STEAM BLOWING OF BOILER & CRITICAL PIPINGS INCLUDING AUXILIARY STEAM LINES

Outline of Presentations
Plant details Objectives Services required Safety State of the plant Method Completion criteria

Plant details
Steam Generator is a controlled circulation plus Radiant Reheat (Type CC+RR) Boiler Pipeline dimensions are: MS pipelines(406X38,559 x 54 ) CRH (864 x 35,660X20),HRH LINES (711X25,914 x 30) HP bypasslines(323.9 x 38 / 508 X 25 ) LP bypass lines(610 x 25 )

Plant Details
3 CC pumps are provided to ensure proper circulation of water in the furnace wall circuits. 9 or 10 Mills/RC feeders 2 Seal air fans/P A/ID/FD fans 2SAPH/2PAPH

Objective of Steam Blowing

PURPOSE OF STEAM BLOWING IS TO REMOVE SCALES, LOOSE MATERIAL, IRON CUTTINGS etc. THAT MIGHT HAVE BEEN ENTRAPPED IN S.H, STEAM PIPING, REHEATERS DURING MANUFACTURE.

Services required
Sufficient quantity of DM water and Fuel Oil. Availability of HT / LT / 220 VDC / 110 VAC and other critical Power / Control supplies. Availability of Instrument / Service Air Availability of Lab facility for boiler water regime maintenance. Availability of Auxiliary steam.

Services required
Availability of dosing systems. Availability of permanent fire fighting system and portable fire extinguishers at identified locations. Availability of required lighting / communication facility / manpower. Availability of Public address System or Siren to communicate the commencement of steam blowing. Availability of Ambulance / Fire tender in the Power station premises.

Safety
The blowing area should be barricaded. Required quantities of safety gears such as helmets, Asbestos hand gloves, Ear mufflers etc should be available. First aid box should be available in control room Service water should be available near the activity area.

State of the plant

Boiler is ready in all aspects including interlocks, protections, alarms and measurements, chemical dosing systems, instrumentation etc. A mutually agreed checklist in respect of above should be prepared. MDBFP is ready with all controls, interlocks and protections.

State of the plant

Hydraulic test of the lines to be steam blown is over. All permanent & temporary pipings are insulated and properly supported to withstand the reaction forces during blowing. Locking of all the hangers is released. Feed water and drum water sampling systems are available.

State of the plant

Steam blow off devices are erected for ESVs, IVs and TDBFPs. These are to be ensured before commencing steam blowing of the concerned section. Arrangement for fixing of Target plates is ready. HP bypass valves and breakdown orifices are not erected. Hand operated valves and spool pieces are to be erected at their places. CRH Attemperator is not erected instead a spool piece is erected till Stage 2b steam blowing is declared complete.

State of the plant

MS stop valves at Boiler outlet and Electrically Operated Temporary Valves (EOTV) are made operational from Control Room. Strainer elements are removed before the steam blowing operation. Flow nozzle, control valves and NRV flaps wherever applicable are not erected before steam blowing and suitable spool pieces are erected. Downstream lines of IVs and LP Bypass valves, cross around pipes are manually cleaned. All drains are left open to atmosphere suitably outside TG Hall. Required allowances are given for the thermal expansion of the pipe lines.

Method
Steam blowing shall be done in eight stages viz Stage 1, 2a, 2b, 3a, 3b, 4a, 4b & 5. Electrically Operated Temporary Valves (EOTVs) shall be located as shown in the scheme. Loop pipes from ESV and IV to Turbine shall not be steam blown. Hence proper care shall be taken for cleanliness of the pipes before erection. All critical pipelines covered in stages 1, 2a, 3a and 3b shall be steam blown using EOTVs. Only in Stage 2b, MS stop valve at Boiler outlet shall be used. Puffing method shall be adopted for carrying out Steam blowing of stages 1, 2a, 2b, 3a & 3b in which Boiler Drum pressure shall be raised to 50 Kg/cm2 and released through a quick opening valve and steam blowing done till the Drum pressure drops from 50 Kg/cm2 to 25 Kg/cm2.

Method
Steam blowing for stages 4a, 4b and 5 shall be carried out by continuous blowing method. Duration of each blow shall be 20 to 30 minutes. The time gap between two blows shall be around 2 hours. The effects of steam blowing shall be evaluated and steam blowing concluded as per the completion criteria

STEAM BLOWING SCHEMEEOTV

MS STOP V/V

A C

R H O H D R

R H I H D R

D E S H

S H I H

S H O H

ESV M S L

D
C R H N R ESV V EOTV

HOTVs HPBP SPOOL PIECE 450

A
C E

THRO / BLANK FLANGE

HPBP LINE LPBP V/V CRH LINE

HRH LINE
-- S.H & MS LINE --THRO / BLANK FLANGE -- CRH & HPBP --TARGET PLATE -- R.H & HRH LINE -- LPBP LINE -- TEMPORARY PIPING -- PERMANENT PIPING LPBP V/V

E
TO CONDENSER

HOTV-HAND OPERATED TEMPORARY VALVE -- OPEN INDICATION -- CLOSE INDICATION EOTV ELECTRICALLY OPERATED TEMPORARY VALVE

--UN TREATED PIPE

STAGE-I
MS STOP V/V

EOTV

A C

R H O H D R

R H I H D R

D E S H

S H I H

S H O H

ESV M S L

D
C R H N R ESV V

HOTVs
HPBP SPOOL PIECE 450

EOTV

A C E

THRO / BLANK FLANGE

HPBP LINE LPBP V/V CRH LINE HRH LINE -- S.H & MS LINE --THRO / BLANK FLANGE -- CRH & HPBP --TARGET PLATE --UN TREATED PIPE -- TEMPORARY PIPING -- PERMANENT PIPING LPBP V/V

TO CONDENSER

-- R.H & HRH -- LPBP

-- OPEN

-- CLOSE

STAGE-1 FLANGES BLOW OFF COVERS "B,"C,"D&"E V/V OPENED SUPER AT 50 MS STOP STEAM BLOWING VALVES IN IS TO BE ARE Ksc HEATERS & BLANKED, CLOSED & MS AT LINE "A 25 IS UP Ksc TO OPEN CARRIED CONDITION OUT USING EOTVS OPENED DRUM ESV PRESSURE

STAGE-IIA
MS STOP V/V

EOTV

A C

R H O H D R

R H I H D R

D E S H

S H I H

S H O H

ESV M S L

D
C R H N R ESV V EOTV

HOTVs

A C E

THRO / BLANK FLANGE

HPBP SPOOL PIECE 450

HPBP LINE

LPBP V/V
CRH LINE

HRH LINE
-- S.H & MS LINE --THRO / BLANK FLANGE -- CRH & HPBP --TARGET PLATE --UN TREATED PIPE -- R.H & HRH -- LPBP -- OPEN -- CLOSE -- TEMPORARY PIPING -- PERMANENT PIPING LPBP V/V

E
TO CONDENSER

FLANGES SUGGESTED STAGE-2 COVERS A,B,"D&"E BLOWING S.H, MS JUMPER MS STEAM DESH STOP IN BLOWING CRH LINE VALVES LINE CONN. IN IS ISTO TO NOT BE CRH TO IS ARE PRESSURE LINE,JUMPER BLANKED, IS AFTER CONNECTING FROM C IS 50KscTO OPEN CARRIED BE TO BE ERECTED CONDITION TAKEN OUT USING EOTVs EOTVS OPENED 25 ESV Ksc & CRH LINE INSTALLED FOR STAGE-1

STAGE-IIB
MS STOP V/V

EOTV

A C

R H O H D R

R H I H D R

D E S H

S H I H

S H O H

ESV M S L

D
C R H N R ESV V EOTV

HOTVs

A C E

THRO / BLANK FLANGE

HPBP SPOOL PIECE 450

HPBP LINE

LPBP V/V
CRH LINE

HRH LINE
-- S.H & MS LINE --THRO / BLANK FLANGE -- CRH & HPBP --TARGET PLATE --UN TREATED PIPE -- R.H & HRH -- LPBP -- OPEN -- CLOSE -- TEMPORARY PIPING -- PERMANENT PIPING LPBP V/V

E
TO CONDENSER

FLANGES STEAM STAGE-2B BLOWING A,"D&"E COVERS IS S.H, TO ARE BE MS DESH EOTVs IN ARE CRH INLINE CLOSED IS NOT TO BLANKED, CARRIED LINE,H.P BYPASS OUT B&C USING LINE& ARE MSCRH CONDITION BE ERECTED OPENED STOP LINE VALVES

STAGE-IIIA
MS STOP V/V

EOTV

A C

R H O H D R

R H I H D R

D E S H

S H I H

S H O H

ESV M S L

D
C R H N R ESV V EOTV

HOTVs

A C E

THRO / BLANK FLANGE

HPBP SPOOL PIECE 450

HPBP LINE

LPBP V/V
CRH LINE

HRH LINE
-- S.H & MS LINE --THRO / BLANK FLANGE -- CRH & HPBP --TARGET PLATE --UN TREATED PIPE -- R.H & HRH -- LPBP -- TEMPORARY PIPING -- PERMANENT PIPING LPBP V/V

E
TO CONDENSER

-- OPEN -- CLOSE

SUGGESTED MS FLANGES STEAM STAGE-3A DESH STOP IN BLOWING CRH VALVES A,B&"E COVERS BLOWING LINE ARE IS CAN S.H, TOARE BE MS BE IN OPEN CONDITION BLANKED, CARRIED LINE,JUMPER ERECTED PRESSURE OUT C&D IS 50 CONNG. USING KscTO ARE EOTVs ESV 25Ksc OPENED &CRH LINE,CRHLINE,R.H,HRH

STAGE-IV A
NEAR DEAERATOR FROM CROSS AROUND PIPES FROM IP / LP CROSS AROUND TO DEAERATOR FROM CRH

BACK TO INDEX

CRH-1

CRH-3

FROM IP / LP CROSS AROUND PIPE CRH-2 CRH-4

FROM APRDS HEADER

TDBFP-A

TDBFP-B

8 February 2014

PMI Revision 00

20

LEGEND :
1) D- Flange with or without dummy or temporary valve 2) TP:Target plate & assembly

5b 5a
APRDS

3) Stages 4a : CRH to TD BFP -1 4b : CRH to TD BFP -2

4b 4a & 5a 4b & 5b
TP

5a : APRDS to TDBFP-1 5b:APRDS to TDBFP-2 5c:CRH to EXT 4 5d : CRH to EXT 4 to D1 5e : CRH to DEA 5f :CRH to HP HEATER

FROM MSL

5i

5h
D
TP

5f

4a TD BFP-1
FROM CRH LINE

TD BFP-2

5g: CRH to GS 5h : CRH to APRDS 5i : MSL to APRDS Temporary Line

HPH 6B

FROM

5f

CRH LINE

5g
NOTE: 1) NRV Flaps to be removed wherever required

5e
HPH 6A

2) Direction of steam blow to be decided as per erection readiness of CRH vis--vis APRDS system

DE

3) Dummies/Temporary valves to be provided

FST

5d

where required.

5c

Completion criteria
Stages 1,2a, 2b, 3a, 4a, 4b, 5a, 5b For the first few blows Target plates need not be kept. Afterwards Target plates made of Mild Steel are to be used. For Final blows (for completion declaration) Stainless Steel Target Plates having mirror finish are used.

Completion criteria
Steam blowing can be declared complete only after ensuring cleanliness of target plates. The highest steam velocity being at the centre of the pipe, the effectiveness of steam blowing is judged by the absolute number of pittings on the target plate in the central zone i.e., the area covered by 3/4th of the diameter of the pipe. The piping is considered clean if there are not more than 5 (five) pittings on the target plate central zone and there are no deformed edges. This should be achieved in three consecutive plates. In addition to this, for stages 1, 2a and 3a Disturbance Factor at selected locations should not be less than 1.4.

Completion Criteria
Stage 3b Minimum 8 (eight) numbers of blows are to be given. Stages 5c to 5j Steam blowing is declared complete based on visual observation. Minimum three nos. of blows shall be given for each sub stage

DISTURBANCE FACTOR
Disturbance factor is the ratio of kinetic energy during blow condition and kinetic energy during MCR condition. Mathematically this is expressed as: b . Vb2 Disturbance factor = --------------- m . Vm2 where . V / . V are density & velocity at b b m m blow /MCRcondition

DISTURBANCE FACTOR
= b. Fb2/ m. Fm2 where b, m - Specific volume at blow & MCR condition and Fb , Fm - Flow at blowing and MCR condition respectively. MCR parameters: Steam flow at SH o/l =1675 t/hr,Sp vol =.018154m3/kg, Fm=465.2778KG/SEC

SKETCH FOR TARGET PLATE & ASSEMBLY (TYPICAL)

Plate A Tube ( Screw on Cap )

Tube Screw Plate Retainer Target Plate B Plate Plate Rod Rod 40 5 25

NOTE:

1 Tempoprary line shall be of carbon steel and size of the line shall be atleast equal to that of main steam line .For the purpose od designing .The rated parameters of the Boiler shall be taken.

25

2. The target plates supplied are of machined and polished one. MATERIAL: Stainless Steel

Special precautions
DRUM LEVEL SHOULD BE MAINTAINED AT LOWEST PORT (VISIBLE LIMIT) BEFORE THE START OF EACH BLOW TO AVOID WATER DROPLETS CARRYOVER TO THE SATURATED STEAM PIPING. NUMBER OF BLOWS PER DAY ARE LIMITED TO 8 WITH AN INTERVAL OF 1 Hrs FOR COOLING IN ADDITION TO OVER NIGHT COOLING