APCPCWM_4828539:WP_0000005WP_0000005

APCPCWM_4828539:WP_0000005WP_0000005

Doc. No.:2015T0016-ERC-A002
Item No. :B-19C

APPROVED FOR CONSTRUCTION

Project :
WEST DAMIETTA COMBINED CYCLE
ADD ON PROJECT
Owner :
ARAB REPUBLIC OF EGYPT
MINISTRY OF ELECTRICITY AND ENERGY
EAST DELTA ELECTRICITY PRODUCTION COMPANY

Consortium :

GE Energy

REFERENCE NBER : Revision :

ECH. / SCALE
DATE 2016.10.19 2016.10.19 2016.10.19

NOM / NAME S.H.SONG B.J.PARK S.D.CHOI

FORMAT / SIZE
VISA S.H.SONG B.J.PARK S.D.CHOI

REDIGE / MADE VERIFIE / CHECKED APPROUVE / APPROVED

TITRE / TITLE

RECOMMENDED PROCEDURES FOR LAYING UP BOILER

REVISION
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 West Damietta HRSG

RECOMMENDED PROCEDURES FOR LAYING UP BOILER

1.0 GENERAL

2.0 SELECTION OF LAYUP METHODS

3.0 DRY LAYUP METHOD

4.0 WET LAYUP METHOD

4.1 HOT WET LAYUP METHOD

4.2 COLD WET LAYUP METHOD

5.0 MONITERING

6.0 MISCELLANEOUS RECOMMENDATION

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1.0 GENERAL

The purpose of layup is to minimize corrosion (pit corrosion or oxygen pitting) as well as to
reduce the subsequent start up after shutdown.

This procedure is for water and steam side, not for gas side. For gas side, refer to chapter
6 miscellaneous recommendation in this procedure.

There are three kinds of key factors for corrosion such as the water, the oxygen and the
metal. In case of the metal, it is unavoidable in HRSG. There are two choices which are
to eliminate water or oxygen. If remove water, it is dry layup method and if remove
oxygen, it is wet layup method.

a) Dry Layup method ( shutdown outage period more than two weeks )
b) Wet Layup method ( shutdown outage period within two weeks)

The concept of dry layup is to fully fill the nitrogen at the inside of tubes, pipes and drums.

The concept of wet layup is to fully fill the water with pH 10 ~ 11, below 20 ppb O2 level
and a low conductivity uniformly throughout the inside of tubes, pipes and drums.

All chemicals herein should be followed the manufacturer’s instructions.

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2.0 SELECTION OF LAYUP METHODS

Desiccant method can be used for transportation before install on site.

It is required to fulfill the preservation and storage as a part of erection manual during
storage on site.

After mechanical completion in field, it shall the hydro pressure test in field in accordance
with hydrostatic pressure test procedure. Before hydro test and after hydro test, it shall
follow layup method on hydrostatic pressure test procedure.

After chemical cleaning, HRSG shall be conserved by wet or dry layup method depending
on the site conditions such as the below maintenance, freezing and availability. Otherwise,
it is required to wet layup method within two weeks and dry layup method more than two
weeks.

There are many factors to select layup method to protect the HRSG heat transfer internal
surfaces:

Maintenance

If maintenance is anticipated, the dry air method should be used.

Freezing

If freezing is anticipated, the dry air method should be used.

Availability

If not to be operated properly the chemistry is anticipated, the dry air method should be
used.

Outage period

If the subsequent start up during the outage is anticipated, the wet layup method should
be used.

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3.0 DRY LAYUP METHOD

The Dry Layup method, which requires nitrogen sealing, is a typical and effective method
used for a long outage period (more than two weeks).

The following are mandatory requirements for the nitrogen gas sealing method:

a) After the HRSG pressure has reached the 1.5 barg, the water existing in the HRSG
shall be gradually drained by opening the blow off valves and charged nitrogen gas
from nitrogen gas injection system of each drum.

b) When nitrogen gas, instead of water, starts to come out from the blowdown tank
outlet (to the sump), drums blow off valves shall be closed.

c) After all HRSG sections have been filled with nitrogen gas, all valves shall be
closed.

d) The nitrogen pressure in all sections shall be maintained at 0.5 barg (min. 0.3
barg). Nitrogen gas shall be recharged when the pressure reaches 0.3 barg. The
nitrogen gas pressure in all sections shall be checked with the related existing
pressure gauges.

e) Nitrogen gas pressure shall be checked daily at the pressure gauges.

f) As the HRSG cools to the ambient temperature, the nitrogen gas pressure shall be
checked frequently because HRSG cooling will decrease nitrogen pressure.

Alternatively, the circulating dehumidified air is able to use instead of nitrogen under
maintaining below 30% related humidity.

Caution ; Nitrogen is a hazard to personnel and can not be used if maintenance

on the systems is going to be proceeded. If there are any leaks from the
inside of tubes and piping to the gas side, anyone on the gas side of HRSG
should be left because of a lethal environment.

If repair works are anticipated, dry air instead of nitrogen has to inject to the

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inside of tubes and piping. The related humidity levels should be checked at
the drain or vent less than 30%.

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4.0 WET LAYUP METHOD

4.1 Hot wet layup method

It is “bottle up” by closing stack damper and drain/vent valve within 48 hours.

The water chemistry shall be kept from the normal value to maximum value.

The following are mandatory requirements for the hot wet layup method:

a) Keep drum level from start up level to normal level.

b) The temperature will gradually down by heat loss.

c) The pressure will be up and down for the time being and then it will gradually
down.

If the pressure in drum approaches to 1.5 barg, the followings are mandatory requirements.

d) If the pressure approaches to 1.5 barg, the steam drum pressure shall be
pressurized by nitrogen on the connection of steam drum.

e) Nitrogen gas pressure shall be maintained at 0.3 barg at any time.

f) Close the nitrogen connections until start up HRSG. Also, close the level gages on
the steam drums if lasts over 3 days layup.

g) Before put in service, open the level gages.

h) Make sure that the level gages / transmitters indicates correctly by blow off the
containments including water / nitrogen.

Caution ; Nitrogen is a hazard to personnel and can not be used if maintenance

on the systems is going to be proceeded. If there are any leaks from the
inside of tubes and piping to the gas side, anyone on the gas side of HRSG
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should leave because of a lethal environment.

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4.2 Cold wet layup method

The wet layup method requires the HRSG, except the superheater, to be completely filled
with feedwater.

The wet layup method, which requires nitrogen sealing in superheater and which requires
water sealing in evaporator / economizer, is a typical and effective method used for a long
outage period (more than 48 hours, less than two weeks).

The following are mandatory requirements for the Wet Layup method:

a) The water quality shall be the same or similar to normal deaerated

feedwater/condensate treated with chemicals. Two hours prior to taking the HRSG
off-load, feed water must be overdosed with volatile chemicals (NH3 injection in
condensate line) to bring the pH of the HRSG water to a value higher than 10. Water
quality requirements for a boiler under conservation are as follows :
- pH higher than 10
- O2 below 20 ppb
The oxygen values can be achieved by operation of the deaerator or chemical injection.
Any deviation from these targets should be limited in duration and magnitude to
maintain a good corrosion protection.

b) Keep drum level from start up level to normal level.

c) The temperature will gradually down by heat loss.

d) The pressure will be up and down for the time being and then it will gradually down.

e) If the pressure approaches to 1.5 barg, the steam drum pressure shall be pressurized
by nitrogen on the connection of steam drum.

f) Purge the superheater. The nitrogen shall be vented downstream the superheater.

g) After the HRSG complete filling, all valves shall be closed, to avoid any air flow into the
HRSG sections

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h) Nitrogen gas pressure shall be maintained at 0.3 barg at any time.

i) HRSG water level shall be checked. If required, additional feedwater shall be filled in.

j) Close the level gages on the steam drums if lasts over 3 days layup.

k) During wet layup, the recirculation of fluid is required for maintaining the chemicals
intended every week for one hour. The temporary layup recirculation pump shall be
connected to the evaporator downcomer and economizer inlet.

l) If not action m), drain the water under 0.3 barg of nitrogen pressure and refill the
economizer and evaporator up to drum level high high with deaerated water, pH
10~11, O2 below 20 ppb.

m) Before put in service, the drain valves are opened to blow off any water. Also, open
the level gages.

n) Make sure that the level gages / transmitters indicates correctly by blow off the
containments including water / nitrogen.

Caution ; Nitrogen is a hazard to personnel and can not be used if maintenance

on the systems is going to be proceeded. If there are any leaks from the
inside of tubes and piping to the gas side, anyone on the gas side of HRSG
should leave because of a lethal environment.

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5.0 MONITORING

Short term layup (two weeks) is required to monitor four hours basis and long term layup
(over two weeks) is required to monitor every day basis.

DRY LAYUP

It should be monitored nitrogen pressure.

.

WET LAYUP

It should be monitored pH, O2, conductivity and nitrogen pressure.

6.0 MISCELLANEOUS RECOMMENDATIONS

At the beginning of the "Lay Up" method, the combustion gas side shall also be inspected.
Soot, etc. must be removed. The surface of tubes and the combustion gas side should be
inspected for corrosion.

Gas side corrosion typically occurs when moist air is present with tube deposits containing
sulfuric acid or other fuel-borne contaminants. The gas side can only be laid up dry, if
necessary Electrical Heaters will be used to prevent condensate. And also silica gel can be
placed inside the gas side. The quantities are 1kg / m3. Periodic inspection of the gas side
should be performed to ensure that conditions promoting rapid corrosion are not present.
Under warm high humidity environment below the ambient dew point, a rust / flaky scale
in finned tube will occur. The desired relative humidity is less than 30%.

If find the gas side corrosion, cleaning of flaky deposits from finned tubes is recommended.

- End of Document -

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