BLOWING OUT STEAM LINES INTRODUCTION

The purpose of blowing the steam lines prior to starting up a new unit is to remove any foreign matter remaining in the equipment (i.e. super heater) and steam piping after erection is completed. Considerable damage could result if such foreign matter was allowed to enter the plant steam system during initial operation. On older units the need for steam line blowing should be considered following major pressure parts repairs, where the possibility of introduction of foreign material into the system exists. Since prevention of damage to the plant steam system is the prime concern, the responsibility for determining the effectiveness of the steam line blowing operation rests with the plant operator. During the steam line blowing process the unit should be operated in accordance with the vendor recommended procedures, with all control systems and protective interlocks functioning. The principle behind steam blowing lines clean is that the thermal cycling (heating/cooling) and high velocity gas flowing through the line will "shock" the pipe and tend to break the mill scale and weld slag away from the pipe wall. Ideally, steam blowing should be done prior to the system being insulated to maximum the thermal cycling of the equipment. If the system is insulated, a greater time between blows may be necessary to allow the system to cool.

Ideally, to obtain optimum cleaning, the flow conditions in the system during steam line blowing should equal those during normal operation at maximum load. Since it is impossible to exactly duplicate these conditions when blowing through the piping to atmosphere, it is desirable to produce equivalent conditions by using lower pressure steam with a flow rate such that the product of steam flow times velocity will equal that under normal full load conditions. The determination of the total obtainable flow quantity must be based on flow resistance in the entire system, including the temporary piping. This determination is normally made by the designer of the blowing system.

The temporary piping is normally equipped with a shutoff valve that is used as a blowing valve. With this arrangement, the superheater and the upstream portion of the temporary piping are maintained at drum pressure at all times when not actually blowing. When a boiler and its associated steam piping have been erected, there is a possibility that debris, such as welding beads and dirt may have been left in the tubes and piping. In addition, these parts may have an internal coating of oxide or mill scale, which will flake off during initial temperature changes.

To avoid any hazard of such material causing obstruction or damage to machinery, it is recommended that arrangements are made to blow the piping systems to atmosphere before the final connections are made and steam is passed to the plant. This blowing through is done with steam which is exhausted through adequate sized, open ended low pressure temporary piping. The steam blowing operation cleans the system and provided the steam of requisite purity for the plant. This low pressure temporary piping must be connected as near as possible to the terminal point of the section of the system being purged. In some cases an appropriate valve cover may be removed and the temporary piping led off the valve chest. The run should be as short as possible consistent with steam discharging freely to atmosphere with out causing danger to personnel or damage to structure and equipment. If a basket type strainer is installed in the steam piping it must be removed prior to steam blowing and subsequently replaced. The precautions listed below must be strictly observed.

REQUIREMENT OF TEMPORARY STEAM LINE FOR BLOWING The diameter of temporary discharge piping shall not be less than the diameter of the respective line to be steam blown. The spool pieces should have an opening equal to the diameter of the respective temporary pipeline. The temporary discharge piping and supports shall be capable to withstand steam blowing parameters. PROCEDURE FOR BLOWING There are two alternative procedures for blowing out the steam lines to the plant. One is to raise pressure in the boiler to just below the permissible pressure in the temporary atmospheric discharge piping, gradually open the boiler stop valve whilst increasing the firing rate to maintain pressure during the blow, then gradually close the stop valve whilst reducing the firing rate. This procedure has the advantage that the blowing period may be as long as is necessary to clean the steam piping thoroughly. Usually the waste steam discharged to atmosphere will be dark in colour when blowing starts, and will become clear as foreign matter is removed from the system. Several successive bows should be made with an adequate cooling period between each, as the associated temperature changes will assist in loosening mill scale. The alternative procedure is the puffing method. The boiler is raised to around 40kg/cm2g pressure or just below the permissible pressure in the temporary atmospheric discharge piping. Shut off the firing. Ensure that the drum water level is at the lowest level.

Open the boiler stop valve quickly; water level in the drum swings upward. The level may even go beyond visible limit. Permit the boiler pressure to drop about 10.5 to 14kg/cm2g. The change in steam saturation temperature is kept less than 42deg.C. Then quickly close the stop valve. This method has the advantage that the sudden change in steam pressure produces a sudden change in saturated steam temperature causing a thermal shock which helps to loosen the adhered scale from the inside of tubes and piping. The steam expands quickly through the system as the pressure drops. The scales are than removed by the expanding steam. How ever, all the pressure parts, including the drum, are subject to thermal shock, and to prevent excessive stresses and differential expansions, the change in saturation temperature should not exceed 42deg.C. To ensure thorough cleaning, a number of successive blows must be made due to the limited blowing period permitted by the allowable pressure reduction. For both procedures, experienced observation can determine when sufficient blowing through has been effected. Clean metal target plates are rigidly secured in the path of the discharging steam at a suitable distance from the pipe end.

These are placed in position for evaluation of debris carry over along with the steam after the initial few blows when the steam is visibly clean. After each blow the target plates are inspected for any pitting by the debris. Target plate assembly is located in the temporary exhaust pipe and placed nearest to the permanent pipe work. Availability of sufficient number of target plates is to be ensured. Stain less steel plates having mirror finish shall be used in final blows. In preceding blows, target plates of aluminium shall be used. Further blows are given until they indicate that no debris remains in the piping. It is a standard practise to limit the number of blows to 6 to 8 per day at an interval of 2 hours between 2 consecutive blows and with an overnight cooling. A complete record of the events and observations are to be maintained.

STEAM BLOWING COMPLETION CRITERIA Steam blowing can be declared complete only after ensuring cleanliness of target plates mounted in the temporary exhaust pipe. As already mentioned, for evaluating the cleanliness and termination point of the steam blowing, aluminium target plates are to be used initially. For the final stages, target plates of stain less steel having mirror finish are to be used. The highest velocity of steam being at the centre of pipe, the effectiveness of steam blowing is judged by the absolute pitting on the target plate in the central zone i.e the area covered by three quarters of the pipe diameter.

The piping is considered clean if there are not more than five pitting on the target plate in the central zone and the edges are not deformed. Besides, there should be no pitting in the rim zone i.e the area other than the central zone. This should be achieved in three consecutive plates.

PRECAUTIONS To prevent excessive strain on pressure parts and danger to personnel, the following precautions must be strictly observed. The securing arrangements of permanent piping must be complete, or adequate temporary bracing installed. For thermal expansion of pipes, proper allowance must be given. First test steam blow should be given at lower pressure and the temporary piping should be surveyed for proper expansion and supports. The temporary low pressure piping exhausting to atmosphere will be subject to strong reaction forces during the blow and must be adequately secured. The exhaust can be diverted at an angle of 30deg. from horizontal to reduce reaction force on temporary piping. During the blowing period steam and debris will be issuing from the discharge pipe at high velocity and the location and direction of this must be carefully considered in terms of safety. The steam must be exhausted to the atmosphere outside the boiler house and so directed that personnel and equipment are not damaged or endangered. The area should be cordoned off and warning/safety notices displayed prominently. Since it is necessary to have a high steam velocity through the system being cleaned during the blowing period, the temporary piping exhausting to atmosphere must be of generous size so that it will not significantly restrict the flow. The boiler pressure used for blowing out the lines must not exceed the design pressure of the low pressure temporary piping and fittings used during the blowing period. The temporary piping should have minimum 1in 100 slopes towards exhaust for removal of condensate and should be well supported. This should have proper provision for thermal expansion. During pressure raising and blowing, all NRV internals, control valves and flow nozzles, orifice plates if any in the blow circuits are to be removed and spool pieces to be provided. An adequate reserve of feed /DM water must be kept readily available to replace the blowing losses. Water level in the boiler must be carefully watched and kept under proper control at all times, particularly as feed heaters may not be in commission. Special care must be taken to prevent priming and carry over. If the water level drops below the bottom of the gauge glass, there is a possibility of quenching the hot drum with cold feed water when regaining level, and causing excessive thermal stresses. The temperature of the water entering the steam drum should be monitored at all times. It is recommended that the differential between water leaving economiser and drum shell temperature shall not excede20deg.C. All the permanent pipelines and temporary pipelines passing through working area should be insulated before the blowing. All permanent hangers and supports for various lines are to be erected and set for proper values as per design figures. All locks and restraints are to be removed from pipelines, Provision should be made for tightening of flanges of holding arrangements for target plates. Spare gaskets for flanges are to be kept ready.

In addition to usual light up instruments, provision is to be made for monitoring / recording pressure and temperature at outlet of boiler and before temporary exhaust. The area around the exhaust point should be cordoned off. For warning sound, prior to blow, siren or PA system can be utilised. Effective communication and lighting system should be ensured at the vulnerable areas. Boiler should be ready in all respects including a. Interlocks, protections, alarms, annunciation and instruments b. Chemical dosing system c. Insulation of furnace and flue gas duct d. Fire fighting system as per designed scheme e. Fuel oil firing equipment Chemical cleaning of the pressure parts internals should be complete prior to steam blowing. All drain connecting piping are to be left open to atmosphere and are not to be connected permanently to drain vessels to ensure proper and quick draining. After checking drain pots for choking, the drain lines are to be connected permanently to vessels after steam blowing.

General Pre-Cleaning Procedures 1. 2. 3. Check all pipe anchors and guides for adequate support of piping, including the temporary vent pipe. Insure that all lines have been inspected and hydrotested. Remove all control valves, desuperheater nozzles, flow elements, thermo wells, pressure gauges, orifice plates, safety valves and instruments that may be damaged during the steam blow. Insure all vent pipes have adequate drains and that these drains are routed to a safe location. Install temporary pressure gauges as required to monitor the progress of the steam blow and make arrangements for to record pressure readings.

4. 5.

6. Establish adequate radio communication between the control room and the operator at the shutoff valve. Back this up with a system of visual communication, such as lights or flags, since audio communication may be difficult due to high noise levels at the steam shutoff valve. 7. Insure personnel traffic is controlled in area during steam blow. Insure the area near the vent pipe is clear of all personnel during the steam blow. Protect neighbouring equipment from damage due to the steam vents. 8. Individuals operating the steam blow valves (especially near the vent pipe) should wear double ear protection.

General Cleaning Procedure 1. Discontinue all firing and gradually open the temporary blowoff valve, to blow through the steam system and out the temporary blowoff piping.

Caution: The first blow should always be done at reduced pressure, in order to check out the temporary piping system, its supports and anchors. 2. When the drum pressure has dropped to the value corresponding with a 100F (56C) saturated steam temperature decrease, close the temporary blowoff valve and refire the unit to re-establish blowing conditions. Repeat the above cycle until it is considered that cleaning is satisfactory as indicated by inspection of impact specimens during the final blows.

3.

Post Cleaning Procedures 1. 2. Drain the temporary and permanent piping. Remove temporary spools, blind flanges, temporary vent piping, etc., and reinstall all components removed prior to steam blow.

Cleanliness Criteria The turbo-generator vendor or the primary end user of the steam will generally specify the criteria to which the system should be cleaned. If steam is used in a turbo-generator the following criteria is generally used: Two successive targets must result in mirror finishes that meet the specified criteria. After a cooling down period of at least 12 hours, two more successive steam blows must result in mirror surfaces that meet the specified criteria.

Criteria No indentation exceeding 0.8 mm diameter Indentation exceeding 0.4 mm diameter to number not more than 2 per 2500 mm of the target plate surface Indentations exceeding 0.2 mm to number not more than 10 per 2500 mm of the target plate surface Indentations less than 0.2 mm to be well dispersed and nowhere present in concentration

S V NAGESH OEG INDIA PVT