.
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 29
6.
6.1
GENERAL
In practice it will happen that regarding internal cleaning prior to first putting into operation, the
plant is to be subjected to pre-operational cleaning and subsequent steam blowing. Here, it is
important to consider the type of cleaning procedure with which the various plant sections can be
cleaned.
Pre-operational cleaning
Pre-operational cleaning can be applied to the total steam-water circuit and, when correctly
planned and performed (see Chapter 6 "Pre-operational Cleaning), in connection with subsequent
by-pass operation will also be suited as single cleaning procedure for the plant.
Steam blowing
Steam blowing can only be applied to the steam section of a plant. When correctly planned and
performed (see chapter 7 "Steam Blowing") steam blowing may be used as single cleaning
procedure for the steam section.
6.2
6.2.1
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 30
Pre-operational cleaning
(1) as a rule, the water velocities obtainable during flushing will be limited. For this reason,
discharge forces are often relatively low so that there is great risk of insoluble residual
matter remaining in the system.
6.2.2
6.2.3
7.
7.1
CHEMICAL CLEANING
DISSOLVED IRON
[kg/m]
7.3
VOLUME
[m]
770
TOTAL OXIDE
[Fe3O4] kg
23,300(1)
The table below shows the amount of dissolved and removed copper during the cleaning of
Kostolac B2.
HP, IP/RH cleaning
(1)
DISSOLVED COPPER
[kg/m]
0.303
VOLUME
[m]
770
TOTAL OXIDE
[CU] kg
233(1)
The given value is a calculated value resulting of the measured dissolved iron and copper value. To this value the amount of iron and copper removed during
flushing process has to be added. As this cannot be clearly evaluated it will be only mentioned in this foot note.
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 31
Da
ring surface
Di
Material Loss I
Sample
Pregrejac 1; 2.5
Pregrejac 1; 2.6.3
Pregrejac 3; 2.8.1
Medju-Pregrejac 2; 2.9
Do
[mm]
Di
[mm]
L
[mm]
Ai
Ao
[mm] [mm]
46,800
44,500
36,300
59,100
41,700
39,600
31,900
55,400
52,80
48,00
65,00
40,10
6917
5972
6514
6979
Material
16 Mo3
13CrMo45
X20CrMoV121
10CrMo910
7763
6710
7413
7445
AR
[mm]
Atot
[mm]
W1
[g]
W2
[g]
m
[g]
mML
[g/m]
709
647
471
665
15389
13329
14398
15090
148,0593
121,2392
119,3452
105,1202
147,9582
121,1519
119,2495
105,0189
0,101
0,087
0,096
0,101
6,6
6,5
6,6
6,7
Do
outer diameter
Ao
outer surface
W1
Di
inner diameter
Ai
inner surface
W2
total length
AR
ring surface
Atot
total surface
mML
Table: During acid cleaning removed base material of the Test coupons (limit as per VGB guideline R 513: 20 g/m).
These pictures of tubes cut in half show the successful chemical cleaning process of Kostlac B2.
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 32
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 33
7.2
STEAM BLOW
steam flow
G in [kg/s]
100% load
1
03.12.2012
pressure
p in [bar]
G in [t/h]
G x v
CFR
277,78
1000,00
182,4
543
0,018167
1401,8
77,0
277,2
12,0
465
0,280773
1665
77,0
277,2
12,0
444
0,272419
1615
77,0
277,2
12,0
460
0,278787
1653
4
5
1,2
1,2
1,2
Target
in
out
18:20
18:40
18:40
19:00
19:00
19:20
0,0
04.12.2012
0,0
74,8
269,4
11,0
457
0,303126
1697
74,8
269,3
11,0
454
0,301828
1689
74,8
269,4
11,0
456
0,302693
1695
0,0
10
0,0
1,2
1,2
1,2
C
F
R
a
G a2 v
2
100
G100 v
steam flow
G in [kg/s]
pressure
p in [bar]
G in [t/h]
G x v
CFR
254,00
914,40
43,8
540
0,083312
5375,0
80,0
288,0
450,0
1,113868
7129
80,5
289,8
450,0
1,113868
7218
80,0
288,0
458,0
1,126278
7208
100% load
4
5
Target
in
out
11:50
12:10
12:10
12:30
12:30
12:50
1,3
1,3
1,3
0,0
04.12.2012
0,0
77,6
279,4
445,0
1,106110
6661
77,6
279,4
445,0
1,106110
6661
77,6
279,2
445,0
1,106110
6653
0,0
10
0,0
1,2
1,2
1,2
C
F
R
a
G a2 v
2
100
G100 v
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 34
Figure 1: RA 10 line
Figure 2: RA 20 line
Figure 4: RB 23 line
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 35
7.2.3
TARGET RESULTS
The targets have been in accordance with VGB R513 Guideline.
At no point of the target plates HP and IP sites on an area of 40 mm x 40 mm impacts were found
with the above mentioned extension and number and therefore steam blowing was performed
successfully.
8.
BIBLIOGRAPHY
(1)
VGB PowerTech e.V. Guideline for "Internal Cleaning of Water-Tube Steam Generating Plants and associated
Pipework" [VGB-R 513 e, 2nd edition 2006].
(2)
Die Verwendung von Flusure bei der chemischen Reinigung von Anlagen
[Use of hydrofluoric acid for chemical cleaning of plants], by Bieler und Borchardt (Therm-Service GmbH), VGB
Kraftwerkstechnik, 1978 No. 12, pp 927 930.
(3)
Studija Mere i postupci za pouzdan i efikasan sistem kontrole korozionog stanja vodeno parnog ciklusa TE i TE-TO
EPS-a i preporuke za primenu novih tehnologija, Beograd 2004, by Prof.-Dr. Ljubinka Rajakovi.
(4)
Engineering for chemical cleaning and continous steam blow for Unit 2 TPP Kostolac B Project in Serbia [Revision
3, September 2012], by Martin Herberg (Therm-Service GmbH).
(5)
Reports of chemical cleaning and continous steam blow for Unit 2 TPP Kostolac B Project in Serbia [December
2012], by M. Herberg/P. Pias (Therm-Service GmbH).
Paper for International Conference POWER PLANTS 2014 Zlatibor Serbia, October 28th-31st.
Operational cleaning and steam blow of large Thermal Power Plant boilers (Kostolac B2 experience).
Page 36