Steam Blowing / Steam Blowing Procedure (PDF)

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Anup Kumar Dey December 15, 2019

Steam blowing is one of the initial cleaning operations before starting any power plant or
steam lines. Steam Blowing of MS lines, CRH, HRH, SH, RH, HP & LP bypass pipelines
of the turbine are carried out in order to remove welding slag, weld bead deposits, loose
foreign materials, iron pieces, rust, etc. from the system, generated during manufacturing,
transportation & erection prior to turbine operation. The cleaning is accomplished by
subjecting the piping systems to heating, blowing steam, and cooling cycles in sufficient
number and duration until clean steam is obtained.

The effect of Steam Blowing depends on the following factors:

Thermal shock
Removal force of steam
Cleaning force of steam

Cleaning Force Ratio or CFR of Steam Blowing

The necessity to create in the system, a steam velocity greater than that is possible at
MCR condition is obvious. These two velocities are expressed as a ratio “Cleaning factor”
or “ Distribution factor” or “Cleaning Force Ratio” denoted by “X” or “K”.

CFR (Cleaning Force Ratio) is also known as Cleaning Factor or CF. CFR is an industry-
accepted factor that determines the required dynamic pressure. CFR in steam blowing
can be defined as the ratio of required dynamic pressure for cleaning to maximum
dynamic pressure experienced during system operation.

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Cleaning Force required (CFR) or distribution Factor

Preconditioning for Steam Blowing

Chemical cleaning should be completed.
SH primary and secondary de-superheater piping and RH’s emergency de-
superheater piping ready for operation
All permanent piping & temporary piping insulated and supports/hangers are
released with cold setting
Silencer should be connected at a temporary pipe exit
Soot blowing for APH should be available
Makeup for the deaerator made ready
Motor-Driven BFP with all controls made ready
Hydraulic test of the following lines completed:
Feed Lines
MS, HRH, CRH Lines
MS to Aux. PRDS Line
All other auxiliary lines identified for steam blowing
The sampling system made ready
Boiler auxiliaries proved serviceable and ready after a pilot operation like:
Fuel oil system
Compressors & Atomizing steam system
Start-up system ( for the continuous system)
Coal Mill system (for the continuous system)
CHP readiness
Economizer hopper and bottom ash hopper and its evacuation system (for the
continuous system)
All safety valve discs installed after removing the hydro-static plugin drum(sub-
critical), superheaters, and reheaters
Adequate communication between the control room, boiler, and TG are ensured.

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 Flow nozzle, control valves, and NRV flaps wherever applicable should be not
erected before steam blowing and suitable spool pieces are erected. Strainers in
the path should be removed.
Required number of Target Plates and holders made available

Chemical Cleaning Process

Boiler Front System Alkaline Flushing
Mass Flushing
Hot water Rinsing
Alkaline Flushing
Hot DM water Rinsing

Main Boiler System Acid Cleaning

Super Heater Filling
Mass Flushing
Alkaline Flushing
Hot DM water Rinsing
Acid Cleaning
Passivation
ACID CLEANING ( BY CITRIC ACID METHOD )will be done by the circulation
method for the effectiveness of the cleaning process.

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 Acid cleaning will be followed by PASSIVATION so that the uniform protective
coating of GAMMA FERRIC OXIDE is formed on the metal surface and
corrosion/oxidation damage to the metal surface is prevented and continue during
normal operation by dosing oxygen. The gamma ferric Oxide formed by using the
chemical 1-2 % sodium Nitrite(NaNO2)

Steam Blowing Procedures Techniques

Normally two methods are historically used for steam blowing

PUFFING METHOD
PURGING METHOD / CONTINUOUS BLOW METHOD

PUFFING Method of Steam Blowing

To give a thermal shock to the contour being purged, to dislodge the scale, etc.

Procedure: Raise the boiler pressure to a pre-determined value (40-60 kg/cm2), shut off
firing, and at the same time open the quick opening valve(EOTV), thus allowing the steam
to escape to atm. with high velocity carrying with it the loose debris.

Precautions during the puffing method

The Pressure drop allowed in the drum is limited to the corresponding saturation temp.
change of 40 OC.

Scheme of puffing method

Steam blowing done in stages

Stage-1(a):

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SH, MSL, ESV, temporary lines from ESV to EOTV, EOTV to CRH line, CRH lines
up to boiler end with the temporary exhaust pipe.
Tap-off lines from CRH to deaerator, auxiliary PRDS, HP heater 6a & 6b, gland
sealing, etc. shall remain closed/isolated.
Stage 1a endpoint will be concluded by observing the indents on the target plate.

Stage- 1(b):

SH, MSL, HP bypass interconnection, hand-operated valve mounted in place of HP

bypass valve, and CRH lines up to Boiler end with temporary exhaust piping.
In this stage, 6 to 8 blows will be given through HP bypass lines to ensure the
cleanliness of the limb.
The boiler MS stop valve will be used for stage 1b. EOTV will be kept closed.
Manually Operated Isolation Valves in HP bypass lines will be kept open fully.

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Stage-2(a):

1a plus reheater, HRH lines, Interceptor Valve, and temporary pipe.

CRH line along with the attemperator shall be welded with a reheater before the
start of stage 2a. LP bypass lines shall be blanked during stage 2a. Stage 2a
endpoint will be concluded by observing the indents on target plates

Stage- 2(b):

2a up to IV + LP bypass lines with the temporary exhaust pipe.

Stage 2b blowing will be a parallel blow in paths 2a & 2b. LP Bypass blanks shall be
removed for stage 2b. 4 blows will be given through the L.P. Bypass line to ensure
the cleanliness of the limbs

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Stage-3:

Auxiliary Steam Lines covered in steam blowing are listed below.

3a) Main steam line to Aux PRDS

3b) CRH to Deaerator
3c) CRH to HPH-6.

All auxiliary steam lines will be steam blown by the continuous blowing method

Stage-4:

The following Aux steam lines, connected to the deaerator are steam blown using
auxiliary steam from the Auxiliary PRDS header.

4a)PRDS to Deaerator.
4b)Extraction 4 to
4c) PRDS to Gland steam header

Continuous Steam Blowing Procedure

The initial procedure is the same as the puffing method except:
Continuous firing till the completion of steam blowing. No need to shut off the firing
during blowing.
Maintain constant pressure during the blow

Recommended blowing parameters for continuous steam blowing

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 Dynamic steam pressure = 3.5 MPa
MS temp = 420(not to exceed)
HRH temp = 480( not to exceed)
Steam flow = 845 TPH
Corresponding Drum pr. = 40 Ksc
Furnace load ≈ 39%

Method of Continuous Steam blowing

Set the Temporary purging valve, by-pass valve, drain valve, and granulating device
behind the temporary pipes
Check the tightness, support, and expansion of the temporary system
Section by section rinse of condensate water piping, feedwater piping, and boiler
through the start-up system to the CW system
Circulation begins when Fe+ in the water of the main feedwater pipe and separator
outlet will be less than 100 ppm.
Maintain the circulation flow or start-up flow at a minimum set value
Start oil firing and raise the temp and press. according to the cold start-up.
rise rate of water wall = less than 2OC / min
rise rate of main steam = 4 ~ 5 OC / min
Before MS press reaches 1.0 Mpa, open the bypass valve of the temporary purging
valve to warm the piping with all water drain valves of the system open.

-The blowing system divided into two parts

1. A) Preliminary Steam Blowing

2. B) Final Steam Blowing

Preliminary Cleaning
PURPOSE-

Primary cleaning out sundries and bulky grain deposited in the RH and main steam
system
To ensure the fastness of supports and hangers with proper expansion
Know well about the operation property of the oil-burning system, condensate water,
and feed water systems

Preliminary Steam Blowing Procedure

Start the oil firing with max. rating of 15%
Control the gas temperature at the furnace outlet below 500 OC (max.538OC )
Raise the SH outlet press to 1.6 – 1.8 Mpa with a steam temperature of around 350
O
C.
Open the temporary purging valve for 15-20 min to blow in the MS system
Maintain K around 0.5.

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 SH & RH desuperheater water system also cleaned

Final Steam Blowing Procedure

The main steam and reheated steam system are purged in series
Start 2-3 coal mills when the oil burner hits the rated firing rate of 15%
Increase the SH outlet press. to 3.5 Mpa.
Maintain the MS temp < 420 OC.
Keep HRH steam temp around 480 OC.
When the steam line blowing parameter reaches, open the temporary purging valve
gradually and increase the fuel and feed water volume to sustain parameter stability.
Establish the MS flow around 40% of the MCR (max.- 50%)
Ensure CFR (K) should be 1.25 to 1.3 for MS and 1.05 to 1.1 for reheated steam
Blow under this operating condition for 20 to 30 min
Gradually reduce coal firing and close the purge valve at 0.5MPa.
Remove the target plate and check it
By estimation, the target may satisfy the requirements after 15 to 20 times in-series
purging
When the steam line temp is above the sat. temp of MS press, close all drains
and Open the boiler MSSV fully.
Maintain the press. through controlled firing
Insert a reference target
Check the CFR
Allow running for 30-60 min

Target Plate in steam Blowing

Generally Stainless steel panel
Target plate set at the first, sixth, ninth, and twelfth purging, thereafter set a target
for each purging until purging results qualified.
Width about 8% of the steam vent tubes inner diameter(ID) and length equal to the
ID
Brinell hardness < 90
Steam velocity – 258 m/sec
Target plates are to be introduced just before steam blowing/light up—to be
removed soon after blowing is completed.

Online Target Plate Change Arrangement

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Debris Filter

Steam Blowing Completion Criteria

At least 2 continuous target plates should not have ORIFICE GRANULARITY on the
target shall be no larger than 0.8 mm.
CFR should be 1.25 to 1.4
of an orifice, granularity shall not surpass 08 nos.

Advantages of Steam Blowing

Required less time for completion of the total process

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 Less time is required to normalize the system for final light-up to synchronization
This reduces the reactionary forces on the temporary pipes
Stresses on the boiler system are lower

Comparison between Puffing & Continuous Method of Steam

Blowing

PUFFING METHOD CONTINUOUS METHOD

—  More time is required for complete steam —  Less time required for
blowing due to stage-wise blowing(8-10 completion (3-4 days)    
days)   —  Less time is required
as only
—  More
time is required for stage-wise valves are to be opened for
temporary pipe erection and shifting of the different systems  
blowing device —  Minimum 02 nos.
of mill

—  No mill required required

—  Quality of cleanliness is better than a

—  The quality of cleanliness is

continuous process slightly less than Puffing.
—  Thermal shock is
the driving force —  Steam velocity or Removal

behind cleaning force is the driving force

—  More thermal
stress on tube material —  Less thermal stress on
tube
and sudden loading on supports material  
—  Repeated light-up and shutdown
—  Light up
only once at the
—  There is a time gap between the
blows beginning of the steam blowing
to make up DM water —  DM water makeup to the system

—  System normalization
time after steam during steam blowing is a challenge
blowing is more —  System normalization time after

—  Silencer use
is optional   steam blowing is less.

—  Silencer use is compulsory.  

Difference Between Puffing and Continuous method of Steam Blowing

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Calculation of Steam Blowing Thrust force at the end of Pipe Exit

The thrust force (F) of the jet at the pipe exit is estimated as

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