STEAM BLOW-OUT

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EGYPTROL View of Commissioning Process

Commissioning is the art of making all the elements of a system play together,
for the first time!

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Steam Blow

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Standard Commissioning Process

What is Commissioning? RTR

&
Performance
The process of assuring that all systems Test
TOAC

and components of an industrial plant are Start Up & 6 7

Planni
Plant tuning
ng
designed, installed and tested to meet 1 5
design requirements and can be operated
2 4 Steam Blow-
and maintained according to the contract Mech.,
3 out
Elec., I&C Commissioni
ng
specifications, standards and operational Erec.
Completion Pre
(ECC) Commissioning
requirements.

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Steam Blow Out

1) Objective

2) Methodology

3) Engineering

4) General Safety Requirements

5) Steam Blow-out Methods & Procedures

6) System Cleanliness

7) A Case study

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Steam Blow Out Objectives

 To remove from plant critical systems steam piping prior to start-up:

o Construction Debris
o Scales
o Rust
o Loose Material
o Construction Leftovers
o Oil
o Weld Spatter…etc.

 Remove debris to meet equipment (Turbine) OEM criteria for accepting steam.

 Failure to remove debris may cause damage to turbine blades, valve internals…. 6
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Methodology

Steam is blown with enough velocity to ensure sufficient cleaning force

Planning

Piping system is divided into different paths (steam blow phases)

Disturbance factors (K) for each path are calculated during engineering

OEM definition of Target Plate specification (Material, size LxWxH)

Verification

Disturbance factors (K) are verified during execution

OEM defines steam purity criteria for his equipment (Target Plate / Color)
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Engineering

 Factors that need to be considered during

Engineering phase:
o Disturbance Factor (K)
o Steam Blow-out method
o Pipe Sizing and Design
o Pipe Routing
o Steam Conditions
o Noise Level
o Thermal Cycling
o Stress analyses for temporary Pipework
and Equipment
o Water Quenching 8
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 Engineering

(K) of a particular design is calculated using the following formula:

Disturbance Factor (K) = (Vb / Vmcr) x (Fb / Fmcr)2 > 1.3
Where
o Vb = specific volume at steam blowing condition
o Vmcr = specific volume at maximum load condition
o Fb = steam mass flow rate at blowing condition
o Fmcr = steam mass flow rate at maximum load condition
o The desired ratio is 1.3 for continuous blowing

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General Safety Requirements

 Operations shall be organized and performed by

expert personnel.
 “Exclusion Zones" to be defined, barricaded by fence,
evacuated and guarded for the duration of the steam
blow-out activity.
 “STEAM BLOWING IN PROGRESS" signs to be posted.
 Direct communication is required with the CCR for all
parties involved.
 The steam Blow-out procedure to be understood by
all concerned parties before proceeding with the
blow-out.
 All personnel working in close proximity to the area
should wear ear protection. 10
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Steam Blow-out Methods & Procedures

1) Puffing or Shock blow 2) Continuous blow

• Steam generator pressure is • Pressure and temperature calculated

raised to the calculated pressure for (K) to be reached and conditions

• Sacrificial valve is opened are maintained for three hours,

including thermal cycling
• Steam velocity is reached, but for
• No pressure drop, with time
a short period of time

• High pressure drop, with time • Completion time: App. 5 to 7 days

• Completion time is incalculable • No operating valve is required

• Quick operating valve is required 11

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Puffing Procedure

 Quick operating valve (sacrificial valve)

open/close time < 10 second.
 Start at low pressure value, then
increase pressure values to reach the
required pressure level.
 First few steam blows are conducted
without target plates until steam color
becomes clear.
 Preliminary target plates are placed to
verify steam cleanliness.
 Final target plate is placed once
preliminary target plates are
acceptable.
 Blowing continues until pits are
acceptable to turbine manufacturer. 12
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Continuous Procedure

 Continuous operation of boiler until K

Factor is reached

 Pressure is maintained during the

blow-out.

 K Factor (1.2 – 1.7)

 Boiler load may reach 50%.

 Thermal cycling is applied in order to

improve the cleaning process.

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Cleanliness

 The Cleaning Force Ratio (K) is used to evaluate if

satisfactory blow conditions are obtained.

 Steam line cleanliness is also determined by the

condition of target plates.

 Sample guidelines state the allowable quantity

and size of particle impacts on the target to be:

o no impact with a size > 1 mm

o less than 4 impacts with a size > 0.5 mm
o less than 10 impacts with a size > 0.2 mm
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Thank You

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