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Sheet 1 of 25
PLANT DETAILS
2.0
OBJECTIVE
3.0
PROPOSAL
4.0
SERVICES REQUIRED
5.0
SAFETY PERECAUTIONS
6.0
EMERGENCY PROCEDURE
7.0
8.0
METHOD
9.0
COMPLETION CRITERIA
10.0
APPENDICES
a) DRAWING
b) LOG SHEET
c) DISTURBANCE FACTOR (CALCULATED VALUE)
d) SKETCH FOR TARGET PLATE & ASSEMBLY (TYPICAL).
Sheet 2 of 25
PLANT DETAILS:
The steam Generator is a controlled circulation plus Radiant
Reheat (Type CC+RR) boiler. Firing equipment consists of five
elevation of remotely controllable high energy arc lgnitors, five
elevations of air cooled, non-retractable steam atomising oil Gun
and nine elevations of pulverized coal nozzies. The nine
elevations of pulverized coal nozzies are supplied with coal from
nine numbers of type XRP 1003 Bowl mills, which form the load
carrying fuel for the boiler.
Control equipment provided consists of furnace safeguard
supervisory system, scanner air control system and a secondary
air control system.
Major auxiliary equipment provided consiss of pulverizers,
feeders, fans and miscellaneous valves. Three number of boiler
circulating pumps are provided to ensure proper circulation of
water in the furnace wall circuits.
The circuits which are subjected to steam blowing are super
HeaterSections of boiler, Manisteam line up to HP Turbine, Cold
Reheat line up to Boiler Reheater inlet, Reheater Sections Hot
Reheat line up to IP turbine inlet, two sections of HP and LP
bypass Sections and all auxiliary steam lines. These circuits are
described stage wise in section 3.0
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Sheet 3 of 25
: 1498.5 TPH
: 1335.2 TPH
: 1480.1 TPH
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Sheet 4 of 25
: 540 deg C
5. RH Outlet Temperature
: 540 deg C
: 328 deg C
7. SH Outlet Pressure
: 176.3 KSC
8. RH Outlet Pressure
: 41.4 KSC
9. Coal
: 339 TPH
Line Sizes
1. SH Outlet Pipes
: 406 x 42
2. MSL
: 564 x 57
3. CRH
: 864 x 24
: 660 x 20
5. RH to HRH
: 720 X 45
6. HRH
:969 X 60
7. HP BP line
:324 X 35
8. LP BP line
:720 X 45
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Sheet 5 of 25
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Sheet 6 of 25
OBJECTIVE:
The objective of steam blowing is to remove scales, loose
material, iron cuttings etc, that might have been entrapped in
Super Heaters, Steam piping, reheaters during manufacture,
storage, erection at site. Failure to remove the debris may result
in damage to turbine blades. Valves etc.
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Sheet 7 of 25
3.2
3.3
3.4
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Sheet 8 of 25
BHEL
Sheet 9 of 25
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Sheet 10 of 25
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Sheet 11 of 25
SERVICES REQUIRED:
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
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Sheet 12 of 25
SAFETY PRECAUTIONS:
5.1
5.2
5.3
5.4
5.5
5.6
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Sheet 13 of 25
EMERGENCY PROCEDURES:
6.1
6.2
6.3
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Sheet 14 of 25
7.1
7.2
7.3
7.4
Feed Lines
7.5
7.6
7.7
7.8
7.9
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Sheet 15 of 25
7.11
Special steam blowing devices are placed for ESV & IV. These
works are to be ensured before commencing steam blowing.
7.12
ii)
iii)
iv)
7.13
7.14
7.15
7.16
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Sheet 16 of 25
7.18
7.19
7.20
7.21
7.22
7.23
7.24
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Sheet 17 of 25
METHOD:
8.1
8.2
First steam blow in stage 1, 2a, 2b, 3a, &3b should be given at a
lower pressure, say 25 kg/sq.cm. at Boiler drum and the pipe
lines including temporary piping are surveyed for proper
expansion and supports. Subsequent blows are given at higher
pressure as given in 8.3.
8.3
Raise the boiler pressure to 50 kg/sq.cm. Shut off firing and at the
same time open the steam blowing valves. (Temporary valve
EOTVs or MS-1, MS-2 as the case may be). The steam lines
which are being steam blown should be warmed up prior to
blowing. The opening of steam blowing valve allows steam to
escape to atmosphere at high velocity carrying with it loose and
dislodged debris. To prevent thermal stresses in the thick walled
shell like drum and headers the saturation temperature change in
drum is limited to 40 deg. C. maximum. Hence, for the purpose of
steam blowing of all critical piping, the steam blowing valve will
be opened at 50 kg/sq.cm. and closed at 25 kg/sq.cm. drum
pressure.
8.4
The water level in the drum swings beyond visible limits at the
start, during and the end of steam blowing. There are chances of
water droplets to carry over to the saturated steam pipes and low
temperature superheater. At the same time too low water level
will affect the C.C. pumps running. Hence optimum level is to be
maintained in the drum. It is preferable to keep just 1 port (50
mm) below the normal level at the time of starting the steam blow.
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Sheet 18 of 25
All the steam lines are purged as per various stages and it is a
standard practice to limit number of blows per day to 8 with an
interval of 1-1 hours for cooling in addition to overnight cooling.
8.7
8.8
8.9
8.10
During steam blowing. MS, CRH & HRH line drains are kept open
to atmosphere without any valve for achieving free and
uninterrupted flow.
8.11
Target Plates will be used for stages 1, 2a & 3a. Stainless Steel
target plates having mirror finish will be used in final stages. In
the preceding stages target plates of M.S will be used. During
steam blowing, pressure and temperature readings at selected
locations will be noted down for the purpose of determining
disturbance factor (Refer Section 10.0 for scheme and method of
calculation).
8.12
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Sheet 19 of 25
8.14
Following steps are followed for steam blowing stage 4a and 4b.
8.15
8.16
8.17
8.18
8.19
8.20
After few blows, Target Plates are put and further blowing
continued. Termination of stage 4a and 4b are as per Target plate
results only as given in Section 9.0.
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Sheet 20 of 25
Following steps are followed for steam blowing of stage 5. All the
sub-stages are mentioned in Section 3.0.
8.22
8.23
System charged as per 8.16 and steam inlet valves in each sub
system are opened gradually & steam blown for 10 minutes
duration.
8.24
8.25
8.26
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Sheet 21 of 25
COMPLETION CRITERIA:
Indications for the result of each blowing is the number of pittings
found on the target plate mounted in the temporary exhaust pipes
nearer to the permanent line. The highest velocity of steam is in
the center of the pipe. Hence, judgement should be made for the
end point of steam blowing in this area. The area for the above is
3/4the the discharge pipe diameter at the center. It is
recommended to install the target plate after completing few
blows in each stage.
For evaluating the cleanliness and termination point of the steam
blowing, target plate of stainless steel of mirror finish are to be
used.
9.1
For stages 1, 2a, 3a, 4a & 4b the result of the blowing operations
can be judged by the absolute number of pittings on the target
plate in the central zone. The piping is considered clean if there
are not more than 5 (five) pittings and shall not have any
deformed edges. Besides, there shall be no pitting in the rim
zone, ie, area other than central zone. This should be achieved in
three consecutive forget plates. At least, one over night cooling is
to be ensured for steam blowing of pipe lines leading to Turbine.
9.2
9.3
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SHEET 22 OF 25
Qb2 x Vb
Disturbance Factor =
Q2 MCR x VMCR
Qb
Qb
QMCR
Vb
VMCR
Sonic Velocity
During blowing
Area
Vb
Where
Qb
Sonic Velocity
KP Vb g
M/sec
Area
Sq.M
Vb
Cu.m/Kg
Constant
Vb
Sp. Volume
1.3
=Cu.M/Kg
SHEET 23 OF 25
10.0 b)
LOG SHEET
DATE :
PROJECT :
UNIT
:
ACTIVITY :
LOCATION
S.NO STAGE
BLOW
NO
I
P
II
DF
III
DF
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REMARKS
IV
DF
DF
SHEET 24 OF 25
10.0
C)
DISTURBANCE FACTOR (CALCULATED VALUE) DURING
STEAM BLOWING (PUFFING METHOD)
A)
MCR Parameters
a)
b)
c)
B)
:
:
:
1498.5 TPH
176.3 KSC
5400C
STAGE
2a
S.NO
Locations
Predicted
Parameter During
Disturbance
Steam Blowing
Factor
Pressure
0
Temp. C
KSC
SH O/L (A1-A2)
18.0
420
2.39
5.0
410
7.15
SH O/L (A1-A2)
20.0
420
1.57
7.0
410
3.98
2.0
400
3.56
Remark
SHEET 25 OF 25
STAGE
3a
S.NO
Locations
Predicted
Parameter During
Disturbance
Steam Blowing
Factor
Pressure
Temp. 0C
KSC
SH O/L (A1-A2)
26.0
420
1.12
ESV (B1-B2)
12.0
410
2.25
5.0
400
1.78
3.0
400
1.79
IV I/L (E1-E2)
2.0
400
2.3
Remark