STEAM INJECTION SYSTEM FOR GAS TURBINES

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STANDARD PROCEDURE FOR STEAM BLOWING (210 MW) PURPOSE The purpose of steam blowing is to descale and remove foreign material from steam pipelines leading to turbine in order to avoid damage to turbine from such material in the course of normal operation. PRINCIPLE Steam blowing is carried out by puffing method. a. b. Dislodge rust/scales from pipe work by thermal shocks. High momentum of expanding steam in the pipe work purges out loosened material. It is required to create a higher momentum during steam blowing than possible during operation of the unit including valves wide open (VWO) condition of the turbine. This is applicable for all steam piping leading to turbine. Disturbance factor is the measure of ratio of momentum during steam blowing to the momentum at TMCR condition. Disturbance Factor = MSB X VSB / MMCR X VMCR Where: MSB VSB MMCR VMCR Mass flow of steam during blowing Specific Volume of steam during blowing Mass Flow of steam of MCR condition Specific volume of steam of MCR parameters.

In case of HP and LP bypass system blowing is carried out to avoid any damage later to valve intervals due to foreign material. Sharp elbows, miter bends and tees are to be avoided as these contribute to increased pressure loss, under steam blowing conditions. Also care to be taken in piping and contour to avoid critical velocities within the piping. Procedure The boiler is to be started in normal manner following start up procedure. All normal recommendations and limitations with respect to fuel firing equipments, draft plant, drains and vents, instrumentation, interlocks, protections etc. should be taken care of as if the unit is started to synchronise the generator with the grid.

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The procedure is to raise the boiler pressure to 40 kg/cm2, shut of firing and same time open temporary valve/boiler stop valve (blow off valve). The steam lines which are blown should be warmed up prior to blowing. The opening of blow off valve allows steam to escape to atmosphere at high velocity carrying with it loose and dislodged debris. To prevent thermal stresses in the thick walled shell like drum and headers the saturation temp. Change in drum is limited to 40 deg C maximum. Hence, for the purpose steam blowing of all critical piping the blow off valve will be opened at 40 kg/cm and closed at 19-kg/cm-drum pressure. The water level in the drum swings beyond visible limits at the start, during and at the end of steam blowing. There are chances of water droplets to get carried over to the saturated steam pipes and low temp. superheater. This can possibly be minimized by keeping the water level in the drum at the lowest port (visible limit) before the start of each steam blow off. All the steam lines are purged in parallel and it is standard practice to limit number of blows per day to 8 with an interval 1-1/2 hrs. For cooling in addition to overnight cooling. Stage I Stages II A Stage II B Stage III A Stage III B SH MS lines ESV Out SH MS lines ESV CRH Out at Blr. End. SH MS lines HPBP CRH Out at Blr. End. SH MS lines ESV CRH RH HRH IV Out SH MS lines ESV CRH RH HRH LPBP Out at cond. End. Preparation Estimated quantity of DM water requirement for steam blowing is about 5000 M3. Fuel oil requirement for the same has been estimated as 2000 MT. Target plate assemblies are to be located in the temporary exhaust pipes, nearest possible to the permanent pipe work. Sufficient quantity of carbon steel and stainless steel polished target plates are to be kept ready. Boiler should be ready in all respects including interlocks, protections, chemical dozing system, instruments etc, as if the unit is started to synchronise the generator with grid.

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STEAM INJECTION SYSTEM FOR GAS TURBINES

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Precautions The temporary discharge piping should be well supported to withstand reaction forces during blowing. The steam must be exhausted to atmosphere outside the turbine hall building and so directed that personnel and equipment are not damaged or endangered. The area should be cordoned off and notices displayed prominently. For thermal expansion of the pipe, proper allowances must be given. First steam blow in every stage should be given at a lower pressure, say 25 kg/cm at boiler drum and the pipe lines including temporary piping is surveyed for proper expansion and supports. All the permanent and temporary piping must be insulated before the beginning of steam blowing operations. The furnace exist gas temperature should be limited to 540C to safeguard superheaters and reheaters. Sufficient storage of DM water should be ensured and the rate of make up water to feed tank is to be matched taking into account the capacity of feed tank. Internal Boiler water treatment to be carried out with liquid Ammonia and Hydrazene Hydrate only, to maintain a pH value of 10.0 in Boiler water and 5 to 25 ppm of N2H4 in feed water. Total dissolved solids in boiler water should not exceed 10.0 ppm before going in for steam blowing. If it is more, rinse the boiler till it comes down to less than 10 ppm. Hot tightening of flanges, studs/bolts is to be done wherever such connections have been made. Drain going to any vessel should be left open to atmosphere suitably outside TG Hall. Before normalizing, the drain pots should be inspected. It should be ensured that all permanent hangers of the various lines should be erected as per drawing and all values set accordingly to the design figures. Also ensure that he locking of all hangers is removed, which would have been done for hydraulic test before steam blowing. Remove all strainer elements before start of steam blowing. Down stream lines of ESV, IV and LP bypass valves are to be manually cleaned. Ensure no loose debris / extraneous materials are left inside the permanent / temporary pipe work. Flow nozzles, Control Valves, NRV flaps and attemperators are not to be erected before steam blowing of lines for cleanliness.

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Any loops coming in the system which is steam blown should be checked after steam blowing. Spool pieces are to be erected in its place wherever applicable. Steam blowing of steam lines are to be started after hydraulic test of respective lines / pressure parts. Steam blowing of Auxiliary steam lines. a) These lines are to be blown by continuous blowing for about 20 to 30 minutes at a pressure of 50% of their normal operating pressure. b) c) Precaution to be taken of control valves etc; as mentioned in item 13 above. Lines, which are to be made ready before boiler first light up should be blown with external steam source. Note: Boiler and main steam valves will be inspected for tightness during drum and superheater safety valve floating. Tightness is to be checked by keeping MSSV closed, raising the SH pressure to MCR conditions and opening the drain lines downstream of MSSV. Valves will be serviced if passing is established. Completion Criteria Indications for the result of each blowing period is the number of pitting found on the target plate. The highest velocity of steam is in the center of the pipe. Hence judgement should be made for the end point of steam blowing in this area. The area for the above is 3/4th the discharge pipe diameter at the center. It is recommended to install the target plate after completing few blows in each stage. For evaluating the cleanliness and termination point of the steam-blowing, target plate of stainless steel are to be used. For initial stages, target plate of carbon steel is to be used. The results of the blowing operations can be judged by the absolute number of pitting on the target plate in the central zone. The piping is considered clean if there are not more than five pitting and shall not have any deformed edges. Besides there shall be no pitting in the rim zone.

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STEAM BLOWING BOM VALVES 1. 2. 3. 4. 5. 6. 7. 10 NOS-GV / Nb 400 / NP 64 / BW 4 NOS-GV / Nb 50 / NP 64 / BW Nb 2 1500 Class 4 nos Nb 2 800 Class 2 NOS Nb 1 800 Class 2 NOS Nb 800 Class 4 NOS Quick closing electrically optd. Valves 2 Nos., Time full stroke 30 s 1 min. Nb 400 / NP 64 / BW

PIPES: 1. 2. 3. 4. f 406.4 x 12.7 = 105 M f 273 x 9.27 = 20 M Nb 2 = 125 M Nb 1 = 15 M

REDUCERS 1. 2. 3. f 406.4 x f 323.9 x 12.5 4 NOS f 406.4 x 219.1 x 10 4 NOS f 457.2 x f 406.4 x 12.7 4 NOS

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BENDS: 1. 2. 3. 4. 5. 6. 7. LR ELBOW 90 f 406.4 x 12.5 = 10 NOS (45 = 7 NOS, 90 = 6 NOS) LR ELBOW 90 f 323.4 x 9.53 = 5 NOS. (45 = 4 + 90 = 6 NOS) LR ELBOW 90 f 406.4 x 12.5 = 10 NOS. (45 = 7 NOS, 90 = 6 NOS) f 406 45 = 7 NOS f 406 90 = 8 NOS f 323 45 = 6 NOS f 273 45 = 6 NOS + 4 NOS = 10 NOS.

SUPPORTING STRUCTURE: 15 MB 450 18 M 15 MB 400 24.5 M 15 MB 200 2.2 M 15 MB 125 5.8 M 15 MB 300 7.5 M 15 MC 150 6.7 M 15 MC 100 74.6 M 15 MB 250 8 M 298.4 Kg

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POSITION OF ISOLATION VALVES DURING STEAM BLOWING Sequence of Blowing Main steam line Cold reheat line Hot reheat line C O C O C O C C O C C O C C 1&2 O 3&4 C Isolation Valves 5&6 C 7&8 C 9&10 C 11&12 C 13&14 C

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HP bypass line LP bypass line O Open C Close

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