Ogn-ops-chem-017-Start Up Shut Down and Layup Practices

(For Internal Circulation Only)
COS-ISO-00-OGN/OPS/CHEM/017
Rev. No. : 0 March 2005
OPERATION GUIDANCE NOTE
Cycle Chemistry Guidelines

for the Start Up, Shut Down
and Lay Up Practices
CORPORATE OPERATION SERVICES
National Thermal Power Corporation Ltd.
NATIONAL THERMAL POWER CORPORATION LTD.

OPERATION AND MAINTENANCE FORMAL DOCUMENTATION SYSTEM
OPERATION GUIDANCE NOTE : COS-ISO-00-OGN/OPS/CHEM/017
Rev. No.: 0
Date : March 2005
Cycle Chemistry Guidelines

for the Start Up, Shut Down
and Lay Up Practices
Approved for
Implementation by ..
Director (O)
Date: ..
Enquiries to: Head of Corp. Operation Services
Cycle Chemistry Guidelines for the Start Up, Shut Down and
Lay Up Practices
INDEX
Sl. No.
Contents
Page No.
1.0
Introduction
2.0
Superseded Documents
3.0
Objective
4.0
Scope
5.0
Start up Procedure
6.0
Shut Down Procedure
7.0
Lay Up Practices
8.0
Review
20
Annexure-I
Dry preservation procedure for WHRB
21
Annexure-II Wet Preservation procedure for WHRB
22
Annexure-III Protocol on Preservation Status
23
Page - 1
COS-ISO-00-OGN/OPS/CHEM/017 Rev. No.: 0
Cycle Chemistry Guidelines for the Start Up, Shut Down and Lay up Practices
Cycle Chemistry Guidelines for the Start Up, Shut Down and
Lay Up Practices
1.0
INTRODUCTION
Improper start up shut down and lay up practices usually lead to serious damage
in the form of pitting, oxidation and corrosion. Corrosive attack during off-load
can also render the plant susceptible to subsequent on-load corrosion or fatigue
damage. To preserve the long term integrity of boiler components require careful
chemical control during start up, shut down and lay up condition as well. This
guidance note covers the above aspects of the plant including the important
factors regarding the choice of the optimum procedures, which will depend on the
type of plant, its metallurgy and outage time.
2.0
SUPERSEDED DOCUMENTS
The storage of the water/steam circuits of the generating plant
3.0
OBJECTIVE
The objective of this guideline is:
(a) To maximize unit life and minimize forced outage
(b) To minimize impurity ingress, generation and transport
(c) To minimize scale formation, corrosion and transport of corrosion material
It has been observed that trouble free operation and minimum forced outages are
achieved by a combination of control of operating stress and optimum steamwater chemistry.
4.0
SCOPE
This guidance note covers various types of fossil fuel and gas fired plant. The start
up and shut down consideration and storage requirements, procedures for the
above have been outlined.
These guidelines will cover
(a)
(b)
(c)
(d)
Drum type and also once through sub-critical units

Units with and without condensate polishers
All ferrous and mixed metallurgy feed water system
Various types of boiler water treatments
Water chemistry , metallurgy, design and operating aspects are profoundly inter
woven and strongly interact with each other .In this document our focus will be
on water and steam chemistry guidelines during start up, shut down and lay up
practices.
Page - 2
5.0
START UP PROCEDURE
It involves the following steps:
Step 1:
If the system has been stored dry, then it should be filled with make up water with
following specification:
Parameter
Sample
Limiting Values
Silica
Sp. Cond.
Dissolved Oxygen
C
C
C
< 20 ppb
< 0.5 to 1.0 s/cm
< 100 ppb (if the water is deaerated)
Refer table - 1 for drum type unit for phosphate treatment

Step-2:
If the system has been stored using low oxygen scavenger procedure, the boiler
can be fired immediately. The boiler vents are to be kept open to 25 psi to remove
any excess ammonia.
Step-3:
If the system has been stored wet with a surplus ammoniated hydrazine, it must be
drained under nitrogen and refilled with water meeting the specification as
mentioned in step-1.
Step-4:
The following limits for the boiler feed water are required prior to firing the
boiler:
Oxygen
< 100 ppb
Iron
< 100 ppb
Copper
< 10 ppb (For mixed metallurgy system)
During start up, the level of corrosion products (iron and copper) can be very high
initially and silica may also be a problem. But at this juncture 100 % condensate
polishing comes in quite handy in achieving the above limits. For units not
equipped with CPU, it is further emphasized that strict compliance of shut down
and lay up guideline will facilitate attainment of pre-firing feed water limits.
Step 5:
After firing the boiler, monitoring must be fully implemented, both for Chemistry
parameters, and to ensure that temperature ramps are maintained according to the
turbine and boiler manufacturers specification.
During start up, the concentration versus pressure curves are to be utilized to
control sodium and silica . Boiler pressure should remain at reduced levels such
that these limits are maintained before pressure can be increased to the next stage.
Adjust boiler chemical feed to take advantage of tolerance for higher alkalinity at
lower pressure (refer figure 1).
Page - 3
Adjust phosphate feed to support anticipated blow down rate.
Anticipate boiler start up and begin pumping chemicals so that target treatments
are in place when boiler is fired.
Maximize boiler blow down and perform bottom blow during start up when solids
are at their highest contamination.
When pressure increases above 1500 psi the phosphate residual should be allowed
to slide back to a concentration consistent with the guidelines values for PO 4 3
versus pressure.
Steam side i.e. shell side of L.P. and H.P. heater needs to be flushed before taking
their drip into system.
Maximum use of blow down and condensate polishing will minimize start up
times.
Steam dumping to be carried out till the steam parameters meet the following
specs:
Parameters
Limiting values
Na
< 5 ppb
SiO2
< 20 ppb
Iron
< 10 ppb
Once main steam parameters attain the above mentioned limits, then only steam
should be allowed to enter the turbine.
A protocol jointly signed by HOD (Operation) and HOD (Chemistry) to this effect
is to be maintained in SCEs log book.
Page - 4
Fig : 1 Boiler water sodium & phosphate Vrs. Operating pressure

Normal
Action Level-I
Action Level-II
Action Level-III
Normal Operating Value

Return to Normal Value within 1 week
Return to Normal Value within 24 hours
Return to Normal Value within 04 hours
Page - 5
Table-1 Chemistry parameters to be monitored in Units

with drum type boiler & phosphate treatment
Sample
Feed
Boiler
Saturated Steam
Deaerator Inlet
Deaerator Outlet
Condensate
CPU Outlet (where
applicable)
Make up water
Parameter
pH (all ferrous metallurgy)
pH (mixed metallurgy)
Ammonia
Cation conductivity
Iron, ppb
Copper, ppb
Dissolved Oxygen, ppb
pH
Phosphate
Sodium phosphate ratio
SiO2 and chloride
Sodium
Silica
Dissolved Oxygen
Dissolved Oxygen
Cation continuity
Sodium
Dissolved Oxygen
Cation conductivity
Sodium
Sp. conductivity
Frequency
Continuous
Continuous
Grab
Continuous
Grab
Grab
Grab
Continuous
Grab
Grab
Grab
Continuous
Grab
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Continuous
Notes :
Step 3
Dry layup
Step 2
Intermedialotengandterm
Yes
Evacuate
reheater
with condenser
vacuum
Breakvacuum
reheater
with
Nitrogen purge
Draiunder
n condenser
Nitrogen
Maintain chemipercalguilidmelitisnes
Yes
Step 4
No
Drain system
remove
all waterto
Pressurize wiwetted
th N alpads
l
netofor9.2OTif uni
ts have copper
** Li* mNoialt Hydrazi
pHloystoin9.0cycl
e. mainunitaitnsHydrazi
ne at 40-50 ppm
Dry air
Yes
Drai
n
system
remove all waterto
Inertautomati
the boic lsystem
er with
Maintaipern chemi
cialnes,limsee
its
gui
d
el
section 5, 6, 7 & 8
No
No
Filwifeed
system
200water
Hydrazi
nae***
10thppm
Ammoni
iofsh5boipsiler
NitrogenEstabl
cap( 0.03
MPa )
Traditional
Yes
Fil boileamoni
r with10a &ppm
200 ppm Hydraziupto
ne*
Step 5
No
Road Map to Develop Shutdown and Layup Guidelines Common to Most Units
AddwhiNitlrogen
to condenser
Maie tubi
ntainneslspiownsNdown
flow
Add Nitrogen
to deaerator
& storage
Maitank
ntainwhislolew stiN l hotflow
MaintainonNitshel
rogensidcape of
feed water lheaters
No
Wet layup
Yes
Step 7
Add
Hydrazine
withto5-10
boi200leppm
r press.
psi ( 1.4decays
MPa )
Add boiNitrogen
cap when
to 5lepsir press.
( 0.03decays
MPa )
Maintaiwinthout
feedchange
water
Low O scavenger2
Yes
Step 6
Isolate reheater
Back fil reheater
&
superheater
with 200 10ppmppmHydrazi
ne*a.
NiAmmoni
trogen cap
Foralmail Nntenance
purge
wi
t
h
ai
frommaiequi
to ber to
2 ntaipment
ed.ronment.
Test
safe nenvi
Very longstorage
term
Back fil superheater

200 ppmHydrazi
10 ppmcap
Ammonia. nNie*trogen
Yes
Step 8
Step 9
6.0
Step 1
Short term shutdown
Yes
Maintainand
condenser
vacuum
turbineseals
Inertandtheheater
deaerator
shells
Page - 6
SHUT DOWN PROCEDURE
A standard road map for implementing shutdown procedures common to most of

NTPC units is outlined below.
Fig. 2 : Shutdown & layup road map
Page - 7
The above figure may be divided into nine (9) considerations which have further
elaborated as follows:
Step-1:
Short term shut down
This very term itself implies that the unit will be required to operate within a
relatively short time frame. Thus, no major changes are required from normal
operating conditions except the fact that it must be protected from air ingress. The
condenser vacuum and turbine seals are maintained, the de-aerator, the heater
shells and boiler are inerted with nitrogen or steam, and, the feed water chemistry
is maintained as follows:
Units with phosphate and all volatile treatment:
Parameter
Limit
pH
9.2 9.6
8.8 - 9.1
< 0.2 s/cm
1-10 ppb
< 5 ppb
(For all Ferrous)

(For mixed metallurgy)
ACC
Oxygen, ppb (For all ferrous)
(For mixed metallurgy)
Units with oxygenated treatment:
Parameter
Limit
pH
ACC
Oxygen, ppb
8.0 8.5
< 0.15 s/cm
30 - 150
Step-2: Intermediate and long term shut down

Intermediate and long term shut down require additional steps to be taken to
prevent corrosion during intermediate periods of lay up, such as for maintenance
and indeterminate cycling requirements; and during long shut down up for
indefinite period of time. It may be noted that certain procedures are common
regardless of whether the units are laid up dry or wet.
During shutdown, the turbine, condenser (steam side) and re-heater are generally
considered together because, unless special facilities are incorporated, there is no
practical way to isolate them. These equipments are normally stored dry.
During shut down, the re-heater should be evacuated by utilizing the vacuum in
the condenser. The vacuum is then broken using nitrogen pressure. The condenser
should be drained under nitrogen.
If the turbine steam is supplied from a header system, all valves must be tight to
prevent moisture entrance into the turbine.
Page - 8
Step-3: Dry air lay up
The dry air lay up procedure requires that all components of the system be drained
by maintaining dry air flow through the equipment
Step 4: Dry lay up with Nitrogen
Nitrogen can be used for blanketing equipment, which is drained but not
completely dry, or for blanketing equipment either filled with water or not, to
prevent air ingress. Step-4 is similar to step-3 except nitrogen is used for a
positive small pressure on all component rather than dry air purge. A small
continuous purge of nitrogen is required to protect the turbine, de-aerator and deaerator storage tank.
Step-5: Wet lay up
Traditional method (Boiler and Feed water heaters)
The traditional method of wet lay up involves filling the boiler, feed water cycle
and super heater with de-mineralized water containing 10 ppm of ammonia and
up to 200 ppm of hydrazine. But for oxygenated treatment, hydrazine should be
eliminated.
For units with copper alloy condenser tubes and/ or feed water heaters, feed water
pH should be restricted to 9.0 to 9.2 by ammonia. Hydrazine is held at 40-50
ppm. For these units, it is most important to maintain reducing conditions to
prevent attack of copper alloys associated with a change of surface oxide layers
from cuprous to cupric oxide.
A nitrogen cap of 5 psi is maintained on the boiler.
Step-6: Wet lay up: Low oxygen scavenger method (Boiler and Feed water
Heaters)
One of the procedures uses 5-10 ppm of hydrazine equivalent is injected through
normal chemical feed system into the boiler when the boiler pressure decays to
200 psi ( usually it takes about 3 days ) thereby facilitating homogenization of
these chemicals in the boiler. When the boiler pressure decays to 5 psi (typically 7
days) a nitrogen cap is applied to the boiler. Up to return to service, the boiler may
be fired without draining the boiler.
Step-7: Wet lay up (Balance of cycle)
As turbine slows down, nitrogen is added to the condenser, which also purges the
re-heater system. A continuous purge of nitrogen is necessary to account for
leakage through the turbine steam seals.
Nitrogen is added to the de-aerator and storage tank while this system is still hot.
A small flow of nitrogen is provided to purge this system.
A nitrogen cap is maintained on the shell side of the feed water heaters. The super
heater is back filled with a solution up to 200 ppm of hydrazine and 10 ppm
ammonia and a nitrogen cap maintained. (In case of O.T. hydrazine solution is not
required)
Page - 9
Step-8: Very long outage
For very long storage periods, the re-heater is isolated from the turbine, and back
filled with a solution of 200 ppm hydrazine and 10 ppm of ammonia capped with
nitrogen. The super heater is treated similarly.
Step-9: Maintenance
Only equipments requiring maintenance needs to be drained (in case of wet
storage), and nitrogen (If used) purged with air to provide an environment suitable
for entry of personnel. Since nitrogen does not support human life, it is extremely
important to ensure that nitrogen is completely displaced by air. The atmosphere
within the equipment should be tested with suitable devices to ensure that the
equipment is safe for personnel entry. How ever if the unit is planned to be taken
under overhauling after shutdown, it advisable to hot drain the unit at 3-5 kg/cm 2
pressure before shut down.
7.0 LAY UP PRACTICES
The shut down and lay up period should be regarded as a continuum of the good
practices used during operation. The key objective of cycle chemistry is to
provide protective oxide surfaces on all components throughout the steam and
water circuits whereas the primary purpose of lay up practice is to maintain those
protective surfaces during offload condition.
The lay up procedure generally fall under two categories i.e. the wet and dry
procedures.
Wet lay up requires filling of most of the system with an alkaline reducing
solution (ammonia and hydrazine) and preventing air ingress by nitrogen capping.
Dry lay up requires drainage while hot, and removal of all water followed by
pressurizing with a moisture free inert gas or by use of dehumidified air to
maintain a low moisture environment.
In selecting a proper lay up procedure for a specific boiler and its equipment, the
following factors come into play:
(a)
compatibility between the chemistry required for lay up and that used
during operation
(b)
maintenance of protective oxides formed during operation
(c)
possibility of the steam generator may be required for operation
(d)
facilities for disposal of lay up solution
(e)
practicality of maintaining all the required conditions of a given procedure
(f)
local atmospheric condition
(g)
availability of various inputs as envisaged in the lay up procedure.
Page - 10
A comparison of various advantages and disadvantages of dry and wet lay up is
outlined below:
Type of Lay Up
Wet storage with
Ammonia/hydrazine
with
nitrogen
capping
Advantages
Independent of relative
humidity
Ease of testing and
maintenance
Super heaters and re
heaters covered
Disadvantage
Pollution hazard
Needs to be re circulated.
Regular monitoring
Tight isolation
High D.M. water consumption
Nitrogen capping is very dangerous;
asphyxiation of workers if not
properly vented before access.
basic Drying equipment and blowers
required
Dry Storage
Readily available
constituent
Depend on climatic condition

Ease of monitoring and
Hermetical sealing required
maintenance
No risk to personnel
System must be completely dry
Sediments may cause corrosion if
hygroscopic
SO2 and dust free air required
Even draining hot and under
pressure may not ensure complete
water removal because of complex
geometry
7.1
Wet lay up
This generally involves filling the unit with D.M. water containing an excess of
N2H4. Circulation may be used coupled with positive nitrogen pressure. A nitrogen
cap allows (a) boiler and feed water equipment to remain full, (b) requires no
excessive addition of chemicals (c) permits nitrogen to rush in where steam
collapses, preventing oxygen from entering the system.
The following procedure for nitrogen addition will be handy:
Main condenser and turbine

1.
Nitrogen addition starts while turbine is spinning down
2.
Nitrogen is added quickly at first, then slowly as the vacuum
approaches zero.
De-aerator and storage Tank

1.
Nitrogen is added when the de-aerator is still hot.
2.
Nitrogen is purged for about 20 minutes followed by maintenance
of a small nitrogen positive flow.
Page - 11
Feed water Heaters

1.
Nitrogen is supplied through shell-side vent line.
Steam Drum
1.
2.
Nitrogen enters the drum through vent lines.

Nitrogen feed is started while the drum is still hot.
The boiler and economizer water should be circulated routinely to prevent

stagnant condition developing.
Nitrogen does not support human life, hence the relevant safety
precautions are extremely important. Before any equipment that has been
laid up with nitrogen can be entered by personnel , all nitrogen supply
lines must be disconnected, the equipment purged with air, and oxygen
levels verified as safe by proper oxygen test procedures like using ORSAT
/ portable oxygen analyser. Minimum oxygen percentage should be 18%
before entry of working personnel.
7.1.1
Wet lay up procedure (for drum type units)
Type of shut down

Pre-operational
period (post hydro)
Procedure
With boiler filled to overflowing
pressurize the unit with nitrogen to
0.35 atm pressure
(Pl. see point 4 of the column Notes )
Refer Figures 3 & 4 at the end of this
section for scheme for nitrogen
Blanketing and filling in case of drum
type boilers
Preoperational
1.
period
(post
chemical cleaning)
2.
Introduce DM water containing 10

ppm of NH3 and 200 ppm of N2H4
into super heater, feed water
heaters (tube side) and associated
piping, economizer and boiler. (Pl.
see note- 3)
Nitrogen cap the super heater, feed
water heater (shell side) and drum.
Maintain 0.5 atm of N2 pressure.
(Pl. see note-4 )
Notes
1. All non-drainable section
to be hydraulically tested and
should be filled with DM
water containing 10 ppm of
NH3 and 200 ppm of N2H4. It
should produce a solution of
pH 10. The super heater
should be first filled to over
flow into the boiler drum.
Then the boiler can be filled
through
normal
fill
connection.
2. Hydrazine and ammonia
are to be added to the system
by pumping concentrated
solution
through
the
chemical dosing pumps. It is
important to have fluid
temperature in the cycle
below 2000C before addition
of hydrazine. If this temp. is
exceeded
N2H4
will
decompose.
Page - 12
Type of shut down
Procedure
Short outage 4 days
1. Maintain the same hydrazine
or less unit not
and ammonia concentration as
drained
those present during normal
operation and normal water
leveling boiler.
2. Establish and maintain 0.35 atm
nitrogen cap on the super heater
and the steam drum (Pl. see
note- 4)
3. Nitrogen cap the shell side of
the feed water heaters.
Short outage 4 days

or less unit drained
1. Maintain the same hydrazine and

ammonia concentration as those
present during normal operation
and normal water leveling boiler.
2. Drain and open only those sections
requiring repair.
3. Isolate the remainder of the unit
under 0.35 atm N2 pressure. ( Pl.
see notes -4 )
4. Nitrogen cap the shell side of the
feed water heaters
Long outage 4 days 1. Establish and maintain a 0.35 atm.
or more unit not
Nitrogen cap on the super heater
drained
and steam drum. (Pl. see note- 4 )
2. After that Fill the super heater
through the outlet of non- drainable
section with DM water containing
10ppm of NH3 and 200 ppm of
Hydrazine.
3.Increase
the
hydrazine
and
ammonia
concentration
to
200ppm and 10 ppm respectively in
boiler, economizer and feed water
heaters (tube side) (Pl. see note 2,3)
feed water heaters
Long outage 4 days 1. Drain and repair only those
or more unit drained
section requiring repair.
2. Fill the super heater through the
outlet of non-drainable section
Notes
3. The tube side of copper
alloy feed water heaters
should be filled with D.M.
water containing 0.5 ppm of
NH3 and 50 ppm of N2H4.
4. Nitrogen cap should be
applied through the drum
vent and super heater outlet
header drain/vent as the unit
is cooled. When pressure
drop to 0.35 atm. Admission
of air through atmospheric
vents should be avoided.
General note :
During every cold start,
visually check the feed water.
Only clear water should be
admitted to into the boiler
and used for de-super heater
spray from the beginning.
Page - 13
Type of shut down
Procedure
with DM water containing 10ppm
of NH3 and 200 ppm of
Hydrazine.
3. Increase the hydrazine and
ammonia concentration to 200
ppm and 10 ppm respectively in
undrained circuit of the boiler ,
economizer and feed water
heaters (tube side) ( see note 2 &
3)
4. Establish and maintain a 0.35
atm. Nitrogen cap on the undrained section of the unit where
possible.( Pl. see note 4 )
feed water heaters.
6. After repair fill the drain section
with hydrazine and ammonia
concentration to 200 ppm and 10
ppm respectively and cap with
nitrogen.( Pl. see note 2,3 )
Notes
FIGURE : 2
SCHEME FOR HYDRAULIC PRESSURE
LINE Nb - 25
SH DRAIN HEADER
NITROGEN SUPPLY LINES TO VENTS

ON DRUM AND SUPERHEATER
PRESSURE GAUGE
( 0 TO 5 ATM.)
W.W. BLOW DOWN HEADER

S
S
PRESSURE REGULATOR
NON RETURN VALVE
ISOLATING VALVE
D.M.WATER
Pr. GAUGE
0 - 20 kg/cm 2
TANK CAPACITY
5 - 10 TONS
CYLIDER ISOLATING VALVES

STOP / GATE VALVES
NITROGEN CYLINDERS
FIGURE : 1
SCHEME FOR NITRGEN BLANKETTING
PUMP
PRESSURE 7 - 10 ATM.
CAPACITY 10 - 25 T/Hr.
NOTE : 1. THICK LINES INDICATE TEMPORARY PIPINGSIZE SHOULD SUIT SUCTION
DELIVERY FLANGES OF THE PUMP.
2. 'S' INDICATES " SAMPLING VALVE".
Figure 3
Scheme for Nitrogen Blanketing
3.
INDICATES STRAINER ASSEMBLY.
Page - 14
FIGURE : 2
SCHEME FOR HYDRAULIC PRESSURE
LINE Nb - 25
SH DRAIN HEADER
NITROGEN SUPPLY LINES TO VENTS

ON DRUM AND SUPERHEATER
PRESSURE GAUGE
( 0 TO 5 ATM.)
W.W. BLOW DOWN HEADER

S
S
PRESSURE REGULATOR
NON RETURN VALVE
ISOLATING VALVE
D.M.WATER
Pr. GAUGE
0 - 20 kg/cm 2
TANK CAPACITY
5 - 10 TONS
CYLIDER ISOLATING VALVES

STOP / GATE VALVES
NITROGEN CYLINDERS
PUMP
PRESSURE 7 - 10 ATM.
CAPACITY 10 - 25 T/Hr.
FIGURE : 1
SCHEME FOR NITRGEN BLANKETTING
NOTE : 1. THICK LINES INDICATE TEMPORARY PIPINGSIZE SHOULD SUIT SUCTION

DELIVERY FLANGES OF THE PUMP.
2. 'S' INDICATES " SAMPLING VALVE".
3.
INDICATES STRAINER ASSEMBLY.
Figure - 4
7.2
Dry lay up
Storage of plant under conditions of complete dry-out is the most satisfactory
procedure for longer periods of storage, however, great care must be taken to
obtain complete dry-out, as the retention in the plant of localized small pools of
water can lead to serious off-load corrosion.
If dry storage is to be used, every effort shall be made to use the residual heat in
the plant to assist in drying out process. As boiler is brought off load, it is normal
to blow the boiler and associated circuit empty from 3-5 bar. How ever if it is
operationally acceptable, considerable advantage can be gained by emptying from
a higher pressure (e.g. 28 bars). If the drying is to be assisted by natural air, whilst
the boiler is cooling, header caps and drum doors shall be removed as quickly as
possible to establish satisfactory ventilation.
Even under these conditions, complete dry-out of super heaters, re-heaters and
economizer tubing might not be achieved and it is now accepted that circulation
of dehumidified air through the plant to remove residual moisture is essential. It
involves the use of clean, dehumidified air (Relative humidity < 30%) to purge
the boiler and auxiliary equipment during lay up periods.
Page - 15
Fig. 5 : Rotary desiccant dehumidifier

Figure 5 depicts rotary desiccant dehumidifier. The system utilized to supply dry
air to the various components of feed water heater, steam and boiler circuits may
be customized to adapt to various heat cycles configurations.
7.2.1 Feed water heaters, condenser, re-heater and turbine
These components are generally treated as one group, because they can not be
isolated without special provision. Particular care needs to be taken during shut
down and lay up so that these equipments are protected properly. Generally all
these components are stored dry.
7.2.2 Turbine
Turbine dry lay up using dehumidifier air can be combined with dry lay up of the
unit steam side circuits. Refer Figures 6 & 7 on the next page.
Page - 16
Fig. 6 : Turbine dry lay up using dehumidified air
Fig. 7 : Block diagram for Dry lay up of turbine showing measured

values of temperature ( 0F / 0C ) and air humidity
Page - 17
7.2.3 Feed water side condensers and feed water heaters
Metallurgy of these devices are of paramount importance while deciding feed
water chemistry for intermediate and long term storage.
For system containing copper alloys, hydrazine and ammonia solution (40-50
ppm of hydrazine and only the desired quantity of ammonia so that it imparts a
pH of 9.0 9.2) and oxygen ingress ought to be avoided to minimize copper
corrosion. High concentration of ammonia should be prevented from coming into
contact with copper alloys.
For all ferrous metallurgy system a wet lay up is accomplished with a pH of up to
10.0 achieved with ammonia, up to 200 ppm of hydrazine and a pressurized
nitrogen blanket.
It is to be noted that for units on oxygenated treatment use of hydrazine is not
recommended.
7.2.4 Shell side feed water heaters
The shell side of feed water heaters should be protected by a nitrogen blanket or a
steam blanket (short term lay up ) when the unit is out of service.
7.2.5 Super heater
For wet lay up it should be back filled with treated water of a composition
identical to that used for lay up of the boiler. A nitrogen cap comes in handy to
prevent air ingress.
7.2.6
De-aerator and storage tank

The de-aerator and de-aerator storage tank should be protected by a small but
steady nitrogen purge.
7.3
Lay up procedure for Waste Heat Recovery Boiler (WHRB)

Sl.No.
1
2.
Outage of Boiler
One shift up to 72 hrs
Procedure
WHRB to be shut down keeping it pressurized.
All efforts to be made to control leakages if any
from boiler parts by tightening the various gate
valves provided in the drain valves.
Keep watch on pressure of S/D boiler.
Maintain availability of D.M. water for boiler
start up.
Shut down is beyond (A) Preserve boiler as per wet preservation
72 hrs. & up to 14 days method as given in annexure-2
(A) Without any maint. (B)Hot drain the boiler as per dry preservation
work on WHRB
method as given in annexure-1
Page - 18
Sl.No.
3.
7.3.1
Outage of Boiler
Procedure
(B) With maint. work Complete all maint. work on boiler then
on WHRB
preserve it as per wet preservation method as
given in annexure-2.
Quality of preservation solution i.e. pH 10.0 &
Hydrazine 50 ppm minimum to be maintained.
Shut down beyond 14 (A) Preserve boiler as per wet preservation
days & upto 30 days
work on WHRB
( B ) With maint. work Complete all maint. work on boiler then
on WHRB
Quality of preservation solution i.e. pH 10.5 &
Hydrazine 100 ppm minimum to be maintained.
Shut down beyond 30 (A) Preserve boiler as per wet preservation
days
work on WHRB
(B) With maint. work Complete all maint. work on boiler then
on WHRB
Quality of preservation solution i.e. pH 10.5
10.7& Hydrazine 200 ppm minimum to be
maintained.
Hydraulic Tests
When carrying out hydraulic tests, the WHRB must be flushed and completely
filled with D.M. water (pH 6.8 7.2), conductivity less than 1.0 s/cm and silica
< 20 ppb. If the boiler is to be returned to service immediately after the hydraulic
test, around 10 ppm of hydrazine and required amount of ammonia is to be dosed
(to give a pH value of 9.2 9.6) with start up vent in open condition. How ever, if
return to service of tested boiler is to be delayed then preserve the boiler as per the
procedures given above.
7.3.2
Procedure for preservation of L. P. Boiler

Sl.No.
1.
2.
3.
4.
Activity
Start filling of LP boiler with established flow of approx 15 m3/hr
Start ammonia and hydrazine dozing pump at required stroke.
Start one LP circulation pump for 30 min as soon as the drum level
reaches 800 mm.
Check pH and Hydrazine of circulating water and adjust dosing
stroke for attaining the desired values.
Page - 19
5.
6.
7.
8.
9.
Keep circulating pump running and fill up LP drum. LP header to

be vented by opening of the isolating line of test measuring line.
Drum vent to be closed.
Pressurize LP system upto 3.0 bar and then close 30 % FW control
valve and economizer inlet bypass valve.
After achieving the desired pH and hydrazine concentration, LP
circulation pumps to be switched off.
After completion of preservation, LP circulation pump to be
operated twice a week for one hour.
Maintain water level in the preserved boiler, conc. of hydrazine
and pH under positive nitrogen pressure. Check every week to
maintain original values by top up.
7.3.3 Procedure for preservation of HP boiler

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
7.4
Drain HP boiler including its superheater and close the drain valves. Vent
valves to be kept open for both evaporator and super heater.
Streamline the chemical dosing valve for HP boiler to be preserved and
keep other valves closed.
Start filling of HP boiler with water flow of 15 m3 / hr.
Start preservation chemical dosing pump at required stroke according to
concentration of solution.
As soon as HP drum level reaches 900 mm, one HP circulation pump
started and kept running for 30 minutes.
Check pH and hydrazine content of circulating water and adjust dozing
accordingly so as to achieve required pH and hydrazine.
Open SH spray control valve (beyond 900 mm level) through attemperator
line. When HP system is completely filled up close the drum and super
heater vent valve. HP drum pressure now to be increased to 5 bar.
Stop chemical dosing pump and close spray control valve, isolating valve
and HP economizer valve.
Run HP circulating pump twice a week for one hour and maintain water
level in HP drum with chemically conditioned water only.
The concentration of hydrazine and pH of the solution to be checked every
week and the original values to be maintained.
Lay up monitoring
All lay up conditions, dry or wet should be monitored at regular interval to
ascertain that the lay up water / air quality (RH-30%) is maintained. In the event
of deterioration of the lay up and water chemistry to corrosive conditions in a
particular component , either that component needs to be drained or if proper
mixing can be provided requisite additional chemicals can be added. Protocol for
all lay ups is to be maintained with SCE as per annexure 3.
Page - 20
7.5
Environmental consideration
The disposal of lay up solution containing high concentration of ammonia and
hydrazine needs to be carried out after treatment so that the final effluent
conforms to the prescribed limits of the respective Pollution control boards. This
is why the most popular choice of lay up procedure is the one which does not
necessitate draining of boiler prior to start up which has been outlined as
follows:
When the boiler is off-line, inject through normal chemical feed system around 510 ppm of hydrazine equivalent to the boiler when the boiler pressure decays to
200 psi. This will ensure sufficient mixing of chemicals in the boiler water. When
the boiler pressure decays to 5 psi pressure a nitrogen cap is applied to the boiler.
Upon requirement the boiler can be fired without draining the lay up solution and
the drum vents are opened until 25 psi is reached to remove excess ammonia from
the system.
Because usually it takes 3 days before the pressure decays to 200 psi, an outage
for three (3) days may not require a chemical injection treatment.
8.0
REVIEW
The Head of Corporate Operation Services will be responsible for reviewing this
document on a 3-yearly basis or as necessary.
Page - 21
Annexure 1
Dry preservation procedure for WHRB

It is the most satisfactory method of preservation but needs to be ensured that
complete dry out is attained.
Sl. No.
1.
2.
3.
4.
5.
6.
7.
ACTIVITY
Plan for outage of WHRB and also its preservation by this method.
Suspend dosing of phosphate in the boiler drum from 24 hrs of its
stoppage. CBD to be kept open till ACC of drum water is < 0.2
s/cm.
Drains and vents for H.P. parts are to be opened at about 8.0 bar
and for LP parts at 2-3 bars so as to facilitate the boiler drained and
allow the water residuals to evaporate completely.
All vents and drains are to be opened in (3) after drying out of LP
and HP system to be closed completely tightly when the system
still has temp. well above the ambient temp.
The economizer to be drained under hot conditions after bringing
the pressure in the feed water tank to 1.0 1.5 bar during final
operating hours of WHRB preservation. The pressure of feed tank
to be restored normal after the supply to WHRB to be preserved is
stopped.
This is to be followed only when one of two WHRB to be
preserved, when all the three WHRB are to be stopped and
preserved, the feed water system including the feed water tank to
be drained under hot conditions at 1.0 1.5 bar .
The stop valve towards the WHRB (to be preserved) to be closed
and the condensate and pre heater system to be drained. This
draining to be completed 30 minutes before the gas diverter is
closed.
If the boiler is to be preserved more than 2 weeks by this method
then trays of silica gel approx. 200 Kg are to be kept in HP and LP
drums during the preservation period. While putting the WHRB
into operation the silica gel trays are to be removed before start up
and it is to be ensured that HP/LP drums are perfectly boxed up.
Page - 22
Annexure -2
WET PRESERVATION PROCEDURE FOR WHRB
This procedure requires complete filling of the WHRB with treated DM water the
details of which is given below.
The WHRB to be preserved needs to be drained under nitrogen capping and then
to be refilled with DM water having a pH of 10.0 10.5 (by adding suitable
amount of ammonia) and 50 200 ppm of hydrazine depending upon the length
of preservation period.
The WHRB needs to be filled up to air cocks. Preservation solution is to be
circulated and analyzed twice a week. If any loss of chemical is noticed in
preservation solution, it may be made up suitably.
Super heaters to be protected by back flushing to boiler drum with preservation
solution of the required concentration so as to remove salts if any. This is to be
done by filling WHRB through attemperator line after stopping the filling of
boiler from normal line when the drum level reaches normal level. After that the
following activities are to be carried out :
i.
Isolate the WHRB to be wet preserved from running boilers and STG
perfectly.
ii.
Simulation of valves for WHRB as per O&M manual
iii.
Complete draining of WHRB under nitrogen capping.
iv.
Preparation of ammonia and hydrazine solution
v.
Streamlining WHRB filling from the line taken from CEP discharge and
isolation of running boilers.
Page - 23
Annexure -3
PROTOCOL ON PRESERVATION STATUS
(To be filled every week)
Station
Unit
Date
I. If under dry preservation

Relative Humidity (%) of dry air
N2 Pressure
pH
Hydrazine
N2 Pressure
II. If under wet preservation
III. Quantity of make up Chemicals (if required)
(Chemistry representative)
(Operation Representative)
The protocol duly filled should be available with Shift Charge Engineer.
Document for Distribution to:

CONTROLLED
I. Power Stations
1. General Manager
2. General Manager
3. General Manager
4. General Manager
5. General Manager
6. General Manager
7. General Manager
8. General Manager
9. General Manager
10. General Manager
11. General Manager
12. General Manager
13. General Manager
14. General Manager
15. General Manager
16. General Manager
17. General Manager
18. General Manager
19. General Manager
20. General Manager
UNCONTROLLED
II Regional Head Quarters
21. Executive Director (NR), Lucknow
22. Executive Director (SR), Hyderabad
23. Executive Director (WR), Mumbai
24. Executive Director (ER), Patna
25. Executive Director (NCR), Noida
Rihand
Vindhyachal
Kahalgaon
Farakka
Dadri (Coal & Gas)
Unchahar
Korba
Ramagundam
Badarpur
Talcher Kaniha
Kayamkulam
Kawas
Simhadri
Singrauli
Tanda
Talcher Thermal
Auraiya
Jhanor Gandhar
Faridabad
Anta
III Corporate Head Quarter

26. STA to Chairman & Managing Director, SCOPE, New Delhi
27. STA to Director (Technical), SCOPE, New Delhi
28. STA to Director (Operations) , SCOPE, New Delhi
29. STA to Director (Commercial), SCOPE, New Delhi
30. STA to Director (Projects) , SCOPE, New Delhi
31. Executive Director, PMI, Noida
32. Executive Director (Engg.), EOC, Noida
33. Executive Director (OS),EOC, Noida
34. General Manager (R&D), Noida
35. General Manager (CENPEEP), Noida
36. Concerned Group Heads in Operation Services, CC
IV
Head of O&M
37. Singrauli
38. Korba
39. Ramagundam
40. Farakka
41. Vindhyachal
42. Rihand
43. Kahalgaon
44. Dadri(Coal)
45. Unchahar
46. Talcher Kaniha
47.Talcher Thermal
48. Badarpur
49. Simhadri
50. Auraiya
51. Anta
52. Kawas
55. Kayamkulam
56. Faridabad
53. Jhanor Gandhar 54. Dadri (Gas)

57. Tanda
Head of Chemistry
58. Singrauli
59. Korba
60. Ramagundam
61. Farakka
62. Vindhyachal
63. Rihand
64. Kahalgaon
65. Dadri(Coal)
66. Unchahar
67. Talcher Kaniha
68.Talcher Thermal
69. Badarpur
70. Simhadri
71. Auraiya
72. Anta
73. Kawas
76. Kayamkulam
77. Faridabad
74. Jhanor Gandhar 75. Dadri (Gas)

78. Tanda

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OPERATION GUIDANCE NOTE

Cycle Chemistry Guidelines

CORPORATE OPERATION SERVICES

National Thermal Power Corporation Ltd.

NATIONAL THERMAL POWER CORPORATION LTD.

Date : March 2005

Cycle Chemistry Guidelines

Shut Down Procedure

Dry preservation procedure for WHRB

Annexure-II Wet Preservation procedure for WHRB

Annexure-III Protocol on Preservation Status

Drum type and also once through sub-critical units

Refer table - 1 for drum type unit for phosphate treatment

National Thermal Power Corporation Ltd.

Fig : 1 Boiler water sodium & phosphate Vrs. Operating pressure

Normal Operating Value

National Thermal Power Corporation Ltd.

Table-1 Chemistry parameters to be monitored in Units

National Thermal Power Corporation Ltd.

Back fil superheater

A standard road map for implementing shutdown procedures common to most of

Fig. 2 : Shutdown & layup road map

National Thermal Power Corporation Ltd.

Short term shut down

(For all Ferrous)

Step-2: Intermediate and long term shut down

National Thermal Power Corporation Ltd.

National Thermal Power Corporation Ltd.

Depend on climatic condition

Main condenser and turbine

De-aerator and storage Tank

Feed water Heaters

Nitrogen enters the drum through vent lines.

The boiler and economizer water should be circulated routinely to prevent

Wet lay up procedure (for drum type units)

Type of shut down

Introduce DM water containing 10

National Thermal Power Corporation Ltd.

Short outage 4 days

1. Maintain the same hydrazine and

National Thermal Power Corporation Ltd.

SCHEME FOR HYDRAULIC PRESSURE

NITROGEN SUPPLY LINES TO VENTS

W.W. BLOW DOWN HEADER

CYLIDER ISOLATING VALVES

SCHEME FOR NITRGEN BLANKETTING

INDICATES STRAINER ASSEMBLY.

National Thermal Power Corporation Ltd.

SCHEME FOR HYDRAULIC PRESSURE

NITROGEN SUPPLY LINES TO VENTS

W.W. BLOW DOWN HEADER

CYLIDER ISOLATING VALVES

SCHEME FOR NITRGEN BLANKETTING

NOTE : 1. THICK LINES INDICATE TEMPORARY PIPINGSIZE SHOULD SUIT SUCTION

INDICATES STRAINER ASSEMBLY.

National Thermal Power Corporation Ltd.

Fig. 5 : Rotary desiccant dehumidifier

National Thermal Power Corporation Ltd.

Fig. 6 : Turbine dry lay up using dehumidified air

Fig. 7 : Block diagram for Dry lay up of turbine showing measured

National Thermal Power Corporation Ltd.

De-aerator and storage tank

Lay up procedure for Waste Heat Recovery Boiler (WHRB)