WELCOME

ADANI POWER MAHARASHTRA LTD,TIRODA, 5 X 660 MW

TOPIC- STEAM BLOWING

By- Operation Team

INTRODUCTION
PURPOSE :

Steam blowing of MS lines, CRH,HRH,SH,RH,HP & LP bypass pipe lines of turbine is carried out in order to remove welding slag, loose foreign materials, iron pieces, rust etc. from the system, generated during manufacturing, transportation & erection.

EFFECT OF BLOWING DEPENDS ON

1) 2) 3) Thermal shock Removal force of steam Cleaning force of steam

REMOVAL FORCE OF STEAM

Blowing Mass Flow , Q flow= 1.25 * Qmcr (Vmcr /Vblow)
Qmc= mass flow at MCR Vmc= velocity at MCR

Vblow=blowing velocity

CLEANING FORCE OF STEAM

The necessity to create in the system, the steam velocity greater than that is possible at MCR condition is obvious. These two velocities are expressed as a ratio Cleaning factor or Distribution factor or Cleaning Force Ratio denoted by X or K.

CLEANING FORCE REQUIRED (CFR) OR DISTRIBUTION FACTOR

a) K=Velocity of steam during blowing / Velocity of steam at MCR

b) K= (Steam flow during blowing)2 *(Sp.vol of steam at blowing (Steam flow at MCR) * ( Sp.vol of steam at MCR) Steam flow can be measured by the net feed water flow CFR & velocities of the steam should be verified to avoid Over Blowing The recommended value K > 1.25 ( between 1.25 and 1.4)

PRECONDITIONS FOR STEAM LINE BLOWING

1) Chemical cleaning should be completed 2) SH primary and secondary de-superheater piping

3)

4)

5) 6) 7)

and RHs emergency de-superheater piping ready for operation All permanent piping & temporary piping insulated and supports/hangers are released with cold setting Silencer should be connected at temporary pipe exit Soot blowing for APH should be available Make up for deaerator made ready Motor Driven BFP with all controls made ready

PRECONDITIONS
7) Hydraulic test of the following lines completed: Feed Lines MS, HRH, CRH Lines MS to Aux. PRDS Line All other auxiliary lines identified for steam blowing 8) Sampling system made ready

PRECONDITIONS
9) Boiler auxiliaries proved serviceable and ready after pilot operation like: - Fuel oil system - Compressors & Atomizing steam system - Start-up system ( for continuous system) - Coal Mill system (for continuous system) - CHP readiness - Economizer hopper and bottom ash hopper and its evacuation system (for continuous system)

PRECONDITIONS
10) All safety valve disc installed after removing hydro-static plug in drum(sub-critical), superheaters and reheaters 11) Adequate communication between control room, boiler and TG area ensured. 12) Flow nozzle, control valves and NRV flaps wherever applicable should be not erected before steam blowing and suitable spool pieces are erected. Strainers in the path should be removed. 13) Required number of Target Plates and holder made available

CHEMICAL CLEANING PROCESS

BOILER FRONT SYSTEM ALKALINE FLUSHING
Mass Flushing Hot water Rinsing Alkaline Flushing Hot DM water Rinsing

MAIN BOILER SYSTEM ACID CLEANIG

Super Heater Filling Mass Flushing

Alkaline Flushing
Hot DM water Rinsing Acid Cleaning Passivation

CHEMICAL CLEANING
ACID CLEANING ( BY CITRIC ACID METHOD )will be done by

circulation method for effectiveness of the cleaning process.

Acid cleaning will be followed by PASSIVATION, so that the uniform

protective coating of GAMMA FERRIC OXIDE is formed on the metal surface and corrosion / oxidation damage to metal surface is prevented and continue during normal operation by dosing oxygen. The gamma ferric Oxide formed by using the chemical 1-2 % sodium Nitrite(NaNO2)

BASIC TECHNIQUE USED

1) PUFFING METHOD

2) PURGING METHOD / CONTINEOUS BLOW

METHOD

PUFFING METHOD
To give a thermal shock to the contour being purged,

to dislodge the scale etc. Procedure: Raise the boiler pressure to a predetermined value (40-60 kg/cm2), shut off firing and at the same time open the quick opening valve(EOTV), thus allowing the steam to escape to atm. with high velocity carrying with it the loose debris.

PRECAUTION
The Pressure drop

allowed in drum is limited to corresponding saturation temp. change of 40 OC.

SCHEME
Steam blowing done in stages Stage-1(a)- SH, MSL, ESV, temporary lines from ESV
to EOTV, EOTV to CRH line, CRH lines upto boiler end with temporary exhaust pipe. Tap off lines from CRH to deaerator, auxiliary PRDS, HP heater 6a & 6b, gland sealing, etc. shall be remain closed/isolated. stage 1a end point will be concluded by observing the indents on the target plate.

STAGE- 1(a)

STAGE- 1(b)
SH,MSL, HP bypass inter connection, hand

operated valve mounted in place of HP bypass valve and CRH lines upto Boiler end with temporary exhaust piping. In this stage 6 to 8 blows will be given through HP bypass lines to ensure cleanliness of the limb. Boiler MS stop valve will be used for stage 1b. EOTV will be kept closed. Manually Operated Isolation Valves in HP bypass lines will be kept opened fully.

STAGE- 1(b)

STAGE-2(a)
1a plus reheater, HRH lines , Interceptor Valve and temporary pipe. CRH line along with attemperator shall be welded with reheater before start of stage 2a. LP bypass lines shall be blanked during stage 2a. Stage 2a end point will be concluded by observing the indents on target plates

STAGE- 2(a)

STAGE- 2(b)
2a upto IV + LP bypass lines with temporary

exhaust pipe.

Stage 2b blowing will be parallel blow in the path 2a & 2b. LP Bypass blanks shall be removed for stage 2b. 4 blows will be given through L.P. Bypass line to ensure cleanliness of the limbs

STAGE- 2(b)

STAGE-3 Auxiliary Steam Lines covered in steam blowing are listed below. 3a) Main steam line to Aux PRDS 3b) CRH to Deaerator 3c) CRH to HPH-6. All auxiliary steam lines will be steam blown by continuous blowing method

STAGE-4
The following Aux steam lines, connected to deaerator are steam blown using auxiliary steam from Aux PRDS header.

4a)PRDS to Deaerator. 4b)Extraction 4 to Deaerator. 4c) PRDS to Gland steam header.

CONTINEOUS BLOWING METHOD

The initial procedure is same as puffing method except: - Continuous firing till the completion of steam blowing. No need to shut of the firing during blowing.
- Maintain constant pressure during the blow

Recommended blowing parameters

Dynamic steam pressure MS temp HRH temp Steam flow Corresponding Drum pr. Furnace load

= 3.5 MPa = 420(not to exceed) = 480( not to exceed) = 845 TPH = 40 Ksc 39%

METHOD
- Set the Temporary purging valve, by-pass valve and drain valve and granulating device behind

the temporary pipes

- Check the tightness, support and expansion of

the temporary system

- Section by section rinse of condensate water

piping, feed water piping and boiler through the start-up system to CW system

METHOD:
- Circulation begins when Fe+ in the water of

main feed water pipe and separator outlet will be less than 100 ppm. - Maintain the circulation flow or start-up flow at minimum set value - Start oil firing and raise the temp and press. according to the cold start-up. Temp. rise rate of water wall = less than 2OC / min Temp. rise rate of main steam = 4 ~ 5 OC / min

METHOD:
- Before MS press reaches 1.0 Mpa , open the bypass valve of temporary purging valve to warm the piping with all water drain valves of the system open.

-The blowing system divided into two parts A) Preliminary Steam Blowing
B) Final Steam Blowing

METHOD
PRELIMINARY CLEANING
PORPOSEa)Primary cleaning out sundries and bulky grain deposited in the RH and main steam system b)To ensure fastness of supports and hangers with proper expansion c) Know well about the operation property of oil burning system, condensate water and feed water systems

PRELIMINARRY STEAM BLOWING

- Start the oil firing with max. rating of 15% - Control the gas temperature at furnace outlet below 500 OC (max.538 OC ) - Raise the SH outlet press to 1.6 1.8 Mpa with

steam temperature around 350 OC. - Open the temporary purging valve for 15-20 min to blow in MS system - Maintain K around 0.5. - SH & RH desuperheater water system also cleaned

FINAL STEAM BLOWING

- Main steam and reheated steam system are purged -

in series Start 2-3 coal mills when oil burner hits the rated firing rate of 15% Increase the SH outlet press. to 3.5 Mpa. Maintain the MS temp < 420 OC. Keep HRH steam temp around 480 OC. When the steam line blowing parameter reaches , open the temporary purging valve gradually and increase the fuel and feed water volume to sustain parameter stability.

FINAL .
- Establish the MS flow around 40% of the MCR

(max.- 50%) Ensure CFR (K) should be 1.25 to 1.3 for MS and 1.05 to 1.1 for reheated steam Blow under this operating condition for 20 to 30 min Gradually reduce coal firing and close the purge valve at 0.5MPa . Remove the target plate and check it By estimation, target may satisfy the requirements after 15 to 20 times in-series purging

- When the steam line temp is above the sat. temp of MS press, close all drains and Open the boiler MSSV fully. - Maintain the press. through controlled firing - Insert a reference target - Check the CFR - Allow to run for 30-60 min

TARGET PLATE

Generally Stainless steel panel Target plate set at the first, sixth, ninth, twelfth purging, thereafter set target for each purging until purging results qualified . Width about 8% of the steam vent tubes inner diameter(ID) and length equal to ID Brinell hardness < 90 Steam velocity 258 m/sec Target plates to be introduced just before steam blowing / light upto be removed soon after blowing is completed.

ONLINE TARGET PLATE CHANGE ARRANGEMENT

GLAND PACKING ARRANGEMENT

GLAND PACKING ARRANGEMENT

DEBRIS FILTER

AUX BOILER TO AUX STEAM HEADER

TDBFP INLET
BOILER MS LINE HPSV HPSV HPBP

TEMPORARY PURGING VALVE

CRH LINE

TDBFP-1 SV

TDBFP-2 SV

TEMPORARY LINE PERMANENT LINE

HP,CRH,REHEATER & HRH

BOILER
HPBP HPSV1 HPSV2 CRH LINE IPSV1 IPSV2

HRH LINE

TEMPORARAY LINE PERMANENT LINE

HP BYPASS TO CRH NRV

BOILER HPBP HPSV1

HPSV2 CRH LINE IPSV1

HRH LINE

IPSV2

TEMPORARAY LINE PERMANENT LINE

LP BYPASS VALVE INLET

BOILER HPBP

HPSV1
HPSV2 CRH LINE HRH LINE

IPSV1
IPSV2

LPBP

TEMPORARAY LINE PERMANENT LINE

STEAM BLOWING COMPLETION CRITARIA

At least 2 continuous target plates should not have

ORIFICE GRANULARITY on the target shall be not larger than 0.8 mm.
CFR should be 1.25 to 1.4

No. of orifice granularity shall not supass 08 nos.

ADVANTAGES
- Required less time for completion of the total process
- Less time required to normalize the system for final light-

up to synchronisation
- This reduces the reactionary forces on the temporary pipes
- Stresses on the boiler system are lower

Comparison between Puffing & Contineous Method

PUFFING METHOD
More time required for complete

CONTINEOUS METHOD
Less time required for

steam blowing due to stage wise blowing(8-10 days) More time required for stage wise temporary pipe erection and shifting of blowing device
No mill required Quality of cleanliness is better

completion (3-4 days)

Less time required as only

valves to be opened for different systems

Minimum 02 nos. of mill

than continuous process

required Quality of cleanliness is slightly less than Puffing.

Comparison
PUFFING METHOD

CONTINEOUS METHOD
Steam velocity or Removal

Thermal shock is the driving

force of cleaning More thermal stress on tube material and sudden loading on supports Repeated light-up and shutdown
There is a time gap between

force is the driving force Less thermal stress on tube material

Light-up only once in the

the blows to make-up DM water System normalization time after steam blowing is more Silencer use is optional

beginning of the steam blowing DM water make-up to the system during steam blowing is a challenge System normalization time after steam blowing is less. Silencer use is compulsory.