GEI 69688F Revised, July 2000 Last Reviewed, October 2003

GE Power Systems

Cleaning of Main Steam Piping and Provisions for Hydrostatic Testing of Reheater

These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchasers purposes the matter should be referred to the GE Company. 1989 GENERAL ELECTRIC COMPANY

GEI 69688F

Cleaning of Main Steam Piping and Provisions for Hydrostatic Testing of Reheater
TABLE OF CONTENTS

I. II.

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TEMPORARY PROVISIONS FOR CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. Steam Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. Temporary Piping For Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Polished Targets in Blowdown Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D. Temporary Blowdown Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E. Blanking The High Pressure Turbine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 3 3 4 9 9 9

III.

BLOWDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 A. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 B. Typical Blowdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 PRECAUTIONS FOR USING CONDENSER HOT WELL AS RESERVOIR FOR CHEMICAL CLEANING SOLUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 PROVISIONS FOR HYDROSTATIC TESTING OF REHEATER . . . . . . . . . . . . . . . . . . . . . . . . A. MHC Turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B. EHC Turbine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C. Low Pressure Admission Steam Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 12 12 12

IV.

V.

LIST OF FIGURES Figure 1. Cleaning Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Figure 2. Blowdown Discharge Velocity and Flow Function (F/30) for 30 psia Discharge Pressure vs. Steam Enthalpy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Figure 3. Pressure Distribution Near End of a Pipe Discharging Steam at Sonic Velocity . . . . . . 7 Figure 4. Bracket Support for Polished Target . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Figure 5. Suggested Arrangement for Blowing Down Steam Piping . . . . . . . . . . . . . . . . . . . . . . 10 Figure 6. Suggested Arrangement for Blowing Down Admission Piping . . . . . . . . . . . . . . . . . . . 13 Figure 7. Diagram for Blowdown Pipe Sizing Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Cleaning of Main Steam Piping and Provisions for Hydrostatic Testing of Reheater
I. INTRODUCTION

GEI 69688F

Experience has shown the importance of thoroughly cleaning the main and reheat steam systems prior to turbine operation, after the completion of a new installation or major repair work to the steam system. Debris left in the system would otherwise be blown into the turbine and cause serious damage to the steam path parts. The temporary fine mesh screens installed on the main stop and combined reheat valves during initial startup are not intended to be a substitute for cleaning the steam lines. There are several proven methods available for cleaning steam pipes by blowing down with either steam or air. The party responsible for selection of a method of cleaning the steam piping should study the advantages of the various methods available and select the method that will be best suited to his particular circumstances. It is also the responsibility of that party to judge if a given method is effectively cleaning his system and to decide when the cleaning has been completed. Blowing down the steam piping with saturated steam is a cleaning method that has traditionally been the method of choice in the power industry. The use of steam causes thermal cycling which helps to loosen debris, allowing it to be blown out. The procedure consists of pressurizing the boiler, termination of firing, and rapidly opening the temporary valve to depressurize the system. This cycle is repeated until the system is judged to be clean. The steam is essentially saturated as the water stored in the boiler flashes as pressure decays. The procedures and sample calculations discussed in Sections II and III of this article are based on the saturated steam blowdown procedure. A variation on the traditional saturated steam blowdown is the extended steam blowdown. The extended steam blowdown involves slowly opening the temporary valve after pressurization so that the boiler can be controlled to maintain firing. The firing is continued for as long as the water supply lasts. This method can result in effective cleaning at a lower initial pressure with less condensate because it produces superheated steam. The high specific volume of the superheated steam will produce the required cleaning ratio at a lower flow rate. The time spent at the design conditions per cycle is increased, therefore fewer cleaning cycles may be needed. Another method of cleaning that has been used with success is the compressed air blowdown. The procedure is similar to a saturated steam blowdown, except that compressed air is used as the cleaning medium. General Electric has studied the theoretical potential cleaning ability of air versus steam and found that for the same initial boiler pressure the cleaning force with either would be about the same. Although thermal cycling is not present, experience has shown cleaning with compressed air to be as effective as steam blows. Compressed air blowdown is preferred by some because it allows for increased construction scheduling flexibility. In one case, strict inspection during assembly was tried instead of blowdown cleaning, in the hope that extra care would maintain the required cleanliness. Since the foreign particles that cause the damage can be produced during erection of the component equipment, this approach was not successful. Chemical cleaning is apparently an effective means of removing certain foreign material from the steam system, however General Electric does not have sufficient data to compare the effectiveness of this method to steam blowdown. We recognize however that under certain circumstances chemical cleaning may be the most practical method available. II. TEMPORARY PROVISIONS FOR CLEANING A. Steam Valves Figure 1 shows sketches of typical main stop and combined reheat valve cross-sections with chemical cleaning and steam blowdown hardware installed.

GEI 69688F

Cleaning of Main Steam Piping and Provisions for Hydrostatic Testing of Reheater

The purchaser may purchase the steam blowdown hardware from General Electric or furnish it himself. In the latter case, General Electric will issue sheet TG-1810 which provides the interface dimensions of the valve casings. Chemical cleaning of the piping upstream of the main stop valve or combined reheat valve will require the installation of special chemical cleaning hardware to protect the turbine and valve internal parts. This is accomplished by removal of most of the valve internal parts, sealing off the seat bore with a special blanking fixture and construction of a temporary masonite and ductseal dam downstream of the seat bore. The hardware will be supplied by General Electric as extra cost items when required. If General Electric is to supply chemical cleaning and/or steam blowdown hardware, the purchaser must furnish the following information: 1. Maximum pressure and temperature at the valve during blowdown and/or chemical cleaning. 2. Details of temporary pipe connections on upper heads. 3. Will chemical cleaning hardware be subject to a boiler hydrostatic test and/or steam blowdown? (Special hardware is normally not required for hydrostatic test, but for scheduling convenience it may be desired to make a hydrostatic test with the chemical cleaning hardware installed). B. Temporary Piping For Blowdown The purchaser must provide the temporary blowdown piping from each main stop valve and combined reheat valve. The piping should be run to an area outside of the station where the blowdown can be safely discharged. The pipes from multiple main stop or combined reheat valves may be manifolded together. If it is impractical to manifold, it will be necessary to blow through each valve individually. In this case, only one temporary upper head for each valve type is required. It can be transferred from valve to valve as the blowdown progresses. In some cases, it may be advantageous to make up one large header and blowpipe to be used both for blowing the main and reheat lines with adequate gate valves for line transfer. It is important that sufficient momentum be developed during blowdown to ensure removal of debris that would otherwise be blown into the turbine during operation. The momentum during cleaning must therefore be equal to or greater than that developed at the maximum operating condition, at all points in the piping system. The blowdown piping must be large enough to develop the required mass- velocity. The size of the temporary piping is usually 8-14 [203-356 mm] nominal diameter, with a minimum boiler pressure of 400 psig [2.76 MPa (gauge)] [28.1 kg/cm2 (gauge)]. Larger pipe sizes and higher boiler pressures are required for reheat piping where longer runs and increased pressure drop are present. Calculations should be made to determine the required drum pressure for a given temporary pipe size. Appendix A gives a sample problem. The procedure is described in the following steps: 1. As a first attempt, assume that the velocity at the pipe exit to atmosphere during blowdown is sonic, and that the pressure, Pp, just inside the pipe at the exit is 30 psia [207 kPa] [2.11 kg/cm2]. To make this assumption, it is necessary that all flow areas in the system be equal to or larger than the discharge area. The size of the temporary pipe is a most important factor. The use of a larger pipe will result in lesser flows and lesser pressure levels required for the same cleaning force. The size effect is proportional to the ratio of diameters to the fourth power. In no case, however, should the temporary pipe have

Cleaning of Main Steam Piping and Provisions for Hydrostatic Testing of Reheater

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greater flow area than the permanent piping area. This may lead to critical flow at some point in the system, making this procedure invalid. .

TYPICAL MAIN STOP VALVE OR COMBINED REHEAT VALVE BLOWDOWN HARDWARE

TYPICAL COMBINED REHEAT VALVE CHEMICAL CLEANING HARDWARE

TYPICAL MAIN STOP VALVE CHEMICAL CLEANING HARDWARE

1. All internal valve parts above the seat are to be removed for chemical cleaning. 2. The blowdown hardware may be used for both steam blowdown and chemical cleaning if specified by the purchaser when ordering. 3. In some types of valve designs, such as main stop valves, it is possible to use the permanent head for chemical cleaning, but it is not possible for the permanent head to be used for blowdown. 4. Before assembly of chemical cleaning hardware into valves, place temporary dam of masonite and ductseal (by Purchaser) in outlet to prevent leakage of chemical solution into the turbine.

Figure 1. Cleaning Hardware

GEI 69688F

Cleaning of Main Steam Piping and Provisions for Hydrostatic Testing of Reheater
Enthalpy Conversions: Btu/lb x 2.326 = kJ/kg Velocity ft/s x 0.3048 = m/s Pressure psig x 6.895 = kPa(gauge)

NOTES: 1. IF STEAM IS SUPERHEATED ENTER CURVE 1 AT ESTIMATED ENTHALPY AT SUPERHEATED OUTLET AND READ FLOW FUNCTION F30. 2. IF STEAM IS SATURATED ENTER CURVE 2 AT DRUM PRESSURE AND READ ENTHALPY. USE ENTHALPY TO ENTER CURVE 1 FOR OBTAINING FLOW FUNCTION F30. 3. CURVE 3 IS FOR REFERENCE IN OBTAINING DISCHARGE VELOCITY.

Figure 2. Blowdown Discharge Velocity (VD) and Flow Function (F30) for 30 psia Discharge Pressure vs. Steam Enthalpy

Cleaning of Main Steam Piping and Provisions for Hydrostatic Testing of Reheater

GEI 69688F

NOTES:

L = EQUIVALENT LENGTH OF PIPE FROM DISCHARGE (ft) D = INSIDE DIAMETER OF PIPE (ft) f = FRICTION FACTOR DEFINED AS hL D 2g hL = HEAD LOSS (ft) V = VELOCITY ft/s P = PRESSURE AT POINT L FROM DISCHARGE (psia) Pp = PRESSURE ASSUMED AT PIPE DISCHARGE (psia)

( L ) V2

WHERE

1 0 1 2 f( L D ) 3 4 5

Figure 3. Pressure Distribution Near the End of Pipe Discharging Steam at Sonic Velocity

GEI 69688F

Cleaning of Main Steam Piping and Provisions for Hydrostatic Testing of Reheater

2. Estimate the steam conditions (pressure, enthalpy) at the boiler outlet expected during steam blowdown. Saturated steam at approximately one-third boiler pressure at max load flow is a reasonable first estimate. From the curves on Figure 2 read the mass flow function, F30, and discharge velocity VD. Calculate the mass flow, Qc, as follows: Qc = F30 x Ap where Ap = area of pipe at discharge (in2) 3. It is necessary to calculate the pressure drop through the temporary and permanent piping to arrive at a boiler pressure. Refer to Figure 3 Pressure Distribution Near the End of a Pipe Discharging Steam at Sonic Velocity. This curve should be used in determining the pressure drop near the discharge end of the temporary piping since the velocity is near sonic and ordinary calculation of pressure drop due to friction does not apply. In applying Figure 3, assume as a first trial that L is the total equivalent length of the temporary piping including the equivalent length of elbows, tees, etc. in the temporary system. Calculate the fL/D and enter the curve in Figure 3 and determine the ratio P/Pp from which the pressure P at the distance L from the exit may be calculated. Where fL/D is greater than 5, the pressure drop is a straight line function of L and can be calculated by conventional method. Then calculate by conventional straight line methods the pressure drop due to friction in the piping from the point located at distance L from the exit to the boiler outlet, thus arriving at the boiler outlet pressure Pc. 4. Then calculate the cleaning force ratio at the boiler outlet using calculated Pc and expected enthalpy. This ratio compares the mass velocity head during cleaning with that developed during normal fullload operation. The cleaning force ratio is expressed by:

R=

( ((QQ )))
c max

(PV ) c (P max) ( PV ) max ( Pc )

where: Qc Qmax (Pv)c (Pmax) (Pc) (Pv)max where: Qc = calculated flow during cleaning (lb/h) Qmax = max load flow (lb/h) vc = Specific volume at boiler outlet during cleaning (ft3/lb) vmax = Specific volume at boiler outlet at max load flow (ft3/lb) 5. If this ratio R is less than one, divide the pressure assumed inside pipe exit, Pp, by this ratio to obtain a corrected Pp and repeat the above process; thus, the required flow and pressures for equivalent cleaning forces can be determined, establishing the required sizes for the temporary blowpipes. = = = = = = calculated flow during cleaning (lb/h) max load flow (lb/h) pressure-specific volume product during cleaning at boiler outlet (ft3/in2) pressure at max load flow at boiler outlet (psia) pressure during cleaning at boiler outlet (psia) pressure-specific volume product at max load flow at boiler outlet (ft3/in2)

Cleaning of Main Steam Piping and Provisions for Hydrostatic Testing of Reheater

GEI 69688F

POLISHED STEEL STRIP 1/8 TO 1/4 [3 TO 6 mm] THICK SAME LENGTH AS BACKING BAR 11/2x11/2x1/4 [38 x 38 x 6 mm] ANGLE BRACKET BACKING BAR 1 X 1 [25 X 25 mm]

POLISHED TARGET STRIP BOLTED TO BACKING BAR TO PREVENT FLUTTER

6 [152 mm]

2 [51 mm]

Figure 4. Bracket Support for Polished Target Note that for a discharge pressure different than 30 psia [207 kPa] [2.11 kg/cm2], the flow function is: Fp = F30 x (Pp/30) C. Polished Targets in Blowdown Pipe Assuming that sufficient mass velocity has been achieved in the blowdown, the progress of the cleaning can be monitored by placing polished targets in the blowdown flow. Particles carried with the flow will cause pitting of the targets. The targets can be made of steel strips, polished on both sides to obtain double use from each. Figure 4 shows one suitable method for fastening the target to the open discharge end of the blowdown piping. The arrangement shown permits easy replacement of the target. The number of polished targets required for a complete blowdown operation will vary. Experience has shown that fifty or more blows may be required. D. Temporary Blowdown Valve In order to control the blowdown flow from the boiler, it will be necessary to provide a temporary blowdown valve in the blowdown piping. The valve should be a gate valve, to achieve the least resistance to flow. In order to maximize the effectiveness of the blowdown, the valve should be as quick opening as practical. The valve manufacturer should be consulted for limitations on valve opening speed. E. Blanking The High Pressure Turbine Exhaust The cold reheat line must be blanked off near the high pressure turbine exhaust to prevent blowdown flow from entering the turbine. Since this line must also be blanked for hydrostatic test of the reheater and reheat lines, the same hardware can be used for the blowdown. Refer to Section V for discussion of provisions for hydrostatic testing of the reheater. III. BLOWDOWN PROCEDURE A. Preparation The boiler manufacturer should be consulted to determine boiler operating characteristics for the blowdown operation. The boiler design may necessitate variations in the procedure suggested below.

GEI 69688F

Cleaning of Main Steam Piping and Provisions for Hydrostatic Testing of Reheater

In order for the blowdown cleaning to be as successful as possible, it is important that sufficient time be scheduled. The purchaser should be aware that it may require as many as 50 to 100 blows to clean a moderately large system. Adequate phone communication between the boiler room and the operator at the blowdown valve must be established. This might also be backed up by a system of visual communication, such as indicating lights, since phone communication may become difficult due to high noise level at the blowdown valve. Pressures should be measured during blowdown at the inlet to the stop valve and near the discharge of the blowdown pipe. These can be compared to the calculated pressures as a means of ensuring that the desired mass velocity is being achieved. The temporary blowdown pipe should be adequately supported, with consideration given to flexibility for thermal expansion. The pipe discharge must be anchored to accept the reaction forces during blowdown. B. Typical Blowdown Procedure The following procedure is typical of a unit with a drum type boiler. Refer to Figure 5. 1. Blowdown the main steam piping:1. a. Check to ensure that the turbine main stop valves are closed tightly. The control valves should also be closed tightly and precautions taken to ensure that the valves cannot be opened inadvertently. This is a necessary precaution against admitting steam to the turbine that could result in damage to the turbine or injury to personnel.
*IF GATE VALVE IS USED, THERE MUST BE A FULL COMPLIMENT OF RELIEF VALVES ON TURBINE SIDE. WITH CHECK VALVES OR BLANKS NO RELIEF VALVES ARE NEEDED OTHER THAN THOSE NORMALLY LOCATED NEAR REHEATER.

PURCHASERS 8 TO 14 [203 to 356 mm] TEMPORARY BLOW PIPE TO SAFE AREA MAKE CONNECTION HERE FOR INITIAL BLOWING OF COLD REHEAT LINES TEMPORARY HEAD COLD REHEAT REHEATER GATE VALVE BLANK OR CHECK VALVE TEMPORARY BLOWDOWN GATE VALVE MAIN STEAM STOP VALVE CLOSED HOT REHEAT PURCHASERS 8 TO 14 [203 TO 356 mm]TEMPORARY BLOW PIPE TO SAFE AREA TEMPORARY HEAD

TEMPORARY JUMPER

RELIEF VALVES

SUPERHEATER

Figure 5. Suggested Arrangement for Blowing Down Steam Piping

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GEI 69688F

b. Remove the permanent upper heads and the steam strainers from the main stop valves. On the stop valve or valves equipped with an internal bypass valve, a temporary cylindrical cover is provided which goes over the valve disk assembly to keep foreign material out of the assembly during blowdown. This cover should be installed for blowdown and must be removed before stop valves are operated through stroke. Stop valves without an internal bypass valve in the main valve disk have a totally enclosed valve disk assembly and do not require special protection during blowdown. If a chemical cleaning is also to be made, the chemical cleaning hardware should be installed and the valve internal parts removed. c. Install steam blowdown hardware on the main stop valve(s). A new gasket is not required. Connect to the blowdown pipe. d. Build pressure up in boiler to calculated value, usually between 400 and 500 psig [2.76 and 3.45 MPa (gauge)] [28.1 and 35.2 kg/cm2 (gauge)]. Crack blowdown valve slightly to warm up all the steam lines. e. When lines are adequately warmed up, open the blowdown valve all the way as fast as possible. When boiler pressure has dropped to approximately 150 psig [1.03 MPa (gauge)] [10.5 kg/cm2 (gauge)], close the blowdown valve rapidly so that boiler pressure does not drop below 100 psig [690 kPa (gauge)] [7.03 kg/cm2 (gauge)]. f. Raise boiler pressure again and repeat above cycle at least two or three more times or until, by visual observation, clean steam emerges from the blowpipe. Install a new polished target for each subsequent blow. Continue the blowing cycle until the system is judged to be adequately clean. The condition of the polished target after each blow is used as an aid in judging the progress of the cleaning operation. 2. Blowdown the cold reheat piping: a. Disconnect the blowdown pipe from the main stop valve(s). Reconnect the main stop valve(s) to the cold reheat line near the high pressure turbine exhaust on the reheater side of the blank in the line. b. Connect the cold reheat piping near the reheater to the temporary blowdown pipe. c. Blowdown the cold reheat piping as in steps 1d, 1e, and 1f above. 3. Blowdown the reheater and hot reheat piping: a. Care should be taken to ensure that the reheat stop valve or the main stop valve cannot be opened during blowdown. b. Remove the intercept valve upper head assembly (which includes the disk assembly, balance chamber and sealing rings) and steam strainer from the combined reheat valves. If chemical cleaning is planned in conjunction with the blowdown, install the chemical cleaning hardware. c. Install the steam blowdown hardware on the combined reheat valve(s) using the same gaskets. d. Connect the blowdown pipe so that the steam will flow from the main stop valve head through the cold reheat piping, the reheater, and the hot reheat piping and out the temporary piping from the combined reheat valve head(s). e. Repeat blowdown operation as described in steps 1d, 1e, and 1f.

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Cleaning of Main Steam Piping and Provisions for Hydrostatic Testing of Reheater

4. Remove temporary piping and steam blowdown hardware from main stop and combined reheat valves. Remove all temporary internal fixtures. Inspect each casing thoroughly for debris. Reinstall all permanent internal parts. Install permanent heads with new gaskets. IV. PRECAUTIONS FOR USING CONDENSER HOT WELL AS RESERVOIR FOR CHEMICAL CLEANING SOLUTIONS When it is desired to use the condenser hot well as a reservoir for cleaning solutions or when chemically cleaning the steam side of the condenser, the low pressure sections must be suitably blanked off to protect the turbine components from direct contact with the cleaning solution or through contact with volatile components of the solution. Contamination of the steam path parts could lead to pitting and stress corrosion cracking during service. Protection of only the turbine would require a blank off at the joint between the condenser neck and the exhaust hood; however protection for the condenser tubing should also be considered, in which case a blank off at the top of the condenser hot well would satisfy both requirements. An effective vapor barrier can be made from a well fitted masonite or plywood plug covered with a heavy gauge plastic sheet. Care must also be taken that there are no bypasses around the barrier by means of drain lines into the condenser hot well. V. PROVISIONS FOR HYDROSTATIC TESTING OF REHEATER On the cold side of the reheater, the purchaser must make proper provisions in the piping for hydrostatic test. These can be gate valves, check valves, or blanks inserted between flanges. If gate valves are used, a full complement of relief valves must be installed between the gate valves and the high pressure section of the turbine. On the hot side of the reheater, the reheat stop valves can be used for closing the line. The intercept valves should be held fully open against their stem seal. The suggested procedure for accomplishing this valve positioning depends upon whether the turbine has MHC or EHC controls: A. MHC Turbine 1. Open the intercept valves by admitting hydraulic oil pressure to the operating mechanism. 2. The reheat stop valves should be blocked closed by manually jacking down the reheat stop test air cylinder to the test position. B. EHC Turbine 1. Apply 115 volts ac to the reheat stop valve test solenoids (refer to the EHC Valve Logic Drawings). 2. Reset the turbine trip system. Because of step 1, the reheat stop valves should stay closed. 3. Select Low Speed Hold at the EHC panel. The intercept valves will open. After the hydrostatic test is completed and there is no danger of water entering the turbine, the temporary provisions applied for keeping the reheat stop valves closed should be removed. C. Low Pressure Admission Steam Lines It will be necessary for the purchaser to provide suitable adapters to take the place of the low-pressure admission valve (and separate strainer if used). Inasmuch as the normal source of the admission steam may not always come from a boiler (exhaust and automatic extraction of other turbines, process steam, etc. are

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examples), it is suggested that temporary connection of the high-pressure boiler be provided for an isolated source of blowdown steam. If this can be arranged, plant operational problems will be avoided. In general, the blowpiping for very low pressures will be smaller than that required for the high-pressure inlet piping, therefore, will make temporary piping matters substantially more simple. The purchaser should size the blowpiping and blowdown valve to ensure that the required mass-velocity head is developed in the piping to be cleaned. This will require on the part of the purchaser the establishment of a suitable balance between blowing pressure and flow as they exist in the piping undergoing the cleaning. The general suggestions as outline Preliminary Preparation and Main Steam Lines apply for the admission piping.

MAIN STEAM THROTTLE TRIP OR STOP VALVE BY G.E. CO.

SUITABLE STEAM SUPPLY FROM BOILER OR HEADER VIA TEMPORARY JUMPER LINE

PURCHASERS NORMAL LP ADMISSION CONN. POINT PURCHASERS LP ADMISSION PIPING

PURCHASERS RELIEF VALVES

SPECIAL FITTING (AS NECESSARY) BY PURCHASER TO TAKE PLACE OF UP TRIP VALVE (AND ADMISSION STRAINER IF USED). PURCHASERS TEMPORARY 8 TO 14 [203 TO 356 mm] BLOW PIPE TO SAFE AREA OUTSIDE BUILDING

BLOWDOWN GATE VALVE BY PURCHASER

Figure 6. Suggested Arrangement for Blowing Down Admission Piping

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Cleaning of Main Steam Piping and Provisions for Hydrostatic Testing of Reheater

Suggested Procedure The following procedure for conducting the blowdown is suggested. See Figure 6. 1. Install special adapter to take the place of trip throttle valve with integral strainer or trip throttle valve (and separate strainer if used). 2. Install temporary blowpiping and pipe to safe area outside of building. 3. quired depending upon actual station conditions.) 4. Provide for a blowdown valve in the system. 5. Ensure that all piping is adequately supported, guided or anchored to give required flexibility to provide for thermal expansion. 6. Make provisions for taking pressure readings and for adequate telephone and/or visual communication between boiler room and operator at blowdown valve. 7. Build steam pressure up to the required calculated value and then crack the blowdown valve to warm up all lines. 8. After lines are adequately heated, open blowdown valve as quickly as possible. Close the valve as rapidly as possible when the boiler pressure drops to a value approximately 50% of the required calculated value. Valve should be closed when the boiler pressure reaches approximately 25% required calculated value. 9. Raise boiler pressure again and repeat the blowing cycle until clean steam emerges from the blowpipe. 10. Dismantle all temporary piping and fittings and complete installation of low-pressure trip valve and strainer (if used).

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Cleaning of Main Steam Piping and Provisions for Hydrostatic Testing of Reheater

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Fossil Turbine 500,000 KW 2400 psig 1000/10000F VWO Flow 4, 158, 173#/hr @ 2520 psig Main Steam Line 12 ID Two-stop Valves Boiler Pressure 800 psig (estimated) h = 1200 btu/lb

Boiler *1st Blowdown Flow Qc=231, 575#/hr *2nd 1,433,881 #/hr

*Main Steam 200L 12ID .785 ft2

*Temporary Pipe 10 ID 200L A = .545 ft2

1

Pp=P1=30 psia *1st VD=1530 ft/s F30=2950 lbs/hr-in2

*1st P2-87 psia *2nd P2=483 psia *1st-Values Based on Estimated Boiler Pressure & Enthalpy *2nd-Refined Blowdown Values

*1st P3-4 = 9.62 psia V3 = 424.6 ft/s h3 = 1197 Btu/lb. v3 = 5.18 ft3/lb. @ 335F

*2nd P3-4 = 67 psia

Figure 7. Diagram for Blowdown Pipe Sizing Problem

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Cleaning of Main Steam Piping and Provisions for Hydrostatic Testing of Reheater
APPENDIX A

D. Sample Problem for Determining Blowdown Pipe Size Refer to figure 7 for Problem Diagram. 1. At Point 1 let Pp = P1 = 30 psia [207 kPa (gauge)] [2.11 kg/cm2 (gauge)] Assume a BOILER PRESSURE of 800 psig [5.52 MPa (gauge)] [56.2 kg/cm2 (gauge)] saturated (as an estimate). Then from curves in Figure 2
h = 1200 Btu/lb [2.79 MJ/kg] enthalpy F30 = 2950 lb/h in2 VD = 1530 ft/s [466 m/s] in temporary pipe

2. Calculate BLOWDOWN FLOW required in Temporary Pipe

Qc = F30 x ATP where ATP = Area of 10 ID pipe Qc = 2950 x 3.14 x (5)2 Qc = 231575 lb/h [29.2 kg/s] Mass Flow

3. To calculate the BOILER PRESSURE required to provide the BLOWDOWN FLOW in the temporary piping proceed as indicated in the text. a. To determine the pressure at point 2 For the 10 ID Temporary Pipe
calculate f D
L

= *.0135 x 200 ft .833 ft fL D = 3.24, find P Pp

= 3.24

*.0135 is a friction factor from CRANE TECHNICAL PAPER 410.

Enter Figure 3 for = 2.9

where P = P2 and with Pp assumed as 30 psia [207 kPa] [2.11 kg/cm2] at discharge end of pipe Then P2 = P = 2.9 x 30 = 87 psia [600 kPa] [6.12 kg/cm2] b. To determine conditions at point 3 Assume P3 = P2 = 87 psia [600 kPa] [6.12 kg/cm2] and BLOWDOWN FLOW Qc = A1V1/v1 = A3V3/v3 solving for V3 = A1v3V1/A3v1

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Cleaning of Main Steam Piping and Provisions for Hydrostatic Testing of Reheater

GEI 69688F

For calculations, initially set specific volume ratio equivalent to the computed pressure ratio of the temporary pipe per BOYLE GAS LAW.
V3 = A1P1V1/A3P2 A1 = 78.5 in2 for 10 pipe

V3 = 78.5 x 30 x 1530
113 x 87

A3 = 113 in2 for 12 ID pipe

V3 = 363 ft/s [111 m/s] The available energy (AE) at this calculated value of V3 is AE = (V/223.7)2 = (363/223.7)2 = 2.63 Btu/lb (approximately 3 Btu/lb) The enthalpy at point 3 therefore is 1200 (Boiler) - 3 = 1197 Btu/lb Enter STEAM TABLES using h3 = 1197 Btu/lb [2.784 MJ/kg] P3 = 87 psia [600 kPa] [6.12 kg/cm2] To yield v3 = 5.18 ft3/lb [0.323 m3/kg] @ 335F [168C] Refine the Velocity Calculation at point 3 V3 = Qcv3/A3 V3 =
231575 lb/hr x 5.18 ft3/lb x 144 in2/ft2 3600 s/hr x 3.14 x (6)2 in2

V3 = 424.6 ft/s [129 m/s] at STOP VALVE.

c. To determine PRESSURE DROP (P3-4) in pipe between Boiler and Stop Valve fL x V32 D 2gv3 .0135 x 200 x (424.6)2 2 x 32.2 x 5.18 x 144 1

P3-4 = P3-4 =

P3-4 = 2.6 x 3.7 P3-4 = 9.62 psia [66.3 kPa] [677 g/cm2]
d. To determine Boiler Pressure P4 required at point 4

P4 = P3 + P3-4 = Pc P4 = 87 x 9.62 P4 = 96.62 psia [666 kPa] [6.79 kg/cm2] at 326F [163C] - saturated steam vc = 4.561 ft3/lb [0.285 m3/kg]

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GEI 69688F

Cleaning of Main Steam Piping and Provisions for Hydrostatic Testing of Reheater

4. To calculate the CLEANING FORCE RATIO (R)

where R + Mass Velocity Head During Cleaning Mass Velocity Head @ VWO

VWO = VALVES WIDE OPEN then R = (Qc/Qmax)2 x (vc/vmax) NOTE Qmax = 1/2 VWO flow for one stop valve in a piping system consisting of two main steam lines each of which has a stop valve. vmax @ 2520 psig - 1000F = .3061 ft3/lb R = (213575 / 2079086)2 x (4.561 / .3061) R = .18 but R must be greater than 1 therefore go to Step 5 page 9. To obtain a corrected Pp
Pp = Pp (assumed) = 30 R .18

Pp = 166.6 psia [1.15 MPa] [11.7 kg/cm2] which is the required discharge pressure of the temporary pipe. 5. To refine all calculations a. The flow function through a temporary pipe with other than a 30 psia [207 kPa] [2.11 kg/cm2] discharge pressure is: Fp = F30 x (Pp/30) Fp = 2950 x (166.6/30) Fp = 16225 lb/hr in2 Qc = FpATP Qc = 16225 x 78.5 Qc = 1,273,662 lb/h P2 = 2.9 x 166.6 P2 = 483 psia [3.33 MPa] [34.0 kg/cm2] Then approximate V3 V3
78.5 x 166.6 x 1530 113 x 483

V3 = 353 ft/s

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Cleaning of Main Steam Piping and Provisions for Hydrostatic Testing of Reheater
AE = (353/223.7)2 AE = 2 Btu/lb Then enter steam tables for h3 = 1198 P3 = P2 = 483 and v3 = .95 ft3 @ 464F. To refine V3 calculation
V3 = 1273662 x .95 x 144 3600 113

GEI 69688F

V3 = 428 ft/s P3-4 =

.0135 x 200 x 1

(428)2 2 x 32.2 x .95 x 144

P3-4 = 67 psia [462 kPa] [4.71 kg/cm2] and Pc = P4 = P3 - 4 + P3 Pc = 67 + 483 Pc = 550 psia [3.79 kPa] [38.7 kg/cm2] at 477F [247C] - saturated steam vc = .8418 ft3/lb [0.0526 m3/kg] then R = (1273662 / 2079086)2 x (.8418/.3061) R = 1.03 The MINIMUM BOILER CONDITIONS for this computed cleaning force ratio are Pc = 550 psia [3.79 kPa] [38.7 kg/cm2] @ 477F [247C] during the BLOWDOWN for each main steam pipe. NOTE Similar calculations must also be performed for the larger REHEAT pipe sizes.

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GE Power Systems
General Electric Company One River Road, Schenectady, NY 12345 518 385 2211 TX: 145354