INTRODUCTION
The purpose of blowing the steam lines prior to starting up a new unit is to remove any foreign
matter remaining in the equipment (i.e. super heater) and steam piping after erection is
completed. Considerable damage could result if such foreign matter was allowed to enter the
plant steam system during initial operation.
On older units the need for steam line blowing should be considered following major pressure
parts repairs, where the possibility of introduction of foreign material into the system exists.
Since prevention of damage to the plant steam system is the prime concern, the responsibility
for determining the effectiveness of the steam line blowing operation rests with the plant
operator. During the steam line blowing process the unit should be operated in accordance
with the vendor recommended procedures, with all control systems and protective interlocks
functioning.
The principle behind steam blowing lines clean is that the thermal cycling (heating/cooling)
and high velocity gas flowing through the line will "shock" the pipe and tend to break the mill
scale and weld slag away from the pipe wall. Ideally, steam blowing should be done prior to
the system being insulated to maximum the thermal cycling of the equipment. If the system is
insulated, a greater time between blows may be necessary to allow the system to cool.
Ideally, to obtain optimum cleaning, the flow conditions in the system during steam line
blowing should equal those during normal operation at maximum load. Since it is impossible
to exactly duplicate these conditions when blowing through the piping to atmosphere, it is
desirable to produce equivalent conditions by using lower pressure steam with a flow rate
such that the product of steam flow times velocity will equal that under normal full load
conditions. The determination of the total obtainable flow quantity must be based on flow
resistance in the entire system, including the temporary piping. This determination is normally
made by the designer of the blowing system.
The temporary piping is normally equipped with a shutoff valve that is used as a blowing
valve. With this arrangement, the superheater and the upstream portion of the temporary
piping are maintained at drum pressure at all times when not actually blowing.
When a boiler and its associated steam piping have been erected, there is a possibility that
debris, such as welding beads and dirt may have been left in the tubes and piping. In addition,
these parts may have an internal coating of oxide or mill scale, which will flake off during initial
temperature changes.
Open the boiler stop valve quickly; water level in the drum swings upward. The level may
even go beyond visible limit. Permit the boiler pressure to drop about 10.5 to 14kg/cm2g. The
change in steam saturation temperature is kept less than 42deg.C. Then quickly close the
stop valve.
This method has the advantage that the sudden change in steam pressure produces a
sudden change in saturated steam temperature causing a thermal shock which helps to
loosen the adhered scale from the inside of tubes and piping. The steam expands quickly
through the system as the pressure drops. The scales are than removed by the expanding
steam. How ever, all the pressure parts, including the drum, are subject to thermal shock, and
to prevent excessive stresses and differential expansions, the change in saturation
temperature should not exceed 42deg.C.
To ensure thorough cleaning, a number of successive blows must be made due to the limited
blowing period permitted by the allowable pressure reduction.
For both procedures, experienced observation can determine when sufficient blowing through
has been effected. Clean metal target plates are rigidly secured in the path of the discharging
steam at a suitable distance from the pipe end.
These are placed in position for evaluation of debris carry over along with the steam after the
initial few blows when the steam is visibly clean. After each blow the target plates are
inspected for any pitting by the debris.
Target plate assembly is located in the temporary exhaust pipe and placed nearest to the
permanent pipe work. Availability of sufficient number of target plates is to be ensured. Stain
less steel plates having mirror finish shall be used in final blows. In preceding blows, target
plates of aluminium shall be used. Further blows are given until they indicate that no debris
remains in the piping. It is a standard practise to limit the number of blows to 6 to 8 per day at
an interval of 2 hours between 2 consecutive blows and with an overnight cooling.
A complete record of the events and observations are to be maintained.
The piping is considered clean if there are not more than five pitting on the target plate in the
central zone and the edges are not deformed. Besides, there should be no pitting in the rim
zone i.e the area other than the central zone. This should be achieved in three consecutive
plates.
PRECAUTIONS
To prevent excessive strain on pressure parts and danger to personnel, the following
precautions must be strictly observed.
-
Check all pipe anchors and guides for adequate support of piping, including the
temporary vent pipe.
2.
3.
Remove all control valves, desuperheater nozzles, flow elements, thermo wells,
pressure gauges, orifice plates, safety valves and instruments that may be damaged
during the steam blow.
4.
Insure all vent pipes have adequate drains and that these drains are routed to a safe
location.
5.
Install temporary pressure gauges as required to monitor the progress of the steam
blow and make arrangements for to record pressure readings.
6. Establish adequate radio communication between the control room and the operator at
the shutoff valve. Back this up with a system of visual communication, such as lights or
flags, since audio communication may be difficult due to high noise levels at the steam
shutoff valve.
7. Insure personnel traffic is controlled in area during steam blow. Insure the area near the
vent pipe is clear of all personnel during the steam blow. Protect neighbouring
equipment from damage due to the steam vents.
8. Individuals operating the steam blow valves (especially near the vent pipe) should wear
double ear protection.
Discontinue all firing and gradually open the temporary blowoff valve, to blow through
the steam system and out the temporary blowoff piping.
Caution: The first blow should always be done at reduced pressure, in order to check out the
temporary piping system, its supports and anchors.
2.
When the drum pressure has dropped to the value corresponding with a 100F (56C)
saturated steam temperature decrease, close the temporary blowoff valve and refire the
unit to re-establish blowing conditions.
3.
Repeat the above cycle until it is considered that cleaning is satisfactory as indicated by
inspection of impact specimens during the final blows.
2.
Remove temporary spools, blind flanges, temporary vent piping, etc., and reinstall all
components removed prior to steam blow.
Cleanliness Criteria
The turbo-generator vendor or the primary end user of the steam will generally specify the
criteria to which the system should be cleaned. If steam is used in a turbo-generator the
following criteria is generally used:
Two successive targets must result in mirror finishes that meet the specified criteria.
After a cooling down period of at least 12 hours, two more successive steam blows
must result in mirror surfaces that meet the specified criteria.
Criteria
S V NAGESH
OEG INDIA PVT