NK - 008 Approved Procedure For STEAM BLOWING of North Karanpura

Format No.
: SP: 02-F07
Rev No. : 00
PROCEDURE OF STEAM BLOWING OF BOILER AND AUXILIARY LINES

FOR
NORTH KARANPURA STPP 3 x 660 MW UNIT I/II/III
DOCUMENT NO. : REV NO. : 01 EFFECTIVE DATE :

NKP-00-LB-DC-PSER- 02.05.2019
TSX-01-01-012
PREPARED BY REVIEWED BY APPROVED BY
R SEN K K DATTA
A K PATRA
ISSUED TO :
COPY NO. : ISSUED BY K K DATTA
DATE OF ISSUE :
AGM/TSX
(NAME, DESGN. /DEPT.) (SIGN.)
BHARAT HEAVY ELECTRICALS LIMITED
POWER SECTOR: EASTERN REGION

NTPC NORTH NTPC Ref No: COS-COMM-NK-Commg-PRO/008
Sheet 13 of 13
KARANPURA BHEL Ref No: NKP-00-LB-DC-PSER-TSX-01-01-012
Plant area: BOILER
LIST OF CONTENTS
1.0 PLANT DETAILS
2.0 OBJECTIVE
3.0 PROPOSAL
4.0 SERVICES REQUIRED
5.0 SAFETY PRECAUTIONS
6.0 EMERGENCY PROCEDURE
7.0 STATE OF THE PLANT
8.0 METHOD
9.0 COMPLETION CRITERIA
10.0 APPENDICES
a) LOG SHEET
b) DRAWING & SCHEMES
c) HIRA & OCP
This procedure is the property of BHEL and is exclusively developed for the
commissioning of NORTH KARANPURA STPP 3 x 660 MW
.This procedure should not be used by any other person or firm without the
written permission of BHEL (Power Sector Eastern Region, Technical Services)
or put to any use other than specified above. This document shall not be
copied in any manner unless authorized.
Sheet 13 of 13
Plant area: BOILER
1.0 PLANT DETAILS
1.1 The Steam Generator is a once through supercritical plus Reheat Boiler. Major auxiliaries of
the Boiler are Pulverizes, Feeders, Fans and miscellaneous valves. Boiler Recirculation Pump
is provided to ensure proper circulation of water in furnace wall circuits during initial
subcritical mode operation.
1.2 The circuits which are subjected to steam blowing are Superheated sections of Boiler, Main
steam lines up to HP Turbine inlet, Cold Reheat lines up to Reheater inlet, Re heater sections,
Hot Reheat lines up to IP Turbine inlet, HP and LP bypass sections and all auxiliary steam
lines.
2.0 OBJECTIVE
To remove scales, loose material, iron cuttings etc that might have remained entrapped in
Super heaters, Re heater & Steam piping’s during manufacture, storage and erection. Failure
to remove the debris may result in damage to Turbine blades, valves etc.
3.0 PROPOSAL:
3.1 Steam blowing shall be done in mainly in 5 stages viz Stage 1A, 1B, 2A, 2B and 2C.
3.2 Electrically Operated Temporary Valves (EOTVs) shall be located as shown in the scheme.
Loop pipes from ESV and IV to Turbine shall not be steam blown. Hence proper care shall be
taken for cleanliness of the pipes before erection. A joint protocol of cleaning may be signed.
3.3 All steam pipelines covered in stages 1A, 1B, 2A, 2B and 2C shall be steam blown using
EOTVs.
3.4 Puffing method shall be adopted for carrying out Steam blowing of stages 1A, 1B, 2A, 2B and
2C in which Boiler separator pressure shall be raised to 60 Kg/cm2 and a degree of superheat
of around 50 degrees to be maintained for effective blowing. Pressure is released through
Electrically Operated Temporary Valves (EOTVs) and steam blowing done till the separator
pressure drops from 60 Kg/cm2 to 45-40 Kg/cm2.
3.5 Steam blowing for Auxiliary lines associated with stage 1A, 2A and Auxiliary boiler shall be
carried out by continuous blowing method at 50% of normal operating pressure of the
respective system. Duration of each blow shall be 10 to 20 minutes. The time gap between
two blows shall be around 1-1.5 hours.
Sheet 13 of 13
Plant area: BOILER
3.6 The effects of steam blowing shall be evaluated and steam blowing concluded as per the
completion criteria given in section 9.0
3.7 Systems covered in various stages shall be:
3.7.1 Stage 1A-- Super heaters, Main Steam Lines up to ESVs, temporary lines from HP turbine
Emergency Stop Valve (ESV) s to EOTVs and temporary lines from EOTVs to CRH line up
to reheater inlet and temporary line for exhaust. Tap off lines from CRH for Deaerator,
TDBFPs, PRDS, HP Heaters 7A&B, gland sealing etc. shall remain closed/isolated. Blowing
of this stage shall be concluded by observing the indents on the Target Plates.
3.7.2 Stage 1B -- Super heaters, Main Steam Lines, HP bypass lines and CRH lines up to Re heater
inlet and temporary lines up to exhaust. EOTVs provided in the temporary loop in HPBP lines
will be used for steam blowing .Total 10 (ten) nos. of blows shall be given through HP
Bypass lines to ensure cleanliness of the limbs and target plate is not required.
3.7.3 Stage 2A -- Super heaters, Main Steam Lines up to ESVs, temporary lines from ESVs to
EOTVs, temporary lines from EOTVs to CRH lines, CRH lines, Re heater, HRH Lines to IP
turbine Interceptor Valve (IV) s, temporary lines from IVs to exhaust. CRH lines along with
attemperators shall be welded with reheater before start of stage 2A blowing. LP bypass lines
shall be remain blanked. Blowing of this stage shall be concluded by observing the indents on
the Target Plates.
3.7.4 Stage 2B-- Super heaters, Main Steam Lines up to ESVs, temporary lines from ESVs to
EOTVs, temporary lines from EOTVs to CRH lines, CRH lines, Re heater, HRH Lines, LP
bypass lines with temporary exhaust pipe. HRH lines shall be remain blanked at the exhaust
point of Stage 2A. Total 10 (ten) nos. of blows shall be given through LP Bypass lines to
ensure cleanliness of the limbs and target plate is not required.
3.7.5 Stage 2C -- Super heaters, Main Steam Lines up to ESVs, temporary lines from ESVs to
EOTVs, temporary loop from one of the EOTV exit, temporary line to overload lines and
from there to exhaust. Tap off lines from CRH for Deaerator, TDBFPs, PRDS, HP Heaters
7A& &7B, gland sealing etc. shall remain closed/isolated. Over load valve insert is removed
and cover plate installed. Blowing of this stage shall be concluded by observing the indents on
the Target Plates.
3.7.6 Following circuits/line are steam blown along with Stage 1A section wise by continuous
blowing method (no target plate is required):
a) From Main steam line to Aux PRDS headers

b) From Aux PRDS header to Seal Steam control station
c) From Aux PRDS header to Interconnection to other unit Aux PRDS.
d) From Super heater header to SH Spray up to control station in reverse direction (NRVs has
to be replaced by spool piece)
Sheet 13 of 13
Plant area: BOILER
e) From Aux PRDS header to Deaerator Pegging line.
3.7.7 Following circuits/line are steam blown along with Stage 2A section wise by continuous
blowing method (no target plate is required): 15-20 minutes duration
a)From CRH line to RH Spray up to control station in reverse direction (NRVs has to be
replaced by spool piece)
b)From CRH line to HP heater 7A & 7B
c) From CRH line to Deaerator Pegging line.
d) From CRH line to Aux PRDS header inlet.
e) From Aux PRDS header to TD BFPs.- 20 minutes after 1-1.5 hours. gap
f) From CRH line to TD BFPs- 20 minutes and after 1-1.5 hours. gap
g) From Ext 4 to TD BFPs. -20 minutes and after 1-1.5 hours.gap
h) From Ext 4 to Deaerator Pegging line.
3.7.8 Following circuits/line are steam blown while/before commissioning of the respective system
section wise by continuous blowing method (no target plate is required): 15-20 minutes duration
a) From Aux boiler to Aux PRDS header inlet.

b) From Aux PRDS header to APH soot blower inlet.
c) From Aux PRDS header to SCAPH inlet.
d) From Aux PRDS header to HFO Atomizing steam header.
e) From Aux boiler to Mill inerting header.
f) From Super heater header to soot blower header.
4.0 SERVICES REQUIRED:
4.1 Availability of required quantity of DM water and Fuel Oil (25000 M3 DM water , 6000 KL
LDO approximately)
4.2 Availability of HT / LT / 220 VDC / 110 VAC and other critical Power / Control supplies.
4.3 Availability of Instrument / Service Air.
4.4 Availability of chemical dosing system .Direct addition of chemicals (ammonia & hydrazine)
in deaerator storage tank through manual means may be made available as an alternative.
4.5 Availability of Auxiliary steam for heating feed water in FST.
4.6 Availability of instrument having magnifying glass for measuring dia of indents on Target
plates.
Sheet 13 of 13
Plant area: BOILER
5.0 SAFETY PRECAUTIONS:
5.1 The blowing area should be barricaded.
5.2 Required quantities of safety gears such as helmets, Asbestos hand gloves, Ear mufflers etc
should be available.
5.3 First aid box should be available in control room
5.4 Required number of sign-boards should be put into position at selected locations to indicate
the on going process of steam blowing.
5.5 Public address system or siren should be available to publicly communicate the
commencement of steam blowing.
5.6 Permanent firefighting system and portable fire extinguisher should be available at identified
locations.
5.7 Ambulance or equivalent vehicle and fire tender should be available in vicinity.
5.8 Required barricades are to be made to prevent personnel from coming into contact with
temporary piping.
5.9 Required stair cases or platform or approaches etc. with hand operated for temporary valves
are to be made available.
5.10 Please refer HIRA & OCP for further safety assistance.
6.0 EMERGENCY PROCEDURES
6.1 The group involved in carrying out steam blowing should be aware of the procedures to be
followed in case of accidents involving injury to personnel.
6.2 The group should be aware of operating procedures of portable fire extinguishers to be used
for quenching minor fires.
Sheet 13 of 13
Plant area: BOILER
7.0 STATE OF THE PLANT
7.1 Boiler is ready in all aspects including interlocks, protections, alarms and measurements,
chemical dosing systems, instrumentation etc.
7.2 MDBFP is ready with all controls, interlocks and protections.
7.3 Hydraulic test of the lines to be steam blown is over.
7.4 All permanent & temporary pipings are properly supported to withstand the reaction forces
during blowing. Exhaustfrom pipes should be away from overhead power line
7.5 Locking of all the hangers is released.
7.6 Feed water and separator water sampling systems are available.
7.7 Reliable communication system is available between control room, Boiler, TG and other
operating area.
7.8 The exhaust area is suitably cordoned off and notices displayed prominently.
7.9 Steam blow off devices are erected for ESVs, IVs, Overload valve and LP Bypass valves.
These are to be ensured before commencing steam blowing of the concerned section.
7.10 Arrangement for fixing of Target plates as indicated in the scheme is ready.
7.11 HP bypass valves and breakdown orifices are not erected.
7.12 MS stop valves at Boiler outlet and Electrically Operated Temporary Valves (EOTV) are
made operational from Control Room (EOTV power to be given emergency supply board
option).
7.13 MS & HRH Strainer elements (if already fixed) are removed before the steam blowing
operation.
7.14 Flow nozzle, control valves and NRV’s wherever applicable are not erected before steam
blowing.
7.15 Downstream lines of IVs and LP Bypass valves, cross around pipes are manually cleaned.
Joint protocol may be prepared.
7.16 Turbine must be on baring gear before starting of steam blowing. All Turbine casing metal
temperatures, barring speed to be monitored.
Sheet 13 of 13
Plant area: BOILER
7.17 No loose debris / extraneous materials are left inside the permanent / temporary piping.
7.18 All drains are left open to atmosphere suitably outside TG Hall. Required allowances are
given for the thermal expansion of the pipe lines.
7.19 Required number of Target Plates and holder are available.
7.20 All safety valves are erected and kept in normal operating position.
7.21 Chemical Dosing system should be ready.
7.22 Target plates must be mounted in the temporary pipe near steam exhaust (as per location
suitability)
7.23 It is recommended to inspect SH/RH headers inside pent house by Boroscope after Steam
Blowing completion.
8.0 METHOD
8.1 The Boiler is started in a normal manner following start up procedure with its protection in
service. ( Protection exemption list may jointly agreed by NTPC and BHEL )
8.2 Make up water from boiler fill pump is given directly to FST. FST heating is done with steam
to raise water temperature to 105 o C. Alternately pegging to be used to raise temperature
while using water through CEP.
8.3 Separator storage tank water level is maintained by running MDBFP. In case of high separator
level, HWL 1 & 2 will get opened. Drained water will get transferred to flash tank and
subsequently to receiving tank. Excess water from receiving tank will go to plant drain instead
of going to condenser through overflow line (related valves will be kept closed).
Sheet 13 of 13
Plant area: BOILER
Stage 1A, 1B, 2A, 2B and 2C.
8.4 First steam blow for each of stage 1A, 1B, 2A, 2B and 2C.is given at a lower pressure
(separator pressure 25 kg/cm2 to 15 kg/cm2) and the pipe lines including temporary piping are
surveyed for proper expansion and supports. Subsequent blows are given at 60 kg/cm2
separator pressure.
8.5 Boiler pressure is raised to 60 kg / cm2. The steam lines to be steam blown are warmed up
prior to blowing. Reducing boiler firing is to 1-2 burners and BRP running, and EOTVs are
opened. The opening of temporary valve allows steam to escape to atmosphere at high
velocity carrying with it loose and dislodged debris. During blowing moderate amount of feed
water flow to Seperator has to be ensured through MD BFP.
8.68.7 The water level in the separator swings beyond visible limits at the start, during and at the end
of steam blowing. There are chances of water droplets getting carried over to super heaters.
Hence optimum water level is maintained in the separator. Boiler water treatment is carried
out with liquid ammonia to maintain pH at 9 to 9.8 in feed water.
8.8 Hot tightening of flanges, studs / bolts is done wherever such connections have been made.
8.9 While carrying out stage 2A blowing, suitable dummies are put at LPBP outlet temporary
line. Similarly, during stage 2B blowing, suitable dummies are put at IVs outlet temporary
lines. Drains of suitable size are provided at the upstream of flange locations for the purpose
of warming up.
Sheet 13 of 13
Plant area: BOILER
9.0 COMPLETION CRITERIA
9.1 Stages 1A, 2A and 2C.
9.11 For the first few blows Target plates need not be kept. Afterwards Target plates to be used.
9.12 Target plates are mounted in the temporary exhaust pipes nearer to the permanent line with a
distance governed by VGB as to be minimum 5D distance from upstream bend.
9.13
The target plate indentation will be judged as per criteria given in VGB513, which is
“At no point of the target plate on an area 40 mm x 40 mm (1600 mm2) shall impacts be
found with following extension and number :
No impact with a size > 1 mm
Less than 4 impacts with a size > 0.5 mm
Less than 10 impacts with a size > 0.2 mm
This evaluation shall only apply to carbon steel, i.e. St 37 material target plates.
Target plates with surface polished with a Hardness of 140 – 160 HB.
surface finish requirement: Average surface roughness Rz: ~ 3 μm
Average surface finish Ra : ~ 0,6 μm
AND
Disturbance factor must be > 1.4
9.2 Stages 1B & 2B:
9.21 10 (ten) no of blows for stage 1B and 2B and target plate

is not required.
9.3 For Auxiliary lines associated with stage 1A, 2A and Auxiliary boiler:
9.31 Steam blowing is declared complete based on visual observation i.e. blowing medium at exit
of the pipe should be visibly clear or minimum three nos. of blows shall be given for each sub
stage , whichever is later.
Sheet 13 of 13
Plant area: BOILER
SAMPLE LOG SHEET

PROJECT:
UNIT No.:
Sl No. Date Blow Separator pressure Target Material Remarks
Time
No. plate used of target
or not plate
Start Finish Duration At the time At the time
of valve of valve
opening closing
Signatures
NTPC BHEL
Sheet 13 of 13
Plant area: BOILER
STEAM BLOWING TEMPORAY PIPILINE SUPPORTS (TYPICAL)

Sheet 13 of 13
Plant area: BOILER

Sheet 13 of 13
Plant area: BOILER

Sheet 13 of 13
Plant area: BOILER

Sheet 13 of 13
Plant area: BOILER
CALCULATION OF DISTURBANCE FACTOR
2
Qb Vb
Disturbance Factor (DF) = 2
Q MCRVMCR
Qb  Steam flow during blowing (in Kg /sec)
QMCR  Steam flow at MCR (in kg/sec)
Vb  Specific Volume of steam during blowing at the pipe inlet (e. g., at SH o/l for MS line) m 3 / kg
VMCR  Specific Volume of steam at MCR ( m 3 / kg )
1
Qb  Sonic Velocity during blowing × Area of temporary pipe ×
Vbt
Sonic Velocity = KPVbt g m/sec
Vbt = Specific Volume of steam at temporary pipe in m 3 / kg
K = Constant = 1.3
P  Pressure at the exit of the temporary pipe = kg / m 2
g = Acceleration due to gravity in m / sec 2
A=Area of temporary pipe in m2

Sheet 13 of 13
Plant area: BOILER
Sample calculation for Disturbance Factor:-
MS
Q mcr 672.22 kg/sec
Tmcr 568 deg Celsius
Pmcr 253.8 ksc
V mcr 0.013024 In cub mtr/kg
P blow at Sh o/l
28 ksc
T blow at Sh o/l
330 deg Celsius
V blow 0.09355 m3/kg
Dia exh pipe 0.813 m
Area 0.519026 m2
P exhaust 1.83 ksc
T exhaust 280 deg cel
V exhaust 1.3879 m3/kg
velocity at exit 575 m/sec
Q blow 215.0298 kg/sec
Q blow total 430.0597 kg/sec
DF ms 2.939887
Doc. No.: PSER:HSEOM:005 : 02
OPERATIONAL CONTROL PROCEDURES Rev. No. : 02
Eff. Date : 15.06.2005
OCP No. : 22 SAFE STEAM BLOWING Page 1 of 3
1. Purpose : To promote safety of power station personnel working under customer,

BHEL and sub contractors by setting out the general requirements while
conducting Steam Blowing activity and the specific requirements to avoid
danger from specific hazards.
2. Scope : PSER Sites
3. Responsibility : Concerned Head/SOX / Commissioning Head
4. Performance criteria : .No. of such incidents / accidents on such cases.
5. Cross reference : ISO : 14001, OHSAS : 18001
6. Procedure :
Sr. Activity Responsibility

1 Identification of hazardous locations: Supervisor
i) Boiler elevation housing MS Stop valve and

Safety valves.
ii) Temporary piping for steam blowing.
iii) Steam Exhaust area.
2 Identification of hazards & risks Supervisor
i) Noise leading to hearing impairment.

ii) Release of heat from un-insulated portions of steam
lines causing heat syncope.
iii) Leakage of steam causing steam burns.
3 Identification of safety equipment: Supervisor
For Personnel -
a) The entire area of Boiler and surrounding covering at
least 100 Meters from the steam exhaust pipe
should be totally cordoned off with barriers and
display boards.
Eff. Date : 15.06.2005
Sr. Activity Responsibility

b) Following items should be made available before steam
blowing:
i) Safety Boots 12 pairs
ii) Asbestos gloves 12 pairs
iii) Helmets 12 nos
iv) Safety goggles (plain glass) 12 nos
v) Ear muffs 12 nos
vi) Face masks(transparent, plastic) 12 nos
vii) First aid box (containing dilute ammonium
hydroxide, 50% sodium bicarbonate solution, eye
lotion, bandages, smelling salts, Iodine, burnol,
cotton and any other medicine prescribed by plant
medical unit doctor)
4 For plant equipment – Supervisor
Fire extingusher / tender
Ladder, temporary platform/scaffolding
5 For Environment – Site Incharge
Pollution control acceptance criteria for noise level.
6 Communication methodology - Site Incharge
i) Control room with telephone, PA system and walki
talki. Medical attendant’s full time presence is
necessary.
ii) Plant hospital to be sounded in advance for any
possible injury prior to start of activity.
7 Notice board display and cordoning of identified hazardous Site HSE
locations to prevent entry of personnel other than authorized coordinator
working personnel.
8 Prevention of any welding/ gas cutting at the time of steam blowing Concerned
HOS
9 For any repair/maintenance work in between the stages of steam Concerned
blowing, related site safety procedure is to be followed with respect HOS
to handling, repair and maintenance of equipment.
10 Working area should be cleared off all debris, scrap and non-related Supervisor
materials.
11 Total area including workstations, passages, main boiler, staircases, Site Incharge
, road should be sufficiently illuminated with floodlight. In addition,
hand lamps are to be made available.
12 For any fire incident, applicable procedure is to be followed for Site HSE
extinguishing. coordinator
Eff. Date : 15.06.2005
7. Records :
Record Title Record No. Location Responsibility Retention

Period
8. Verification, Corrective and Preventive Actions :
HOD / Site Incharge shall ensure effective implementation of the above procedure. In case of
any deviation, shall take suitable corrective and preventive action.
Doc. No. : PSER:HSEOM:001:02
REGISTER OF OHS HAZARDS AND RISKS Rev. No. : 05
Eff. Date : 01.08.2013
Page: 8 of 50
PSER
Annexure-I
CRIITERIA FOR HAZARD AND RISK IDENTIFICATION AND ASSESSMENT

RISK IDENTIFICATION RISK ASSESSMENT
Activity Haz Condition Risk Adequacy of Scale Severity Total Risk Overriding Risk Control
ard Measure (Se) Classification Factor Measure
(Sc) Se = L x C Sc+ Se And (LC/DC/A
Color Code ny other)
D/I N/AN/ Likelih Consequ Existing Gaps, Likelihood Level of
E ood ence if any Consequence
R (L)
(C)
/
N
R
Spot Highly Slightly Harmful
(1) Unlikely SH Trivial
HUL (1) (3)
(1)
Within Unlikely Harmful
Dept UL H Moderate
(2) (2) (2) (4-6)
Within Likely Very Harmful

Site L VH Substantial
(3) (3) (3) (7-12)
Outside Very Likely Extremely

Site VL Harmful Intolerable
(4) (4) EH (13-20)
(4)
Legend:
Condition Likelihood Level of Consequence
D = Direct N: Normal HUL = Highly Unlikely SH = Slightly Harmful
I = Indirect AN: Abnormal UL = Unlikely H = Harmful
R = Routine E: Emergency L = Likely VH = Very Harmful
NR = Non-routine VL = Very Likely EH = Extremely Harmful
Eff. Date : 01.08.2013
Page: 9 of 50
PSER
DETERMINING RISK-CONSEQUENCE LEVEL - GUIDANCE CRITERIA
Level of Harm Human Property Exposure level
Slightly Harmful Momentary Discomfort No Action Required Below / Equal to Prescribed Threshold
Limit Value (TLV) (8
Hrs)
Harmful Minor Injuries ( Non reportable ) Minor Damages Above the Prescribed Threshold Limit
requires First Aid Value (TLV) ;
(8 Hrs) however < 20%
Very Harmful Major Injuries, absence from the Severe damages Above the Prescribed Threshold Limit
work 48 hours / temporary Value (TLV) ;
disability (8 Hrs) however within
20% - 40 %
Extremely Harmful Fatal / Permanent Disability, Major Annihilation Above the Prescribed Threshold Limit
incidents involving large (Complete destruction) Value (TLV) ;
number of people (8 Hrs) AND > 40 %
RISK LIKELIHOOD
Weightage Probability Risk Likelihood
1 > Month Highly Unlikely ( HUL )
2 ≤ Month > Week Unlikely ( UL)
3 ≤ Week > Day Likely ( L )
4 ≤ Day Very Likely ( VL )

Eff. Date : 01.08.2013
Page: 10 of 50
PSER
RISK MATRIX
MATRIX-1
Severity Rating (LxC) Risk Classification
Scale of Incident
Level of consequence © Likelyhood of incident (L) Sc+Se (Sc)
Rating 1 2 3 4
Description Highly Very
Unlikely Likely
Unlikely Likely Rating Desc
(UL) (L)
(HUL) (VL)
Slightly Harmful T T M M
1 1 2 3 4
(SH) (2) (3) (4) (5)
Harmful T M S S
2 2 4 6 8
On Spot
(H) (3) (5) (7) (9)
1
Very Harmful M S S I
3 3 6 9 12
(VH) (4) (7) (10) (13)
Extremely Harmful M S I I
4 4 8 12 16
(EH) (5) (9) (13) (17)
MATRIX-II
T M M M
1 Slightly Harmful (SH) 1 2 3 4
(3) (4) (5) (6)
Within Dept/Area
Harmful M M S S
2 2 4 6 8
(H) (4) (6) (8) (10)
2
3 3 6 9 12
(VH) (5) (8) (11) (14)
Extremely Harmful M S I I
4 4 8 12 16
(EH) (6) (10) (14) (18)
Eff. Date : 01.08.2013
Page: 11 of 50
PSER
MATRIX-III
Severity Rating (LxC) Risk Classification
Scale of Incident
Level of consequence © Likelyhood of incident (L) Sc+Se (Sc)
Rating 1 2 3 4
Highly Very
Description Unlikely Likely
Unlikely Likely Rating Desc
(UL) (L)
(HUL) (VL)
M M M S
1 Slightly Harmful (SH) 1 2 3 4
(4) (5) (6) (7)
Within Office/ Site

Harmful M S S S
2 2 4 6 8
(H) (5) (7) (9) (11)
3
3 3 6 9 12
(VH) (6) (9) (12) (15)
Extremely Harmful S S I I
4 4 8 12 16
(EH) (7) (11) (15) (19)
MATRIX- IV
Slightly Harmful M M S S
1 1 2 3 4
(SH) (5) (6) (7) (8)
Beyond Dept/Area
Harmful M S S S
2 2 4 6 8
(H) (6) (8) (10) (12)
4
Very Harmful S S I I
3 3 6 9 12
(VH) (7) (10) (13) (16)
Extremely Harmful S S I I
4 4 8 12 16
(EH) (8) (12) (16) (20)

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Format No.

PROCEDURE OF STEAM BLOWING OF BOILER AND AUXILIARY LINES

DOCUMENT NO. : REV NO. : 01 EFFECTIVE DATE :

PREPARED BY REVIEWED BY APPROVED BY

COPY NO. : ISSUED BY K K DATTA

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR: EASTERN REGION

PROCEDURE OF STEAM BLOWING OF BOILER AND AUXILIARY LINES

1.0 PLANT DETAILS

4.0 SERVICES REQUIRED

5.0 SAFETY PRECAUTIONS

6.0 EMERGENCY PROCEDURE

7.0 STATE OF THE PLANT

9.0 COMPLETION CRITERIA

PROCEDURE OF STEAM BLOWING OF BOILER AND AUXILIARY LINES

1.0 PLANT DETAILS

PROCEDURE OF STEAM BLOWING OF BOILER AND AUXILIARY LINES

3.7 Systems covered in various stages shall be:

a) From Main steam line to Aux PRDS headers

PROCEDURE OF STEAM BLOWING OF BOILER AND AUXILIARY LINES

e) From Aux PRDS header to Deaerator Pegging line.

a) From Aux boiler to Aux PRDS header inlet.

4.0 SERVICES REQUIRED:

4.3 Availability of Instrument / Service Air.

4.5 Availability of Auxiliary steam for heating feed water in FST.

PROCEDURE OF STEAM BLOWING OF BOILER AND AUXILIARY LINES

5.0 SAFETY PRECAUTIONS:

5.1 The blowing area should be barricaded.

5.3 First aid box should be available in control room

6.0 EMERGENCY PROCEDURES

PROCEDURE OF STEAM BLOWING OF BOILER AND AUXILIARY LINES

7.0 STATE OF THE PLANT

7.2 MDBFP is ready with all controls, interlocks and protections.

7.3 Hydraulic test of the lines to be steam blown is over.

7.5 Locking of all the hangers is released.

7.11 HP bypass valves and breakdown orifices are not erected.

PROCEDURE OF STEAM BLOWING OF BOILER AND AUXILIARY LINES

7.19 Required number of Target Plates and holder are available.

7.21 Chemical Dosing system should be ready.

PROCEDURE OF STEAM BLOWING OF BOILER AND AUXILIARY LINES

Stage 1A, 1B, 2A, 2B and 2C.

PROCEDURE OF STEAM BLOWING OF BOILER AND AUXILIARY LINES

9.0 COMPLETION CRITERIA

9.1 Stages 1A, 2A and 2C.

Disturbance factor must be > 1.4

9.2 Stages 1B & 2B:

9.21 10 (ten) no of blows for stage 1B and 2B and target plate

PROCEDURE OF STEAM BLOWING OF BOILER AND AUXILIARY LINES

SAMPLE LOG SHEET

PROCEDURE OF STEAM BLOWING OF BOILER AND AUXILIARY LINES

STEAM BLOWING TEMPORAY PIPILINE SUPPORTS (TYPICAL)

PROCEDURE OF STEAM BLOWING OF BOILER AND AUXILIARY LINES

STEAM BLOWING TEMPORAY PIPILINE SUPPORTS (TYPICAL)

PROCEDURE OF STEAM BLOWING OF BOILER AND AUXILIARY LINES

STEAM BLOWING TEMPORAY PIPILINE SUPPORTS (TYPICAL)

PROCEDURE OF STEAM BLOWING OF BOILER AND AUXILIARY LINES

PROCEDURE OF STEAM BLOWING OF BOILER AND AUXILIARY LINES

CALCULATION OF DISTURBANCE FACTOR

Qb  Steam flow during blowing (in Kg /sec)

QMCR  Steam flow at MCR (in kg/sec)

VMCR  Specific Volume of steam at MCR ( m 3 / kg )

Sonic Velocity = KPVbt g m/sec

Vbt = Specific Volume of steam at temporary pipe in m 3 / kg