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KPCL – 163MW CCPP – Steam Blowing Operation

1. Normal Procedure:
The steam blowout will be carried out by discontinuous / puffing method using steam from the
HRSG, i.e., no separate source of steam will be used.

One blow is planned for every 4 hours in respective circuit, in order to reduce the temperature of
steam piping, before the next planned blow.

This technique will give thermal shock to the contour being purged to loosen and dislodge the scale
and other debris, which will be subsequently carried by expanding steam and the flow, to the
atmosphere.

2. Steam Blowing Parameter:


Steam blowing parameter is decided based on the guideline of HRSG supplier, CMI (FCH89P06 _ Rev
A, FCH94D98 _ Rev B). As per the recommendations, Cleaning Force Required (CFR) has been
considered as the deciding factor to identify the steam blowing parameter.

In order to ensure physical integrity of HRSG equipment and to achieve the proper efficiency, the
CFR will be maintained in between 1.2 and 1.7.

With above requirements the following steam blowing parameters has been decided for this project:

System Pr. (Bar a) Temp. (Deg. C) Flow (TPH)


HP Steam 25 430 120
LP Steam 5 237 35

The calculation is indicated in ANNEXURE – 1.

However, finalization of the parameters mentioned above are subjected to approval from CMI.

3. Steam Blowing Scheme:


Please refer ANNEXURE – 2 for the steam blowing scheme.

4. Readiness Requirement:

A. Mechanical Readiness:
1. Completion of steam blowing temporary piping arrangement.
2. Completion of requirements as indicated in CMI guideline “FCH89E21_HRSG PREREQUISITE
FOR COMISSIONING EQP_REV-B”.
3. HP / LP steam piping hydro test completion.
4. Spring support erection as per isometric.
5. Temporary arrangement in place of damper support.
6. Clean drain tank piping completion.
7. Service water piping readiness to supply quenching water to Blow Down Tank & Clean Drain
Tank.
8. Service water piping readiness to supply cooling water to LP recirculation pump and BFP.
9. Erection of clean drain tank pit pump.
10. Blowdown pump & Clean drain tank pit pump discharge piping completion up to ETP.
11. Other piping completion as per piping schedule.
12. Temporary piping supports in steam blowing temporary lines (to be provided by MM).
13. WTP DM supply circuit completion.

B. Electrical Readiness:
1. LP recirculation pump running test.
2. LP recirculation pump local panel (low speed to high speed conversion) operation check.
3. BFP / CEP running test with push button arrangement.
4. Temporary MOV (LAB31 AA301) connection in HP steam blowing circuit.
5. Service water pump running test.
6. HRSG blowdown pump, HRSG blowdown pit pump, clean drain tank pit pump running test.
7. HP / LP Main Steam Stop Valve local start / stop operation.

C. C&I Readiness:
1. Completion of instrument erection and associated cabling in HRSG area, HP / LP steam on
priority.
2. Powering on the following transmitters:
a. HP drum level transmitter.
b. LP drum level transmitter.
c. HP drum pressure transmitter (HAD70 CP002).
d. LP drum pressure transmitter (HAD20 CP002).
e. LP economiser outlet pressure transmitter (HAC20 CP001).
f. HP steam header pressure transmitter at STG inlet.
g. LP steam header pressure transmitter at STG inlet.
3. Temporary temperature indicator to be provided for the flowing:
a. LP economiser outlet temperature TW (HAC20 CT800)

D. Operation Readiness:
1. Review of GE functional description to identify the operation philosophy of HRSG.
2. Operation team shall identify the team / persons responsible for manual steam blowing,
with respect to each area of operation.
3. Manpower required by operation team from EPC team (electrical / mechanical / C&I) shall
be informed and approved from PD EPC.
4. Proper training to the team on communication and criticality to be ensured prior to steam
blowing, along with mock drill for this operation.
5. Steps of Steam Blowing Operation:

A. Common Steps:
1. LP Economiser, LP Evaporator, HP Economiser, HP Evaporator to be filled with DM water
using temporary fill pump.
2. LP & HP drum to be filled up to Normal Water Level with DM water using temporary fill
pump.
3. Hotwell to be filled up to 90% with DM water.
4. Ammonium hydroxide dosing to be done in DM water before filling in LP & HP circuit to
maintain the pH in the range of 10 – 10.5.
5. 1 (One) no. service water pump shall be operational to ensure water supply to HRSG
blowdown tank quenching, clean drain tank quenching, LP economiser recirculation pump
cooling and BFP seal cooling. The other service water pump shall be made available to start
if there is any problem in the running pump.
6. Clean drain tank drain shall be kept open to ensure proper draining of tank in to the pit.
7. 1 (One) no. HRSG blowdown pump and 1 (One) no. clean drain tank pit pump shall be
operational to ensure complete emptiness of blowdown tank and clean drain tank pit
respectively to the ETP. The other standby pumps shall be made available to start if there is
any problem in the running pump.
8. All the superheater vents shall be kept in closed condition.
9. All the steam line drains shall be kept in open condition.
10. HP live steam isolation valve (LBA10 AA300) and LP live steam isolation valve (LBD10 AA300)
at HRSG end shall remain close.
11. HP live steam start up vent (LBA10 AA251) and LP live steam start up vent (LBD10 AA200)
shall remain closed.
12. HP sky vent isolation valve (LBA30 AA510) to be kept in closed condition. HP sky vent motor
operated valve (LBA30 AA311) and HP sky vent control valve (LBA30 AA201) shall be opened
manually.
13. LP sky vent motor operated valve (LBD30 AA301) shall be kept in closed condition. LP sky
vent control valve (LBD30 AA201) shall be opened manually.
14. HP & LP steam blow sacrificial / martyr valve at temporary piping shall be in closed
condition.
15. HP feed control valve to be kept open suitable for 120 TPH flow.
16. HP steam blow sacrificial valve “limit-close” set point to be set for 120 TPH flow.

B. HP Circuit Steam Blow _ Stage I A:


1. Auxiliary steam supply line to be isolated by closing the manual valve LBA70 AA001 and HP
bypass line to be blocked using blind flange in temporary piping.
2. Based on the GT load, the diverter damper shall be opened as indicated in ANNEXURE – 3, in
a step of 10%.
3. HP live steam start up vent (LBA10 AA251) to be opened and closed manually at HP drum
pressure of 1 bar(g) and 2.5 bar(g) respectively.
4. LP live steam start up vent (LBD10 AA200) to be opened manually at LP drum pressure of 1
bar(g).
5. BFP to be started as soon as the HP drum level decreases to 20%.
6. CEP to be started as soon as LP drum level decreases to 20%.
7. HP live steam isolation valve (LBA10 AA300) to be opened when HP drum pressure reaches
up to 2.5 bar(g) and the steam shall be charged up to steam blowing sacrificial / martyr
valve.
8. All the steam line drains to be closed manually when the HP drum pressure reaches 17
bar(g).
9. If the ramp rate of HP drum pressure is more than 2 bar / min, then the sky vent manual
isolation valve (LBA31 AA510) will be opened to maintain the ramp rate.
10. As soon as the HP drum pressure reaches the steam blowing parameter, the HP steam blow
sacrificial valve shall be opened through local push button.
11. During HP circuit blowing, LP live steam isolation valve (LBD10 AA300) shall remain close and
LP live steam start up vent (LBD10 AA200) shall remain open in order to prevent pressurizing
of LP drum and LP circuit.
If this arrangement fails to keep LP drum depressurized, then the LP live steam isolation
valve (LBD10 AA300) shall be opened and the LP sky vent motor operated valve (LBD30
AA301) to be opened manually.
12. During HP circuit blowing, the LP economiser recirculation valve (LAC95 AA200) will be kept
open, LP economizer bypass control valve (LCA90 AA200) will fully bypass the LP economizer
and LP economiser outlet control valve (HAC20 AA251) shall be kept open. Operation of
these valve will be manual.
13. The LP economiser recirculation pump will run in low speed operation.
14. An approach of 10 Deg. C (approx.) will be maintained in LP economiser outlet temperature
by operating the LP economizer bypass control valve (LCA90 AA200) manually.
15. The sacrificial valve shall be closed if any of the following condition is arrived:
a. HP drum pressure reaches up to 7 bar (g).
b. HP drum level decreases up to Low-Low level.
16. CEP will be stopped through manual push button, if any of the following condition is arrived:
a. Hotwell level decreases up to 10% of full volume.
b. LP drum level increases up to High-High level.
17. BFP will be stopped through manual push button, if any of the following condition is arrived:
a. LP drum level decreases up to Low-Low level
b. HP drum level increases up to High-High level.
18. After blowing the diverter damper will be closed completely if any of the following condition
is arrived:
a. Sacrificial valve is closed.
b. CEP is stopped.
c. BFP is stopped.
19. First target plate will be installed after 8 nos. of consecutive blows. Further use of target
plates will be decided based on the number of indent observed in first target plate.

C. HP Circuit Steam Blow _ Stage I B:


1. Auxiliary steam supply line to be isolated by closing the manual valve LBA70 AA001.
2. HP steam blowing sacrificial valve will be closed and the bypass line to be connected in
temporary piping before the target plate arrangement.
3. Step No. B2 to B16 to be followed for the further steam blowing process, except Step No.
B7, B9 & B10
4. In this stage there will not be any separate sacrificial valve. The HP live steam isolation valve
(LBA10 AA300) will be used to blow the circuit.
5. If the ramp rate of HP drum pressure is more than 2 bar / min, then the HP live steam
isolation valve (LBA10 AA300) will be opened accordingly to maintain the ramp rate.
6. Further number of blow / use of next target plate to be decided based on the number of
indent observed in first target plate.

D. LP Circuit Steam Blow _ Stage II A:


1. Auxiliary steam supply line to be isolated by closing the manual valve LBD75 AA010 and LP
bypass line to be blocked using blind flange in temporary piping.
2. Based on the GT load, the diverter damper shall be opened as indicated in ANNEXURE – 3, in
a step of 10%.
3. LP live steam start up vent (LBD10 AA200) to be opened and closed manually at LP drum
pressure of 0.5 bar(g) and 1.5 bar(g) respectively.
4. HP live steam start up vent (LBA10 AA251) to be opened manually at HP drum pressure of
1.5 bar(g).
5. LP live steam isolation valve (LBD10 AA300) to be opened when LP drum pressure reaches
up to 2.5 bar(g) and the steam shall be charged up to steam blowing sacrificial / martyr
valve.
6. CEP to be started as soon as LP drum level decreases to 20%.
7. All the steam line drains to be closed manually when the LP drum pressure reaches 2.5
bar(g).
8. As soon as the LP drum pressure reaches the steam blowing parameter, the LP steam blow
sacrificial valve shall be opened.
9. The sacrificial valve shall be closed if any of the following condition is arrived:
a. LP drum pressure reaches up to 1.2 bar (g).
b. LP drum level decreases up to Low-Low level.
10. During LP circuit blowing, HP live steam isolation valve (LBA10 AA300) shall remain close and
HP live steam start up vent (LBA10 AA251) shall remain open in order to prevent
pressurizing of HP drum and HP circuit.
11. The LP economiser recirculation valve (LAC95 AA200) will be kept open, LP economizer
bypass control valve (LCA90 AA200) will fully bypass the LP economizer and LP economiser
outlet control valve (HAC20 AA251) shall be kept open. Operation of these valve will be
manual.
12. The LP economiser recirculation pump will run in low speed operation.
13. An approach of 10 Deg. C (approx.) will be maintained in LP economiser outlet temperature
by operating the LP economizer bypass control valve (LCA90 AA200) manually.
14. CEP will be stopped through manual push button, if any of the following condition is arrived:
a. Hotwell level decreases up to 10% of full volume.
b. LP drum level increases up to High-High level.
15. After blowing the diverter damper will be closed completely if any of the following condition
is arrived:
a. Sacrificial valve is closed.
b. CEP is stopped.
c. HP drum level decreases up to Low-Low level.
16. First target plate will be installed after 8 nos. of consecutive blows. Further use of target
plates will be decided based on the number of indent observed in first target plate.
E. LP Circuit Steam Blow _ Stage II B:
1. Auxiliary steam supply line to be isolated by closing the manual valve LBD75 AA010.
2. LP steam blowing sacrificial valve will be closed and the bypass line to be connected in
temporary piping before the target plate arrangement.
3. Step No. D2 to D15 to be followed for the further steam blowing process, except Step No. D5
& D8
4. In this stage there will not be any separate sacrificial valve. The LP live steam isolation valve
(LBD10 AA300) will be used to blow the circuit.
5. Further number of blow / use of next target plate to be decided based on the number of
indent observed in first target plate.

F. Auxiliary Circuit Steam Blow _ Stage III A:


1. Steps for stage IIB shall be followed with auxiliary steam supply line isolation valve (LBD75
AA010) opened partially.
2. As this stage is service blow, therefore, there will not be any target plate installed in the
circuit.

G. Auxiliary Circuit Steam Blow _ Stage III B:


1. Steps for stage IB shall be followed with auxiliary steam supply line isolation valve (LBA70
AA001) opened partially.
2. As this stage is service blow, therefore, there will not be any target plate installed in the
circuit.

6. Acceptance Criteria:
The target plate shall be fixed in the temporary piping as indicated in STEAM BLOWING PROCEDURE
(RIC8990001 _ Rev 4).

For the lines directly connected to steam turbine, on an area of 40 mm x 40 mm of mirror polished
target plate, impacts of following size and numbers are allowed:

1. No impact with a size > 1.5 mm

2. Less than 4 impacts with a size of > 0,5 mm

3. Less than 10 impacts with a size of > 0,2 mm


Once obtained the first acceptable test piece, the last two plates must be installed to have the
confirmation of the executed cleaning. The interval between last two plates shall be approx. 8 hours. If
these two test pieces also appear clean, the blowing can be considered completed.

7. Reference Document:
A. STEAM BLOWING PROCEDURE _ RIC8990001 – Rev 4.
B. HRSG STEAM BLOWING - CMI RECOMMENDATIONS _ FCH89P06 – Rev A.
C. STEAM BLOW OUT CALCULATIONS _ FCH94D98 – REV A.
D. HRSG VALVE LIST _ FCH23E21 – Rev E.
E. HRSG PREREQUISITE FOR COMISSIONING EQP _ FCH89E21 – REV B.
F. STEAM BLOWDOWN EQUIPMENT SIZE H320 _ SKO2587181 – Rev 1.
G. Steam Blowing Kit drawing for HP Bypass PCV, LP Bypass PCV.
H. Condensate System P&ID _ MM-363075-M-PI-12-LCA-12009 – Rev J.
I. Feed Water P&ID _ MM-363075-M-PI-12-LAB-12008 – Rev I.
J. Blowdown System for HRSG _ MM-363075-M-PI-12-LCQ-12022 – Rev F.
K. Clean Drain System P&ID _ MM-363075-M-PI-12-LCM-12006 – Rev F.

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