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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. Introduction.................................................................................................................................................... 4
1.1 Therm Service GmbH ...................................................................................................................................... 5
1.2 Kostolac B2 Project Data................................................................................................................................. 5
1.2.1 Boiler design data ......................................................................................................................................... 5
1.2.2 Volumes ........................................................................................................................................................ 5
1.2.3 Key dates acid cleaning ................................................................................................................................ 5
1.2.4 Key dates steam blow................................................................................................................................... 5
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 The cleaning effect ........................................................................................................................................ 25
5.6 Cleaning force ratio (CFR)............................................................................................................................. 25
5.7 Target plate ................................................................................................................................................... 26
5.7.1 Dimensioning and surface quality ............................................................................................................... 26
5.7.2 Location of target plate installation ............................................................................................................. 26
5.7.3 Steam blowing results, control, evaluation and records .............................................................................. 27
5.8 Absolute number of impact size per unit area ............................................................................................... 27
5.9 Relative number of impacts ........................................................................................................................... 28
5.10 Control of cleanliness prior to and after steam blowing ................................................................................. 28
5.11 Noise reduction measures ............................................................................................................................. 28
5.11.1 Silencers ..................................................................................................................................................... 29
5.11.2 Silencing through water injection ................................................................................................................ 29
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:
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 THERM SERVICE GMBH
Therm-Service GmbH, was founded in 1966 and has its head office in Seevetal near Hamburg in
Germany.
The main activities are the pre-operational chemical cleaning of steam boiler plants and the operational
chemical cleaning of watersteam circuits of conventional and nuclear power plants as well as the steam
blowing during commissioning to include the related pipework needed for steam blowing, and design
calculations.
The integrated services offered for power and industrial plants as well as with partners in Argentina,
England, Spain, Serbia, Belgium, the Netherlands, Kuwait, India, Saudi Arabia, United Arab Emirates,
Malaysia, Singapore and China support our customers world-wide.
1.2.2 VOLUMES
Unit sections
Volume HP 416 m3
Volume IP 244 m3
Volume total 660 m3
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 PROJECT KOSTOLAC B2 (TIME RELATED)
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 ERECTION AND BUILT UP OF TEMPORARY PIPING
2.1.4.1 Chemical Cleaning
02.10.-09.11.2012 Erection of temp piping
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. BASICS OF CHEMICAL CLEANING BASED ON VGB R 513
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.
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.
Fluids engineering, the determination of the right procedure in consideration of the materials used, and
the selection of the respective chemicals are decisive for successful cleaning.
It is advised to perform pre-operational cleaning whenever the amount of deposits exceeds 100 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 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.
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.
Pre-flushing
Pre-treatment of the system to be cleaned by means of chemicals, e.g. H2O2, wetting agents or
ammonium.
Removal of chemicals, where required.
Heating-up.
Treatment with inhibited acid (e.g. 1 % hydrofluoric acid)
o dynamic phase
o static phase
Removal of acid.
Flushing to low conductivity.
Alkaline treatment with ammonia and passivation with hydrogen peroxide.
Removal of passivation solution with treated DI water (ammonia pH value approx. 10), where
required.
Pre-flushing.
Where required, pre-treatment of the system to be cleaned by means of chemicals, e.g. of H2O2,
wetting agents.
Removal of chemicals, where required.
Heating-up.
Treatment with inhibited acid (e.g. 1% hydrofluoric acid).
Removal of acid.
Flushing to low conductivity.
Removal of initial rust, if any.
Alkaline treatment with ammonia and passivation with hydrogen peroxide.
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.
1,2 12
Hydrofluric acid [%]
0,8 8
HF inlet
0,6 HF outlet 6
Iron Fe
0,4 4
0,2 2
0 0
0 5 10 15 20 25 30 35 40
time [min]
3.3.4 ACID TREATMENT WHEN CLEANING TO THE CLOSED CIRCUIT (CIRCULATION) METHOD
When applying the circulation method for pre-operational acid cleaning, the required temperature shall
be obtained. During heating-up, in-situ temperature control measurements shall ensure that all tubes
are flown through. If the required acid concentration has been obtained, auxiliary pumps shall maintain
circulation until a constant iron content with free acid has been achieved.
Circulation method
7 7
6 6
]
[% 5 5 /l]
l
C
H [g
t
n 4 4 n
io e
t
t n
a HCl
tr 3 o
3 c
n
e
c
Iron n
n r o
o 2 2 I
C
1 1
0 0
0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 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 FLUSHING TO LOW CONDUCTIVITY
Flushing to low conductivity at flow rates > 0.5 m/s shall follow the displacement of acid to ensure that
dissolved mill scale particles are flushed out. Flushing shall be finished if a conductivity of less than 20
S/cm has been obtained referring to the conductivity measured at the inlet.
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.
Chemical cleaning is aimed at removing deposits, improving heat transfer, reducing pressure losses,
and avoiding overheating of materials and corrosion risks. The removal of deposits from the water-
steam cycle of operational plants requires careful selection of chemicals and cleaning methods. Apart
from protective layers, the deposits may also contain hardening salts, phosphates and silicates, carbon,
but also metals and metal oxides (copper, manganese, chromium, aluminium, etc.).
To determine the chemical and process cycles, tube samples shall be examined by all means and the
results of the examination be documented. Prior to chemical cleaning the samples should be taken at
locations where the highest amount of deposits is to be expected with respect to the operational
characteristics and the water-steam analyses. Experience gained from former tube damage, if any, as
well as from observations made during other repair work or change in mode of operation should be
considered. Such locations are e.g. the high heat-release surfaces of the evaporator, the first
superheater tubes as well as the heating surface portions downstream of the spray attemperator, and
the final superheater and reheater.
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.
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 of downstream systems.
An important prerequisite to successful chemical cleaning is the treatment of upstream parts (pre-
boiler system), such as auxiliary steam system, condenser, de-ionised water storage tanks, feed
water tanks, and LP feed heating trains unless included in the operational cleaning cycle.
Where the open-circuit method is applied, all welded joints of the temporary acid dosing line shall be
fully radiographed.
In the case of large steam boiler plant cleaning, the sampling points for analytical control of the acid
cleaning solution should be arranged horizontally. The sampling lines should be provided with ball
valves and the connected hose lines be safeguarded with clamps.
The handling of concentrated acids requires careful attention. Medical care shall be ensured. Eye
washers and safety showers shall be available, and e.g. where cleaning is performed with
hydrofluoric acid, calcium gluconate solutions shall be provided.
The availability of elevators and the provision of functionally fit communication equipment are
important.
When first filling and venting the system to be treated, the emergency shut-off specifically defined for
chemical cleaning, of the feed pump shall be tested at the latest. The plant shall be checked for leak-
tightness. Non-drainable components (e.g. pendant superheaters) shall be completely filled.
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.
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.
The treatment to the open-circuit method comprises several procedural steps as follows:
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 CLOSED CIRCUIT (CC)
According to their design, natural-circulation boilers can only be treated to the circulation method.
Circulation is effected with acid-resisting auxiliary pumps, often supported by the injection of nitrogen to
achieve internal circulation (auto-circulation method) in the evaporator. The drains usually installed will
not suffice for the return of sufficient volume flows from the bottom evaporator headers to the acid
cleaning tank and an as rapid as possible draining of the evaporator. Therefore, the existing inspection
nipples should also be used for draining. The connected temporary pipework should be attached to
ensure safe cleaning operation.
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.
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 ACID TREATMENT WHEN CLEANING IN OPEN CIRCUIT METHOD
The process step "acid treatment" comprises a dynamic and a static phase.
When cleaning the system to the open-circuit method, samples shall be taken at each sampling point
until measurements show an iron content 2g/ and an outlet acid concentration more or less equal to
the inlet concentration. The time required to perform the open-circuit method depends on the reaction
rate of the acid used. A steady phase of 2 to 3 hours shall follow the dynamic phase to remove the
remainder of residual deposits.
Open-circuit method
1,4 14
1,2 12
Hydrofluric acid [%]
0,8 8
HF inlet
0,6 HF outlet 6
Iron Fe
0,4 4
0,2 2
0 0
0 5 10 15 20 25 30 35 40
time [min]
7 7
6 6
]
%
[ 5
l 5 l]/
C g
[
H t
n 4 4 n
io
t
e
t
a
rt n
HCl o
n 3 3 c
e Iron n
c
n
o 2 2 I
ro
C
1 1
0 0
0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 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 FLUSHING TO LOW CONDUCTIVITY
Flushing to low conductivity at flow rates > 0.5 m/s shall follow the displacement of acid.
For the removal of acid and suspended contaminants approx. 3 to 4 plant volumes of DI water are
required. Flushing shall be finished if a conductivity of less than 20 S/cm has been obtained at all
measuring points.
Care should be taken to ensure that all auxiliary lines, water level indicators, blowdown lines, injection
lines, drains and measuring lines are flushed (to avoid back diffusion of acid solution as well as
deposits).
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.
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
Copper removal in acid solutions
During chemical cleaning thiocarbamide will be dosed at the end of the cleaning process in order to
remove the copper film from the deposits and to complex it in the solution. The Fe content in the
cleaning solution will again be increased upon addition of thiocarbamide and should be constant
after approx. 2 hours.
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:
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:
Guide value
Procedural steps Condition Parameter Open-circuit method Circulation
method
Operating supplies Available
Functional check
Temperature Acid 1 10 % 1 10 %
50 - 80 C Corrosive attack on Inhibitor test ok Inhibitor test ok
metal
(Steel wool test)
Metal loss Weight max. 40 g/m2 per max. 40 g/m2 per
loss treatment treatment
Flushing to low Flow rate Conductivity < 10 S/cm < 20 S/cm
conductivity > 0.5 m/s difference
Iron < 1 g/
Removal of initial Temperature Citric acid > 0.5 %
rust < 40 C No visible sign of
flocculation during
alkalisation
Required
Optional
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.
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.
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 EFFLUENT (AMOUNT AND TREATMENT)
Depending on the procedure and plant design up to 14 filling volumes are required. For the collection of
chemical solvents the storage tanks and collecting basins, temporary tanks and foil-lined excavated
basins or the cooling tower basin or pond may be used. To blend the solution, the injection equipment
(lances, perforated hoses) for pressurised air shall be used.
Where hydrofluoric/hydrochloric acid has been used for chemical cleaning, the acid, for the purpose of
waste water treatment, shall be neutralised by the addition of lime (calcium hydroxide) as well as
fluoride and metal hydroxides be precipitated.
In addition, the COD value may be reduced by adding pulverised activated carbon. Upon analysis and
release of the effluent by the competent body or authority, the waste water may be pumped off. The
remaining thin slurry, upon desiccation, e.g. in a chamber filter press, shall be disposed off at a dumping
ground in accordance with the relevant dumping plan. Where the solution is discharged into the public
sewage system, the national local discharge conditions shall be observed.
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 21
5. STEAM BLOWING OF STEAM BOILER PLANTS AND ASSOCIATED PIPEWORK
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.
5.2 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.
5.3 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.
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 STEAM BLOWING PROCESSES
In general there are two different steam blow methods available on the market Pressure built up
method (huff and puff method),
Sliding pressure method.
Prior to steam blowing from cold condition the entire piping system which must have been
completely drained before it should be warmed up with the allowable temperature gradients. This
should especially be considered for thick-walled components (headers, valves and the like).
Condensate, if any, shall be completely discharged.
At the beginning of steam blowing, the first steam blowing operation (initial blowing step) should
not be made at maximum blowing velocity so that problems, if any (restraint to expansion, etc.) in
the steam blowing system can be detected and removed.
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.
For this combined steam blowing process the boiler shall be started up as cold start requirement.
Upon start-up, the steam pressure shall slowly be raised during steam blowing by throttling via
the valves installed in the steam blow circuit and subsequently be reduced to the initial pressure
by opening these valves in due consideration of the maximum allowable pressure and
temperature gradients.
Steam blowing operation shall be performed 2 to 3 times to cover section by section. Then the
steam generator shall be shut down and be cooled. To attain adequate cooling rates the
aforementioned steam blowing operation should be performed only once or two times a day.
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 THE CLEANING EFFECT
The cleaning result of steam blowing is based on two effects.
Effect 1:
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:
Thermal-shock induced exfoliation of adhesive deposits.
Due to the cooling down of the system temperature differentials of up to 350 K will be achieved
which additionally support the thermal-shock induced exfoliation of adhesive iron oxides, since
the metal and the iron oxide show different strain behaviour.
To achieve sufficient thermal-shock on components (e.g. headers and fittings), the metal
temperature of these components should be reduced to approx. 150 C (100 C VGB
recommendation).
Experience has also shown that, at steam blowing temperatures < 300 C, thermal-shock induced
exfoliation has little effect.
B2 vB
m
K= ; the following should be obtained: K = 1.2 to 1.7
V2 vV
m
where:
B
m = mass flow under steam blow conditions, [kg/s]
V
m = mass flow under full-load operating condition, [kg/s]
vB = specific volume of steam during steam blowing, [m3/kg]
vV = specific volume of steam during full-load operation, [m3/kg]
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 DIMENSIONING AND SURFACE QUALITY
The result of steam blowing shall be checked by means of a target plate to consist of a holding
fixture to which a mirror-finished impingement plate of carbon steel with a Brinell hardness
between 140 and 140 HB at room temperature, e.g. S235JRG2 (St 37(3)) is attached.
Should other materials than S235JRG2 (St 37) be used for the target plate, specific agreements
shall be made regarding the assessment of steam purity (impact of debris).
A A
Section A - A
40 mm
0.85 x d
Flow direction
d
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 STEAM BLOWING RESULTS, CONTROL, EVALUATION AND RECORDS
Proper steam blowing results can only be expected if the process and the steam parameters
correspond to the statements made before. Apart from the persons and companies involved, all
relevant data, such as:
disturbance factor,
steam pressure and temperature,
firing rate,
steam mass flow rate,
pressure reduction and number of bursts per steam blowing operation
cooling time and metal temperature of thick-walled components after the cooling phase prior to
repeated steam blowing,
shall be entered in tables and be ordered numerically and recorded with the number of steam
blowing operation.
Foreign matter entrained by the steam will impinge on the target plate surface and leave impacts.
The number, size and edge shape of the impacts will be used to evaluate the results of steam
blowing.
Steam blowing can be completed if the blow criteria have been satisfied. The relative evaluation
shall only be understood as auxiliary means to evaluate the result of steam blowing.
At no point of the target plate reference area shall impacts be found with the following extension
and number:
This evaluation shall only apply to carbon steels, e.g. S235JR (St 37). For other materials specific
agreements shall be made.
In the case of new plants, the evaluation and acceptance of the steam blowing result should be
made by representatives of the plant user and the manufacturers of the steam generator,
pipework and steam turbine. For old plants special agreements shall be made.
The positive completion of steam blowing operations shall be entered in a record to be signed by
the plant user and the manufacturers of the steam generator, pipework and steam turbine. By
signing the record the parties involved recognise the proper completion and positive results of
steam blowing.
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 RELATIVE NUMBER OF IMPACTS
With each additional steam blowing operation (performed with same steam blowing parameters)
the number of impacts on the target plate should be clearly reduced.
For clarification the relative decrease of impact frequency may be illustrated by a diagram as
follows:
A
A B =:Steam blowing operations with reduced steam blow parameters
100 A
B A
20 A A
0
No. of blowing operations [-]
Further internal inspections, where required, should depend on the results obtained. Where dirt
traps are installed in the steam lines, they shall be controlled and be cleaned, where necessary.
Main steam line runs forming dead pockets/legs (e.g. headers or tees) or which have not been
flown through during steam blowing, should be checked for cleanliness when dismounting the
temporary pipework.
It is recommended to cut the caps of sand-blasted headers and to check the headers for freedom
from blasting media.
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.
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. COMBINATION OF PRE-OPERATIONAL CLEANING AND STEAM BLOWING
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.
Cleaning procedures
Steam blowing
o can only be applied to the steam section.
o for the water section an additional cleaning procedure is required.
o the period of time for steam blowing directly depends on the plant fouling condition and
therefore cannot be predicted exactly.
o the necessary temperature cycles are time-consuming and will lead to additional loading of
material.
o is always time-consuming with respect to keeping scheduled commissioning times.
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.
Advantages
maximum obtainable cleaning result and consequently a minimum risk of damage.
more effective keeping to scheduled set of dates is possible.
Disadvantages
higher costs since more temporary equipment, especially for the high-temperature range
> 450 C.
under certain circumstances, require additional project lead times.
Combining pre-operational chemical cleaning and steam blowing by using the same temporary
connections between RA-RC pipelines and release from RB outlet an optimal structure of
temporaqry piping has been obtained. By avoinding installation of separate temporary piping for
each of cleaning steps an economi of time along the criticval pat had been obtained. As addition
a cost saving for temporary piping installation has been achieved.
The table below shows the amount of dissolved and removed copper during the cleaning of
Kostolac B2.
DISSOLVED COPPER VOLUME TOTAL OXIDE
[kg/m] [m] [CU] kg
HP, IP/RH cleaning 0.303 770 233(1)
(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
7.1.2 SAMPLE TUBES / PIECES
The table below show the results of the measured base metal removal rate of the sample
tubes/pieces. The results indicate the good protection due to the inhibitor during the cleaning.
Material loss
Da
ring surface
Di
Material Loss I
Do Di L Ai Ao AR Atot W1 W2 m mML
Sample Material
[mm] [mm] [mm] [mm] [mm] [mm] [mm] [g] [g] [g] [g/m]
Pregrejac 1; 2.5 16 Mo3 46,800 41,700 52,80 6917 7763 709 15389 148,0593 147,9582 0,101 6,6
Pregrejac 1; 2.6.3 13CrMo45 44,500 39,600 48,00 5972 6710 647 13329 121,2392 121,1519 0,087 6,5
Pregrejac 3; 2.8.1 X20CrMoV121 36,300 31,900 65,00 6514 7413 471 14398 119,3452 119,2495 0,096 6,6
Medju-Pregrejac 2; 2.9 10CrMo910 59,100 55,400 40,10 6979 7445 665 15090 105,1202 105,0189 0,101 6,7
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
7.1.4 TREATMENT OF THE WASTE
The waste water stored in a mobile temporary tank (900 m) was neutralised by use of lime
together with demin water to cover the increase of temperature due to thermal reaction. Therefore
two trucks with lime were connected (one after another) to the disposal line and during draining of
the acid solution the lime was injected. After the lime dosing additional demin water was dosed
(approx. 100 t/h) using the existing discharge line coming from the boiler. Before the inlet into the
concrete ash and bottom ash basin, the pH was measured. According to the result the flow of
acid was than adjusted.
Injection of lime during acid neutralisation Mobile waste water tank 900 m
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
7.2.1 DPR-FACTOR (DISTURBANCE FACTOR)
The K-Factors during steam blow of the different parts of the system were equal or
higher than 1.2.
G a2 v
a
CFR =
G100 v
2
100
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
7.2.2 IMPACT INVESTIGATION
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
Investegation was done with mobile microsope MMX 200.
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