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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.
Vblow=blowing velocity
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)
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
Alkaline Flushing
Hot DM water Rinsing Acid Cleaning Passivation
CHEMICAL CLEANING
ACID CLEANING ( BY CITRIC ACID METHOD )will be done by
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)
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
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.
= 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
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
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
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.
DEBRIS FILTER
TDBFP INLET
BOILER MS LINE HPSV HPSV HPBP
CRH LINE
TDBFP-1 SV
TDBFP-2 SV
HRH LINE
HRH LINE
IPSV2
HPSV1
HPSV2 CRH LINE HRH LINE
IPSV1
IPSV2
LPBP
ORIFICE GRANULARITY on the target shall be not larger than 0.8 mm.
CFR should be 1.25 to 1.4
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
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
Comparison
PUFFING METHOD
CONTINEOUS METHOD
Steam velocity or Removal
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
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.