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STEAM BLOWING PROCEDURE

09.02.09

FOR APPROVAL

REV

DATE

DESCRIPTION OF REVISION

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CHKD

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OWNER
WEST COAST POWER PRIVATE LIMITED

PROJECT

300 MW CCPP, KERAWALAPITIYA


SRILANKA

EPC CONTRACTOR
LAKDHANAVI LIMITED

CIVIL CONTRACTOR
LTL PROJECTS (PVT) LTD

ENGINEERS FOR
EPC CONTRACTOR

FICHTNER
CONSULTING ENGINEERS (INDIA) PVT LIMITED
CHENNAI, INDIA

PROJECT NUMBER

DOCUMENT NUMBER

DOCUMENT TYPE

REVISION

7856

7856-ME-SPC-198-025

WCPPL
300 MW Combined Cycle Power Plant

Steam Blowing Procedure

TABLE OF CONTENTS
1.0.0.

INRTRODUCTION...............................................................................................................3

2.0.0

GENERAL DESCRIPTION .................................................................................................4

3.0.0

GENERAL PREPARATION FOR STEAM BLOWING.........................................................6

4.0.0

PLANT READINESS............................................................................................................8

5.0.0

CRITERIA FOR COMPLETION OF STEAM BLOWING.....................................................9

6.0.0

PROCEDURE FOR STEAM BLOWING............................................................................10

7.0.0

POST CLEANING NORMALISATION...............................................................................17

8.0.0

LIST OF DRAWIING ENCLOSED.....................................................................................17

Doc. No. 7856-ME-SPC-232-010, Rev A


Steam blowing procedure.DOC

FICHTNER India

Page : 2 of 17

WCPPL
300 MW Combined Cycle Power Plant
1.0.0.

Steam Blowing Procedure

INRTRODUCTION
This document contains the information and the procedure to be followed to carry out the steam
blowing of the HP, LP main steam and auxiliary steam lines after erection and before start-up of
steam turbine is to ensure that no foreign materials like dirt, scales or deposits remain inside of the
pipes. Such foreign material if otherwise left on the inside of pipes would be carried over to the
turbine causing serious damage to the turbine nozzles, buckets and glands.
The principle is to blow-out the HRSG produced steam to atmosphere until the cleanliness of steam is
acceptable for the steam turbine operation. Under normal operating conditions, the maximum drag
would occur at MCR. To obtain an effective purge, the drag or disturbance across the surface of
particles must be increased above that occurring at MCR. To obtain optimum cleaning, the steam flow
condition (dynamic pressure) in the system during blows, should be 1.3 times that would occur
during normal operation.
While steam blowing, the steam is generated by the HRSG itself and thereby ensures cleaning of the
HRSG super-heater tubes and headers. Therefore, the HP and LP main steam lines as well as the HP
and LP super heaters are also cleaned by steam blowing.

Doc. No. 7856-ME-SPC-232-010, Rev A


Steam blowing procedure.DOC

FICHTNER India

Page : 3 of 17

WCPPL
300 MW Combined Cycle Power Plant
2.0.0

Steam Blowing Procedure

GENERAL DESCRIPTION
It is not practically possible to have similar flow conditions as those of full load condition while steam
blowing of pipes. Therefore equivalent conditions while blowing so as to match the full load
conditions can be generated. Ideally, by reducing pressure and temperature and at the same time
increasing the steam flow rate such that the product of steam mass flow times velocity (or square of
steam mass flow times specific volume) will be equal to or greater than that at full load operation.
However, due to several constraints it is hard to meet these criteria always. Therefore efforts shall be
made to get as close as possible to this criteria. The disturbance factor (D.F.) as defined above can be
expressed as follows:
D.F =

Fb
Vb

Fm
Vm

Fb
Fm

Dm
Db

= 1. 3 or higher

Where,
Fm

Steam mass flow at full load

Fb

Steam mass flow at steam blowing condition

Vm =

Velocity of steam in pipe at full load

Vb

Velocity of steam in pipe at steam blowing condition

Dm =

Density of steam at full load = Inverse of steam specific volume

Db

Density of steam at steam blowing condition = Inverse of steam specific

volume.
The steam blowing shall be carried out with GT load 30% because of practical consideration of
makeup water requirement. The following table shows the steam parameters.

Steam

Design Case (At HRSG outlet)


Pressure Temp.
Flow
(bar a)
(C)
(TPH)

While Blowing (At HRSG outlet)


Pressure
Temp.
Pressure
Flow (TPH)
(bar a) start
( C)
(bar a) end

HP Main
Steam

93.368

502.1

317.86

40

370

269.725

20

LP
Admission

6.619

220.1

85.24

175

76.03

2.1

The above steam blowing parameters are decided based on practical consideration and can be slightly
modified depending on actual operation data during steam blowing like drum level and condenser make
up flow etc to get higher disturbance factor.
It is to be noted that the disturbance factor cannot be calculated and applied as precisely as defined,
since the steam temperature and pressure will vary rapidly during the steam blowing. Therefore,
adhering strictly to the disturbance factor is not practically possible.

Doc. No. 7856-ME-SPC-232-010, Rev A


Steam blowing procedure.DOC

FICHTNER India

Page : 4 of 17

WCPPL
300 MW Combined Cycle Power Plant

Steam Blowing Procedure

The disturbance factor considered is at HRSG outlet, and the process of steam blowing is a throttling
process. In this throttling process, the exit pressure is less than the inlet pressure and therefore, exit
specific volume and velocity will be more at HRSG outlet conditions. So disturbance factor at Turbine
Stop Valve will be more than the values given in the above table. Therefore complete cleaning is
ensured in all the steam lines.

Doc. No. 7856-ME-SPC-232-010, Rev A


Steam blowing procedure.DOC

FICHTNER India

Page : 5 of 17

WCPPL
300 MW Combined Cycle Power Plant
3.0.0

Steam Blowing Procedure

GENERAL PREPARATION FOR STEAM BLOWING

General checks to be followed during preliminary blowing of pipes are as below: Flanges shall be used in such a way that their gasket surfaces do not get damaged and that the inside
surface of the flange is without any burns which would chip off later on.
All parts shall be subjected to thorough inspection and if necessary cleaning of pipes should be done.
For carrying out the blowing of main steam pipelines before turbine, temporary piping as indicated in
isometric drawing(to be submitted) shall be provided. The outlet of this temporary piping, to
atmosphere, shall be located outside building at a safe height in a slightly inclined position from
horizontal.
The main steam blowing can be performed by suitably branching of the temporary lines to the
atmosphere from upstream of the main steam stop / control valve by following the procedure as given
by GE (Doc No.: GEK 41745B Cleaning of main steam piping for combined cycle Plant).
The end of the blowing outlet line must be free anchored against movement in two sides and against
oscillations. The exhaust end however will be free to move in axial direction.
The steam pipelines except the temporary lines to be blown with steam must be insulated.
Disconnect and blank all instrumentation connections, which do not have isolation valve and are not
needed to monitor the steam blow operations. Thermowells shall not be installed during steam blowing.
Caps on drip legs for HP steam lines shall not be welded during steam blowing. However, the drip legs
shall be provided with temporary caps.
After trial blow, which will be at a lower pressure than the actual blow pressure tighten leaky flanges,
connections, adjust supports, etc. as necessary.
After each blow or as directed, open the valves on drip pots.
The pipeline shall be first heated up with steam when HP steam pressure is at 14bar, by slightly opening
the temporary valve, in order to remove internal tension caused during erection and to neutralise defects
in erection.
The drum pressure shall be raised gradually and its rate should not exceed 3.0bar / minute for HP
steam, and 0.7bar / minute for LP steam.
It shall be ensured that all condensate accumulation in the piping at any stage of blowing is drained
completely before the next blowing stage of the pipe.
Care must be taken while doing the permanent welds after completion of steam blowing to ensure that
pipe is free from foreign material during and after final welding of joints. Final welding after steam
blowing shall be by TIG process for root pass and by SMAW process for filler pass.
Doc. No. 7856-ME-SPC-232-010, Rev A
Steam blowing procedure.DOC

FICHTNER India

Page : 6 of 17

WCPPL
300 MW Combined Cycle Power Plant

Steam Blowing Procedure

The operating procedure of the HRSG for steam blowing shall be as per the HRSG operation manual.
After steam blowing is completed, the internals of both the isolation valves of the respective HRSGs
shall be removed and the internals are checked for any wear and tear and the same shall be replaced if
required.
The pipelines and drains are to be warmed up completely before pressurising the pipelines for steam
blowing. For this purpose, temporary drain lines including valves are to be installed in required areas
and also for temporary valves. Therefore, all temporary blow-out valves are to be provided with bypass
arrangement for initial warming up.

Doc. No. 7856-ME-SPC-232-010, Rev A


Steam blowing procedure.DOC

FICHTNER India

Page : 7 of 17

WCPPL
300 MW Combined Cycle Power Plant
4.0.0

Steam Blowing Procedure

PLANT READINESS

HRSG shall be ready after alkali boil out.


Make up for condensate system shall be made ready
Feed water storage tanks to be filled up to maximum level before each blow.
DM water shall be available.
Chemical dosing system shall be made ready.
Electrically operated temporary blow off valves shall be tested for operation from control room.
Control room indication for following parameters for both HRSGs shall be made available:
-

HP / LP Drum level

HP / LP Drum pressure

HP / LP SH outlet pressure

HP / LP SH outlet temperature

HP / LP Feed water flow

Feed control valves and start up vents/drains shall be made ready for operation from control room.
Turning gear of steam turbine shall be made ready (recommendable).
Other Requirements
a.

Target plates machined and ready for use

b.

Temporary barriers to prevent encroachment in areas of danger.

Doc. No. 7856-ME-SPC-232-010, Rev A


Steam blowing procedure.DOC

FICHTNER India

Page : 8 of 17

WCPPL
300 MW Combined Cycle Power Plant
5.0.0

Steam Blowing Procedure

CRITERIA FOR COMPLETION OF STEAM BLOWING

Target plate made of mild steel with polished surface of required size shall be placed at the downstream
of temporary piping. The steam with the foreign particle will impinge on the target plate. After each
blowing cycle the target plate is carefully analysed by visual observation for nos. of impingement pits,
their location on the target plate and their diameters. The results of the visual examination of the target
plate are recorded. The decision to end the steam blowing or completion of the steam blowing is made
based on the degree of pits on the surface.
GE TO PROVIDE THE CRITERIA FOR STEAM BLOWING COMPLETEION
The following sketch gives a recommendation for the installation and the dimensions of the target

0.85 D

plates.

Fig1. Typical sketch for target plate installation

Doc. No. 7856-ME-SPC-232-010, Rev A


Steam blowing procedure.DOC

FICHTNER India

Page : 9 of 17

WCPPL
300 MW Combined Cycle Power Plant
6.0.0

Steam Blowing Procedure

PROCEDURE FOR STEAM BLOWING

The steam blowing involves both the GT and the HRSG in operation. The steam turbine, condenser and
condenser vacuum pump will not operate. The GT being already in operation, the HRSG start-up and
operation shall be in line with units cold start up operation.
The related temporary piping, as per sketch enclosed, should be erected. However, depending on the
pipeline to be steam blown at any given time some spool pieces are to be disconnected / connected /
blanked as necessary and as per the sketch enclosed. The temporary piping should be adequately
supported to withstand blowing reaction forces. Remove the valve bonnet of MSCV / LP and connect
through adapter to temporary pipe.
Ensure that the DM water storage tank is full of DM water and DM plant is in service. Ensure that both
the HRSGs are chemically cleaned and ready after preservation either wet or dry.
In case the HRSG had been dry preserved the HRSG has to be filled with 8-10 pH DM water through
the HRSG fill pump. Before filling open the HP and LP drum vents and close all the drains. Fill water
in the drums up to normal water level by starting HRSG fill pump one after another.
In case the HRSG had been wet preserved the levels have to be adjusted as required either by filling or
by draining water. In order to get required pH, hydrazine may be dosed into the system by dosing pump.
Fill the condenser hot-well with DM water by HRSG fill pump up to NWL.
Start one CEP and continue operation under minimum flow condition. The other CEP will be in stand
by mode. The LP drum level control valve shall be in auto mode.
Start one HP FWP continue their operation under minimum flow condition. The other BFP'
s shall be in
stand by mode. The HP drum level control valves shall be in auto mode.
The DM water shall be maintained at a pH of 8 10.
Keep the drum vents and SH start up vents, start up drains and economizer by pass vent open during
initial filling.
Before carrying out the actual blowout the pipelines shall be blown with steam at comparatively low
pressure to check for any leaks and for stability of the temporary pipelines.
The steam blow out shall be carried out individually for HP circuits and LP circuit.
The steam blow out shall be carried in the sequence as explained below.
The steam piping to be cleaned by steam blow are the following:
Doc. No. 7856-ME-SPC-232-010, Rev A
Steam blowing procedure.DOC

FICHTNER India

Page : 10 of 17

WCPPL
300 MW Combined Cycle Power Plant

6.1.0

Steam Blowing Procedure

Step 1

HRSGs HP and common header

Step 2

HRSGs HP bypass line

Step 3

HRSGs LP and common header

Step 4

HRSGs LP bypass line

STEAM BLOWING OF HP / LP STEAM LINE AND MS HEADER

The HRSG shall follow the cold start-up procedure as provided by NEM.
The HP / LP main steam lines are blown with HRSG 2, then with HRSG 1 and the same is repeated
while both HRSGs are in operation. Both the HRSGs are provided with isolation valves and the same
shall be used for isolating the HRSGs from each other. When both HRSGs are blown together the
respective isolation valves are to be kept in full open condition.
Ensure that before start of each blow, the HP / LP drum level is slightly above minimum water level
(MWL) in order to prevent excessive decrease in water level.
HP vent and drain valves will be 100% open before start up. The valve closes when the drum pressure
reaches 5 bar and after confirmation of complete draining. By-pass valves (11HHR04 AA001 &
11HHR08 AA001) in temporary line can be used to warm-up the blowing circuit.
When the HP steam pressure reaches the blow out condition pressure, give open command to temporary
blow off valve (11HHR04 AA401) in HP line. The drum pressure in all section will fall continuously
when full flow is established through the temporary blow off valve. When HP pressure drops to the
blow out condition end pressure, give open command to all drains and vent valves and give close
command to temporary valve simultaneously.
LP vent and drain valves will be 100% open before start up. The valve closes when the drum pressure
reaches 2.1bar and after confirmation of complete draining.
When the LP steam pressure reaches the blow out condition pressure, give open command to temporary
blow off valve (11HHR08 AA401) in LP line. The drum pressure in all section will fall continuously
when full flow is established through the temporary blow off valve. When LP pressure drops to the
blow out condition end pressure, give open command to all drains and vent valves and give close
command to temporary valve simultaneously.
After each blow open all the temporary drain valves provided in the line to drain any condensate
present.

Doc. No. 7856-ME-SPC-232-010, Rev A


Steam blowing procedure.DOC

FICHTNER India

Page : 11 of 17

WCPPL
300 MW Combined Cycle Power Plant

Steam Blowing Procedure

STEP 1

In this Step, HRSG # 2 HP steam line is blown therefore, ensure that the respective isolation valves are
closed.
The main plant valves will be positioned as below described.
VALVE DESCRIPTION

TAG

POSITION

HRSG # 1 HP isolation valve

10LBA70 AA003

Close

HRSG # 1 HP bypass isolation valve

10MAN70 AA001

Close

HRSG # 2 HP isolation valve

20LBA70 AA003

Open

HRSG # 2 HP bypass isolation valve

20MAN70 AA001

Close

HRSG # 1 LP isolation valve

10LBA20 AA003

Close

HRSG # 1 LP bypass isolation valve

10MAN20 AA001

Close

HRSG # 2 LP isolation valve

20LBA20 AA003

Close

HRSG # 2 LP bypass isolation valve

20MAN20 AA001

Close

STEP 2

In this Step, HRSG#2 HP Bypass steam line is blown therefore, ensure that the respective isolation
valves are closed.
The main plant valves will be positioned as below described.
VALVE DESCRIPTION

TAG

POSITION

HRSG # 1 HP isolation valve

10LBA70 AA003

Close

HRSG # 1 HP bypass isolation valve

10MAN70 AA001

Close

HRSG # 2 HP isolation valve

20LBA70 AA003

Close

HRSG # 2 HP bypass isolation valve

20MAN70 AA001

Open

HRSG # 1 LP isolation valve

10LBA20 AA003

Close

HRSG # 1 LP bypass isolation valve

10MAN20 AA001

Close

HRSG # 2 LP isolation valve

20LBA20 AA003

Close

HRSG # 2 LP bypass isolation valve

20MAN20 AA001

Close

Doc. No. 7856-ME-SPC-232-010, Rev A


Steam blowing procedure.DOC

FICHTNER India

Page : 12 of 17

WCPPL
300 MW Combined Cycle Power Plant

Steam Blowing Procedure

STEP 3

In this Step, HRSG#2 LP steam line is blown therefore, ensure that the respective isolation valves are
closed.
The main plant valves will be positioned as below described.
VALVE DESCRIPTION

TAG

POSITION

HRSG # 1 HP isolation valve

10LBA70 AA003

Close

HRSG # 1 HP bypass isolation valve

10MAN70 AA001

Close

HRSG # 2 HP isolation valve

20LBA70 AA003

Close

HRSG # 2 HP bypass isolation valve

20MAN70 AA001

Close

HRSG # 1 LP isolation valve

10LBA20 AA003

Close

HRSG # 1 LP bypass isolation valve

10MAN20 AA001

Close

HRSG # 2 LP isolation valve

20LBA20 AA003

Open

HRSG # 2 LP bypass isolation valve

20MAN20 AA001

Close

STEP 4

In this Step, HRSG#2 LP Bypass steam line is blown therefore, ensure that the respective isolation
valves are closed.
The main plant valves will be positioned as below described.
VALVE DESCRIPTION

TAG

POSITION

HRSG # 1 HP isolation valve

10LBA70 AA003

Close

HRSG # 1 HP bypass isolation valve

10MAN70 AA001

Close

HRSG # 2 HP isolation valve

20LBA70 AA003

Close

HRSG # 2 HP bypass isolation valve

20MAN70 AA001

Close

HRSG # 1 LP isolation valve

10LBA20 AA003

Close

HRSG # 1 LP bypass isolation valve

10MAN20 AA001

Close

HRSG # 2 LP isolation valve

20LBA20 AA003

Close

HRSG # 2 LP bypass isolation valve

20MAN20 AA001

Open

Doc. No. 7856-ME-SPC-232-010, Rev A


Steam blowing procedure.DOC

FICHTNER India

Page : 13 of 17

WCPPL
300 MW Combined Cycle Power Plant

Steam Blowing Procedure

STEP 5

In this Step, HRSG # 1 HP steam line is blown therefore, ensure that the respective isolation valves are
closed.
The main plant valves will be positioned as below described.
VALVE DESCRIPTION

TAG

POSITION

HRSG # 1 HP isolation valve

10LBA70 AA003

Open

HRSG # 1 HP bypass isolation valve

10MAN70 AA001

Close

HRSG # 2 HP isolation valve

20LBA70 AA003

Close

HRSG # 2 HP bypass isolation valve

20MAN70 AA001

Close

HRSG # 1 LP isolation valve

10LBA20 AA003

Close

HRSG # 1 LP bypass isolation valve

10MAN20 AA001

Close

HRSG # 2 LP isolation valve

20LBA20 AA003

Close

HRSG # 2 LP bypass isolation valve

20MAN20 AA001

Close

STEP 6

In this Step, HRSG # 1 HP bypass steam line is blown therefore, ensure that the respective isolation
valves are closed.
The main plant valves will be positioned as below described.
VALVE DESCRIPTION

TAG

POSITION

HRSG # 1 HP isolation valve

10LBA70 AA003

Close

HRSG # 1 HP bypass isolation valve

10MAN70 AA001

Open

HRSG # 2 HP isolation valve

20LBA70 AA003

Close

HRSG # 2 HP bypass isolation valve

20MAN70 AA001

Close

HRSG # 1 LP isolation valve

10LBA20 AA003

Close

HRSG # 1 LP bypass isolation valve

10MAN20 AA001

Close

HRSG # 2 LP isolation valve

20LBA20 AA003

Close

HRSG # 2 LP bypass isolation valve

20MAN20 AA001

Close

Doc. No. 7856-ME-SPC-232-010, Rev A


Steam blowing procedure.DOC

FICHTNER India

Page : 14 of 17

WCPPL
300 MW Combined Cycle Power Plant

Steam Blowing Procedure

STEP 7

In this Step, HRSG # 1 LP steam line is blown therefore, ensure that the respective isolation valves are
closed.
The main plant valves will be positioned as below described.
VALVE DESCRIPTION

TAG

POSITION

HRSG # 1 HP isolation valve

10LBA70 AA003

Close

HRSG # 1 HP bypass isolation valve

10MAN70 AA001

Close

HRSG # 2 HP isolation valve

20LBA70 AA003

Close

HRSG # 2 HP bypass isolation valve

20MAN70 AA001

Close

HRSG # 1 LP isolation valve

10LBA20 AA003

Open

HRSG # 1 LP bypass isolation valve

10MAN20 AA001

Close

HRSG # 2 LP isolation valve

20LBA20 AA003

Close

HRSG # 2 LP bypass isolation valve

20MAN20 AA001

Close

STEP 8

In this Step, HRSG # 1 LP Bypass steam line is blown therefore, ensure that the respective isolation
valves are closed.
The main plant valves will be positioned as below described.
VALVE DESCRIPTION

TAG

POSITION

HRSG # 1 HP isolation valve

10LBA70 AA003

Close

HRSG # 1 HP bypass isolation valve

10MAN70 AA001

Close

HRSG # 2 HP isolation valve

20LBA70 AA003

Close

HRSG # 2 HP bypass isolation valve

20MAN70 AA001

Close

HRSG # 1 LP isolation valve

10LBA20 AA003

Close

HRSG # 1 LP bypass isolation valve

10MAN20 AA001

Open

HRSG # 2 LP isolation valve

20LBA20 AA003

Close

HRSG # 2 LP bypass isolation valve

20MAN20 AA001

Close

Doc. No. 7856-ME-SPC-232-010, Rev A


Steam blowing procedure.DOC

FICHTNER India

Page : 15 of 17

WCPPL
300 MW Combined Cycle Power Plant

Steam Blowing Procedure

STEP 9

In this Step, HRSGs HP steam line is blown therefore, ensure that the respective isolation valves are
closed.
The main plant valves will be positioned as below described.
VALVE DESCRIPTION

TAG

POSITION

HRSG # 1 HP isolation valve

10LBA70 AA003

Open

HRSG # 1 HP bypass isolation valve

10MAN70 AA001

Close

HRSG # 2 HP isolation valve

20LBA70 AA003

Open

HRSG # 2 HP bypass isolation valve

20MAN70 AA001

Close

HRSG # 1 LP isolation valve

10LBA20 AA003

Close

HRSG # 1 LP bypass isolation valve

10MAN20 AA001

Close

HRSG # 2 LP isolation valve

20LBA20 AA003

Close

HRSG # 2 LP bypass isolation valve

20MAN20 AA001

Close

STEP 10

In this Step, HRSGs LP steam line is blown therefore, ensure that the respective isolation valves
are closed.
The main plant valves will be positioned as below described.
VALVE DESCRIPTION

TAG

POSITION

HRSG # 1 HP isolation valve

10LBA70 AA003

Close

HRSG # 1 HP bypass isolation valve

10MAN70 AA001

Close

HRSG # 2 HP isolation valve

20LBA70 AA003

Close

HRSG # 2 HP bypass isolation valve

20MAN70 AA001

Close

HRSG # 1 LP isolation valve

10LBA20 AA003

Open

HRSG # 1 LP bypass isolation valve

10MAN20 AA001

Close

HRSG # 2 LP isolation valve

20LBA20 AA003

Open

HRSG # 2 LP bypass isolation valve

20MAN20 AA001

Close

Doc. No. 7856-ME-SPC-232-010, Rev A


Steam blowing procedure.DOC

FICHTNER India

Page : 16 of 17

WCPPL
300 MW Combined Cycle Power Plant
7.0.0

Steam Blowing Procedure

POST CLEANING NORMALISATION

After steam blowing is completed all the temporary piping shall be dismantled. The valve bonnets shall
be put in place and the system shall be normalised. The complete HRSG shall be drained by opening
the drain and vent valves and wet / dry preservation as recommended by NEM for HRSG shall be
followed.
8.0.0

LIST OF DRAWIING ENCLOSED

Scheme for steam blowing

Doc. No. 7856-ME-SPC-232-010, Rev A


Steam blowing procedure.DOC

10-7856-M-079 (10 sheets)

FICHTNER India

Page : 17 of 17