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PS-DC-186-500-0003
Sheet 1 of 25
NTPC Ref no SIM/1/TS/1/006
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING OF BOILER AND ASSOCIATED STEAM LINE
INCLUDING AUXILIARY STEAM LINES
SLNO
LIST OF CONTENTS
2.0 OBJECTIVE
3.0 PROPOSAL
8.0 METHOD
10.0 APPENDICES
a) DRAWING
b) LOG SHEET
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0003
Sheet 3 of 25
NTPC Ref no SIM/1/TS/1/006
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING OF BOILER AND ASSOCIATED STEAM LINE
INCLUDING AUXILIARY STEAM LINES
SL.NO STATUS
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0003
Sheet 4 of 25
NTPC Ref no SIM/1/TS/1/006
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING OF BOILER AND ASSOCIATED STEAM LINE
INCLUDING AUXILIARY STEAM LINES
SL.NO STATUS
Line Sizes
2. MSL : 564 x 57
3. CRH : 864 x 24
5. RH to HRH : 720 X 45
6. HRH :969 X 60
7. HP BP line :324 X 35
8. LP BP line :720 X 45
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0003
Sheet 5 of 25
NTPC Ref no SIM/1/TS/1/006
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING OF BOILER AND ASSOCIATED STEAM LINE
INCLUDING AUXILIARY STEAM LINES
SL.NO STATUS
Plant Item completion list for areas such as mechanical, Electrical
and C & I are to be listed out at site.
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0003
Sheet 6 of 25
NTPC Ref no SIM/1/TS/1/006
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING OF BOILER AND ASSOCIATED STEAM LINE
INCLUDING AUXILIARY STEAM LINES
SL.NO STATUS
2.0 OBJECTIVE:
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0003
Sheet 7 of 25
NTPC Ref no SIM/1/TS/1/006
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING OF BOILER AND ASSOCIATED STEAM LINE
INCLUDING AUXILIARY STEAM LINES
SL.NO STATUS
3.0 PROPOSAL:
3.1 The steam blowing is done in five stages. Viz Stage 1 Stage 2
(2a & 2b), Stage 3 (3a & 3b) stage 4a & 4b and Stage 5. The
Electrically Operated Temporary Valve (EOTV) is to be located in
the place as shown in the scheme. Loop pipes from ESV and IV
to turbine are to be taken care for cleanliness before erection and
not to be steam blown.
All critical pipe lines covered in stage 1, 2a, 3a & 3b will be steam
blown using EOTV. Only in Stage 1b, MS stop valve at boiler end
will be used.
3.3 Steam blowing for stages 4a & 4b and 5 are carried out by
continous method. Steam blowing by continous method shall be
done at 40-50% of normal operating pressure of the respective
system for period of 20 to 30 minutes. Blowing repeated after a
time gap of 2 Hrs.
3.4 Both the above techniques give a thermal shock to the contours
being purged and results in loosening of the adhered scale which
is subsequently removed by expanding steam.
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0003
Sheet 8 of 25
NTPC Ref no SIM/1/TS/1/006
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING OF BOILER AND ASSOCIATED STEAM LINE
INCLUDING AUXILIARY STEAM LINES
SL.NO STATUS
3.5 The effects of steam blowing are evaluated and steam blowing
concluded as per the completion criteria given in section 9.0
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0003
Sheet 9 of 25
NTPC Ref no SIM/1/TS/1/006
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING OF BOILER AND ASSOCIATED STEAM LINE
INCLUDING AUXILIARY STEAM LINES
SL.NO STATUS
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0003
Sheet 10 of 25
NTPC Ref no SIM/1/TS/1/006
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING OF BOILER AND ASSOCIATED STEAM LINE
INCLUDING AUXILIARY STEAM LINES
SL.NO STATUS
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0003
Sheet 11 of 25
NTPC Ref no SIM/1/TS/1/006
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING OF BOILER AND ASSOCIATED STEAM LINE
INCLUDING AUXILIARY STEAM LINES
SL.NO STATUS
4.1 Availability of required quantity of DM water and Fuel Oil for the
operation.
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0003
Sheet 12 of 25
NTPC Ref no SIM/1/TS/1/006
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING OF BOILER AND ASSOCIATED STEAM LINE
INCLUDING AUXILIARY STEAM LINES
SL.NO STATUS
5.3 Service water shall be made available near the activity area.
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0003
Sheet 13 of 25
NTPC Ref no SIM/1/TS/1/006
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING OF BOILER AND ASSOCIATED STEAM LINE
INCLUDING AUXILIARY STEAM LINES
SL.NO STATUS
6.1 The group consisting of NTPC and BHEL, which is carrying out
steam Blowing should be aware of procedures to be followed in
case of accidents involving injury to personnel.
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0003
Sheet 14 of 25
NTPC Ref no SIM/1/TS/1/006
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING OF BOILER AND ASSOCIATED STEAM LINE
INCLUDING AUXILIARY STEAM LINES
SL.NO STATUS
- Feed Lines
7.8 All safety valve disc installed after removing hydro-static plug.
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0003
Sheet 15 of 25
NTPC Ref no SIM/1/TS/1/006
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING OF BOILER AND ASSOCIATED STEAM LINE
INCLUDING AUXILIARY STEAM LINES
SL.NO STATUS
7.11 Special steam blowing devices are placed for ESV & IV. These
works are to be ensured before commencing steam blowing.
7.13 HP bypass valves and breakdown orifices are not erected before
steam blowing. Hand operated temp. valves (HOTV 1 & 2) along
with spool piece are erected in its place.
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0003
Sheet 16 of 25
NTPC Ref no SIM/1/TS/1/006
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING OF BOILER AND ASSOCIATED STEAM LINE
INCLUDING AUXILIARY STEAM LINES
SL.NO STATUS
7.19 Flow nozzle, control valves and NRV flaps wherever applicable
are not erected before steam blowing and suitable spool pieces
are erected.
7.24 Required number of Target Plates and holder are made available.
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0003
Sheet 17 of 25
NTPC Ref no SIM/1/TS/1/006
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING OF BOILER AND ASSOCIATED STEAM LINE
INCLUDING AUXILIARY STEAM LINES
SL.NO STATUS
8.0 METHOD:
8.2 First steam blow in stage 1, 2a, 2b, 3a, &3b should be given at a
lower pressure, say 25 kg/sq.cm. at Boiler drum and the pipe
lines including temporary piping are surveyed for proper
expansion and supports. Subsequent blows are given at higher
pressure as given in 8.3.
8.3 Raise the boiler pressure to 50 kg/sq.cm. Shut off firing and at the
same time open the steam blowing valves. (Temporary valve
EOTVs or MS-1, MS-2 as the case may be). The steam lines
which are being steam blown should be warmed up prior to
blowing. The opening of steam blowing valve allows steam to
escape to atmosphere at high velocity carrying with it loose and
dislodged debris. To prevent thermal stresses in the thick walled
shell like drum and headers the saturation temperature change in
drum is limited to 40 deg. C. maximum. Hence, for the purpose of
steam blowing of all critical piping, the steam blowing valve will
be opened at 50 kg/sq.cm. and closed at 25 kg/sq.cm. drum
pressure.
8.4 The water level in the drum swings beyond visible limits at the
start, during and the end of steam blowing. There are chances of
water droplets to carry over to the saturated steam pipes and low
temperature superheater. At the same time too low water level
will affect the C.C. pumps running. Hence optimum level is to be
maintained in the drum. It is preferable to keep just 1 port (50
mm) below the normal level at the time of starting the steam blow.
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0003
Sheet 18 of 25
NTPC Ref no SIM/1/TS/1/006
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING OF BOILER AND ASSOCIATED STEAM LINE
INCLUDING AUXILIARY STEAM LINES
SL.NO STATUS
8.5 At the end of steam blowing, water level in drum will be low and
hence make up the drum level by establishing suitable feed water
flow rate through feed pump.
8.6 All the steam lines are purged as per various stages and it is a
standard practice to limit number of blows per day to 8 with an
interval of 1-1 ½ hours for cooling in addition to overnight cooling.
8.7 The furnace exit gas temperature should be limited to 540 deg. C
to safeguard superheaters and reheaters.
8.10 During steam blowing. MS, CRH & HRH line drains are kept open
to atmosphere without any valve for achieving free and
uninterrupted flow.
8.11 Target Plates will be used for stages 1, 2a & 3a. Stainless Steel
target plates having mirror finish will be used in final stages. In
the preceding stages target plates of M.S will be used. During
steam blowing, pressure and temperature readings at selected
locations will be noted down for the purpose of determining
disturbance factor (Refer Section 10.0 for scheme and method of
calculation).
8.12 Completion criteria for all the stages of steam blowing is given in
Section 9.0.
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0003
Sheet 19 of 25
NTPC Ref no SIM/1/TS/1/006
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING OF BOILER AND ASSOCIATED STEAM LINE
INCLUDING AUXILIARY STEAM LINES
SL.NO STATUS
8.13 While blowing stage 3a, suitable dummies will be put at LPBP
outlet temporary line. Required flange provisions are made in
these temporary lines for installation of dummies. Drains of
suitable size to be provided at the upstream of flange locations
for warm up purposes.
8.14 Following steps are followed for steam blowing stage 4a and 4b.
8.18 Steam inlet valves CRH – 1 CRH - 3 are gradually opened and
steam blowing carried out for 20-30 minutes at about 40-50% of
system operating pressure.
8.19 This blowing is continued with a gap of 2 Hrs between the blows.
8.20 After few blows, Target Plates are put and further blowing
continued. Termination of stage 4a and 4b are as per Target plate
results only as given in Section 9.0.
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0003
Sheet 20 of 25
NTPC Ref no SIM/1/TS/1/006
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING OF BOILER AND ASSOCIATED STEAM LINE
INCLUDING AUXILIARY STEAM LINES
SL.NO STATUS
8.21 Following steps are followed for steam blowing of stage 5. All the
sub-stages are mentioned in Section 3.0.
8.23 System charged as per 8.16 and steam inlet valves in each sub
system are opened gradually & steam blown for 10 minutes
duration.
Signatures
NTPC BHEL
Station: NTPC- Simhadri BHEL Ref No.PS-DC-186-500-0003
Sheet 21 of 25
NTPC Ref no SIM/1/TS/1/006
Plant area: BOILER
PROCEDURE FOR STEAM BLOWING OF BOILER AND ASSOCIATED STEAM LINE
INCLUDING AUXILIARY STEAM LINES
SL.NO STATUS
9.1 For stages 1, 2a, 3a, 4a & 4b the result of the blowing operations
can be judged by the absolute number of pittings on the target
plate in the central zone. The piping is considered clean if there
are not more than 5 (five) pittings and shall not have any
deformed edges. Besides, there shall be no pitting in the rim
zone, ie, area other than central zone. This should be achieved in
three consecutive forget plates. At least, one over night cooling is
to be ensured for steam blowing of pipe lines leading to Turbine.
9.2 In addition to this, for stages 1, 2a, & 3a Disturbance factor value
at selected locations should be 1.4 and above.
Signatures
NTPC BHEL
SHEET 22 OF 25
Q2 MCR x VMCR
Vb
Where
Area = Sq.M
Vb = Cu.m/Kg
K = Constant = 1.3
LOCATION
BLOW
S.NO STAGE I II III IV REMARKS
NO
P T DF P T DF P T DF P T DF
Signatures
NTPC BHEL
SHEET 24 OF 25
10.0 C)
A) MCR Parameters
Predicted
Parameter During
Disturbance
STAGE S.NO Locations Steam Blowing Remark
Factor
Pressure 0
Temp. C
KSC
1 SH O/L (A1-A2) 18.0 420 2.39
1
2 ESV Inlet (B1-B2) 5.0 410 7.15
1 SH O/L (A1-A2) 20.0 420 1.57
2a 2 ESV Inlet (B1-B2) 7.0 410 3.98
3 CRH O/L (C1- C2) 2.0 400 3.56
SHEET 25 OF 25
Predicted
Parameter During
Disturbance
STAGE S.NO Locations Steam Blowing Remark
Factor
Pressure
Temp. 0C
KSC
1 SH O/L (A1-A2) 26.0 420 1.12
2 ESV (B1-B2) 12.0 410 2.25
3a 3 CRH O/L (C1-C2) 5.0 400 1.78
4 HRH O/L (D1-D2) 3.0 400 1.79
5 IV I/L (E1-E2) 2.0 400 2.3