Steam Blowing Procedure

DOCUMENT COVER SHEET
PROJECT NAME : SIPAT SUPER THERMAL POWER PROJECT

STAGE-I (3 x 660MW)
CONTRACT NO. :
ITEM : N) PERFORMANCE PROCEDURE
DOCUMENT TITLE : 1.9 Boiler & aux. Pipe lines Steam Blowing
Change pressure value at pre-step and add VGB R513

E 07/02/22 SWKang SWKang S.J.SA Y.T.Seo
completion criteria
D 06/08/25 Revised based on Joint meeting SWKang SWKang
C 06/05/26 Added sampling calculation SWKang SWKang SCSong YTSeo
B 05/12/05 Second issue SWKang SWKang K.T.Son
H.J.Hyu
A 05/05/11 First issue SWKang K.T.Son
n
REV. DATE DESCRIPTION DGN CHK REVIEW APPR
NTPC Limited
(A GOVERNMENT OF INDIA ENTERPRISE)
DOOSAN HEAVY INDUSTRIES &

CONSTRUCTION CO., LTD.
DOOSAN DOCUMENT NO. T04019-SY-M0003
NTPC DOCUMENT NO. 9518-108-11-KO-PVM-W-065 SHEET REV.
CATEGORY APPROVAL 26 E
Record of Revisions
Rev Date Page affected Description of Revision
A 2005.05.11 First Issue

B 2005.12.05 NTPC comment
C 2006.05.26 Added CFR sample calculation
D 2006.08.25 Revised based on Joint meeting
discussions and NTPC comments
E 2007.02.22 Change the pressure value of Pre-steps
and add VGB R513 Code of completion criteria
This Document is the property of Doosan Heavy Industries and Construction Co., Ltd., Chang-won, KOREA,
and is to be used only for the purpose of the agreement with Doosan pursuant to which it is furnished.
STEAM LINE BLOWING
TABLE OF CONTENTS TITLE PAGE NO.
STEAM LINE BLOWING PROCEDURE ........................................................................... 4

1. Introduction ............................................................................................................... 4
2. Principle of Steam blowing...................................................................................... 4
3. Precautions ............................................................................................................... 4
BLOWING PROCEDURES ............................................................................................... 5

1. Phase 1: Pre–Step Flushing..................................................................................... 5
2. Phase 2: Main–Step Cleaning .................................................................................. 6
PREPARATIONS FOR STEAM BLWING ......................................................................... 8

1. Readiness/Completion of major Equipments/Systems/Activities........................ 8
2. Preparing items......................................................................................................... 9
3. Check points ............................................................................................................. 9
BOILER START-UP AND OPERATION ......................................................................... 12
PROCEDURE FOR STEAM BLOWING.......................................................................... 16
DRAIN LINE BLOW OUT PROCEDURE ........................................................................ 21

1. Requirements .......................................................................................................... 21
2. Procedure ................................................................................................................ 22
STEAM LINE BLOWING - FLOW DIAGRAM ................................................................. 23
ATTACHMENTS
1. ISOMETRIC DRAWING ………………………………………………………….8 SHEETS
2. PIPING ARRANGEMENT DRAWING…..………………………………………3 SHEETS
3
STEAM LINE BLOWING PROCEDURE
1. Introduction
The purpose of steam line blowing is to remove pipe slag, weld bead deposits and other
foreign material from the main and reheat steam systems 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.
2. Principle of Steam blowing

To ensure that sufficient cleaning forces are applied to the piping, the steam momentum
during the steam blow must be equal to or greater than the steam momentum at normal
maximum load condition. The Cleaning Force Ratio (CFR) is typically used to evaluate if
satisfactory blow conditions are obtained.
CFR = ( vb / vmcr ) x ( Fb / Fmcr )2 > 1.00

Where vb = specific volume at steam blowing condition
vmcr = specific volume at maximum load condition
Fb = steam mass flow rate at blowing condition
Fmcr = steam mass flow rate at maximum load condition
Steam line cleanliness is determined by the appearance of polished target plates that are
mounted in the pipe during the final steam blows. The acceptance criteria for maximum
number and size of pits in the target plate are typically specified by the turbine supplier.
The design of the temporary piping and supports is the responsibility of Doosan. This
procedure is a suggested method of steam line blowing and does not attempt to address
all aspects of the blowing operation that will be required. The Commissioning-in-charge
has the ultimate responsibility for the comprehensive steam line blowing procedure or
implementation at the Project Site after due approval of NTPC site. E
3. Precautions
The process of steam line blowing imposes abnormal and severe conditions upon the
unit and steam piping. Large, rapid temperature changes occur during each blowing
cycle, which is far more severe than is incurred in normal operation. Thermal stresses
may be high in the thick walled portions of the unit. It is prudent to consider this fact
when performing this procedure and to limit the number of blowing cycles to the
minimum consistent with cleaning the system.
CAUTION: The operators must continuously monitor pressure in the

temporary and permanent piping and be ready to take action to
prevent over pressurization.
4 SIPAT STAGE-1 (3x660MW)

Since the temporary piping may be designed for a lower pressure than
the steam generator, care must be taken to prevent over-pressurization
during the entire steam blow operation.
CAUTION: Prevent the introduction of wet steam or de-superheater

spray water into the SH or RH assemblies. Poor distribution of the
water particles into the Superheater or Reheater assemblies causes
excessive temperature differentials resulting in bowing or
overstressing damage in attachments or supports. Therefore, the
steam entering any SH or RH section must be superheated at all
times.
The temperature of steam entering sections that are downstream of de-superheating

points, and subject to injection of water, should be monitored; a minimum of 14° C(25° F)
above the saturation temperature existing at that point should be maintained at all times.
The piping system and headers upstream of all SH and RH sections should be drained
and free of condensate at all times during the blowing operation.
The initial blow of each phase should be done at reduced pressure in order to check the
temporary piping anchors and supports.
Steam blowing operation is the first occasion on which the unit is fired at significant rate,
therefore special attention must be paid to the start-up and operation at all times. The
unit must be started much slower the initial time while all equipment is checked for
expansion movement.
BLOWING PROCEDURES
The steam line blowing procedure is divided into two (2) phases. Phase 1 consists of two
(2) pre-step blows, and phase 2 consists of two (2) main-step blows. In each phase,
specific sections of piping will be cleaned.
1. Phase 1: Pre–Step
The steam lines to be cleaned in the pre-step are the main steam line, the HP bypass
lines, and the cold RH lines. These are cleaned first in order to avoid carrying debris into
the RH assemblies and possibly causing tube blockage and subsequent overheating
problems. Since there will be no flow through the RH during this phase, the firing rate
must be limited such that the gas temperature at the furnace outlet does not exceed
537°C. Use the Furnace Gas Temperature Probe (at DDCMIS) to monitor the furnace
outlet temperature.
The unit is started up in accordance with normal start-up procedures. The two (2) martyr
valves located in the temporary piping downstream of the MSV will initially be closed and

the bypass valve is opened. The pressure at the separator outlet will be raised to the
value calculated to produce the desired blowing flow (approximate 40 kg/cm2(g)). E
Elevation AB oil burners will be used for the pressure and temperature raising. When the
required separator pressure is attained and stabilized, the oil burners are shut off and the
BCP will be stopped. Immediately the martyr valves will be opened wide to get the
maximum possible steam blowing flow. When the pressure has reduced to approximately
20 to 40 kg/cm2(g), the martyr valves are reset to the closed position. Oil firing is then re-
started and the process is then repeated until clean white smoke is observed at the
exhaust of tailpipe.
The suggested steam flow path is as follows: The final steam flow paths will be
determined based on discussions and mutual agreement between DOOSAN, NTPC and
Turbine supplier.
(Note: Temporary blanks or valves may be required to establish the suggested flow
path).
Pre-step 1 : Separator SH main steam line MSV temporary pipe martyr valve
tailpipe to atmosphere.
Pre-step 2: Separator SH main steam line HP Bypass Cold RH line backward flush
through drain pot near RH inlet header temporary pipe tailpipe to
atmosphere.
Note: During pre-step 2, the isolators at CRH line are kept open and the isolators at
HRH line are kept in closed position.
The pre-step steam blowing out operation shall be carried out with a Cleaning Force
Ratio below 1.0.
2. Phase 2: Main–Step Cleaning

There are two (2) phases of main-step cleaning. The firing required will be about
15%TMCR firing Light Oil/Heavy Fuel Oil. The suggested steam parameters for steam
blowing are as indicated elsewhere in this section. The firing rate is not limited to 537°C
at the furnace outlet in this case because sufficient steam is flowing through the RH.
The unit is started up in accordance with normal start-up procedures. The two (2) martyr
valves located in the temporary piping downstream of the MSV will initially be closed and
the bypass valve is open. The pressure at the separator outlet is raised to approximately
80 kg/cm2(g) while firing Light Oil/HFO. Elevation AB and CD oil burners will be used for
the pressure raising. The feed water flow, firing rate, and steam pressure will then be
increased in coordinated fashion until the desired steam production is achieved.
The SH and RH outlet temperatures are controlled by the burner tilts and the respective
de-superheating stations, as required.
The estimated steam conditions for this main step are:

Main steam flow App. T/hr 1310
Separator outlet Pressure Kg/cm2g 80
SHO Temp Deg. C 390
RHO Temp Deg. C 370
Feed water temp Deg. C 120
Firing rate %TMCR 15
NOTE: These operating conditions are estimated only. The actual steam
flow, pressure, and temperature in the steam lines during the steam blow
must be evaluated to determine if the minimum cleaning forces have been
obtained. It may be necessary to adjust these operating conditions as actual
blow conditions dictate.
It is assumed that the feedwater temperature is maintained at 120°C. Variation from this
temperature will have an impact on the firing rate required to generate the target steam
flow.
When the required steam parameters are attained and stabilized, the oil burners are shut
off and the BCP will be stopped. Immediately the martyr valves will be opened wide to
get the maximum possible steam blowing flow. When the pressure has reduced to
approximately to 40 kg/cm2g, the martyr valves are reset to the closed position. Oil firing
is then re-started and the process is then repeated until clean target plate is achieved
and the appearance of the target plate is acceptable to the turbine supplier.
The duration of each main-step blow may be for about three (3) minutes.
The main step steam blowing out operation shall be carried out with a Cleaning Force
Ratio above 1.0.
The suggested steam flow path is as follows: The final steam flow paths will be
determined by the NTPC / Turbine Supplier.
Main Step 1: Separator-SH-main steam line-MSV-temporary pipe with martyr-valve-

NRV-CRH-RH-HRH-IPT Stop Valve-temporary pipe-target-tailpipe to
atmosphere
Main Step 2: Separator-SH-main steam line-MSV-temporary pipe with martyr-valve-

NRV-CRH-RH-HRH-LP Bypass valve-temporary pipe-tailpipe to
atmosphere
Main Step 3: As determined by discussions and mutual agreement between DOOSAN,

NTPC and Turbine supplier, the cleaning of BFP turbine lines, turbine
steam seal lines, and other auxiliary lines will be done.

PREPARATIONS FOR STEAM BLOWING
1. Readiness/Completion of major Equipments/Systems/Activities
Before taking up the steam blowing operation, the following major equipments / systems
/activities are scheduled to be completed.
A. All structural steel work
B. Boiler proper & accessories

1) Casing
2) Buckstay
3) Hanger of Boiler
4) Header
5) Waterwall tube
6) Superheater assembly
7) Reheater assembly
8) Economiser assembly
9) Separator & storage tank
C. Link & Connection
D. Refactories, Insulation & Cladding
E. Main steam, Cold Reheat, Hot Reheat, HP & LP BP, Auxiliary steam & Interconnection
piping and valves
F. Soot blowing system
G. Draft system including SCAPH, Duct and dampers
H. Fuel Oil & Firing system
I. Miscellaneous system
1) Equipment for Oxygenation Treatment
2) LP Dosing system
3) Equipment for Cooling Water system
4) Chemical cleaning equipment
5) Lifting device
6) Garbage Chute
J. Electrical, Controls & Instrumentation for SG
The following major activities are scheduled to be completed before commencing steam
blowing operation.
A. Hydraulic Test
B. Readiness of SG C&I for Boiler
C. Boiler Light up & Chemical cleaning

2. Preparing Items
A. Temporary Piping
B. Temporary Motor Operated Valve
C. Blind Plate & Flange
D. Test Piece (Target Plate-Mild Carbon Steel of roughness of surface 0.8 microns &
having mirror like finish)
E. Test Piece and Flange assembly and de-assembly facilities.
F. Tele-communication facility
G. Recording Sheet
H. 415V AC Power Distribution Local Panel
3. Check points
A. Care should be exercised not to over-pressurize the unit during steam blowing
operation since the temporary piping may designed for a lower pressure than boiler.
B. All welded connection should be done 100%RT for safety and confirm the flange
connections.
C. Install steam piping/temporary piping with proper hanger, support and expansion
provisions.
D. Temporary piping will be insulated locally (only insulation without cladding) at
measurement locations & target plate location where personnel movement is
expected.
E. To check the drain valve for main steam line and Hot/Cold reheat line for steam
blowing.
Install the temporary piping at drip pot of main steam line and Hot/Cold reheat line in
order to drain the foreign materials easily.
Confirm that the drain lines for boiler and turbine piping are not blocked due to flange
or intentional blockage.
F. Confirm that well ground test pieces are ready and check the ease of insert and
tacking-off of test piece.
G. Test piece should be installed in the temporary piping with horizontal direction.
H. Check the condition of temporary motor valve and bypass valve of temporary motor
valve.
(1) Check the torque set value of temporary motor valve.

(2) Paint to reduce the friction between valve stem and gland.
(3) Check the valve’s open / close time.
I. During steam blowing operation period following inter-lock should not be worked in
order to prevent from being broken with frequent start and stop of auxiliary equipment
according to the burner firing and extinguishment.
(1) All BFP stop inter-lock by MFT
(2) MFT inter-lock by feed water flow low//low-low
(3) MFT inter-lock by all burner putting-off

(4) Purge inter-lock when all burner putting-off.
J. Boiler feed water pump with motor operation should be kept operating condition until
ending of steam blowing to hot banking. Boiler feed water pump with motor operation
should be kept operating at minimum feed water supplying condition when boiler does
not need feed water.
K. Check all instruments to be used during steam blowing, its attachment condition and
calibration.
L. Check all boiler expansion indicator should be adjusted as “o” point.
M. Confirm adjustments of the following instruments to be used during steam blowing.

(1) Indications and Alarms
a. Economizer Inlet Feed Water Temp. TE LAB50CT001, T002
b. Furnace Inlet Temp. TE HAC30CT003
c. Separator Inlet Temperature TE HAD30CT001 ~ 008
d. Separator Metal Temperature MTE HAD40CT001 ~ 003

MTE HAD45CT001 ~ 003
e. Separator Storage Tank Level LT HAD50CL001 ~ 003
LIE HAD50CL501 ~ 502
f. BRP Inlet Temperature TE HAG20CT001
g. BRP Diff. Pressure PDT HAG20CP01 ~ 003
h. BRP Motor casing Temperature TE HAG50CT003 ~ 005
i. Finish SH Outlet Temp. TE LBA11CT001 ~ 002
TE LBA12CT001 ~ 002
j. No.1 SH Spray Water Flow FT LAE51CF001 ~ 002
FT LAE52CF001 ~ 002
k. No.2 SH Spray Water Flow FT LAE61CF001 ~ 002
FT LAE62CF001 ~ 002
l. RH De-superheater Flow FT LAF51CF001, 002
FT LAF52CF001, 002
m. Feed Water Tank Level LATER
n. De-aerator Pressure LATER
o. Condensate Flow LATER
p. Warm-up Light Oil Flow FT EGD50CF001
q. Atomizing Air Pressure PT HJN50CP001 ~ 003
r. FD Fan A Air Flow FT HLA30CF001 ~ 003
s. FD Fan B Air Flow FT HLA40CF001 ~ 003

t. Flue Gas O2 Content AP HNA10CA001, 003 ~ 005

AP HNA10CA006, 008 ~ 010
u. Furnace Temperature TX HBK10CT001 ~ 010
TE HBK10CT021
TE HBK20CT021
v. Flue Gas Temperature Outlet Eco. TE HNA12CT001 ~ 004
TE HNA13CT001 ~ 004
TX HBK10CT001 ~ 003
TX HBK20CT001 ~ 003
w. Flue Gas Temp. Outlet of Sec. GAH A TE HNA12CT005 ~ 008
x. Flue Gas Temp. Outlet of Sec. GAH B TE HNA13CT005 ~ 008
y. Sec. Air Inlet Temperature GAH A TE HLA10CT002 ~ 005

aa. Sec. Air Inlet Temperature GAH B TE HLA20CT002 ~ 005
bb. DP Windbox to Furnace PDT HLA30CP001

PDT HLA40CP001
cc. Furnace Pressure PT HBK10CP001, 002
PT HBK10CP 006, 007
PT HBK20CP 001, 002, 003
PT HBK20CP 005, 006
dd. Feed Water Flow FT LAB50CF001, 002
(2) Recordings and Alarms
a. Eco. Inlet Flow FT LAB50CF001 ~ 002
b. Eco. Outlet Temp. TE HAC30CT001 ~ 003
c. Separator Outlet Temp. TE HAH10CT001 ~ 004
d. Separator Outlet Pressure PT HAH10CP001 ~ 004
e. Separator Storage Tank Water Level LT HAD50CL001 ~ 003
f. Finish SH Outlet Pressure PT LBA11CP003
PT LBA12CP003
g. MSV Inlet Pressure PT LBA31CP001
PT LBA32CP001
h. HP Turbine Outlet Pressure PT LBC11CP001
PT LBC12CP001
i. Primary RH Inlet Pressure PT LBC21CP001
j. Finish RH Outlet Pressure PT LBB21CP001, 002, 003

k. IPT Stop Valve Inlet Pressure PT LBB31CP001, 002
PT LBB32CP001, 002
l. Flue Gas Temp. Eco. Outlet TE HNA12CT001 ~ 004

TE HNA13CT001 ~ 004
m. Flue Gas Temp. Outlet of Sec. GAH A/B TE HNA12CT005 ~ 008
TE HNA13CT005 ~ 008
n. Secondary Air Inlet Temp. GAH A/B TE HLA10CT002 ~ 005
TE HLA20CT002 ~ 005
N. Check the preparation and readiness of tele-communication facility.
O. Keep the safety area around steam blowing outlet and steam blowing facilities. Clear of
all obstructions and personnel.
P. Check other necessary things for steam blowing. If there are any discrepancies /
problems associated with steam blowing procedure/operation, consult DOOSAN site
representative
BOILER START-UP AND OPERATION

A. The following facilities should be checked before steam blowing.
(1) Water Treatment System

(2) Condensate Transfer Pump
(3) Condenser & Condensate Pump
(4) Motor Driven Feed Water Pump
(5) Condenser Level Measurement
(6) Feed Water System and Feed Water Control System
(7) HP Bypass System
(8) Boiler Start-up System and Drain Transfer Pumps
(9) Gas Air Pre-heater and Soot Blower System
(10) Steam Coil Air Heater
(11) Oil Burners and Flame Scanning System
(12) FD Fan, ID Fan, PA Fan, Scanner Cooling Air Fan
(13) Electrostatic Precipitator: The Electro Static Precipitators are not in Doosan’s scope
of work. During steam blowing operation, at least two (2) electro static Precipitators
must be available for service with all controls and instrumentation in place.
(14) All Necessary Ancillaries and Aux. Systems (Cooling Water, Compressed Air, etc.)
(15) Fire Fighting System
(16) Control Air
(17) CCTV
(18) Light Oil / heavy Fuel Oil Supply System
(19) Auxiliary Steam System
(20) All boiler protection and inter-locks checked.

B. Boiler Start-up and Operation
Hot start-up is performed during steam blowing. Keep the boiler hot during night by boxing
up the unit. The following procedure shall be followed from light-off to raising pressure.
Please refer to the operating manual for details.
(1) Checkup before boiler water filling.

The following are check points for boiler proper, Boiler circulation pump system,
separator storage tank before filling boiler water.
- Boiler Vent Station Valve (Economizer / Water Wall / SH / RH) Open

- Boiler proper each kind Drain Valve Close (Economizer / Water Wall & Intermediate
Header)
- SH / RH Drain Valves Open at boiler proper
- SH / RH Spray Temp Control Valves Close
- BCP operating mode switched to manual and BCP inlet/outlet MOV open
- Warm-up Control Valve Close and Circulation Line Vent Valve Open.
- Open the MOV upstream of WR / ZR valve.
(2) Boiler water filling and improving water quality

To fill up the boiler water and to improve water quality BFP-M is used.
- Start boiler filling at 10%TMCR of feed water flow with BFP-M
- Increase 10% to 30%TMCR of feed water flow when WR valve is open due to
separator storage tank level increasing.
- Boiler filling water is finished when WR valve is full open (100%) and ZR valve is open
over 30% for a duration of 2 minutes.
- Boiler water flows through WR/ZR and flash tank and then goes to condenser.
- Until satisfactory water quality is obtained, repeat above steps.
- After boiler filling, reduce the feed water to a minimum flow of 110 ton/hr.
(3) Starting BCP operation

BCP will be started when the boiler water filling is over. The following are regarded as
pre-check and start-up.
- The motor cooling water is more than 300 lit/min and the BCP motor temperature
should be less than 65℃.
- Open the following valves : Circulation Line Vent Valve (HAG10-AA051), BCP
inlet/outlet MOV (HAG20-AA051, HAG20-AA053) and BCP Shut Off MOV (HAG10-
AA052)
- When BCP is on after BCP operating mode switches from manual to auto, the UG
valve is closed to minimum to enable BCP start.
- UG valve is changed to auto and then follows the economizer inlet flow, 596 t/hr.
- Confirm that whether the pressure differential of BCP is kept over 9.4 kg/cm2 and
close the circulation line vent valve.
- Close Economizer Outlet Link Vent Valve (HAC30-AA551, AA552).
- If water quality is too bad to use as boiler water it is drained after discussing with
client. If water quality is not good for boiler water but it can be used after discussing
with client, only some part of boiler water is sent to the water treatment facility.

(4) Preparations for the operation of the draft system:

- Check the tank level, oil pump and the temperature of the lubrication oil system of FD
& ID Fans.
- Check the operation of the ESP.
- Check the closed cooling water systems
- Check the damper of the draft system
(5) Startup of draft system train “A” (GAH, IDF, FDF)

- When the GAH Train “A” start-up SQC is switched auto, the lube oil pump is started.
The start-up motor is started and then the main drain motor will be started 300
seconds later.
- When the GAH Train “A” operation’s IDF Train “A” Start-up SQC is set to auto the
lube oil pump is started. The sealing/cooling fan is started and the IDF Train “A”
entrance damper is closed. Then the IDF Train “A” pitch blade position is set to
minimum when starting the IDF Train “A”.
- IDF Train “A” is started then the IDF entrance damper is opened, after this the pitch
blade is switched to auto to control the furnace pressure as -12mmH2O.
- In case of FDF Train “A” start-up SQC is switched to auto with the condition of
operating the IDF Train “A”, the lube oil pump is started. After the FDF Train “A” exit
damper is closed, the FDF is started on the condition of FDF Train “A” pitch blade is
set to minimum position.
- After the FDF Train “A” is started, the FDF exit damper is opened, and the pitch blade
is set to auto and air flow is supplied as 30%~40%TMCR airflow.
(6) Start-up of draft system Train “B” (GAH, IDF, FDF)

The same as a Train “A”.
(7) Start-up of SCAH Train “A”, “B”

- Check the pre-heating and pressure of the SCAH Aux-steam piping, and check the
SCAH drain pump lube oil levels and the cooling water amount.
- Change the operation mode of the drain tank level control valve and the SCAH drain
pump to auto.
- Open the SCAPH’s temp control valve manually to pre-heat the SCAPH. Then raise
the secondary air temp by at least 10℃. Than ignite the boiler and control the temp.
control valve manually until the mean temp of the GAH cold end reaches 70℃, then
the temp. control valve is switched to auto.
(8) Purge
- When the purge ready conditions are satisfied the purge start should be turned on.
- Purge is carried on for 10 minutes and then purge is done, MFT is reset again.
- Auxiliary Air damper is switched to auto. That means the differential pressure
between Windbox and Furnace is changed depending on the load increase.
(9) Check points before ignition

- The operation of Air pre-heater soot blowing
- Confirming a drain in the main body of a boiler and the operation of a Vent Valve
- The normalization of Light oil system after the light oil pump operate, the pressure
of Header is increased to approximately 18 to 21 Kg/cm2g by controlling the
Pressure Control Valve.

If the operating condition is good, Light Oil Leak test is conducted.

- The pressure of Atomizing Air is kept at 6kg/cm2g by controlling the pressure
Control Valve
- Confirmation of Elevation Oil Ball Valve Open in site and inspection of Oil Gun
Remote Position.
(10) The ignition of a boiler

- The Nozzle Tilt is kept horizontal initially. After the oil burners are ignited, tilt is put
into Auto.
- The Air flow is maintained around 35%TMCR flow.
- If the AB and CD Elevations Start/Stop turn on, the Oil guns are ignited in a
sequence namely corners 1,3, 2 & 4 with 15 sec time interval.
- For introduction of oil elevations AB/CD/ EF, please refer to the fuel start up
sequence recommended under start up and shut down procedure. Once auxiliary
steam is available at 16 kg/cm2(a) and 310℃ required for steam atomization of
Heavy Fuel Oil, Light Diesel Oil firing can be replaced by Heavy Fuel Oil firing.
- Inspect the flame on CCTV and confirm the sensing of flame by Flame Scanner
- Check up that the furnace pressure is maintained around -12 mmWC by adjusting
the pressure and flow rate of Light Oil.
(11) Operation/inspection checks after ignition

- Confirming that the state of SH & RH Spray Control Valve is auto.
- Keeping the adequate amount of feed water in Economizer at 600 t/h and Storage
Tank Level at approximately 9m.
(12) Temperature and Pressure Rising

- SH & RH Temperature is set the range 370~ 390 ℃ in manual operation mode .
- The main Drain and Vent Valve operation is as followings.
- More than 1.0 Kg/cm2g at the separator pressure : The Separator inlet of boiler,
S/H and RH Vent Valves should be closed
- More than 3.5kg/cm2g at the separator pressure : The backpass Lower side Drain
valves(SH MV 02,03) should be closed
- More than 3.5kg/cm2g at the hot reheat pipe pressure : The Cold R/H Drain
Valves(CR MV 51A, 51B) should be closed
- Boiler pressure increasing rate is maintained like this.
Pressure 0~10kg/cm2g : 0.5kg/cm2 per minute
- Combustion rate in pre-step can be increased maintaining furnace exit
temperature below 538˚C.
- During main step steam blowing, boiler pressure and combustion rate increasing
is as follows:
If BLR separator pressure is 50kg/cm2(g), oil burner of CD elevation is ignited in
sequence as corner #1, 3, 2, & 4 with 15 sec time interval.
In main step, it is not necessary to limit the furnace exit temperature 537˚C,
because steam flows through re-heater.
Combustion rate is maintained about 15%TMCR.

C. HOT BOXING-UP
During steam blowing, box-up the unit to conserve heat at night, and operate hot
start up in the morning.
For more details, it is recommended to follow Boiler operating manual.
The step to shut down is as follows:
(1) After igniting boiler and increasing boiler pressure as a next step of final steam
blowing on that day, put out the burner and operate purge.
(2) When final oil burner gun scavenge and furnace purge are finished, stop the BCP
after maintaining the UG valve at minimum point.
(3) Stop the BFP-M after closing BFP-M exit flow control valve manually.
(4) Drain valve of main steam system will be closed during boxing- up.
(5) Stop the steam coil air heater.
(6) Stop FDF and IDF, and control the damper of air/gas system to box- up mode.
PROCEDURE FOR STEAM BLOWING

A. General
(1) After igniting Oil Burner and raising boiler pressure, according to the
recommended range for Pre-step and Main Step, steam blowing is operated
following temporary MOV installed in temporary piping Open/Close signal.
(2) To prevent any equipment damage during steam blowing, the steam pressure
shall be maintained as suggested such that-during Pre-step, Cleaning Force
Ratio should be maintained less than 1.0, and during Main Step, Cleaning Force
Ratio should be kept greater than 1.0.
(3) The final evaluation of steam cleaning is decided by inspection of the target plate
installed in temporary pipe for steam blowing
(4) During cold start-up, drain of every piping should be fully operated so that Steam
Hammering phenomenon would not occur.
(5) During steam blowing, feed water is fed to boiler by motor operated BFP. Oil
burner is ignited and boiler pressure raised after securing re-circulation flow.
Burner is extinguished and stopped before starting steam blowing. The steam
blowing operation is repeated till successful completion.
B. Steam condition of steam blowing
(1) During steam cleaning, the recommended steam pressure to ensure desired
Cleaning Force Ratio at each section is 40 ~ 80 kg/cm2g range of pressure at
Separator outlet.
(2) The steam pressure for initial test blow is approximately 20 Kg/cm2g. For the pre-
step blowing operation, the steam pressure is maintained as 40 Kg/cm2g and for E

the main step blowing, the pressure is maintained approximately 80 Kg/cm2g. The
required Cleaning Force Ratio is calculated during each blowing operation.
(3) Loss of standard pressure for comparison with Cleaning Force Ratio is listed as
below
Item Pressure instrument location Loss of standard
From To pressure
Main steam pipe 10LBA11CP003 10LBA31CP001 7.29kg/cm2
10LBA12CP003 10LBA32CP001
Low-temp reheat 10LBC11CP001, 10LBC31CP001 0.76 kg/cm2
steam pipe 10LBC12CP001 10LBC32CP001
High-temp reheat 10LBB11CP003 10LBB31CP002 0.97 kg/cm2
steam pipe 10LBB12CP003 10LBB32CP002
* Cleaning Force Ratio is evaluated by standard pressure loss calculated at VWO

operation condition, and ∆pv represents calculation pressure loss between
pressure instrument locations.
(4) Steam Pressure & Temperature condition for each process (reference)
E
Process Pressure Temp.(℃) Estimated Blowing Remark
(kg/cm^2g) Discharge Force
rate (ton/h)
Pre- Operating ~40 ~370 ~ 212 <1 Separator
step martyr outlet base
valve
Main Operating ~80 ~ 390 1310~1400 >1 Separator
Step martyr outlet base
valve ~80 ~ 390 1310~1400 > 1 Separator
outlet base
Above Cleaning Force Ratio table is only for reference. Actual operation must be
done after finding the right pressure which satisfies Cleaning Force Ratio of each
sector by gradually increasing pressure for each stage of Steam Blowing.
Sample Calculation for Cleaning Force Ratio:
1. Steam flow at VWO kg/hr : 2160000
2. Specific volume of main steam
at 255 kg/cm2(a) & 540˚C m3/kg : 0.012429
2
3. Estimated Pr. Drop in main steam pipe kg/cm : 7.29
4. Estimated steam flow at 80 kg/cm2(g)
separator outlet pressure kg/hr : 1310000
2
5. Pr. Drop in main steam pipe for (4) kg/cm : (1310000/2160000)² x 7.29
(Value to be read from pr. Transmitters = 2.68
mentioned in table under (3)

6. Specific volume of steam at 80 kg/cm2(g)

and 390˚C m3/kg : 0.033789
7. Cleaning Force Ratio
CFR = ( vb / vmcr ) x ( Fb / Fmcr )2 > 1.00
= (0.033789/0.012429) x (2.68/7.29)
= 1.0
8. Hence, from the Pr. Drop values read from the Pr. Transmitters located in the
main steam piping, cold reheat piping & hot reheat piping, the CFR can be
calculated as above. Depending on the pre step/main step blowing, the CFR
has to maintained less than or greater than 1.0
C. Cautions
Following cautions must be strictly followed in order to protect operating personnel

during the process of Steam Blowing.
(1) Control room Operators and field personnel must be in close communication.
(2) The First Steam Blowing for each stage of Steam Blowing process must be done
in lower pressure than setting pressure in order to check (protect) Temporary
Piping, Supports, Anchor Bolts.
(3) BFP-M must be operated under curve given by BFP-M manufacture, for the
safety of operation. One must check that motor driven feed water pump trips
when it operates beyond its limit.
D. Pre-step
(1) Steam Blowing circuit
Blowing sequence of Pre-Step stage is as given below:
- Pre-step 1: Separator Superheater Main Steam Line Main Stop Valve

Temporary Piping Temporary MOV tailpipe to atmosphere
- Pre-step 2 : Separator Superheater Main Steam Line HP Bypass Valve

Cold RH line backward flush through drain pot near RH inlet
header Temporary Piping tailpipe to atmosphere
Note: During pre-step 2, the isolators at CRH line are kept open and the isolators at
HRH line are kept in closed position.
(2) Start up & Washing

In order to prevent impurities entering into Reheater coils, flushing of boiler
pressure parts namely water walls, separator, Superheater, main steam line and
HP Bypass piping is carried out. During the flushing operation, there is no flow

through Reheater coils. Hence, the firing rate is controlled so that the furnace
outlet temperature is maintained below 538℃. Elevation AB Oil guns are put into
service maintaining approximately 10%TMCR firing. Boiler pressure is slowly
increased till the separator outlet pressure is approximately 40 Kg/cm2g. Oil firing
is put off and BCP is turned off. The temporary MOV is open and flushing the
steam flow path as in Pre-step-1 is carried out for 30 seconds.
For the pre-step steam cleaning, start up & operation of boiler is as per boiler
operation manual and the procedures outlined as above.
Order Step Operation & confirmation note

1 Boiler filling -- Set WR, ZR and UG valve on auto.
- Start boiler filling at 10% BMCR feed water with
BFP-M
- After boiler water filling, Start BCP with UG valve
set at minimum position
- UG valve follows ECO inlet water flow, 596 ton/hr.
2 Oil burner firing
- After Furnace purging, Start Oil Elevation AB
Operation of
burners according to the sequence of corner
vent/drain valve
numbers #1,3,2,4 (with 15 secs time interval).
- Keep the firing rate about 10 ~ 15% TMCR.
- When separator outlet pressure is higher than 1.0
kg/cm2g, close the vent valve at separator outlet,
SH and RH.
- When separator outlet pressure is higher than 3.5
kg/cm2g, close the vent valve backpass lower side
drain valves.
- When RH outlet pressure is higher than 3.5
kg/cm2g, close the cold RH drain valves. (LBC31-
AA451, LBC32-AA451)
3 Start raising Raise the boiler pressure slowly.
pressure The temporary MOV will be in closed condition and
bypass valve will be kept open to preheat the steam
flow path.
4 Depute Ensure that trained operating personnel are ready
personnel in their assigned places in control room and field.
Carry out checks Check measurement instruments & safety zones.
5 Check for steam Check that steam pressure at separator outlet is

condition approximately 40 Kg/cm2g and steam flow rate is
adequate to give a Cleaning Force Ratio of below
1.0.

Order Step Operation & confirmation note

6. Putting off firingPut off the Oil burners in service.
7 Operation of UG UG-valve will be set to minimum position
valve, WR/ZR WR/ZR valves will be on MANUAL mode and will be
closed.
valves
The BCP will be shut off.
The BFP-M exit steam control vale is manually
closed and the BFP-M is stopped
The drain valve of the boiler main steam system is
closed
8 Steam blowing - The steam cleaning temporary MOVs are
out manipulated in the order of: slightly opened ->
Full open -> closed
- The time maintained in the Full Open position is
decided by the blowing force or kept under 3
minutes.
9 Test Piece Take- Confirm the following items and perform the test
off and Insertion piece insertion and take-off.
- Close the steam blowing valve and bypass valve.
Open the bypass valve after inserting the test
piece.
- Confirm that the steam issues at the tailpipe
outlet.
To start with, the initial steam blow outs will be done
without target plate. Subsequent steam blow outs,
the target plate will be inserted for every alternate
blow out. During the final blow outs, the target plate
will be inserted for each and every blow out until NO
MARKS are seen on the target plate.
10 End of steam Purge the boiler for 10 minutes. Prepare the unit for
blowing next steam blowing process as above
E. Main Step
(1) Blowing path
- Main Step 1 : Separator Superheater Main Steam Line Main Stop Valve
Temporary Piping Temporary MOV Non-return Valve Cold
Reheat Line Reheater Hot Reheat Line IPT Stop Valve
Tailpipe to atmosphere
- Main Step 2 : Separator Superheater Main Steam Line Main Stop Valve
Temporary Piping Temporary MOV Non-return Valve Cold
Reheat Line Reheater Hot Reheat Line LP Bypass Valve
Tailpipe to atmosphere

(2) Start-Up and blowing Process
Start-up and blowing process for main step are same as that of pre-step except
that the steam blowing path and steam blowing pressure are different.
Steam blowing is fulfilled with Cleaning Force Ratio above 1.0 and also checking
that the pressure drop in main steam piping is over 7.29 Kg/cm2 at selected
measurement points.
The amount of Pressure drop in Cold Reheat piping and Hot Reheat Piping
should be satisfied over 0.76 Kg/cm2 and 0.97 Kg/cm2 respectively, so that the
Cleaning Force Ratio is over 1.0 in those lines.
It is important to increase pressure step by step to find out proper Cleaning Force
Ratio before steam blowing. It is necessary to check the pipe and equipment after
each steam blowing.
F. Decision on successful Blowing Out:

After performing the Blowing operations as outlined above, the target plate is
removed for inspection of maximum number and size of pits in accordance with
VGB R513 Code(German VGB guideline, first issue 2000) and decision to
continue steam blowing out is taken in consultation with turbine supplier.
-VGB R513 Completion Criteria ; E
No impacts with an diameter larger than 1 mm

Not more than 4 impacts with an diameter larger than 0.5 mm
Not more than 10 impacts with an diameter of 0.2 to 0.5 mm
DRAIN LINE BLOW OUT PROCEDURE
1. Requirements
Each boiler drain line must be blown free of debris with steam water prior to boiler
operation at full pressure. Utilize the following procedure while boiler pressure is between
10 and 20 Kg/cm2g. The best time to perform this procedure is while raising pressure in
preparation for steam line blowing as outlined in the previous procedures. Failure to
adequately blow out the lines will result in debris damage to the seating surfaces on the
drain valves.
2. Procedure
NOTE: Ensure that all drain valves are closed, except for those needed to
correctly fire and raise pressure on the boiler.

1. Walk down the drain line that is to be blown out with steam/water.
Ensure that there are no closed valves, blanks or other obstructions
except the two drain valves located at the header.
2. Open the root or upstream valve (the valve closest to the header) on the drain line to
be blown out.
3. Fully open the second or downstream valve SLOWLY in order to allow the line to
warm up. This should take no more than 2 minutes.
4. Verify that there is flow in the line by checking the temperature of the second or
downstream drain valve. The valve should be noticeably hot. If not then report this to
the Site Representative immediately.
5. Close the second or downstream drain valve.
6. Wait 2 minutes and then open the second or downstream drain valve wide open.
7. Wait 5 minutes, then close the second or downstream drain valve.
8. Wait 5 minutes, then open the second or downstream drain valve.
9. Wait 5 minutes, then close the second or downstream drain valve.
10. Close the first or upstream drain valve.
11. Ensure that there is no leakage through the two valves when closed. If flow is
suspected, immediately inform the Site Representative.
Move on to the next drain line and repeat steps 1 to 11. Do this for each drain line. Refer
to applicable P&ID's.

STEAM LINE BLOWING - FLOW DIAGRAM
OPEN
CLOSED
RSV
NRV
RCV
From
HP Cyl. IP/LP Cyl.
Separator, MSV
Superheater
HP-Bypass
LP-Bypass
CLOSED
OPEN
Martyr Valve Temporary Pipe

Spectacle Flange
FIGURE 1: PRE – STEP 1
23
Martyr Valve
RSV
HP-Bypass
NRV
CLOSED RCV
From
MSV HP Cyl. IP/LP Cyl.
Separator,
Superheater
CLOSED
HP-Bypass
LP-Bypass
Temporary Pipe
FIGURE 2 : PRE – STEP 2
24
CLOSED Target Plate
OPEN
CLOSED
RSV OPEN
NRV Spectacle Flange
RCV
From
MSV HP Cyl. RH IP/LP Cyl.
Separator,
Superheater
OPEN
LP-Bypass
HP-Bypass
CLOSED
OPEN
CLOSED Temporary Pipe

Martyr Valve Target Plate
Spectacle Flange
FIGURE 3 : MAIN STEP 1
25
CLOSED Target Plate
Temporary Pipe OPEN
OPEN
RSV CLOSED
NRV Spectacle Flange
RCV
From
MSV HP Cyl. RH IP/LP Cyl.
Separator,
Superheater
CLOSED
LP-Bypass
HP-Bypass
OPEN
OPEN
CLOSED Temporary Pipe

Martyr Valve Target Plate
Spectacle Flange
FIGURE 4 : MAIN STEP 2
26

Steam Blowing Procedure

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DOCUMENT COVER SHEET

PROJECT NAME : SIPAT SUPER THERMAL POWER PROJECT

Change pressure value at pre-step and add VGB R513

D 06/08/25 Revised based on Joint meeting SWKang SWKang

C 06/05/26 Added sampling calculation SWKang SWKang SCSong YTSeo

B 05/12/05 Second issue SWKang SWKang K.T.Son

DOOSAN HEAVY INDUSTRIES &

NTPC DOCUMENT NO. 9518-108-11-KO-PVM-W-065 SHEET REV.

Rev Date Page affected Description of Revision

A 2005.05.11 First Issue

TABLE OF CONTENTS TITLE PAGE NO.

STEAM LINE BLOWING PROCEDURE ........................................................................... 4

BLOWING PROCEDURES ............................................................................................... 5

PREPARATIONS FOR STEAM BLWING ......................................................................... 8

BOILER START-UP AND OPERATION ......................................................................... 12

PROCEDURE FOR STEAM BLOWING.......................................................................... 16

DRAIN LINE BLOW OUT PROCEDURE ........................................................................ 21

STEAM LINE BLOWING - FLOW DIAGRAM ................................................................. 23

1. ISOMETRIC DRAWING ………………………………………………………….8 SHEETS

2. PIPING ARRANGEMENT DRAWING…..………………………………………3 SHEETS

STEAM LINE BLOWING PROCEDURE

2. Principle of Steam blowing

CFR = ( vb / vmcr ) x ( Fb / Fmcr )2 > 1.00

CAUTION: The operators must continuously monitor pressure in the

4 SIPAT STAGE-1 (3x660MW)

CAUTION: Prevent the introduction of wet steam or de-superheater

The temperature of steam entering sections that are downstream of de-superheating

5 SIPAT STAGE-1 (3x660MW)

2. Phase 2: Main–Step Cleaning

The estimated steam conditions for this main step are:

6 SIPAT STAGE-1 (3x660MW)

Main steam flow App. T/hr 1310

Separator outlet Pressure Kg/cm2g 80

SHO Temp Deg. C 390

RHO Temp Deg. C 370

Feed water temp Deg. C 120

Firing rate %TMCR 15

Main Step 1: Separator-SH-main steam line-MSV-temporary pipe with martyr-valve-

Main Step 2: Separator-SH-main steam line-MSV-temporary pipe with martyr-valve-

Main Step 3: As determined by discussions and mutual agreement between DOOSAN,

7 SIPAT STAGE-1 (3x660MW)

PREPARATIONS FOR STEAM BLOWING

1. Readiness/Completion of major Equipments/Systems/Activities

A. All structural steel work

B. Boiler proper & accessories

C. Link & Connection

D. Refactories, Insulation & Cladding

F. Soot blowing system

G. Draft system including SCAPH, Duct and dampers

H. Fuel Oil & Firing system

J. Electrical, Controls & Instrumentation for SG

8 SIPAT STAGE-1 (3x660MW)

(1) Check the torque set value of temporary motor valve.

9 SIPAT STAGE-1 (3x660MW)

(4) Purge inter-lock when all burner putting-off.

L. Check all boiler expansion indicator should be adjusted as “o” point.

M. Confirm adjustments of the following instruments to be used during steam blowing.

b. Furnace Inlet Temp. TE HAC30CT003

c. Separator Inlet Temperature TE HAD30CT001 ~ 008

d. Separator Metal Temperature MTE HAD40CT001 ~ 003

g. BRP Diff. Pressure PDT HAG20CP01 ~ 003

h. BRP Motor casing Temperature TE HAG50CT003 ~ 005

i. Finish SH Outlet Temp. TE LBA11CT001 ~ 002

j. No.1 SH Spray Water Flow FT LAE51CF001 ~ 002