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POWER PLANT ENGINEERING

Procedure Of Steam Blowing Test

Date: May 19, 2015 Author: Sujit  0 Comments

STEAM BLOW OUT

1.0 OBJECTIVE
The purpose of steam blowing is to dislodge scales, remove loose material, iron pieces, weld
slag etc., that might have been entrapped inside the piping of Superheaters and other station
steam piping during erection. Failure to ensure absolute cleanliness of the steam piping may
result in damage to the Turbine blades, Valves etc. The steam blow out operation is carried out
after Boiler acid cleaning.

2.0 BASIC – TECHNIQUE

2.1 The steam blow out is carried out by the ‘puffing method’. The dynamic disturbance
available in this method will give a thermal shock to the system being purged to dislodge the
scale etc., which will be subsequently carried away by the expanding steam.
2.2 For the steam blowing to be effective, the ratio of the kinetic energy at steam blowing
conditions to MCR conditions should be greater than one(1).This is determined by what is
called the ‘DISTURBANCE FACTOR’ and is calculated by using the following formula :
Disturbance Factor, K = Vb x Fb2/Vm x Fm2

Where,
Vb = Specific volume of the steam at blowing pressure
Fb = Mass flow rate of steam at the blowing pressure
Vm = Specific volume of the steam at Boiler MCR condition
Fm = Mass flow rate of steam at Boiler MCR condition.
Before the steam blowing operation the blowing pressure should be decided/calculated to
give the required Disturbance Factor. The pressure normally adopted is 40 Kg/cm2.
2.3 During the blow out operation the cleanliness of the piping is determined by the use and
study of ‘ Target Plates’ made of specified material (MS, SS, Aluminum or others) located in an
assembly in the steam blow path, in the temporary exhaust piping at a location nearest
possible to the permanent pipe work.
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3.0 THE SCHEME

The steam blow out operation is carried out in stages to include the maximum possible length
of steam piping. In order to achieve effective cleaning, all the station piping is sectionalised
and steam blown. Turbine is bypassed during steam blowing . The stages normally followed
are;

Superheater : The superheater and main steam pipes are are steam blown through to the
turbine main steam chests, and from there to atmosphere using temporary pipe work. The
turbine steams valve are replaced by temporary blanks.
Superheater and reheater :  After superheater steam blowing is complete, the temporary pipe
work  is rearranged so that the turbine main steam chest discharge pipe work is replaced with
temporary connections to the cold reheat steam pipes,  discharging to atmosphere using the
turbine reheat intercept steam chests, and temporary pipe work.
4.0 PREPARATIONS, PRECAUTIONS & CHECKS
4.1 Boiler acid cleaning and passivation operation are satisfactorily completed. All the
temporary piping for acid cleaning is removed and permanent pipe connections restored,
Drum intervals are fixed and hydro test conducted.
4.2 Main steam and all the station steam piping erection are completed, with all supports and
hangers provided as per drawing
4.3 Temporary piping for blow out erected. Temporary blanks installed wherever applicable.
4.4 Temporary blow out piping checked for proper anchoring and safe discharge outside the
building. They should be able to withstand the excessive reaction forces of steam blowing.
The exhaust area suitably fenced and ‘ CAUTION ‘ notice displayed prominently.
4.5 The diameter of the temporary piping should not be less than the diameter of the
respective lines to be steam blown.
4.6 All the permanent and temporary piping included in the scheme of blow out are
adequately insulated before commencing the steam blow out operation.
4.7 Electrically operated Temporary blow out valve, if used, should be installed on the Main
steam line and its operation checked. For the blow out to be effective these valves be fast
acting with an actuation time of about 30 to 40 seconds.
4.8 All Flow nozzles, Strainers, Orifice plates, Control valves and Attemporators are removed
and temporary spool pieces fixed in place. NRV flaps should be removed from NRV’s in the
steam blowing path.
4.9 Hydrostatic test plugs should be removed and all the safety valves are thoroughly cleaned
and assembled.

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4.10 The target plate fixing arrangement erected and checked. Sufficient quantity of target
plates of the specified material are available.
4.11 Sufficient quantity of DM water available and the DM Plant is in operation.
4.12 The Boiler is ready in all aspects, including, protections, interlocks, instrumentation,
chemical dozing etc., for Light up and raising pressure.
4.13 Ensure that no loose debris or other material are left inside permanent or temporary
piping.
4.14 Drains going to any Vessel should be left open to atmosphere, preferably outside the TG
Hall.
4.15 Before beginning the steam blow out determine/decide on the pressure for the blow out
to achieve correct disturbance factor.
5.0 STEAM BLOWING – PROCEDURE
5.1 Boiler is started up, following normal startup procedures. All the normal
recommendations and permitted operational limitation should be strictly observed.
5.2 Light up the Boiler and raise the steam pressure slowly as per O & M procedures up to 20
–25 Kg/cm2. Warm up the line by opening the bypass of Boiler steam stop valve and then
open the Boiler stop valve. Boiler fires are put off and electrically operated temporary valves
are opened and valves are closed at 10 kg/cm2 start up vent to be closed during the above
period. During 1st blow, the boiler associate and station piping are completely inspected for
any abnormality.
5.3 After inspection, light up the Boiler and raise the pressure to the predetermined value – 40
Kg/cm2, for the first stage of the blow.
5.4 Kill the Boiler fire. Open the electric operated temporary valves EOTVs and give blow till
the pressure drops to a specified value, so that the saturation temperature change is limited to
a maximum of 40C (This is to prevent undue thermal stresses in the Drum and Headers).
Close the EOTVs.
5.5 During steam blowing, the following observations are recorded.
i) Drum level swings.
ii) Steam pressure drop at various sections.
iii) Steam temperature at various sections.
iv) Duration of steam blow.

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5.6 After EOTVs are closed at stop steam blowing, boiler is relighted up and conditions are re-
established for next blow. The standard practice is to limit the number of blows per day to 6 to
8 at an interval of 1½ hrs. for each blow, with overnight cooling.
5.7 Continue steam blowing until Target Plate is clean (decided by completion criteria– see
clause 6.0 ). Use Target Plates after every three (3) or four (4) blows and for every blow in the
last stage.
5.8 After First stage completion, prepare for the second stage operation.
5.9 Complete second stage at specified pressure till target plate is clean
5.10 Prepare for the next stage steam blowing.
5.11 Complete all stages of steam blowing one by one.
5.12 Each stage will normally be steam blown at specified pressure.
5.13 After completion of steam blowing remove the temporary piping and blanks, install Flow
nozzles, Control valves etc., and reweld piping as per drawing.
6.0 TARGET PLATE ANALYSIS & COMPLETION CRITERIA
The number of impacts found on the Target plates give indication of the pipe cleanliness. The
highest velocity of steam is in the centre of the pipe. Hence judgement should be made for the
end point of steam blowing in the central zone of the target plate. The piping shall be
considered clean if number of impacts on an area of 40mmX40mm:
– No impact with a size > 1mm
– Less than 4 impacts with a size > 0.5mm
– Less than 10 impacts with a size > 0.2mm
However, it is best that such completion criteria be discussed and finalized, before start of the
steam blow out operation.

7.0 STEAM BLOWING OF MISC. STEAM LINES

• Steam lines like ; steam headers to various HP, MP and LP consumers are to be steam blown
by continuous blowing method. The parameters of steam blowing for these lines will be
different and should be strictly followed.
• HP Steam consumers for turbine drives, the line shall be steam blown till the target plates
are clear. In other areas steam lines shall be steam blown till the steam quality at outlet is
clear.
8.0 SAFETY
8.1 Personnel not in volved in the steam blow operation should be moved away from the area.
8.2 Adequate communication system should be setup to warn personnel when each blow is
about to commence and on completion.
8.3 Personnel should be stationed at strategic points and in case of any abormality/emergency
situation blow out to be stopped and problem investigated / corrected before commencing
steam blow out.
8.4 All personnel in the vicinity of steam blow out must wear ear plug.
8.5 While fixing and removing target plate , the steam supply will be isolated by closing stop
valve and its bypass and permit for work will be issued.
9.0 STEAM PARAMETERS FOR STEAM BLOWING
• HHP Steam lines : Pressure / Temperature : 40 kg/cm2/ 400 deg C
• HP Steam lines : Pressure / Temperature : 30 kg/cm2 / 350 deg C
• MP Steam lines : Pressure / Temperature : 10 kg/cm2 / 250 deg C
• LP Steam lines : Pressure / Temperature : 5 kg/cm2 / 250 deg C

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9,0 REFERENCES

9.1 VGB Guide line for steam blowing ( VGB-R513e)

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Published by Sujit

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