ESSAR POWER ORISSA LTD

2X30 MW THERMAL POWER PROJECT, PARADEEP

Report: Steam blowing Activity

2×30 MW CPP PARADEEP

DETAILED PROCEDURE OF STEAM BLOWING

ACTIVITY IN PHASE #1

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Commissioning Team
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 ESSAR POWER ORISSA LTD
2X30 MW THERMAL POWER PROJECT, PARADEEP
Report: Steam blowing Activity

CONTENTS

S.NO LIST OF CONTENTS PAGE NO

1 PLANT DETAILS 3
2 OBJECTIVE OF STEAM BLOW 3
3 SCOPE OF STEAM BLOW 3
4 PROCEDURE OF STEAM BLOWING 4
5 OPERATIONAL PRECAUTIONS 4
6 SAFETY 5
7 DYNAMIC PRESSURE CONDITIONS 5
8 CLEANLINESS OF THE SYSTEM 6
9 PROCEDURE FOR MIRROR INSTLN. 7
10 SAMPLE LOG SHEET STEAM BLOWING 8

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 ESSAR POWER ORISSA LTD
2X30 MW THERMAL POWER PROJECT, PARADEEP
Report: Steam blowing Activity

PLANT DETAILS:
Phase -1 of Paradeep 2×30 MW thermal power plant includes 2 sets of Single drum AFBC
water tube Boilers each of capacity 125 TPH,, both supplied by Cethar Vessels Limited.Total
water volume of the boiler pressure parts is 64.56M³.

OBJECTIVES OF STEAM BLOW:

Steam Blowing or purging is an established practice for the purpose of physically removing
any impurities and rust deposited from the inner surface of boiler super heaters and
Associated steam piping during manufacture, transportation, storage and construction. The
purpose is to protect turbine rotor from being damaged due to dirty steam admitted into
turbine, and protect boiler tubes, improve safety and economy of unit operation, and steam
quality during normal operation. The turbine must not be started before the boiler and the
steam piping to the turbine have been cleaned.

The actual procedure includes installation of temporary piping at the down stream of main
steam line which leads the steam to the atmosphere. The temporary piping is properly
supported and anchored to resist the high nozzle reaction created during blowing period.

SCOPE OF STEAM BLOW:

Steam blowing shall cover the following systems from boiler and Turbine Area –

 Main Boiler pressure parts.

 Super heaters and Main Steam Piping.
 Turbine extraction piping.
 PRDS system
 Gland sealing system
 HP dump piping
 Deaerator initial heating piping
 Auxiliary steam line for Ejectors

The boiler steam blowing adopts the temperature shock method for removing loose scales.
These scales will subsequently driven out by the dynamic velocity of expanding steam.
Sufficient shock is obtained with a series of blows where the steam temperature changes
with each blow. Temporary valve is required to control the blowing rate and duration of
blowing period.
Boiler pressure and temperature are to be maintained during blowing period by continuous
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 ESSAR POWER ORISSA LTD
2X30 MW THERMAL POWER PROJECT, PARADEEP
Report: Steam blowing Activity

firing . If firing is discontinued during blowing period, it must be remembered that any
change in boiler pressure changes the saturation temperature throughout the boiler.

Consumables required for steam blowing are

Coal consumption

No. Of Running
Details of Steam Steam Boiler Coal
Steam parameter blow hour of Enthalpy
Pipe line required Effi. consumption
Assumed Boiler

Temp
Pressure Nos Hours MT MT
Deg C
Main steam line 40 400 50 100 10228 768 0.65 3180
Deaerator Initial
40 400 30 60 6120 683 0.60 1908
heating HP
Deaerator Initial
4.5 200 Continuous 48 576 683 0.60 173
heating LP
Turbine Extraction
2.8 140 Continuous 48 576 655 0.60 165
line
HP dump line HP
40 400 25 50 3068 768 0.60 1033
side
HP dump line LP
2.5 130 Continuous 48 4560 650 0.60 1300
side
SJAE line 10 400 Continuous 48 13 780 0.60 5
Total Coal
for Steam 7765
blow out

DM water requirement :

PROCEDURE FOR STEAM BLOWING

01 Start the boiler as per the recommended start up procedure and slowly raise the pressure
up to 40 Kg/Cm2 by throttling the start up vent valve.
02 Once 40 kg/Cm2 pressure is reached , open the main steam stop valve IBV to warm up the
pipe line on the down stream side of the valve for 10 mins.
03 Stop the boiler when pressure reaches 40 kg/Cm2 and open the main steam stop valve to
commence blowing. Steam blowing shall be continued till the pressure decreases to 25
kg/Cm2. Once the pressure reaches 25 kg/Cm2, Close the main steam stop valve . Target

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Commissioning Team
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 ESSAR POWER ORISSA LTD
2X30 MW THERMAL POWER PROJECT, PARADEEP
Report: Steam blowing Activity

plate shall not be fixed for first couple of blows and further successive blows target plate
shall be fixed. Aluminum foil shall be used as target plates.
04 Steam blowing shall be continued with the gap of 2 hrs between successive blows.
05 The above mentioned procedure shall be repeated for successive blows.

OPERATIONAL PRECAUTION:
01 The steam blowing operation is the first occasion to fire the unit . The boiler must be
brought up much slower while all equipments are checked and expansion movements are
monitored closely.
02 During blowing water level in drum gauge glass may fluctuate very widely. Hence feed
regulation station must be checked for remote operation. Sufficient quantity of D.M water
must be ensured.
03 Temporary discharge piping must be at least equal to the diameter of the pipe to which it is
connected and must be properly supported to withstand reaction forces during blowing.
04 Discharge piping is to be diverted such that personnel and equipment are not endangered.
The area should be cordoned off.
05 The internals of NRV shall be removed to avoid damage. Similarly the Orifice and
thermowell shall be removed to avoid damage during blowing.
06 The target plate should be clean and the impression on target plate should not be more
than three nos per sq.Cm area.

SAFETY PRECAUTIONS

1.0 Before stating blow out all the steam pipe lines to be blow out are to be insulated to avoid the
danger of accidents and burns or fire ( Cables, Oil etc.)
2.0 Areas are to be clearly identified by means of Tapes and ensure security staff cordon off the area.
3.0 Ensure that no unauthorized personnel’s are present
4.0 Noise prevention measures are to be ensured, Use of Ear plugs are to be ensured.
5.0 Silencer to be installed at the discharge end of blow out pipe to reduce noise pollution.

DYNAMIC PRESSURE CONDITIONS:

Adequate dynamic pressure is the most important factor for achieving high velocity of flow. During bowing
out , The dynamic pressure in the entire boiler and piping system must be greater than the subsequent
maximum in full load operation.
Index A for the maximum through flow in full load operation and index B for blowing out.

C = Steam velocity m/s

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 ESSAR POWER ORISSA LTD
2X30 MW THERMAL POWER PROJECT, PARADEEP
Report: Steam blowing Activity

V = Specific volume m3/Kg

m = Mass flow rate Kg/Sec
p = Pressure Bar
t = Temperature deg C

(c2/2v)B > (c2/2v)A

(m 2 .v)B > (m2.v)A

mB > mA ( vA/vB)

The following empirical values are used to specify the pressure and temperature for blowing out.

Pressure pB > 50 % of rated pressure pA

Temperature > minimum of 50 k overheating relative to the rated pressure pA

CLEANLINESS OF THE SYSTEM :

1.0 Aluminium mirror is to be used to assess the cleanliness of the system.

2.0 Mirror to be installed at the end of the piping to be blown out after the blowing gate valve into the
provisional blow out pipe, An undisturbed section of piping at least ten times the diameter of
piping must be available in front of the steel mirrors installation position.

Installation position of the steel mirror :

 10 D
The dimension of the mirror depends upon the dia of steam piping.

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 ESSAR POWER ORISSA LTD
2X30 MW THERMAL POWER PROJECT, PARADEEP
Report: Steam blowing Activity

Adequate cleanliness of the pipes are to be ensured by complying the conditions below.

1.0 Two successive blasts must result in mirror surfaces that have no strikes that are out side the assessment
limits stated below.
2.0 After a cooling down period of 12 hours , two more successive blasts must result in mirror surfaces that
have strikes that comply with the stated assessment limits.
The entire surface is considered for assessing a blowing mirror
The assessment limits for an acceptable mirror are as follows.

- No strikes with diameters greater than 0.8 mm

- Not more than 2 strikes with diameters greater than 0.4 mm per 2500 mm2
- Not more than 10 strikes with diameters greater than 0.2 mm per 2500 mm2
- Strikes with diameters of less than 0.2 mm must be uniformly distributed

PIPE DIA in mm L in mm B in mm
100 90 15
150 135 20
200 180 25
250 225 30
300 270 35
350 315 40
400 360 45

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 ESSAR POWER ORISSA LTD
2X30 MW THERMAL POWER PROJECT, PARADEEP
Report: Steam blowing Activity

LOG SHEET FOR STEAM BLOWING

BLOW BLOW BLOW STEAM Remarks

BLOW PRESSURE
START FINISH TEMPERATURE
DATE BLOW No. (IN MPa)
TIME (IN TIME (IN ( IN ˚c)
HRS) HRS) START FINISH START FINISH

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Commissioning Team
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 ESSAR POWER ORISSA LTD
2X30 MW THERMAL POWER PROJECT, PARADEEP
Report: Steam blowing Activity

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Commissioning Team
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