A Guideline for

Preservation of Power Plants Units

“A brief study prepared by “

Ahmed Yehia
Shift Utilities Operator

“A brief study prepared by “

Ahmed Yehia Harhash

Shift Utilities Operator
New Abu Qir thermal power plant (1300 MW Gas/Oil fired units)
West Delta Electricity Production Co.
Egyptian Ministry of Electricity
nd
2 Apr. 2021

1
Contents
1. Introduction
1.1. Necessity of Boiler Preservation

1.2. Types of Corrosion

1.3. Metal passivation

2. Power plant units preservation

2.1. Preservation of the Boiler water/ steam side
2.1.1. Wet preservation under hydraulic pressure.
2.1.2. Dry preservation
2.1.3. Inert gas Blanketing
2.1.4. Preservation by amine substances
2.2. Preservation of steam turbine
2.3. Preservation of LP steam condenser
2.4. Storage of Feed water Heaters and Deaerators

3. Fireside Storage and Layup

4. Duration of the Outage

4.1. Short term shutdown
4.2. Intermediate shutdown
4.3. Long term shutdown

5. Conclusion
6. References

2
 1. Introduction:
The preservation of the boiler and steam systems during shutdown periods is an important
objective at any power plant. While shutdown the unit is considered to be in “layup”. This is
often one of the most neglected aspects of Boiler operations. Improper layup will lead to
increased corrosion, which can be the initiator of serious major failure mechanisms that will
affect plant availability.

Guidelines for layup practice at thermal power plants have been issued by a number of industry
organizations including ASME, EPRI and VGB.

The ASME guidelines are relatively succinct yet comprehensive. The EPRI layup guidelines are
contained in water chemistry guidelines for fossil plants with the view that layup should be a
considered an integral part of operating water chemistry. The VGB guidelines focus on case
studies from German plants and include a section on gas-side layup. In addition, the Boiler
OEM usually provides recommendations on layup in the design documentation provided with
the plant.

1.1. Necessity of Boiler Preservation

The goal of unit preservation during layup is achieved by reducing corrosion during idle periods
and thereby:

 Extend useful life of equipment

 Reduce repair, replacement, and maintenance costs
 Prevent start-up delays
 Prevent loss of steam plant performance

There are five factors that influence the rate of corrosion on carbon steel surfaces:

1. Moisture
2. Dissolved Oxygen
3. pH
4. Contaminants
5. Deposits

In layup the goal is primarily to act on the first two factors: reduction of corrosion is
accomplished by preventing the simultaneous presence of moisture and oxygen on metal
surfaces. This includes surfaces in the feed water, steam and circulating water piping, steam
turbine blades and disc, the condenser and the feed water heaters.

3
Pitting, crevice corrosion, stress corrosion and general surface corrosion will occur throughout
these systems if metal surfaces are insufficiently protected during the inactive
periods. Damage will also occur upon return to service with initiation of corrosion fatigue at
pits and deposition of corrosion products on heat transfer surfaces or turbine blades.

1.2. Types of Corrosion:

Corrosion control techniques vary according to the type of corrosion encountered. Major
methods of corrosion control include maintenance of the proper pH, control of oxygen, control
of deposits, and reduction of stresses through design and operational practices.

Galvanic Corrosion
Galvanic corrosion occurs when a metal or alloy is electrically coupled to a different metal or
alloy.

Caustic Corrosion
Concentration of caustic (NaOH) can occur either as a result of steam blanketing (which allows
salts to concentrate on boiler metal surfaces) or by localized boiling beneath porous deposits
on tube surfaces.

Caustic corrosion (gouging) occurs when caustic is concentrated and dissolves the protective
magnetite (Fe3O4) layer. Iron, in contact with the boiler water, forms magnetite and the
protective layer is continuously restored. However, as long as a high caustic concentration
exists, the magnetite is constantly dissolved, causing a loss of base metal and eventual failure.

Acidic Corrosion
Low makeup or feed water pH can cause serious acid attack on metal surfaces in the preboiler
and boiler system. Even if the original makeup or feed water pH is not low, feed water can
become acidic from contamination of the system.

Hydrogen Embrittlement
Hydrogen embrittlement is rarely encountered in industrial plants. The problem usually occurs
only in units operating at or above 1,500 psi.

Hydrogen embrittlement of mild steel boiler tubing occurs in high-pressure boilers when atomic
hydrogen forms at the boiler tube surface as a result of corrosion. Hydrogen permeates the
tube metal, where it can react with iron carbides to form methane gas, or with other hydrogen
atoms to form hydrogen gas. These gases evolve predominantly along grain boundaries of the
metal. The resulting increase in pressure leads to metal failure.

4
Oxygen Attack
Without proper mechanical and chemical deaeration, oxygen in the feed water will enter the
boiler. Much is flashed off with the steam; the remainder can attack boiler metal. The point of
attack varies with boiler design and feed water distribution. Pitting is frequently visible in the
feed water distribution holes, at the steam drum waterline, and in down comer tubes.

Oxygen is highly corrosive when present in hot water. Even small concentrations can cause
serious problems. Because pits can penetrate deep into the metal, oxygen corrosion can result
in rapid failure of feed water lines, economizers, boiler tubes, and condensate lines.
Additionally, iron oxide generated by the corrosion can produce iron deposits in the boiler.

Oxygen attack is an electrochemical process that can be described by the following reactions:

Cathode:

Fe Fe2+ + 2e¯
Anode:

½O + H O + 2e 2OH
2 2
¯ ¯

Overall reaction:
Fe + ½O2 + H2O  Fe(OH)2

When the boiler is kept standby for long period it is very necessary to keep boiler in
preservation to avoid internal corrosion of tube. If water is left in boiler without properly
treating for oxygen removal, can lead to corrosion.

The attacks on metals take place due to improper pH level too. Corrosion of the steam/water
circuit, at ambient temperature is the result of oxidization of metal by combined effect of
water, oxygen and lowering of pH from absorption of CO2 and SO4.

5
 1.3. Metal passivation
A passivation processes were done in the stage of Pre-commissioning of boiler to prevent
corrosion that is made by oxidizing iron to the most oxidized stable form which named
magnetite Fe3O4.

The establishment of protective metal oxide layers through the use of reducing agents (such as
hydrazine, hydroquinone, and other oxygen scavengers) is known as metal passivation or metal
conditioning. Although "metal passivation" refers to the direct reaction of the compound with
the metal oxide and "metal conditioning" more broadly refers to the promotion of a protective
surface, the two terms are frequently used interchangeably.

The reaction of hydrazine and hydroquinone, which leads to the passivation of iron-based
metals, proceeds according to the following reactions:

N2H4 + 6Fe2O3  4Fe3O4 + 2H2O + N2

Hydrazine hematite magnetite water nitrogen

C6H4(OH)2 + 3Fe2O3  2Fe3O4 + C6H4O2 + H2O

hydroquinone hematite magnetite benzoquinone water

Magnetite form protective films on the metal surface. Because this oxide is formed under
reducing conditions, removal of the dissolved oxygen from boiler feed water and condensate
promotes their formation. The effective application of oxygen scavengers indirectly leads to
passivated metal surfaces and less metal oxide transport to the boiler whether or not the
scavenger reacts directly with the metal surface.

6
 2. Power plant units preservation
2.1. Preservation of the Boiler water/ steam side:
Protection of surfaces during layup can be implemented either wet or dry. So there are
generally two types of preservation done as,

1) Wet preservation under hydraulic pressure.

Wet layup means that water-touched surfaces remain immersed during the shutdown
period. Water chemistry is controlled to keep oxygen levels low. Steam-touched surfaces are
dried and then protected with a nitrogen blanket, or kept dry using desiccants or by circulating
dehumidified air.
Here in this preservation the plant item is completely filled with DM Water containing 200 ppm
hydrazine ammonia is added to raise the pH to 10. Chloride should be below 2 ppm. Keep
proper pre-mixing of the chemicals with the water to ensure a uniform mixture entering the
boiler it is necessary to back fill the boiler from Superheater section and ensure the water
overflows from Superheater to the steam drum. The water should be filled from the lowest
point to ensure the air is properly released from boiler. The boiler pressure should be
maintained 5 bar that means above atmospheric pressure to prevent ingress of air. Every day
pressure should be monitored. Sample may be collected and checked periodically and if
needed, add chemicals.

2) Dry preservation.
Dry layup means that all surfaces are dried and then protected with either a nitrogen blanket or
with desiccants, or by circulation of dehumidified air. The primary reason for choosing wet
layup is that the time to restart the boiler is considerably shorter than with dry layup as the unit
does not need to be refilled. Choice of the ideal layup practice depends greatly on the length of
the idle period. Most guidelines and industry practice attempt to define these periods.
The dry preservation method is effective provided the boiler is completely drainable. If Super
heater/economizer sections are completely drainable then this method can be practicable. The
plant which will remain unopened during outage can be completely filled with N 2 gas and a
little over pressure is maintained to prevent O2 ingress. The problem with N2 preservation is
that if there is any leakage than that has to repair. N 2 being odorless, colorless and chemically
inactive gas; it is very difficult to detect N2 leakage.

3) Inert gas Blanketing

Blanketing, also known as inerting, is the process of injecting an inert gas during steps in the
storage, transport or production of products and at specific stages in the industrial process to

7
eliminate oxygen or moisture present in atmospheric air. Because an inert gas does not interact
directly with other compounds or materials, products are preserved and converted from a
flammable or reactive condition into a safe, non-flammable and non-reactive state. Typical
inert gases include nitrogen, argon and carbon dioxide.

Nitrogen blanketing is used to provide an inert, corrosion-free environment. Nitrogen is an

odorless, colorless gas with an extremely low dew point. It is used routinely to purge oxygen
from enclosed vessels. Corrosion cannot occur in an inert nitrogen environment. Under wet lay-
up conditions, nitrogen may be connected to the steam vent to provide a low pressure nitrogen
blanket to prevent oxygen ingress. Alternatively, nitrogen may be used during dry lay-up
conditions to provide a positive nitrogen pressure (5 psig) in the closed boiler vessel to prevent
oxygen and moisture intrusion. It may also be used to inert superheaters, and provide a
nitrogen blanket in deaerators and feed water heaters.

4) Preservation by amine substances

Apart from the classical preservation procedures, preservation with film-forming amines
presents an interesting alternative. The preservation procedure using the active substance
octadecylamine (ODA). Although a wet-chemical method, the preservation effect remains intact
and stable, even after draining or partial draining.
ODA is a long-chain, aliphatic amine with the chemical formula C18H37NH2. Due to its volatility
and a distribution coefficient similar to that of ammonia, a good distribution in the water and
steam cycle is ensured.
Preservation in the shutdown process presents the best method for preserving a complete
power plant unit. The emulsion is added continuously, while the plant is still running. This is
done ca. 3 – 10 days before the planned shutdown. The time period depends on the size of the
facility, as well as the steam generating capacity and the dosing quantity. Initially, the dosing
quantity is kept small and then the ODA concentration required for preservation is slowly
increased. This ensures that any mobilization effects of oxide deposits, as well as those of oils
and fats, are controlled. Due to its volatility, the active substance is distributed throughout the
water-steam cycle. This not only protects the boiler, but also the steam pipes, the turbine and
the condensate system. Once the desired concentration necessary for preservation is reached,
dosing is discontinued and the facility can be shut down.

8
 2.2. Preservation of steam turbine
Poor layup practices also affect steam turbines. Left open to the atmosphere and sitting over a
full and warm hot well, the steam turbine is bathed in warm and humid conditions that are
conducive to pitting, particularly on the low-pressure turbine blade/disk surfaces in the phase
transition zone, which is a precursor to corrosion fatigue on the turbine (image 1).

(image 1) Pitiful problem. Deposits that contain chloride aggressively pit the turbine when it is allowed to
sit in moist conditions. These pits become sites for corrosion fatigue.

In cases where the turbine has been contaminated (for example, following a condenser tube
leak), corrosion can be rapid and severe.

There is a method of preservation of steam turbine and its auxiliary equipment with nitrogen,
which consists in filling the last of the internal space of the turbine, a steam and water space
heaters and condenser, maintaining its pressure, thus the supply of nitrogen passes through the
upper point of the filling volume and the exhaust through the bottom point.

Another method involves Heaters and dehumidifiers are installed at the ST exhaust to keep the
moisture level below 40% RH. Air temperature and humidity inside the turbine are monitored
continuously.

9
A ST dehumidifier was permanently installed outside the LP section (Fig 1) and arranged as
shown in (Fig 2) to eliminate the need for installing/removing plastic curtains and the
scaffolding needed to accommodate their installation and removal.

(Fig 1,2) Steam turbine has a separate dehumidifier (left) which is located external to the unit (right)

2.3. Preservation of LP steam condenser

The condenser hot well is drained in accordance with the OEM’s recommendations and the ST
LP section originally was separated from the condenser with a plastic curtain.

The shutdown and layup periods should be viewed as a continuation of the good water
chemistry practices used during operation. The primary purpose of the cycle chemistry is to
provide protective oxide surfaces on all components throughout the steam and water circuits in
order to minimize corrosion and reduce concentrating and performance-robbing deposits on
heat transfer and aerodynamic surfaces.

The primary purpose of the shutdown and layup practice should be to preserve those
protective oxide surfaces and prevent damaging corrosion (Figure 3).

10
(Fig.3) Trouble spots. Areas of the steam cycle affected by layup and startup practices.

2.4. Storage of Feed water Heaters and Deaerators

The tube side of a feed water heater is treated in the same way the boiler is treated during
storage. The shell side can be steam blanketed or flooded with treated condensate.

All steel systems can use the same chemical concentrations recommended for wet storage.
Copper alloy systems can be treated with half the amount of oxygen scavenger, with pH
controlled to 9.5.

Deaerators are usually steam or nitrogen blanketed; however, they can be flooded with a lay-
up solution as recommended for wet lay-up of boilers. If the wet method is used, the deaerator
should be pressurized with 5 psig of nitrogen to prevent oxygen ingress.

11
 3. Fireside Storage and Layup
When boilers are removed from the line for extended periods of time, fireside areas must also
be protected against corrosion.

Fireside deposits, particularly in the convection, economizer, and air heater sections, are
hygroscopic in nature. When metal surface temperatures drop below the dew point,
condensation occurs, and if acidic hygroscopic deposits are present, corrosion can result.

The fireside areas (particularly the convection, economizer, and air heater sections) should be
cleaned prior to storage.

High-pressure alkaline water is an effective means of cleaning the fireside areas. Before alkaline
water is used for this purpose, a rinse should be made with fresh water of neutral pH to prevent
the formation of hydroxide gels in the deposits (these deposits can be very difficult to remove).

Following chemical cleaning with a water solution, the fireside should be dried by warm air or a
small fire. If the boiler is to be completely closed up, silica gel or lime can be used to absorb any
water of condensation. As an alternative, metal surfaces can be sprayed or wiped with a light
oil.

If the fireside is to be left open, the metal surfaces must be maintained above the dew point by
circulation of warm air.

Gas-side corrosion occurs during shutdown. It is highest in the cold-end tube sections because
of the presence of acidic deposits. Cold-end corrosion is particularly active in cycling units
because the deposits are initially hygroscopic; air condenses on the tubes and forms acids that
greatly accelerate the corrosion process. If the Power Station is located in a dry climate there
will be lower risk than in some other locations; corrosion is very dependent on the ambient
humidity (Figure 4).

12
 (Fig.4) Iron Corrosion vs. Humidity

Adding a stack damper will reduce the amount of humidity reaching the interior of the
Boiler. The damper will also reduce cyclic stress from thermal expansions and to reduce start
times after a short shutdown because it greatly reduces cooldown rates.

If a stack damper is in place then gas path corrosion can be further reduced by installing an
industrial dehumidifier. The unit should include built-in heater and air filters and have
sufficient capacity to exchange five gas path volumes within one day.

Unit should allow turndown to lower output to operate in a keep-dry mode. The direction of
flow is not particularly important although a common approach is to inject dry air into the cold
end and circulate in counter flow to exit at transition duct. A hygrometer should be installed to
monitor circulating air discharge humidity.

13
 4. Duration of the Outage
The length of shutdown is fundamental to the type of layup procedure or technique selected.
The rapidity with which plant personnel need to return a unit to service can place constraints
on how it is shut down or on the procedures and practices used for layup. Although certain
approaches are considered more appropriate for certain types of outages, more than one layup
approach can provide equipment protection.

We can define shutdown periods as follows:

 A “short-term shutdown”

Involves periods extending overnight or through a weekend. This shutdown period is typical of
cycling operation and utilizes a wet layup or hot standby approach. Wet layup is generally
considered for shorter durations of a weekend or one to two weeks, but it can be effective for
months, if properly implemented and maintained. Dry layup is effective even for the shorter
durations, but it might be desirable to avoid draining the equipment if the unit could be
returned to service on short notice. Some components especially super-heaters, re-heaters,
and, most importantly, the steam turbine system require the avoidance of moisture or steam
condensation; maintaining temperatures above saturation may be effective but is not practical
for extended periods.

 An “intermediate shutdown”

Is longer than a weekend and up to one week. This duration typifies a shutdown for minor
equipment repairs. Either wet or dry approaches can apply.

 A “long-term shutdown”

Is one extending from a few weeks to six months. Such outages can involve major equipment
repair, a planned outage, or a long-term layup due to system load requirements. It also could
include “mothballing” a unit. Both wet and dry approaches can apply, but if return-to-service
timing is not an issue, totally dry layup is preferred for extended outages.

14
 5. Conclusion

Boilers must be stored under carefully controlled conditions during non-operating periods to
avoid corrosion damage that can occur in the absence of proper lay-up procedures. Improper
lay-up and storage will result in rust formation, pitting-type corrosion and general deterioration
of boiler metal surfaces. This damage can occur on both the waterside and fireside of the
boiler.

If the waterside of the boiler is exposed to the atmosphere, corrosion will occur at the liquid-to-
air interface. Corrosion damage is also possible in the pre-boiler and after boiler sections. Once
formed, the by-products of corrosion can then be transported to the operating boiler when the
system is returned to service. These corrosion products may deposit on critical heat transfer
surfaces, increasing the potential for localized corrosion or overheating during system
operation.

The two major factors which determine the corrosion rate on boiler metal are moisture and
dissolved oxygen. Under completely dry conditions, the corrosion of steel is negligible. In a
moist or wet environment, however, the amount of dissolved oxygen in the water determines
the severity of the corrosion. Conditions that increase the oxygen concentration in the water,
or allow the continued addition of oxygen, will increase the corrosion rate.

The fireside of the boiler is also subject to corrosion damage. Like the waterside, corrosion
damage to the fireside will occur if the metal surfaces are wet and exposed to oxygen.
Sulfurous and sulfuric acid residues, which are by-products of the condensation of acidic flue
gases, will also promote corrosion attack.

For these reasons, proper boiler storage procedures must be followed to protect and prolong
the useful life of the steam generating equipment.

Ongoing Research

Electric Power Research Institute (EPRI) is conducting research on barrier coatings or inhibitors
that protect exposed metal surfaces by preventing interaction of air or moisture with the metal
surface. These alternative preservation techniques can be applied when convenient, do not
require capital expenditures and complicated operating procedures, and are flexible to changes
in outage duration period. Current research has demonstrated that the development of a
protective barrier on the metal surface established by the hydrophobic formation of polyamine
products inhibits corrosion and pitting activity in the presence of aggressive chemical species
and moisture.

15
New products and application methods are currently under test. Showing good promise are
various proprietary products used in predetermined dosages in the hours or days preceding
shutdown. Application during operation of the unit ensures complete distribution to all steam-
and water-touched surfaces. It also provides the needed time and conditions to establish the
impervious barrier on the metal surfaces. The flexibility of this technique, requiring only turning
on a chemical injection pump prior to shutdown, would provide an economic and simple way to
preserve equipment in a wet unit for a period of up to 30 days or in a dry storage condition for
many months. Expect introduction of these new products within the next few years.

____________

16
6. References

1. The operation and maintenance manual of Boilers in new Abo Qir power station
presented by ANSALDO CLADAIE S.p.A Company.
2. Marcos Freitas, Fernando Albuquerque, Jean Ferreira- Araucaria Power Station
September 2002 “Preservation program works for outages from one month to
several years”
3. Nalco chemical company paper titled “How to protect your boiler during
shutdowns”.
4. Mittwoch, Fußzeilen -November 2013” Chemical cleaning of thermal power
stations “
5. shantiboilers@blog-2020 “Do you know how is the boiler preserved during
shutdown?
6. Michael A. Brenner- GE Water Technologies “How steam system chemistry and
control affect side coil corrosion”.
7. K.K.PARTHIBAN, Boiler Consultant - Venus Energy Audit System “Preservation of
boilers”.
8. Ronny Wagner-Article in VGB PowerTech · March 2014 “Preservation of boilers
and turbines with the surface active substance octadecylamine (ODA).
9. W Moore, J Ford, T Callagy, Dr D G Robertson- Final Report/ Guidelines-2013
“Preservation Guidelines for CCGT & Conventional Power Plant during Short- and
Long-Term Shutdowns”.
10. Fachverband Dampfkessel-, Behälter- und Rohrleitungsbau e.V., Düsseldorf
(FDBR)-VGB PowerTech Guidline “preservation of power plants “-VGB-R 116 e
Second Edition 2009.
11. https://boilersinfo.com/boiler-preservation-methods-dry-and-wet
12. https://www.askpowerplant.com/boiler-preservation-shut-boiler/
13. https://www.tdsasia.net/pages.php?pageID=57
14. https://www.powermag.com/layup-practices-for-fossil-plants/
15. https://www.powermag.com/layup-practices-for-fossil-plants/
16. https://watertechnologyreport.wordpress.com/2017/07/24/boiler-layup-procedures/
17. https://tetra-eng.com/en/resources/technical-white-papers/30-white-papers/193-hrsg-
preservation
18. https://www.suezwatertechnologies.com/handbook/chapter-11-preboiler-and-boiler-
corrosion-control

17