Académique Documents
Professionnel Documents
Culture Documents
Approved for
Implementation by ........................................................
Director (Operation)
Date :....................................
Enquiries to : Executive Director, Operation Services
Introduction
2.0
Superseded Documents
3.0
Scope
4.0
Safety2
5.0
Storage Situations
6.0
7.0
7.1
Complete Dry-out
7.2
Incomplete Dry-out
8.0
10
8.1
10
8.2
12
8.3
12
8.4
Nitrogen Capping
13
9.0
Hydraulic Tests
13
10.
Review
13
Table 1
14
16
17
Page 1
OGN/OPS/CHEM/010
Issue-1 Aug., 94
INTRODUCTION
Damage can occur in the water/steam circuits of plants if they are not
stored correctly off-load. Corrosive attack off-load can also render the plant
susceptible to subsequent on-load corrosion or fatigue damage. To
preserve the long term integrity of boiler components requires careful
chemical control off-load as well as on-load. This Guidance Note covers
the storage of plant including the important factors regarding the choice of
the optimum procedures, which will depend on the type of plant, its history
and outage time.
2.0
3.0
SCOPE
This Guidance Note covers the storage of various types of fossil fuel and
gas fired plant. The storage requirements, procedures available and their
practical applications are outlined. The Guidance Note enables storage
procedures for drained and undrained plant to be drawn up for individual
stations.
Dry storage is the best method for longer outage periods and methods for
ensuring complete dry-out of the boiler are described.
For incompletely drained boilers, corrosions may be inhibited either by
dosing the boiler so that any residual water contains a prescribed
concentration of nitrite-borax or by nitrogen filling (to exclude air).
For plant that is not easily drained a range of procedures such as nitrogen
capping, nitrite-borax or hydrazine-ammonia is available. The latter
process enables rapid return to service.
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OGN/OPS/CHEM/010
Issue-1 Aug., 94
4.0
SAFETY
The storage procedures discussed in this Guidance Note require the use
of a range of chemicals and nitrogen and should be considered in
conjunction with the NTPC Safety Code of practice. In applying these
procedures to plant, it is essential that the correct safety measures are
taken in :
i)
ii)
iii)
iv)
5.0
STORAGE SITUATIONS
5.1
ii)
iii)
Page 3
OGN/OPS/CHEM/010
Issue-1 Aug., 94
5.2
With few exceptions, plant required to be stored may be divided into four
categories as follow:
i)
ii)
iii)
iv)
5.3
Items of plant falling into categories (i) and (ii) will almost invariably have to
be drained at some period to carryout further erection or repair work. Plant
items in category (iii) may be stored under a variety of conditions, but
storage empty and dry is preferred. Plant coming under category (iv) will
be stored full or have sufficient water available to meet the requirement of
a rapid return to service.
5.4
Page 4
OGN/OPS/CHEM/010
Issue-1 Aug., 94
The storage procedure followed will also depend on the anticipated length
of the storage period and the notice of return to service that will be given. It
is therefore, essential that there is full co-operation between power stations
and System Operations to determine, as accurately as possible, the
required period of plant storage.
6.0
7.0
7.1
Complete Dry-out
7.1.1
7.1.2
If dry storage is to be used, every effort shall be made to use the residual
heat in the plant to assist in the drying-out process. As boiler plant is
brought off-load, it is normal practice to blow the boiler and associated
circuits empty
Page 5
OGN/OPS/CHEM/010
Issue-1 Aug., 94
7.1.4
7.1.5
If salts are retained within crevices in the plant, the presence of sufficiently
high humidity will lead to moisture adsorbtion by the salts and the probable
initiation of corrosion. To avoid this situation arising in salts derived from
Page 6
OGN/OPS/CHEM/010
Issue-1 Aug., 94
7.2
Incomplete Dry-out
Unless adequate measures are taken to ensure complete dry-out of plant,
it must be assumed that drained plant contains pockets of trapped water at
nondraining sites. It is considered that most cases of severe off-load pitting
corrosion occur in plant in this condition which must be avoided whenever
possible.
7.2.1
7.2.1.1
This procedure is the most convenient technique for the storage of partially
dry operational section of plant, particularly economizes and where access
is required to the water/steam circuits, e.g. during repairs and manaccess
(See also Section 8.0, "Wet Storage Techniques for Undrained Plant").
7.2.1.2
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OGN/OPS/CHEM/010
Issue-1 Aug., 94
(ii)
7.2.1.3
7.2.1.4
The plant item to be stored is drained and refilled with inhibitor solution.
The treated water may be left in the plant for the full period of storage, or
may be drained from the plant to allow maintenance and repairs to be
carried out. The required duration of contact before draining is related to
the strength of nitrite-borax solution used; with the 200 mg/kg sodium
nitrite and 200 mg/kg borax solution the period of contact is immaterial,
whilst with the 2000 mg/kg sodium nitrite and 1000 mg/kg borax used on
unoxidized steel surfaces, a minimum contact time of 24 hrs. is advisable if
fresh rusting is to be avoided.
7.2.1.5
Page 8
OGN/OPS/CHEM/010
Issue-1 Aug., 94
ii)
iii)
7.2.2
Nitrogen Filling
7.2.2.1
7.2.2.2
Two procedures have been used to introduce nitrogen into plant items as
follow:
i) The plant item is brought to atmospheric pressure and drained down.
Nitrogen is then purged through the circuit in a flowing system and
the oxygen content of the exit gas monitored. The purging is
continued until the oxygen content of the exit gas is less then 1.0%
by volume. The gas vent is then closed and the nitrogen supply to
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OGN/OPS/CHEM/010
Issue-1 Aug., 94
7.2.2.3
7.2.2.4
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OGN/OPS/CHEM/010
Issue-1 Aug., 94
7.2.2.5
8.0
8.1
8.1.1
affords protection to mild steel immersed in fully aerated water. With both
hydrazine and ammonia additions a lower pH can be tolerated, i.e. not less
than pH 10.0 (50 mg/kg NH3) if 50 mg/kg N2 H4 is added to the storage
water. In this instance, the hydrazine would act as an oxygen scavenger
and possibly as a corrosion inhibitor. Both regimes have been found to be
satisfactory. It should be stressed that aerated solutions of pH 10.7 must
not be used for the storage of plant items containing copper alloys (See
8.3).
Page 11
OGN/OPS/CHEM/010
Issue-1 Aug., 94
8.1.2
When using either of the above water compositions, it is essential that the
plant item be completely filled with the storage solution and that the pH in
particular, is maintained at or above the minimum figure quoted.
Furthermore, guaranteed protection can only be obtained if the chloride
content of the storage water is less than 2 mg/kg. Therefore, when putting
plant into a wet storage regime, every effort shall be made to meet this
limit, either when the plant is first put into storage or soon afterwards. If
water production/storage limitations are likely to preclude draining and
refilling with low chloride water, then increased blowdown shall be used as
far as possible to reduce chloride levels prior to bringing the plant off-load.
It is also essential that any water used to `top-up' the plant to replace
leakage losses shall be demineralized and chemically treated to meet the
above standards.
8.1.3
8.1.4
8.1.5
Page 12
OGN/OPS/CHEM/010
Issue-1 Aug., 94
8.16
8.2
8.3
8.3.1
8.3.2
ii)
Page 13
OGN/OPS/CHEM/010
Issue-1 Aug., 94
8.4
Nitrogen Capping
8.4.1
8.4.2
As when using full nitrogen storage, care must be taken to ensure that
nitrogen displaced from plant being brought back into service is vented
safely (See 7.2.2.5)
9.0
HYDRAULIC TESTS
When carrying out hydraulic tests, the plants must be flushed and
completely filled with deionized water (minimum temperature 7C,
electrical conductivity less than 0.5 s/cm and chloride less than 0.1
mg/kg) to which has been added suitable alkalizing or inhibiting agents. If
the plant is to be returned to service immediately, the addition of ammonia
to give pH of 9.3-9.4 is satisfactory. However, if return to service is to be
delayed a test should be carried out using one of the solutions described in
Section 8.0. The choice of solution shall be made with due regard to the
limitations on use given for each particular composition and materials
present in the plant (See Section 6.0 and Section 8.0).
10.0
REVIEW
The Executive Director, Operation Services, will be responsible for
reviewing this document on a 2-yearly basis.
Page 14
OGN/OPS/CHEM/010
Issue-1 Aug., 94
Period of
Application
Required Plant
Modifications
Special Conditions of
Application
Monitoring Requirements
Returning to
Service
Dry
Storage
(See 7.1)
Indefinite
Installation of equipment
to generate hot or
dry air. Additional
pipework for the
circulation of hot or
dry air. Additional
sampling points.
Reinstate plant
item. As required
fill with
demineralized
dearated water
with correct
chemical dosing.
Return to service.
Nitriteborax (See
7.2.1)
Indefinite
Ensure composition
of inhibitor solution
selected is appropriate
for type and condition
of plant.
Nitrogen
Indefinite
Regular monitoring of O2 in
Reinstate plant
item as required
fill with correct
filling
(See 7.2.2)
nitrogen injection.
Additional sampling
points.
chemical dosing.
Ensure that
nitrogen displaced
from the plant is
safely dispersed.
Return to Service
Page 15
OGN/OPS/CHEM/010
Issue-1 Aug., 94
Procedure
Period of
Application
Required Plant
Modifications
Special Conditions of
Application
Monitoring Requirements
Returning to
Service
Wet
storage
(see 8.0)
Indefinite
Plant to be filled
to air cocks with
storage solution of
correct composition.
Drain. Ensure
safe disposal of
storage solution.
Reinstate plant
Circulate storage
solution at regular
intervals and
prescribed specification.
pH>10
N2 H2 - 50 ppm
Ammonia-Commensurate with pH
Chloride - <2 ppm.
required, refill
with demineralised dearerated
water with correct
chemical dosing.
Return to service.
Isolate nitrogen
injection equipment as
necessary. Return
to service
ensuring that
nitrogen displaced
from plant is safety
dispersed.
maintain required
composition.
Nitrogen
Capping
(see 8.4)
Hydrotest
4 weeks
Installation for
nitrogen storage
and distribution.
Additional pipework
for nitrogen injection.
DM water having
specific conductivity- <0.5 S/cm
Chloride - <0.1 ppm.
pH - 9.3 to 9.4
Ammonia - commersurate with pH.
Page 16
OGN/OPS/CHEM/010
Issue-1 Aug., 94
Fig. 1 The relationship between moisture content, temperature and relative humidity for air
Page 17
OGN/OPS/CHEM/010
Issue-1 Aug., 94
Power Stations
1.
General Manager
SSTPS
2.
General Manager
KSTPS
3.
General Manager
RSTPS
4.
General Manager
FSTPP
5.
General Manager
RhSTPP
6.
General Manager
VSTPP
7.
General Manager
NCTPP
8.
General Manager
BTPS
9.
General Manager
KhSTPP
TSTPP
FGUTPP
BCPP
An.GPP
Au.GPP
KGPP
Ja.Gan.GPP
DGPP
II.
III.
Allahabad
Hyderabad
Nagpur
Patna
New Delhi
New Delhi
- do -
- do -
- do -
- do -
- do -
- do -
- do -
Noida