Drum HRSG Layup Procedure

RECOMMENDED LAYUP PROCEDURE FOR DRUM-TYPE HRSGs
TABLE OF CONTENTS
TITLE PAGE NO.
INTRODUCTION 3
TABLE 1 - RECOMMENDED PROCEDURES FOR WET LAYUP 4

OF DRUM-TYPE HRSGS
TABLE 2 - RECOMMENDED PROCEDURES FOR DRY LAYUP 10

OF DRUM-TYPE HRSGS
Drum HRSG Layup Procedure 5/28/02 Page 1 of 10

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INTRODUCTION
If extensive oxygen-related corrosion during outage conditions is to be avoided, proper layup

methods are essential. The interior surfaces of HRSG components must be kept free of
moisture (water) or oxygen since the simultaneous presence of both moisture and oxygen is
required for this corrosion to occur.
Layup has been defined for two conditions; wet and dry, and for two durations (short and
long) regarding wet layup. A short outage is defined as any period where the HRSGs is out
of service for up to four days. A long outage is defined as any period where the HRSGs is
out of service for more than four days.
For dry layup, the most effective and practical means for excluding oxygen is to maintain an
overpressure of nitrogen. For wet layup, protection against corrosion is provided by an amine
(e.g. ammonia) for pH control and an oxygen scavenger (e.g. hydrazine) to maintain a
protective oxide film and a reducing environment. A nitrogen overpressure is also
established and maintained to preclude oxygen ingress.
Tables 1 and 2 below summarize the Company’s recommended layup procedures for drum-
type HRSGs. These layup procedures are intended to be general guidelines for minimizing
corrosion of HRSG components under outage conditions. Plant-specific circumstances may
dictate alternative layup measures.

Table 1
Recommended Procedures for Wet Layup of Drum-Type HRSGs
TYPE OF PROCEDURE
SHUTDOWN
Pre-Operational With the HRSG components (economizers, evaporators, superheaters, and
Period Post-Hydro reheaters, if present) filled to overflowing, pressurize the system with
(See Note 1) nitrogen to 5 psig (See Notes 3, 4, 5, 6).
Note 1. All sections to be hydrostatically tested should be filled with demineralized or

condensate quality water containing 10 ppm of ammonia and 200 ppm of hydrazine. This
should produce a solution pH of approximately 10. The superheater should be filled first to
overflow into the steam drum. The remaining components can be filled through normal fill
connections (See Note Note 2). If demineralized or condensate quality water is not
available, please consult with the Company’s site representative.
Note 2: Hydrazine and ammonia should be added in a manner that results in a uniform
concentration throughout. They may be added to the system in several ways, as for
example:
a) By pumping concentrated solutions through the chemical feed equipment and blend
filling to achieve the desired concentration.
b) If condenser leakage is not a cause for shutdown, concentrated solutions can be
introduced directly into the hotwell where they can be mixed to achieve the desired
concentrations. If condensate demineralizers are employed, they must be bypassed
during the operation.
It is important to have the fluid temperature in the cycle below 400°F before the addition
of hydrazine. If this temperature is exceeded, hydrazine will decompose.
The use of hydrazine (N2H4) has been found acceptable as an oxygen scavenger.
However, in cases where the use of hydrazine is prohibited due to local environmental
regulations, ammonia treated water will suffice provided that a pH of 10 is maintained.
When using ammonia for extended layup, it is important to establish and maintain a
nitrogen cap to prevent air ingress.
Note 3. If freezing is a problem, the water can be displaced with nitrogen and the unit laid up
under 5 psig nitrogen pressure.
Note 4. If the reheater cannot be isolated and the outage is expected to extend beyond two
months, provisions should be made to isolate and nitrogen cap the reheater.
Note 5. Nitrogen cap should be applied through the drum vent and superheater outlet
header drain/vent as the unit is cooled, when pressure drops to 5 psig. Admission of air
through atmospheric vents should be avoided.
Note 6. When it is not possible to maintain a nitrogen cap, the pressure parts shall be
maintained completely full of treated water. Compete filling can be proven when water is
vented from the high point vents.

Table 1 (cont.)
Pre-Operational 1. Introduce demineralized or condensate quality water containing 10 ppm

Period, Post of ammonia and 200 ppm of hydrazine into the HRSG components (See
Chemical Cleaning Note 1).
Note 1. If freezing is a problem, the water can be displaced with nitrogen and the unit laid
up under 5 psig nitrogen pressure.
2. Nitrogen cap the system. Maintain 5 psig nitrogen overpressure (See

Notes 2, 3, 4).
Short Outage, 1. Maintain the same water chemistry conditions as those present during
4 Days or Less normal operation.
2. Establish and maintain a 5 psig nitrogen cap on the system (See Notes 1
& 2 ).
Short Outage, 1. Drain and open only those sections requiring repairs.
4 Days or Less, 2. Isolate remainder of system under 5 psig nitrogen pressure where
Unit Partially Drained possible (See Notes 1, 2, 3).
for Repairs Note 1. If the reheater cannot be isolated and the outage is expected to extend beyond two

Table 1 (cont.)
Short Outage, Note 2. Nitrogen cap should be applied through the drum vent and superheater outlet
4 Days or Less, header drain/vent as the unit is cooled, when pressure drops to 5 psig. Admission of air
Unit Partially Drained through atmospheric vents should be avoided.
for Repairs
vented from the high point vents
3) Maintain the same chemistry conditions for water remaining in the cycle
as those present during normal operation.
Long Outage, 1. Fill the superheater and reheater with demineralized or condensate
Longer than 4 Days quality water containing 10 ppm of ammonia and 200 ppm of hydrazine.
The pH of the solution should be about 10. Add the fill water from an
available connection. Do not spill over or fill from the steam drum (See
Notes 1 & 2).
Note 2. A reheater may or may not be present in the cycle.
2. Increase the hydrazine and ammonia concentrations in the remaining

components to 200 ppm and 10 ppm, respectively (See Notes 3 & 4).
Note 3. Hydrazine and ammonia should be added in a manner that results in a uniform
example:
a) By pumping concentrated solutions through the chemical feed equipment and
blend filling to achieve the desired concentration.
b) If condenser leakage is not a cause for shutdown, concentrated solutions can
be introduced directly into the hotwell where they can be mixed to achieve the
desired concentrations. If condensate demineralizers are employed, they must
be bypassed during the operation.
It is important to have the fluid temperature in the cycle below 400°F before the
addition of hydrazine. If this temperature is exceeded, hydrazine will decompose.
The use of hydrazine (N2H4) has been found acceptable as an oxygen scavenger.
However, in cases where the use of hydrazine is prohibited due to local
environmental regulations, ammonia treated water will suffice provided that a pH of
10 is maintained. When using ammonia for extended layup, it is important to
establish and maintain a nitrogen cap to prevent air ingress.

Table 1 (cont.)
Long Outage, Note 4. If freezing is a problem, the water can be displaced with nitrogen and the unit laid
Longer than 4 Days up under 5 psig nitrogen pressure.
3. Establish and maintain a 5 psig nitrogen cap on the superheater and

steam drum (See Notes 5, 6, 7).
Long Outage, 1. Drain and open only those sections requiring repairs.
Longer than 4 Days, 3. Fill the superheater and reheater (if not requiring draining for repairs)
Unit Partially Drained with demineralized or condensate quality water containing 10 ppm of
for Repairs ammonia and 200 ppm of hydrazine. The pH of the solution should be
about 10. Add the fill water from an available connection. Do not spill
over from the steam drum (See Notes 1 & 2).
3. Increase the hydrazine and ammonia concentrations in the remaining

components to 200 ppm and 10 ppm, respectively (See Notes 3 & 4).
example:
desired concentrations. If condensate demineralizers are employed, they
must be bypassed during the operation.

Table 1 (cont.)

Long Outage, It is important to have the fluid temperature in the cycle below 400°F before the
Longer than 4 Days, addition of hydrazine. If this temperature is exceeded, hydrazine will decompose.
Unit Partially Drained
for Repairs The use of hydrazine (N2H4) has been found acceptable as an oxygen scavenger.
However, in cases where the use of hydrazine is prohibited due to local
environmental regulations, ammonia treated water will suffice provided that a pH of
10 is maintained. When using ammonia for extended layup, it is important to
1. Establish and maintain a 5 psig nitrogen cap on the undrained

components where possible (See Notes 5, 6, 7).
Notes:
2. After completion of the repairs, fill the drained sections with

demineralized or condensate quality water containing 10 ppm of ammonia
and 200 ppm of hydrazine. Cap with nitrogen (See Notes 8, 9 and 10).
example:
desired concentrations. If condensate demineralizers are employed, they
must be bypassed during the operation.
It is important to have the fluid temperature in the cycle below 400°F before the
addition of hydrazine. If this temperature is exceeded, hydrazine will decompose.

Table 1 (cont.)

Long Outage,
Longer than 4 Days, The use of hydrazine (N2H4) has been found acceptable as an oxygen scavenger.
Unit Partially Drained However, in cases where the use of hydrazine is prohibited due to local
for Repairs environmental regulations, ammonia treated water will suffice provided that a pH
of 10 is maintained. When using ammonia for extended layup, it is important to
Note 10. If the reheater cannot be isolated and the outage is expected to extend beyond
two months, provisions should be made to isolate and nitrogen cap the reheater.

Table 2
Recommended Procedures for Dry Layup of Drum-Type HRSGs
TYPE OF PROCEDURE
SHUTDOWN
Pre-Operational 1. Inspect the HRSG components (economizers, evaporators,
Period (See Note 1) superheaters, and reheaters, if present) and dry up any visible water (to
the extent practical) which may have inadvertently entered the
components during shipment (See Notes 2 & 3).
Note 1. Pre-operational period is defined as the period > 30 days following mechanical
completion but prior to the initial water filling of the components. Components are shipped
in a dry condition.
Note 3. If dehumidification equipment is available, dry the components with dehumidified

air. This requires monitoring absolute humidity at air intake and discharge points.
2. Pressurize the system with nitrogen to 5 psig and maintain pressure

throughout the layup period (See Note 4).
Notes:
Post Operational 1. Completely drain the components to be laid up. Hot draining of the
Period, Including components using a nitrogen purge will facilitate drying.
Post Hydro 2. Dry the components to the extent practical (See Note 1).
Note 1. If dehumidification equipment is available, dry the components with dehumidified

air. This requires monitoring absolute humidity at air intake and discharge points.
3. Nitrogen cap the system. Maintain 5 psig nitrogen overpressure

throughout the layup period (See Note 2).

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RECOMMENDED LAYUP PROCEDURE FOR DRUM-TYPE HRSGs

TITLE PAGE NO.

TABLE 1 - RECOMMENDED PROCEDURES FOR WET LAYUP 4

TABLE 2 - RECOMMENDED PROCEDURES FOR DRY LAYUP 10

Drum HRSG Layup Procedure 5/28/02 Page 1 of 10

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Drum HRSG Layup Procedure 5/28/02 Page 2 of 10

If extensive oxygen-related corrosion during outage conditions is to be avoided, proper layup

Drum HRSG Layup Procedure 5/28/02 Page 3 of 10

Recommended Procedures for Wet Layup of Drum-Type HRSGs

Note 1. All sections to be hydrostatically tested should be filled with demineralized or

Drum HRSG Layup Procedure 5/28/02 Page 4 of 10

Recommended Procedures for Wet Layup of Drum-Type HRSGs

Pre-Operational 1. Introduce demineralized or condensate quality water containing 10 ppm

2. Nitrogen cap the system. Maintain 5 psig nitrogen overpressure (See

Drum HRSG Layup Procedure 5/28/02 Page 5 of 10

Recommended Procedures for Wet Layup of Drum-Type HRSGs

Note 2. A reheater may or may not be present in the cycle.

2. Increase the hydrazine and ammonia concentrations in the remaining

Drum HRSG Layup Procedure 5/28/02 Page 6 of 10

Recommended Procedures for Wet Layup of Drum-Type HRSGs

3. Establish and maintain a 5 psig nitrogen cap on the superheater and

Note 2. A reheater may or may not be present in the cycle.

3. Increase the hydrazine and ammonia concentrations in the remaining

Drum HRSG Layup Procedure 5/28/02 Page 7 of 10

Recommended Procedures for Wet Layup of Drum-Type HRSGs

1. Establish and maintain a 5 psig nitrogen cap on the undrained

2. After completion of the repairs, fill the drained sections with

Drum HRSG Layup Procedure 5/28/02 Page 8 of 10

Recommended Procedures for Wet Layup of Drum-Type HRSGs

Drum HRSG Layup Procedure 5/28/02 Page 9 of 10

Recommended Procedures for Dry Layup of Drum-Type HRSGs

Note 2. A reheater may or may not be present in the cycle.

Note 3. If dehumidification equipment is available, dry the components with dehumidified

2. Pressurize the system with nitrogen to 5 psig and maintain pressure

Note 1. If dehumidification equipment is available, dry the components with dehumidified

3. Nitrogen cap the system. Maintain 5 psig nitrogen overpressure

Drum HRSG Layup Procedure 5/28/02 Page 10 of 10

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