Steam Blowing

CPP Steam & BFW System Commissioning Methods

Position : SFE (SG & D)

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 S*D+ ,E ME,DS & P!CED*!ES F! S$FE P!ECMM#SS#%#%G & CMM#SS#%#%G F SE$M & BFW S+SEM

C,EC-ED B+: '"B $PP!.ED B+: %-M

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C%E% S"

opi6

1

SILENT STEAM BLOWING

2

NON CONVENTIONAL CLEANING METHODS

3

CHEMICAL CLEANING OF PIPE LINES


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SILENT STEAM BLOWING INTRODUCTION This is a well establishe !eth" that has bee# $se e%te#si&el' e%te#si&el' (") *lea#i#+ "( all t',es "( stea! )aisi#+ ,la#t- i#*l$i#+ la)+e ia!ete) stea! li#es. The basis "( the !eth" is t" $se stea! at the l"west ,"ssible ,)ess$)e *"#siste#t with a*hie&i#+ the )e/$i)e stea! (l"ws. This stea! has a hi+h s,e*i(i* &"l$!e a# the)e(")e the stea! &el"*ities a)e hi+h $)i#+ stea! bl"wi#+- !a0i#+ it )elati&el' eas' t" a*hie&e the )e/$i)e CF Clea#i#+ F")*e ati" with stea! !ass (l"ws that a)e !$*h less tha# the #")!al (l"w )ates. T',i*all'- (") a hi+h ,)ess$)e s'ste!- the stea! (l"w #eee t" a*hie&e the CF is ab"$t 456 "( #")!al (l"w. This ,)"*e$)e i((e)s ()"! *"#&e#ti"#al- ,)ess$)e *'*le- stea! bl"wi#+ i# that the stea! $se (") bl"wi#+ is ,)"$*e *"#ti#$"$sl' a# the e%it stea! &el"*it' is *"#t)"lle t" bel"w s"#i* &el"*it' at the e%it "( the stea! ,i,i#+ whi*h +)eatl' )e$*es the #"ise ,)"$*e $)i#+ stea! bl"wi#+. athe) tha# e%ha$sti#+ t" at!"s,he)e i)e*tl'- the e%ha$st stea! e%its i#t" te!,")a)' ,i,e w")0 (itte with a se)ies "( /$e#*h atte!,e)at")s. Ea*h atte!,e)at") *"!,)ises a ste,wise e%,a#si"# i# li#e si7e with a (a*ilit' t" s,)a' wate) i#t" the (l"wi#+ stea!. 8$e#*h wate) is i#9e*te i#t" the stea! at ea*h atte!,e)at"). A(te) the (i#al atte!,e)at") the stea! e%its t" at!"s,he)e &ia a M$77le).

The e((e*t "( the e%,a#si"# a# atte!,e)ati"# is t" )e$*e the &el"*it' a# e#e)+' "( the stea! i# the te!,")a)' ,i,e w")0 the)eb' !i#i!i7i#+ the #"ise "# is*ha)+e. F") ea*h "( the stea! s'ste!s bei#+ *lea#e- the te!,")a)' e%it ,i,i#+ be(")e the (i)st atte!,e)at") is (la#+e t" a**e,t a )e!"tel' ",e)ate ta)+et ,late i#se)te). This all"ws ta)+et ,lates t" be sa(el' i#se)te a# )e!"&e whilst bl"wi#+ is i# ,)"+)ess. I# this wa'- a se)ies "( ta)+et ,lates *a# be )$# t" !"#it") the ,)"+)ess "( the stea! bl"w.

This !eth" "((e)s se&e)al si+#i(i*a#t a&a#ta+es.

I#*)ease ist$)ba#*e (a*t") b' )e$*i#+ e%it ,)ess$)e. La)+e )e$*ti"# i# #"ise b' eli!i#ati#+ the s"#i* &el"*it' e%it stea!. L"w ,)ess$)e e%it ,i,i#+ )e/$i)e. N" ,i,e )est)ai#ts )e/$i)e. C"#ti#$"$s bl"wi#+ !i#i!i7es the ti!e )e/$i)e. Eli!i#ates the #ee (") te!,")a)' bl"w:"$t stea! &al&es.

     

The stea! bl"wi#+ is esi+#e t" ,)"$*e a ist$)ba#*e (a*t") *lea#i#+ (")*e )ati" "( 1.5- ") hi+he)- at the i#lets "( the li#es bei#+ bl"w#. The !ai# a&a#ta+e "( *"#ti#$"$s stea! bl"wi#+ is the &e)' sh")t ,)"+)a!!e ti!e #eee t" a*hie&e a**e,table ta)+et ,lates. T',i*all' ea*h s'ste! bei#+ stea! bl"w# will ta0e 12 t" 35 bl"wi#+ h"$)s (") a**e,ta#*e ta)+ets e,e#i#+ "# ta)+et *)ite)ia. The "the) a&a#ta+e is that the l"w ,)ess$)es $se !ea# that the e%it ,i,i#+ is (ab)i*ate ()"! thi# wall steel ,i,e a# #" s,e*ial ,i,e s$,,")ts a)e #eee. This +)eatl' )e$*es the *"st (") the e%it ,i,i#+.


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P!CESS The silent steam blowing procedure consists basically of four major steps: 

Warming up the line



Blowing the line



Thermal cycling the line



Re blowing the line



Target insertion & certification

WARMING UP THE LINE: The li#e t" be bl"w# is (i)st wa)!e $, b' *)a*0 ",e#i#+ the &al&e. The ,)i!a)' ,$),"se "( this is t" wa)! $, the li#e a# )ai# the *"#e#sate i( a#' i# the heae). The se*"#a)' ,$),"se is the ete*ti"# "( lea0s i# the sile#t stea! bl"wi#+ asse!bl'. I( the)e a)e a#' lea0s i# the te!,")a)' ,i,i#+- the' *a# be ete*te $)i#+ this ,hase a# *a# be )e*ti(ie a**")i#+l' a**")i#+l' s" that a sa(e sile#t bl"wi#+ ",e)ati"# is e#s$)e.

BLOWING THE LINE: A(te) wa)!i#+ wa)!i#+ $, the li#eli#e- the s"$)*e &al&e &al&e is ",e#e t" +et the )e/$i)e )e/$i)e (l"w (") stea! stea! bl"wi#+. D$)i#+ D$)i#+ this (i)st bl"w- the $st a# "the) i)t ,a)ti*les a)e )e!"&e ()"! the stea! li#e. B$t besies these


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thi#+s- the)e a)e "the) !a9") et)i!e#tal thi#+s ,)ese#t i# the stea! li#e s$*h as wel sla+- !ill s*ales et*. D$)i#+ this (i)st bl"w- these thi#+s e%,a# $e t" the hi+h te!,e)at$)e "( the stea!.

THERMAL CYCLING The)!al *'*li#+ "( stea! li#es is $se t" assist with )e!"&al "( st)"#+l' ahe)e#t eb)is s$*h as !ill s*ale. This )e$*es the bl"wi#+ ti!e )e/$i)e t" a*hie&e a**e,table ta)+et ,lates. D$)i#+ a the)!al *'*le the te!,e)at$)e "( the li#e bei#+ stea! bl"w# is )e$*e t" the !i#i!$! sa(e &al$e the# all"we t" )ise ba*0 t" the #")!al stea! te!,e)at$)e. The)!al *'*li#+ is a*hie&e b' &a)'i#+ the te!,e)at$)e "( the stea! (l"wi#+ i# the li#e. Te!,e)at$)e &a)iati"# *a$ses the !etal li#e t" *"#t)a*t $)i#+ *""li#+ the# e%,a# as the te!,e)at$)e )ises. P)"&ie that the "%ie s*ales "# the ,i,e s$)(a*e ha&e a i((e)e#t i((e)e#t *"e((i*ie#t "( the)!al e%,a#si"# *"!,a)e *"!,a)e t" the $#e)l'i#+ !etal- this !"&e!e#t "( the ,i,e s$)(a*e )elati&e t" the s*ale will *a$se the s*ale t" eta*h ()"! the !etal s$)(a*e. The l""se#e s*ale is the# )eail' )e!"&e $)i#+ the stea! bl"w. The)!al *'*li#+ *a# be a*hie&e eithe) b' #at$)al *""l:"w# ") b' (")*e stea! *""li#+ $)i#+ stea! bl"wi#+. I( the stea! bl"wi#+ is )est)i*te t" bl"wi#+ (") a set ,e)i" ea*h a'- e.+. bl"wi#+ $)i#+ a'li+ht h"$)s "#l'- a# is *"#ti#$e "&e) at least 3 a's- the# #")!all' s$((i*ie#t the)!al *'*li#+ will be a*hie&e b' #at$)al *""li#+. Whe)e stea! bl"wi#+ is "# a 24 h"$) ,e) a' basis- (")*e stea! *""li#+ is $se (") i#$*i#+ the)!al *'*les. I# this !eth" a the)!al *'*le is e((e*te b' i#9e*ti#+ s$itable /$alit' wate)- #")!all' b"ile) (ee wate)- i#t" the stea! (l"w at ") be(")e the i#let t" the se*ti"# "( li#e bei#+ stea! bl"w#. F") the)!al *'*lesThe stea! te!,e)at$)e is &a)ie b' ab"$t 255 C. D$)i#+ a the)!al *'*le- the stea! te!,e)at$)e sh"$l #"t be )e$*e t" less tha# 35 C ab"&e the sat$)ati"# te!,e)at$)e (") the stea! t" a&"i the ,"ssibilit' "( *"#e#sate sl$+s (")!i#+. I( ,e)!a#e#t atte!,e)ati"# e/$i,!e#t is #"t a&ailable- te!,")a)' (a*ilities *a# be ,)"&ie. N")!all' this will )e/$i)e i#9e*ti#+ e!ate)iali7e e!ate)iali7e wate) at a *"#t)"lle )ate i#t" the stea! li#e eithe) $,st)ea! "( the i#let ") as *l"se as ,"ssible a(te) the i#let. The wate) *a# be i#9e*te &ia a s,)a' #"77le i( a s$itable (la#+e *"##e*ti"# e%ists ") !")e *"!!"#l'- i)e*tl' i#t" a stea! li#e !$ b""t )i, le+ )ai#. The wate) s$,,l' #ees t" be at a hi+he) ,)ess$)e tha# the li#e ,)ess$)e $)i#+ bl"wi#+- t',i*all' ab"$t ; ba) ab"&e the li#e ,)ess$)e.

Steam Fow Ca69ations The ,)i!a)' *al*$lati"# is t" esti!ate the stea! (l"w )e/$i)e $)i#+ stea! bl"wi#+ t" a*hie&e a s,e*i(ie Clea#i#+ F")*e ati" CF. CF is a )ati" "( the stea!
The operating conditions were used to calculate the mass flow rate required for steam blowing as follows:

CFR = Mb2 x Vs / Mo2 x Vo

Where, CFR M b

=

=

leaning !orce Ratio

"ass !low rate required for blowing


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CPP Steam & BFW System Commissioning Methods V b M o V o

= #pecific $olume $olume %steam =

=


blowing condition

'perating "ass !low rate #pecific $olume $olume %operating condition

I# the ab"&e e/$ati"#- the &al$es "( M"- V"V"- Vs = CF a)e 0#"w#. F)"! these &al$es t he &al$e "( Mb *a# be ete)!i#e $si#+ the ab"&e e/$ati"#. The &al$es "( M" a# V" *a# be "btai#e with the hel, "( LDT >Li#e Desi+#ati"# Table?. A sa!,le *al*$lati"# is +i&e# bel"w.

I# ")e) t" *al*$late the !ass (l"w "( stea! )e/$i)e (") stea! bl"wi#+ t" a*hie&e a s,e*i(ie &al$e "( CF it is #e*essa)' t" esti!ate the stea! ,)ess$)e $)i#+ stea! bl"wi#+. D$)i#+ *"#ti#$"$s stea! bl"wi#+ the stea! ,)ess$)e at the i#let t" the li#e is ete)!i#e "#l' b' the ,)ess$)e )", $e t" the (l"w "( stea! $)i#+ bl"wi#+. This is be*a$se the e%it ,i,i#+ is ",e# t" at!"s,he)e at its te)!i#ati"# a# the stea! &el"*ities $)i#+ bl"wi#+ a)e alwa's s$b:s"#i*- he#*e *h"0e (l"w "es #"t "**$).

Va)i"$s !eth"s a)e $se t" esti!ate ,)ess$)e )",s (") (l"w "( s$,e)heate stea!. F") *"!,le% s'ste!s s'ste!s #")!all' #")!all' s"(twa)e s"(twa)e $se a)e Fl"w !aste)!aste)- a *"!!e)*i *"!!e)*ial al "#e i!e#si"#al i!e#si"#al CFD s"(twa)e s"(twa)e ,a*0a+e ") C)a#e S"(twa)e.

Sampe 6a69ation or ;owing steam re<9irement BLOW NO@ 1 > ;1 A)ea HHP li#e at West e#? 

!eeren6e P&#D %o.@ %o.@ G42:EE;1:535



S*!CE: HHP Stea! ()"! HHP Stea! Heae). >;1:S:255:25:EL2E:HC:145?



$ppro=3 D9ration@ D9ration@ 24 h)s.

!R ( " b) * $s + "o) * $o Taing !R( -., " o and $ o /alues from the 01T & $s /alue from the steam table at 2 g+cm) a and 3-4 deg , we obtain -. ( " b) * 4. 352 + 6-47 ) * 4.484 9ence

Mb = 55 tp The same procedure was followed to establish the flow rates of all the lines. !aw Water S9ppies aw wate) s$,,lies a)e )e/$i)e (") ",e)ati"# "( the /$e#*h atte!,e)ati"# atte!,e)ati"# s'ste!- $se t" )e$*e the C,EC-ED B+: '"B $PP!.ED B+: %-M

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is*ha)+e #"ise "( the stea! $)i#+ stea! bl"wi#+. Fi)e wate) shall be $se (") the ,$),"se.

Dis6harge %oise The /$e#*h atte!,e)ati"# s'ste! is &e)' e((e*ti&e at )e$*i#+ the stea! is*ha)+e #"ise. Dis*ha)+e #"ise le&els a)e t',i*all' a)"$# ; BA at "#e !et)e ()"! the is*ha)+e ,"i#t . Ta)+et I#se)ti"# E/$i,!e#t The ta)+et i#se)ti"# e/$i,!e#t *"!,)ises a ,#e$!ati*all' ",e)ate is"lati"# &al&e- a ,#e$!ati*all' ",e)ate i#se)ti"# )a! a# a *"#t)"l ,a#el.

Engineering Design I# ")e) t" ,e)(")! the etaile e#+i#ee)i#+ esi+#- the ("ll"wi#+ i#(")!ati"# is )e/$i)e. 







 

A**$)ate ,i,i#+ ,i,i#+ = i#st)$!e#tati"# i#st)$!e#tati"# ia+)a!s P=ID P=ID (") all li#es li#es t" be *lea#e. *lea#e. These These will be $se t" ,)"$*e (l"w ia+)a!s (") stea! bl"ws. A**$)ate is"!et)i* is"!et)i* *"#st)$*ti"# *"#st)$*ti"# )awi#+s )awi#+s ISO a#") a#") ,i,i#+ ,i,i#+ ,la#s )awi#+s )awi#+s (") all all li#es t" be *lea#e i#*l$i#+ b"ile) etails. These )awi#+s will be $se $)i#+ the etaile esi+# *al*$lati"#s. St)ess a# !"&e!e#t esi+# i#(")!ati"# "# the li#es t" be bl"w# t" *a))' "$t a st)ess a#al'sis "# the te!,")a)' ,i,i#+. A**$)ate i#(")!ati"# i#(")!ati"# "# "# the t',e- i!e#si"#s i!e#si"#s a# a# C& &al$es (") (") all &al&es i# the the li#es t" be *lea#e. Ma%i!$! ,)ess$)e a# te!,e)at$)e li!itati"#s (") all li#es t" be bl"w#. Ma%i!$! *"#ti#$"$s )ati#+ MC &al$es (") stea! !ass (l"ws- ,)ess$)es a# te!,e)at$)es (") all li#es t" be bl"w#.

E=e69tion Pan This w"$l i#*l$e the ("ll"wi#+@ Detaile E#+i#ee)i#+ Desi+# (") stea! bl"wi#+ Detaile Meth" State!e#t (") stea! bl"wi#+ Site is0 assess!e#t. assess!e#t.

  

GE%E!#C SE$M B"W P!CED*!ES C,EC-ED B+: '"B $PP!.ED B+: %-M

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P)eli!i#a)' Che*0s. Li#e Wa)!i#+ P)"*e$)e. Ta)+ete Stea! Bl"w P)"*e$)e.

  

Preliminary Checks Ste

Acti!n

1.1

Ma0e s$)e all the i#li#e i#st)$!e#ts li0e FT- PT a)e is"late. TT the)!"wels a)e )e!"&e a# bli#e.

1.2

PSV
1.3

Sa(e a**ess t" all )i, le+s = is"lati"# &al&es a&ailable.

1.4

Sa(et' ba))i*aes a)"$# e%it ,i,i#+ i# ,"siti"#

1.5

Wa)#i#+ #"ti*es i# ,"siti"#

1.6

Stea! li#e i#s$lati"# *"!,lete as )e/$i)e

1.7

E%it ,i,i#+ ($ll' s$,,")te

1.8

E%it ,i,i#+ la++e i# )e/$i)e a)eas

1.9

Sa(e a**ess t" ta)+et i#se)te)

1.10 1.11 1.12

Acti!n "y

#eri$icati!n Init Initia iall

Date Date & time time

Atte!,e)ati"# Atte!,e)ati"# wate) (i)e (i)e wate)  *"##e*te *"##e*te as )e/$i)e Fi)e wate) heae) *ha)+e a# h')a#t ($#*ti"#i#+. Ai) s$,,l' t" ta)+et ta)+et i#se)te) i#se)te) *"##e*te *"##e*te

1.13

Ta)+et i#se)te) ($#*ti"#i#+

1.14

N" (la!!abl (la!!able e !ate)ia !ate)ials ls i# *l"se *l"se ,)"%i!it ,)"%i!it' ' t" stea! stea! li#es ") e%it ,i,i#+

1.15

E((l$e#t wate) M$77le) )ai# )ai# t" sa(e l"*ati"#

1.16

DM wate) ") *"l *"#e#sate *"##e*ti"# is a&ailable #ea) the stea! s"$)*e ,"i#ts (") the)!al *'*li#+.

Line %arm & r!ce'&re C,EC-ED B+: '"B $PP!.ED B+: %-M

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Ste Note

Acti!n


Acti!n "y

#eri$icati!n Initial

Date & time

O# *"!!e#*i#+ stea! bl"wi#+ it is i!,")ta#t t" *"#t)"l the stea! (l"w a# te!,e)at$)e "( the e%it li#e- t" ,)e&e#t wate) ha!!e)< a# e%*essi&e li#e st)esses. The The )e/$i) )e/$i)e! e!e#t e#t is t" sl"wl' sl"wl' heat heat the stea! li#e $si#+ $si#+ a *"#t)" *"#t)"lle lle  (l"w (l"w "( stea!stea!+)a$all' i#*)easi#+ the (l"w )ate i( #e*essa)'. It is esse#tial t" )ai# wate) *"#e#se $)i#+ the heati#+ ,)"*ess. This *"#t)"lle ",e)ati"# als" ,)"&ies ti!e t" *he*0 the e%it li#e (") lea0s ") "the) ,)"ble!s $e t" the)!al e%,a#si"#.

2.1

All )i, le+ )ai#s betwee# stea! s"$)*e a# the !ai# stea! st", &al&es t" be ",e#e.

2.2

O,e# B',ass &al&e "# stea! heae) is"lati"# &al&e

2.3

I( #" b',ass is ,)ese#t the# *)a*0< ",e# the !ai# st", t" wa)! $, stea! li#es.

2.4

Wal0 li#e *l"si#+ all )i, le+ )ai#s a# *he*0i#+ all (la#+es (") lea0s a# (") a#' ,)"ble!s $e t" the)!al e%,a#si"#. e*ti(' as )e/$i)e. Whe# Whe# the the e%it e%it ,i, ,i,e te!, te!,e) e)at at$) $)ee- as sh"w sh"w# # "# Te!,e)at$)e Ga$+e- has )ea*he 155C- li#e wa)!i#+ is *"!,lete.

Tar(ete' Steam Bl!% Pr!ce'&re Ste

Acti!n

N!te

The ("ll"wi#+ ,)"*e$)e is +e#e)i* (") all Ta)+et Stea! Bl"ws. F") i#i&i$al bl"w ,)"*esses see Ste, b' Ste, P)"*e$)e.

3.1

Establish (l"w )e/$i)e as !e#ti"#e i# bl"w w")0 sheet ,)"&ie i# e#+i#ee)i#+ ,a*0a+e.

3.2

C"#ti#$e bl"wi#+ (") 2 h)s.

3.3

e$*e (l"w t" hal( "( the t"tal bl"wi#+ (l"w.

3.4

Pe)(")! the)!al *'*li#+ TC b' s,)a'i#+ DM wate) ") *"l *"l *"# *"#e# e#sa sate te at #ea) #ea)es estt ,"i# ,"i#tt "( s"$) s"$)*e *e.. All" All"w w te!,e)at$)e t" )", b' 1;5 e+ C.

3.5

C"#ti#$e TC (") a)"$# 1.; h)s.

3.6

St", TC a# establish #")!al bl"wi#+ (l"w.

3.7

C"#ti#$e bl"wi#+ (") 1 h).

Acti!n "y

#eri$icati!n Initial Initial

Date & time time

3.8

Sta)ti#+ ()"! the )ai#s #ea)est t" the stea! s"$)*ese/$e#tiall' bl"w "w# all stea! li#e )ai#s. F$ll' ",e# C,EC-ED B+: '"B !E"#$%CE '$M%$G$! C$P#.E PWE! P"$% $PP!.ED B+: %-M

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ea*h )ai# &al&e a# all"w the )ai# t" bl"w $#til *lea#the# *l"se )ai# &al&e. 3.9

I#se)t a )e(e)e#*e ta)+et. ee, ta)+et e%,"s$)e (") 25 !i#$tes.

3.10

e!"&e the ta)+et sa(el' b' ",e)ati#+ the a!.

3.11

N"te the ("ll"wi#+ i# the ta)+et ,late l"+@ a Li#e #$!be) b Plate #$!be) * Ti!e "( i#se)ti"#

3.12

E%a!i#e (") i!,)essi"# whe# ,late is *""l.

3.13

St")e the ,late (") ($t$)e )e(e)e#*e.

3.14

e,eat ste, ()"! 3.1 t" 3.13 till ta)+et !eets the *)ite)ia.

N!te

Ta)+et a)+et a**e, a**e,ta# ta#*e *e *)ite) *)ite)ia ia !a' be i((e) i((e)e# e#tt (") i((e)e#t t$)bi#e &e#"). e(e) t" t$)bi#e &e#"). 9ydrochem standard specifies following criteria. Target e*posure of )4 minutes shall result in no impacts larger than 4.mm diameter and fewer than -4 impacts on two successi/e occasions. The top and bottom half inch of the target surface should be disregarded, due to the effects of its attachment on the Target Target inserter ram.

NON CON#ENTIONAL CLEANING MET)ODS A,a)t ()"! sile#t stea! bl"wi#+ the)e a)e &a)i"$s "the) N"# *"#&e#ti"#al *lea#i#+ !eth"s C,EC-ED B+: '"B $PP!.ED B+: %-M

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as liste bel"w. ; ; ;

Chemical Cleanin(* )y'r! Millin( )y"ri' Chem steam cleanin(

Chemical Cleanin(+, Che!i*al *lea#i#+ $ses the !"st *"st e((e*ti&e a# e#&i)"#!e#tall' s"$# !ea#s t" )ea*h the esi)e "b9e*ti&e whethe) it is si!,l' e+)easi#+ ") )e!"&al "( !ill s*ale. The *he!i*al !i%t$ !i%t$)e )e is (")!$l (")!$late ate  t" )e!"&e )e!"&e ha) ha) e,"si e,"sits ts ") s"(t s"(t (il!s (il!s ()"! ()"! &i)t$a &i)t$all' ll' a#' t',e t',e "( !etal !etall$) l$)+' +'.. Che!i Che!i*al *als s $se $se a)e e#&i)" e#&i)"#!e #!e#ta #tall ()ie# ()ie#l' l'.. The ,)"*es ,)"*ess s i#9e*t i#9e*ts s ,)"&e# ,)"&e# *he!ist)ies i#t" sat$)ate stea!. B' #"t (illi#+ with li/$is the *he!ist)' is able t" a*t i)e*tl' "# the s$)(a*e "( the ,i,e. C"#ti#$"$s !"#it")i#+ "( the *"#e#sate ,)"$*t *"#t)"ls ,H a# i)"# *"#te#t. The &a,"$) is *"#e#se at the "$tlet ,"i#t a# #e$t)ali7e (") is,"sal t" ,la#t waste s'ste!. A(te) !ill s*ale )e!"&al a (i#al bl"w (") 4 h"$)s is +i&e# at *al*$late (l"w t" )e!"&e the *"#st)$*ti"# eb)is. T"tal ti!e )e/$i)e is a)"$# 1 h)s i# ,la*e "( 3 h)s (") *"#&e#ti"#al *"#&e#ti"#al sile#t stea! bl"w. bl"w. The ,)"*ess )e$*es *"#sie)able stea! *"#s$!,ti"#.

Fi+.:1 Chem Steam 6eaning pro6ess@ E9ent 6oe6tion3

,ydro Miing H')" Milli#+ is hi+h ,)ess$)e wate) 9etti#+ ,)"*ess whe)e all eb)is a# !ill s*ale )e!"&e ()"! the ,i,e s$)(a*e is t)a#s,")te "$t "( the ,i,e whe# the hi+h ,)ess$)e #"77le is )et)a*te. This is a**"!,lishe &ia a ,$she)(l$she) ")i(i*e b$ilt i#t" the *lea#i#+ #"77le- $tili7i#+ a t',i*al C,EC-ED B+: '"B $PP!.ED B+: %-M

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w")0i#+ ,)ess$)e "( 12-555 ,si (") !ill s*ale )e!"&al a# a# a&e)a+e wate) (l"w "( 45 GPM. All )es$lti#+ eb)is a# !ill s*ale !a' be *"#tai#e a#") *"lle*te (") ,)",e) is,"sal. This ,)",)ieta)' ,i,e *lea#i#+ s'ste! is *a,able "( ha#li#+ *ha#+es "( i)e*ti"# i#*l$i#+ !$lti,le 5 e+)ee t$)#s a# ,i,e "((sets t" ista#*es "( 155 !t)s &e)ti*all' ") 35 !t)s h")i7"#tall' ()"! the ,"i#t "( e#t)' with ,)e*ise t)a*0i#+ *a,abilities. The h')" !illi#+ ,)"*ess is *a,able t" all ,i,e si7es ()"! 2 ia !ete) a# $,. This ,)"*ess is best s$ite (") De ae)at") li#es- PDS li#es.

,+B!#D C,EMSE$M P!CESS G$l( St)ate+i* Pa)t#e)s has *"!bi#e th)ee !eth"s "( *lea#i#+ t" (")! the H'b)i Che! Stea! *lea#i#+ ,)"*ess HCS P)"*ess t" !eet the state "b9e*ti&es

  

Hydro Milling Vapor Phase Chemical Cleaning Steam blow

With the a&e#t "( !$*h la)+e) ,i,i#+ s'ste!s the ,)e&i"$s !eth"s "( *he!i*al *lea#i#+- li#e (l$shi#+- a# stea! bl"wi#+ ha&e be*"!e *$!be)s"!e- e%,e#si&e- ti!e *"#s$!i#+- a# i# s"!e *ases i!,"ssib i!,"ssible le t" ,e)(")! ,e)(")! $tili7i# $tili7i#+ + the ,)e&i"$s ,)e&i"$s !eth"s. !eth"s. I# aiti"# aiti"# t)aiti"#al t)aiti"#al !eth"s "(te# *)eate la)+e /$a#tities "( waste e((l$e#t *)eati#+ is,"sal ,)"ble!s. The ab"&e state *lea#i#+ !eth"s a)e *"!bi#e with the t he ("ll"wi#+ "b9e*ti&es@        

Clea#i#+ !eets ") e%*ees the t he )e/$i)e sta#a)s a# s,e*i(i*ati"#s e$*es C"!!issi"#i#+ Clea#i#+ ti!e )e/$i)e!e#ts E#+i#ee)e ,)e ti!e *lea#i#+ *'*les (") )ealisti* s*he$li#+ As (le%ibilit' (le%ibilit' t" C"!!issi"#i#+ C"!!issi"#i#+ Clea#i#+ Clea#i#+ S*he$le Mi#i!i7es waste is,"sal )e/$i)e!e#ts a# liabilit' Mi#i!i7es wate) a# stea! *"#s$!,ti"# Fle%ible a,,li*ati"# a,,li*ati"# a# *"!bi#ati"# "( the ,)"*esses t" s$it site *"#iti"#s e$*es "&e)all *"sts

H'b)i Che! Stea! bl"w ti!e is 15:256 "( #")!al sile#t stea! bl"w $)ati"# a# 2:;6 "( *"#&e#ti"#al *"#&e#ti"#al stea! bl"w $)ati"#.

C,EM#C$" C"E$%#%G F P#PE "#%ES #%!D*C#% C,EC-ED B+: '"B $PP!.ED B+: %-M

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The "b9e*t "( *he!i*al *lea#i#+ "( *a)b"# steel ,i,i#+ is t" )e!"&e the l""se )$st- isl"+i#+ the b$)sweli#+ sla+ = !ill s*ales ahe)i#+ t" the i#te)#al s$)(a*e "( the ,i,eli#es. The ,)"*e$)e s,e*i(ies the !eth" "( *lea#i#+ = ,assi&ati"# with s"i$! #it)ite ,)i") t" ta0i#+ i# se)&i*e (") the (i)st ti!e a(te) i#stallati"# "( ,i,eli#e. This *lea#i#+ e#ables t" )e!"&e J a G)eas ease ") ") "il b Mill s* s*ales * L""se )$st  Weli# li#+ + sla sla+ e Pai#t Pai#t ") &a)# &a)#ish ish i( $se (") ,)"t ,)"te*ti& e*ti&e e ,$),"se ,$),"ses s (

A#' l""se l""se (")ei+ (")ei+# # ,a)ti ,a)ti*le *le $)i# $)i#+ + (l$shi (l$shi#+ #+ "( "( s'ste! s'ste!

The se/$e#*e "( ",e)ati"#s i#*l$es (l$shi#+ b' *"l = h"t wate)wate)- e+)easi#+- a*i ,i*0li#+- *it)i* )i#se,assi&ati"#- )'i#+ = ,)ese)&ati"#. I# betwee# this ,)"*esses i((e)e#t ,a)a!ete)s li0e ,H- Al0ali#it'te!,e)at$)ete!,e)at$)e- a*i *"#*e#t)ati"#- t"tal i)"# = *la)it' "( wate) t" be !"#it")e. !"#it")e. Va)i"$s *he!i*als *he!i*als $se i# *he!i*al *lea#i#+ ,)"*ess i#*l$es S"a ash- Ca$sti* s"a- S"i$! #it)ite- Wetti#+ a+e#t- COONIL 2B- *it)i* a*i = a!!"#ia.

C%E%S


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CPP Steam & BFW System Commissioning Methods Sr3 %o3


P$!#C*"$!S

1

Te!,")a)' A))a#+e!e#ts

2

Lea0 Test

3

C"l Wate) (l$shi#+

4

H"t Wate) (l$shi#+

;

De+)easi#+



Wate) (l$shi#+

K

A*i Pi*0li#+



Wate) (l$shi#+



Cit)i* i#se = Passi&ati"#

15

D)'i#+ = P)ese)&ati"#

11

Testi#+ P)"*e$)e

Chemi6a Ceaning Se<9en6e /3

emporary $r $rrangements J F") sta)ti#+ = s!""th ",e)ati"# "( *he!i*al *lea#i#+ ("ll"wi#+ a))a#+e!e#ts has t" !ae be(")e C,EC-ED B+: '"B $PP!.ED B+: %-M

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sta)ti#+ "( 9"b J

a b * *  e e ( ( + h h i i 9 9 0 l 43

S*a(( S*a(("l "li# i#+ + (") all the the &al&e &al&es s ",e) ",e)ati ati"# "#s. s. F") F") &e#ts &e#ts-- H"t ta, ta, *"# *"##e #e*ti *ti"# "#s s = wate) wate) s$,,l s$,,l' ' &al&es &al&es et*. M"t") M"t") *"# *"##e* #e*ti" ti"# # t" be be !ae !ae eith eithe) e) ()"! ()"! DG DG set set ") th)" th)"$+ $+h h elia elia#*e #*e s'ste! s'ste! e,e e,e# #i#+ i#+ $,"# $,"# the the *"#iti"#s. F") this ,e)!it- is"lati"# ta+ et* t" be ,)"&ie i# *"#s$ltati"# with ele*t)i*al ,e)s"##el. et$ et$)# )# H"se H"se *"## *"##e* e*ti ti"# "# ()"! ()"! all all &al &al&e &es s t" t" ,$! ,$!, , s$* s$*ti ti"# "#.. H"se H"se *"##e *"##e*ti *ti"# "# (") (") DM Wate Wate))- $tilit $tilit' ' wate) wate)-- LP *"# *"#e# e#sat sate e et* ()"! ()"! heae heae)) &al&e &al&e t" *he *he!i !i*al *al *i)*$lati"# ta#0. Che! Che!i* i*al als s st") st")a+ a+e e at ,)e ,)ee( e(i# i#e e ,la* ,la*e. e. Tie i# betw betwee ee# # *he! *he!i* i*al al *i)* *i)*$l $lat ati" i"# # ta# ta#0 0 = e(( e((l$ l$e# e#tt ta# ta#0. 0. H"se H"se *"##e* *"##e*ti" ti"# # ()"! ()"! e((l$e e((l$e#t #t ta#0 ta#0 t" ta#0e) ta#0e)-- t" is*ha) is*ha)+e +e e((l$ e((l$e# e#tt a(te) a(te) *"#it *"#iti"# i"#i#+ i#+ i# i# E((l$e E((l$e#t #t ta#0. Ta#0e a#0e)) a))a a))a#+ #+e! e!e# e#tt t" is, is,"s "se e e((l e((l$e $e#t #t at at ,)", ,)",e) e) ,la* ,la*e. e. All All *"# *"#t) t)"l "l &al& &al&es es-- (l" (l"w w !ete !ete)s )s = "the "the)) i#st i#st)$ )$!e !e#t #ts s )e!" )e!"&a &al. l. S,"" S,""ll (i% (i%i# i#+ + i# i# ,la ,la*e *e "( C"#t C"#t)" )"ll &al &al&e &e = N NV i(i( )e/ )e/$i $i)e )e. . S$*ti"# st st)ai#e) )e )e!"&al. Da# Da#+e) Ta+s = Ba)) a))i*ati *ati" "# i# i# wh wh"le a)ea. ea. "eaA est J This is t" be "#e t" a&"i a#' lea0a+e i# betwee# the ,)"*ess = t" a&"i a#' ha7a) be*a$se "( that.

a b *

A(te A(te)) *i)* *i)*$i $itt *"!, *"!,le leti ti"# "#-- the the s'st s'ste! e! wil willl be (ill (ille e with with $ti $tili lit' t' wat wate) e).. Wate) Wate) *i)*$l *i)*$lati ati"# "# (") (") 35 35 !i#. !i#. t" t" *he*0 *he*0 the lea0a lea0a+es +es i# s'st s'ste! e! = lea0a+ lea0a+es es t" t" be )e*ti )e*ti(ie (ie  i( ("$ ("$# # a#'. Wate) )ai# i# st")! wate) *ha##el. End o eaA test: N" lea0a+e ()"! a#' 9"i#ts

73

Cod Water 9shing J T" )e!"&e l""se sla+- i)t- (")ei+# ,a)ti*les et* ()"! the s'ste! J

a b

C"#t C"#ti# i#$" $"$s $s s'st s'ste! e! (l$s (l$shi hi#+ #+ with with $til $tilit it' ' wat wate) e) (") (") a,, a,,)" )"% % 1 h"$) h"$).. Wate) Wate) (illi# (illi#+ + = *i)* *i)*$la $lati" ti"# # i# s'st s'ste! e! a# a# )ai )ai#a+ #a+e e i# st")! st")! wate wate)) *ha# *ha##el #el till till )ai )ai# # wate) wate) will will be *lea). End o 6od 9shing: Cla)it' "( wate) is +"" &is$al *he*0i#+ 

83

,ot Water F9shing J T" )e!"&e l""se sla+- i)t- (")ei+# ,a)ti*les et* ()"! the s'ste! while +i&i#+ a the)!al sh"*0 J S'ste! (l$shi#+ with h"t wate).

a Wate) Wate) (illi# (illi#++- *i)*$l *i)*$lati ati"# "# i# s'ste s'ste! ! a# a# )aise )aise the te!,e) te!,e)at$ at$)e )e $, t" !i#. !i#. ;5 * * D)ai D)ai#a #a+e +e i# st") st")! ! wat wate) e) *ha# *ha##e #ell til tilll )a )ai# i# wate wate)) wil willl be be *le *lea) a).. C,EC-ED B+: P$GE '"B !E"#$%CE '$M%$G$! !E. C$P#.E PWE! P"$% #SS*E $PP!.ED B+: D$E %-M $*,!

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End o hot 9shing J 9shing J T$)biit' "( wate) is +"" Vis$al *he*0i#+ 23

Degreasing J Pro6ess (i & Grease remova) J remova) J CH2 J COO<

CH2 : COONa



K5

CH J COO

*

 3 NaOH

 CH J COONa

 3 H2O

 CH2 J COO

CH2 : COONa

Oil = +)ease Fatt' a*i a b * i ii ii iii iii i& i&  e ( +

S'st S'ste! e! (ill (illi# i#+ + wit with h *"# *"#e e#s #sat ate e ") ") DM DM wat wate) e) = *i)* *i)*$l $lat ati" i"#. #. Te!,e)at$)e )ise t" K5 * Che!i*als aiti"# J S" S"a Ash Ash : 3555 ,,! Ca$s Ca$sti ti* * S"a S"a : 3555 3555 ,,! ,,! S"i$! S"i$! Nit)i Nit)ite te : ;55 ;55 ,,! Wetti Wetti#+ #+ A+e# A+e#tt : 255 255 ,,! ,,! T"tal "tal al0a al0ali li#i #it' t' = ,H ,H !"# !"#it it") ")i# i#+ + i# i# e&e e&e)' )'  h"$ h"$)). Ci)*$l Ci)*$lati ati"# "# till till the the stabil stabili7a i7ati" ti"# # "( "( t"ta t"tall al0a al0ali# li#it' it' = ,H ,H #" #")! )!all all' ' 2 t" 3 h)s h)s D)ai# "( e((l$e#t i# i# E((l$e#t ta ta#0. Ne$t)a Ne$t)ali7 li7e e the the e((l$ e((l$e# e#tt with with wate) wate) = H') H')"*h "*hl") l")i* i* a*i a*i be(" be(")e )e is*h is*ha)+ a)+e e i# i# ta# ta#0e) 0e)..

Parameter to ;e monitored J monitored J ,H = T"tal Al0ali#it'

End o degreasing@ ,H a# T"tal T"tal al0ali#it' al0ali#it ' "( s'ste! at i#let a# "$tlet "( *lea#i#+ l"", is e/$al a# stabili7e. stabili7e .

>3

Water F9shing J

a b *

S'ste! (l$shi#+ b' DM wate) St", St", (l$sh (l$shi# i#+ + whe# whe# ,H ,H "( s'ste! s'ste! i# i#let i#let = "$tle "$tlett ,"i#t ,"i#ts s a)e a)e e/$i e/$i&al &ale#t e#t t" the the ,H "( "( wate) wate) bei#+ bei#+ $se. C"!,lete ) )ai#a+e "( "( wa wate). End o water 9shing ater degreasing:@ ,H "( the s'ste! at i#let a# "$tlet "( *lea#i#+ l"", is e/$al t" DM wate) $se a# stabili7e. stabili7e .

53

$6id Pi6Aing J


!E"#$%CE '$M%$G$! C$P#.E PWE! P"$%

P$GE !E. #SS*E D$E $*,!

: /> F /0 : 11 : 1/ : /231434115 : '-P





Pro6ess (#ron !emova) J !emova) J K5 * Fe2O3



2 H3 Cit)ate

Fe))i* O%ie

a b *  e ( + h

2 Fe Cit)ate  3 H2O

Cit)i* A*i

Fe))i* Cit)ate

e(ill e(ill the the s'ste s'ste! ! with with *"#e *"#e#sa #sate te ") ") DM DM wate wate))- *i)*$ *i)*$lat late e = )aise )aise te!,e) te!,e)at at$)e $)e t" K5 * A A 5.2 5.26 6 "( *")) *"))"s "si" i"# # i#h i#hib ibit it") ") C") C")"# "#il il 2 2 B = *i) *i)*$ *$la late te (") (") "#e "#e h"$ h"$)). A(te A(te)) 1 h"$) h"$) a a 36 36 "( "( Cit Cit)i )i* * A*i A*i i#t" i#t" the the s"l s"l$t $ti" i"#. #. Mai# Mai#ta tai# i# ,H "( s"l s"l$t $ti" i"# # bet betwe wee# e# 3.; t" 4 $si $si#+ #+ A!!" A!!"#i #ia. a. M"#i M"#it" t")) *"# *"#*e *e#t #t)a )ati ti"# "# "( a*i a*i-- ,H ,H = t"ta t"tall i)" i)"# # i# i# e&e e&e)' )' h"$) h"$).. Ci)* Ci)*$l $lat ate e til tilll the the a*i a*i *"#* *"#*e# e#t) t)at ati" i"# # = t"ta t"tall i)" i)"# # )e! )e!ai ai#s #s *"#s *"#sta ta#t #t.. A(te) A(te) stabil stabili7i i7i#+ #+ )ai# )ai# the s"l$ti s"l$ti"# "# t" e((l$ e((l$e# e#tt ta#0. ta#0. I( ,"ssi ,"ssible ble $#e) $#e) #it)" #it)"+e +e# # Ne$t Ne$t)a )ali li7e 7e the the s"l s"l$t $ti" i"# # with with wat wate) e) = b$)# b$)#tt li!e li!e be( be(") ")e e is* is*ha ha)+ )+e e i# ta# ta#0e 0e)). Pa)a!ete) t" be !"#it")e J ,H- A*i *"#*e#t)ati"# = T"tal i)"# End o a6id pi6Aing: I)"# a!"$#t i# ,,! at s'ste! i#let "$tlet sh"$l be e/$al a# stabili7e at !a%i!$! le&el.

?3

Water 9shing J

a b *

S'ste! (l$shi#+ b' DM wate) St", St", (l$sh (l$shi# i#+ + whe# whe# ,H ,H "( s'ste! s'ste! i# i#let i#let = "$tle "$tlett ,"i#t ,"i#ts s a)e a)e e/$i e/$i&al &ale#t e#t t" the the ,H "( "( wate) wate) bei#+ bei#+ $se. C"!,lete ) )ai#a+e "( "( wa wate). End o water 9shing ater a6id pi6Aing : I)"# a!"$#t i# ,,! at s'ste! i#let "$tlet sh"$l be e/$al a# stabili7e at !a%i!$! le&el

03

Citri6 !inse & Passivation J Pro6ess : Pro6ess : NH3 Fe2O3



CHOK

FAC Fe))"$s a!!"#i$! *it)ate

,H  : .; CHOK  NH 3  NaNO2

Fe3O4 5 *

a b * 

Ma+#etite La'e)

e(i e(ill ll s's s'ste te! ! wit with h *"# *"#e# e#sa sate te ") ") DM wate wate))- *i)* *i)*$l $lat ate e = )ai )aise se te! te!,. ,. t" t" K5 K5 *. *. A A Cit Cit)i )i* * a*i a*i  i#t i#t" " the the s'st s'ste! e! = *i) *i)*$ *$la late te (") (") 1 h"$) h"$).. ais aise e the the ,H "( the the s"l s"l$t $ti" i"# # t" t"  J .; .; b' ai ai#+ #+ a!!" a!!"#i #ia. a. A(te A(te)) att attai ai#i #i#+ #+ the the ,H ,H a a 16 OF s"i s"i$! $! #it) #it)it ite e i#t i#t" " sa! sa!e e s"l s"l$t $ti" i"#. #.


!E"#$%CE '$M%$G$! C$P#.E PWE! P"$%

P$GE !E. #SS*E D$E $*,!

: /5 F /0 : 11 : 1/ : /231434115 : '-P

CPP Steam & BFW System Commissioning Methods e (


Ci)*$late th the s" s"l$ti"# (" (") 3: 3:4 h" h"$)s. D)ai D)ai# # the the t"ta t"tall s"l$ s"l$ti ti"# "# = #e$t #e$t)a )ali li7e 7e the the e((l e((l$e $e#t #t.. End o 6itri6 rinse and passivation: ,H sh"$l be a)"$# .5:.; a# +et stabili7e.

/13

Drying & Preservation J

a b

D)' D)' the the s'st s'ste! e! $si#+ si#+ i#st i#st)$ )$! !e#t e#t ai) ai)  Nit) Nit)"+ "+e e#. The ,assi ,assi&at &ate e li#e li#e sh"$l sh"$l be ,)e ,)ese) se)&e &e i# *le *lea# a# = )' )' *"# *"#iti iti"# "# with with sli+ sli+ht ht ,"s ,"siti iti&e &e ,)e ,)ess$ ss$)e )e $si#+ #it)"+e# t" ,)e&e#t e#t)' "( !"ist$)e- $st ") (")ei+# ,a)ti*les. * T" ,)e&e ,)e&e#t #t )e:"% )e:"%i iati ati"# "#-- ,assi& ,assi&ati ati"# "# s"l$ s"l$ti" ti"# # !$st !$st be i#t)" i#t)"$* $*e e i!! i!!ei eiat atel' el' a(te a(te)) (l$sh (l$shi# i#+ + the the s'ste!. //3

Che*0 ,assi&ati"# la'e)- )e!"&e te!,")a)' a))a#+e!e#t- #")!ali7e the s'ste! = )est")e the a)ea a(te) h"$se0ee,i#+.

ES#%G P!CED*!E /3

ota $Aainity@ : 15 !l sa!,le  3 t" ; )",s "( !i%e i#i*at")- tit)ate a+ai#st 5.1 N H 2SO4

End Point J Point J G)ee# t" e *"l"$)

T"tal Al0ali#it' as CaCO 3 6



T"tal V"l$!e Q 5.1 Q ;5 Q 155  15 Q 1555 

43

T"tal V"l$!e Q 5.;

Citri6 $6id Strength@ : 15 !l sa!,le  3 t" ; )",s "( Phe#"l,hthalei# i#i*at") tit)ate a+ai#st 5.1 NaOH.

End Point J Point J C"l"$)less t" Pi#0 C"l"$)

Cit)i* A*i St)e#+th 6



T"tal V"l$!e Q 5.1 Q K5 Q 155  15 Q 1555 


T"tal V"l$!e Q 5.5K

!E"#$%CE '$M%$G$! C$P#.E PWE! P"$%

P$GE !E. #SS*E D$E $*,!

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CPP Steam & BFW System Commissioning Methods 73


ota #ron Content: @ 15 !l sa!,le  1 +! S"i$! A*etate A*etate  1 +! Chl")" A*eti* A*i  1 +! S$l,h" Sali*'li* a*i  1 +! P"tassi$! Pe)s$l(ate - tit)ate a+ai#st 5.51 M EDTA

End Point J Point J e t" Pale Rell"w

T"tal I)"# as Fe !+L




T"tal V"l$!e Q 5.51 Q ;;.; Q 1555  15



T"tal V"l$!e Q ;;.;

!E"#$%CE '$M%$G$! C$P#.E PWE! P"$%

P$GE !E. #SS*E D$E $*,!

: /0 F /0 : 11 : 1/ : /231434115 : '-P

Steam Blowing

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