1 Added to section 4.

2.Water Quality parameters have been added to the appendix tables – Identical for Hot Clean
Up Procedure

3.Formula for Cleaning Force Ratio & Disturbance Factor calculation already included in
Procedure Section 2.0. Similar reference calculation is included in IHI Typical Steam Blow
Reference document E097-918 mentioned in section 8.7 a)

4.Service Blow Parameters are min 150C at 5Barg (< CRH design pressure) with exception of
the HP Bypass which is blown at MS conditions but without target.

5 Target plate to be of a width 30mm - & Length 85% of internal pipe diameter (attachment c)

6. Valve Technical specification are included as an attachment b. Opening and closing time
of the temporary blow valve is specified <60 sec Open & Close
7. Water quality standards (attachment d) will be the same as First Fire requirements
Ref: IHI guidelines Table 9.5.2 Completion Value of Boiler Cold Clean-up (Preconditions for Light off)

8 P&ID’s are already included in the procedure (imbedded .pdf file) (Attachment a)
 CIVIL
CONTRACTOR DOCUMENT REVIEW
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LOG DATE : V ELECT
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IN COMM NO : E I&C
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A APPROVED SUPPORT

B APPROVED AS NOTED CONTRACTOR

C NOT APPROVED D RECORD

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APPROVAL DOES NOT RELIEVE CONTRACTOR I
FROM RESPONSIBILITY FOR ERROR OR B
DEVIATIONS FROM CONTRACT U
REQUIREMENTS T
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OUT COMM NO :

1 IFI 22/04/2020 Incorporated PLN Comments PP GB BO For Info

0 IFI 5/04/2019 Initial Issue as a Site Document PP CG For Info
NO STATUS DATE REVISIONS AND RECORD OF ISSUE DRN DES CHK APP Comment

PT. PERUSAHAAN LISTRIK NEGARA (PERSERO)

AGENCY OF THE MINISTRY OF MINES AND ENERGY GOVERMENT
OF THE REPUBLIC OF INDONESIA
LONTAR EXTENSION COAL FIRED STEAM POWER PLANT (1X315MW)
CONTRACT NO : 0436.PJ/DAN.02.01/DIR/2015

PT. PLN (PERSERO)

PUSAT ENJINIRING KETENAGALISTRIKAN

PLN DWG No.

OWNER DRAWING TITLE OWNER DRAWING NUMBER OWNER REV NO

LONTAR EXTENSION PROJECT DRAWING NUMBER REV

COAL FIRED STEAM POWER PLANT (1 X 315 MW) 190145 96.1100.002 1

CODE
Main Steam Blow Procedure
AREA
Commissioning Procedure: Main Steam Blow Procedure Effective Date: 22 Apr 2020
96.1100.002 Rev. 1

Commissioning Procedure
Steam Blow Procedure
Process Owner: Site Commissioning Manager

TABLE OF CONTENTS

1.0 OVERVIEW ............................................................................................................ 2

2.0 STEAM CLEANING BACKGROUND ........................................................................ 4
3.0 SAFETY .................................................................................................................. 5
4.0 PREREQUISITES .................................................................................................... 5
5.0 ACCEPTANCE CRITERIA ........................................................................................ 6
6.0 PREPARATIONS .................................................................................................... 7
7.0 PROCEDURE ....................................................................................................... 10
8.0 REFERENCES ....................................................................................................... 16

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1.0 OVERVIEW
The Lontar project is a supercritical coal fired boiler and steam turbine generator (STG) rated
for 315 MW. The boiler is provided approximately 890,000 kg/hr of High-Pressure Steam to
the STG at 25,000 kPa and 582°C, and 735,000 kg/hr of Hot Reheat Steam at 4900 kPa and
600°C.

The Lontar project steam blow will include the blows as described below.

Due to project scheduling needs and equipment commissioning sequences, all of the
“Auxiliary Steam” blows will be performed before the primary flow path steam blows (Main
Steam, Cold Reheat, Hot Reheat.)

Quench water is mentioned in the procedure below, but it is optional and may only be used if
required for noise abatement.

A silencer is anticipated for use during the primary cycle piping blows but may or may not be
used for the Auxiliary Steam piping blows.

(Refer to Section 8 for the marked-up P&ID’s outlining the specific blow paths):

1.1 Main Boiler to Turbine Steam Piping Blows:

The main boiler will be used to provide steam through four (4) piping configurations,
as listed below that will clean the Main Steam (LBA), Cold Reheat (LBC), and Hot
Reheat (LBB) systems, plus the HP Bypass inlet and outlet pipeline which bypasses
steam from Main Steam to Cold Reheat, and the LP Bypass inlet piping which bypasses
steam from Hot Reheat to the Condenser. The piping from the LP Bypass valve outlet
to the Condenser will be cleaned by other means.

The Main Steam (LBA), Cold Reheat (LBC), and Hot Reheat (LBB) pipelines will be
targeted steam blows and the acceptance criteria shall be in accordance with Section
5. There will be temporary piping use between these systems, including a Temporary
Steam Blow (TSB) valve, main target inserter, quench water supply (if necessary), and
a silencer.
During the temporary steam blow operations, all drip leg drains in these permanent
systems will be fitted with temporary drain piping. The temporary piping will be
connected to the drip leg cap and field routed to a safe location to remove condensate
that collects in the pipeline during the steam blowing operations.

These four (4) piping configurations will use a steam-cyclic pressure blowout method
consisting generally of the following:

1) Build pressure and temperature in the steam generator.

2) Open the TSB valve to achieve Disturbance Factor. Steam will escape to the
atmosphere.
3) Boiler pressure and temperature will decay as the stored energy is released.
4) Close TSB valve and repeat Steps 1 through 3.

Note: Initial blows will be started with a low boiler pressure, gradually building up to
the pressure required to achieve the proper Disturbance Factor. The above cycle is
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repeated until the target bars placed in the blowout piping comply with the
Acceptance Criteria defined in Section 5.

1.1.1 Main Boiler #A: Main Steam

A steam cyclic blow from the boiler superheater outlets through the main
steam piping will be a targeted steam blow. The general steam blow path is
as follows:
Boiler Water Separator Superheaters Main Steam Pipe STG Main
Steam Stop Valves (with blow kits) Temporary Pipe TSB Valve
Main Target Quench Water Silencer Exhaust to Atmosphere

Note: It is not anticipated, but the Auxiliary Boiler will be available if needed
to provide steam to the reheater for cooling during this piping configuration.

1.1.2 Main Boiler #B: Main Steam Bypass Inlet and Outlet piping
A steam cyclic blow from the boiler superheater outlets through the main
steam HP Bypass Valve via a “blow-through kit” and cold reheat piping
(reverse flow from normal operation) will be a non-targeted steam blow.

Note, the subject blow-through kit for the HP Bypass Valve will not permit a
cleaning factor greater than 1, so prior to this blow, and possibly during the
construction and assembly of this pipeline, means must employed to pre-
clean this pipe either by manual cleaning methods followed by clean
assembly methods.

The general steam blow path is as follows:

Boiler Water Separator Superheaters Main Steam Pipe Main Steam

(HP) Bypass Valve and Piping (with blow-through kit) Cold Reheat Piping
(Reverse Flow) HP Turbine Exhaust Non-Return Valve Temporary Pipe
TSB Valve Quench Water Silencer Exhaust to Atmosphere

1.1.3 Main Boiler #C-1: Cold Reheat / Reheater / Hot Reheat / LP Bypass
A steam cyclic blow from the boiler superheater outlets through the main
steam piping, cold reheat piping, the boiler reheater, the hot reheat piping,
and in parallel through the LP Bypass valve via a “blow-out kit” will be a non-
targeted steam blow. The general steam blow path is as follows:

Boiler Water Separator Superheaters Main Steam Pipe STG Main

Steam Stop Valves (with blow kits) Temporary Pipe TSB Valve Cold
Reheat Pipe HP Turbine Exhaust Non-Return Valve Boiler Reheater
Hot Reheat Pipe LP Bypass Valve (with blow-out kit) Temporary Piping
Quench Water Silencer Exhaust to Atmosphere

1.1.4 Main Boiler #C-2: Cold Reheat / Reheater / Hot Reheat

A steam cyclic blow from the boiler superheater outlets through the main
steam piping, cold reheat piping, the boiler reheater, and the hot reheat
piping will be a targeted steam blow. The general steam blow path is as
follows:

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Boiler Water Separator Superheaters Main Steam Pipe STG Main

Steam Stop Valves (with blow kits) Temporary Pipe TSB Valve Cold
Reheat Pipe HP Turbine Exhaust Non-Return Valve Boiler Reheater
Hot Reheat Pipe CRV Valve (with blow kit) Temporary Piping Main
Target Quench Water Silencer Exhaust to Atmosphere

2.0 STEAM CLEANING BACKGROUND

The flow of steam in a piping system exerts a force on loose particles and debris, which tends
to carry the debris downstream. Various definitions are used to define the force exerted by a
flow stream, all of which are equal in quantifying the cleaning effect of a flow stream. These
definitions include, “Mass-Velocity Head,” “Cleaning Force,” and “Cleaning Pressure.” This
procedure will utilize “Cleaning Force,” which is defined as follows:

CF = m2 / [ 2 A (den)]

Where,

CF = Cleaning Force (N)

M = Mass Flow in pipe (kg/s)

A = Area of pipe (m2)

den = Density of fluid (kg/m3)

This equation shows that the Cleaning Force in a pipe section is dependent on the steam mass
flowrate, steam density, and pipe cross sectional area. The goal of a steam blow is to generate
a steam flow condition during steam blow which has a larger Cleaning Force than the
Reference Condition. The Reference Condition is defined as the cleaning effect experienced
during plant full load operating conditions. The ratio of these two forces is called the
“Disturbance Factor,” which is defined as follows:

DF = CFsb / CFrc

Where,

DF = Disturbance Factor

CFsb = Steam Blow Cleaning Force (N)

CFrc = Reference Condition Cleaning Force (N)

Targeted steam blows must have a Disturbance Factor equal to or greater than 1.05 in all
permanent steam piping.

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3.0 SAFETY
The following safety items shall be followed:
1. Prior to the start of steam blows, the Commissioning Manager or his designee shall
walk down all systems to assure all piping and supports, flow paths, equipment
scaffolding, barricades, and target bar inserter are complete and ready for steam
blows. All safety issues found must be resolved prior to the start of the blows.
2. All exposed temporary steam lines will be insulated with blankets or barricaded off
for personnel protection and anchored properly.
3. The steam blow exhaust path will be cleared of nonpermanent structures, vehicles,
materials and personnel. Inspect the areas of the permanent and temporary steam
blow piping and clean any wood, oil, or other flammable material out of the area.
Access to this area shall be limited.
4. The Local Governing Body will be informed that the sound levels are temporary and
do not reflect typical facility noise levels.
5. The plant Lockout/Tagout procedure shall be followed for valve lineups and flow
paths.
6. All boiler manufacturers recommended operating procedures shall be followed during
the steam blows.
7. Hearing protection is required near all steam piping during the blows. Warning signs
noting the high noise levels shall be placed in areas around the temporary piping tie-
in points and all steam exit points.
8. Commissioning and operations personnel shall have radio communications with the
control room throughout the blows.
9. All personnel working in the vicinity of the steam blows shall receive a safety
orientation regarding the steam blows and associated hazards.
10. No unauthorized personnel shall be permitted in the vicinity of the temporary steam
piping and exhausters during the blows.

During steam blow, the steam flow paths to the steam turbine will be isolated from the steam
turbine such that the turbine cannot be rolled off. The main steam supply will be physically
isolated from the stop valves, the hot reheat will be physically isolated from the reheat stop
valves and the cold reheat will be isolated from the turbine exhaust.

4.0 PREREQUISITES
The following systems are needed for steam blow and should be operational with alarms,
interlocks and protective devices functional.
Construction TOP/BAPPK will be reviewed and issued including partials for the following
systems

• Compressed Air Generation

• Station Air
• Instrument Air
• Auxiliary Cooling Water
• Closed Cycle Cooling Water
• Fuel Oil Transfer
• Fuel Oil Supply
• Fuel Oil Burners
• Plant Fire Protection
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• Site Fire Protection

• Boiler Vents and Drains
• Turbine Vents and Drains (including Miscellaneous Drains Tank)
• Boiler Feedwater
• Condensate / Condenser
• Cycle Chemical Feed
• Cycle Makeup and Storage
• Circulating Water
• Circulating Water Chemical Feed
• Steam Generator
• Forced Draft Fans
• Induced Draft Fans
• Primary Air Fans
• Electrostatic Precipitator
• Chimney
• Service Water
• Wastewater Collection & Treatment
• Oily Waste Drains
• Temporary Demineralized Water System (e.g. water pumps, trailers, etc.)
• Water & Steam Sampling System Available and In Service

5.0 ACCEPTANCE CRITERIA

These criteria will be used to determine when a piping segment has been thoroughly cleaned.
The acceptance criteria are:

Service Blow These criteria shall apply to vents, drains, auxiliary systems, and any pipe not
specifically identified as requiring a Target Blow.

Blow the piping until the steam plume/drain is visibly clear of debris. Visually inspect the
permanent and temporary piping for abnormal expansion levels.

Target Blow These criteria and/or the Steam Turbine Manufacturer’s criteria shall apply to all
sections being steam blown that are targeted and require certification. In the case of a
conflict between the two criteria, the more stringent of the two will be applied.

Blow the pipe until the steam plume is free of visible dirt and debris. The Disturbance Factor
during this steam blow period shall equal or exceed 1.05 unless limited by boiler restrictions.
Targets may be inserted at any time once the plume has cleared. A minimum of 2 consecutive
acceptable targets shall be taken for each steam blow. The final acceptance target must be
inserted after a minimum 3hour time period has passed. Successful completion of a target
steam blow shall be witnessed and signed off by the Startup Manager, the Toshiba or Siemens
TA, and the Owner.

The target bar shall be fabricated of brass polished to a surface texture R max. 6.3 µ. The target
bar area subject to inspection shall be 30 mm in width and middle 85% of the internal pipe
diameter. The target shall remain in the steam flow path for 10 minutes.

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A target bar shall be judged acceptable if the following criteria are met.

• No marks > 0.5mm in length or depth.

• No more than two (2) marks < 0.5mm in length and depth on entire target surface
and no more than one (1) mark on any 25mm square area on target.
• There are no more than five raised surface marks between 0.3 mm and 0.5 mm per
25 mm square area.
• All marks under 0.3 mm and unraised marks under 0.5 mm shall be ignored.
• The target area corresponds to the middle 85 percent of the pipe inside diameter.
• The above criteria are met in two consecutive steam blows.

Cleanliness criteria for the main Turbine are listed in Toshiba document SPC- GMH-XILT4-
0003.

Cleanliness criteria for the Boiler Feed Pump Turbines are listed in Siemens document
2CWN002896.

6.0 PREPARATIONS
Install the temporary piping as called for in the Steam Blow (LBK) system P&ID and Steam Blow
(LBK) system isometric drawings. This is including, but not limited to the following:

• Main Boiler Steam Blow Large Bore Temporary Piping

• Hydraulically activated or Motor operated TSB valve
• Boiler Area Temporary Piping Spools; target inserter(s), quench water spray (if
required), and silencer
• Drip leg small bore temporary piping routed to a safe area.
• BFPT Gland Seal Steam small bore temporary piping, routed to a safe area vented to
atmosphere.
• Soot blowing Large Bore Temporary Piping

Prior to the start of any steam blow, a walkdown the piping shall be completed and verification
that all valves, flanges, piping sections, etc. are in accordance with the correct open/close
position.
Close all isolation valves for any PTC connections and any instrumentation not needed
specifically for the steam blow process or needed for system control in the MS, HRH, CRH, or
LBG steam systems.
Close all manual drain valves in all the drip legs of the MS, HRH, CRH and LBG steam systems.

The following is general summary of modifications specific to each piping configuration and is
not an all-inclusive list:

Note: The AST valve will initially be connected to the desalination temporary piping until the
Auxiliary Boiler #1 steam blow is completed. It will then be relocated and connected to the
temporary piping near the turbine building.

6.1 Main Boiler #A: Main Steam

• Install blow kits in each of the Main Turbine Stop Valves, MS-01 & MS-02, and
connect to temporary blow piping.
• Remove the blind from 40LBK20BLNK001.
• Remove the blind from 40LBK20BLNK002.
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• Remove the blind from 40LBK40BLNK004.

• Install the blind for 40LBK22BLNK001.
• Install the blind for 40LBK23BLNK001
• Install the blind for 40LBK40BLNK001.
• Install the blind for 40LBK50BLNK001.
• HP Bypass Valve 40MAN10AA001 shall be isolated.
• Isolation valves for pressure instruments shall be open if needed for control of
the process. Otherwise the valves shall be closed.
• Sampling isolation valve 40LBA60AA501 shall be closed.
• Isolation valves for PTC connections shall be closed (LBA, LBB, and LBC systems.)
• Safety valves shall be open and operable (LBA, LBB, and LBC systems.)
• Drain isolation valves 40LBA61AA851 and 40LBA62AA851 shall be closed.
• Temporary drain valves 40LBK13AA801, 40LBK14AA801, 40LBK40AA001,
40LBK40AA003, and 40LBK40AA851 shall be opened periodically to drain
condensate as necessary.
• Temporary bypass valve 40LBK21AA501 shall be open.
• AST valve 40LBK41AA002 shall be closed.

6.2 Main Boiler # B: Main Steam (HP) Bypass

• Install blow kits in each of the Main Turbine Stop Valves, MS-01 & MS-02, and
connect to temporary blow piping.
• Remove the internals from the CRH non-return valve, 40LBC10AA701
• Install temporary Blanking plates at the two Main Turbine HP Exhaust
connections to Cold Reheat, 40LBC11BLNK001 and 40LBC12BLNK001.
• Install the blow-through kit internals for HP Bypass Valve 40MAN10AA001.
• Remove the blind from 40LBK22BLNK001
• Remove the blind from 40LBK20BLNK002.
• Remove the blind from 40LBK40BLNK004
• Install the blind for 40LBK20BLNK001
• Install the blind for 40LBK23BLNK001
• Install the blind for 40LBK40BLNK001
• Install the blind for 40LBK50BLNK001
• Isolation valves for pressure instruments shall be open if needed for control of
the process. Otherwise the valves shall be closed.
• Isolation valves for PTC connections shall be closed (LBA, LBB, and LBC systems.)
• Safety valves shall be open and operable (LBA, LBB, and LBC systems.)
• Cold Reheat Level Switch Isolation Valves shall be closed (40LBC10AA903,
40LBC10AA905, 40LBC10AA907, 40LBC10AA909, 40LBC10AA911,
40LBC10AA913, 40LBC10AA915, 40LBC10AA917)
• Main Steam drain isolation valves 40LBA61AA851 and 40LBA62AA851 shall be
closed.
• HP Bypass attemperating spray isolation valve 40LAE10AA502 shall be closed.
• Main Steam sampling isolation valve 40LBA60AA501 shall be closed.
• LP Bypass Valve 40MAP10AA001 shall be isolated.
• Cold Reheat drain isolation valves 40LBC10AA851 and 40LBC10AA861 shall be
closed.
• Cold Reheat isolation valve 40LBC50AA201 shall be closed.
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• Hot Reheat sampling isolation valve 40LBB60AA501 shall be closed.

• Hot Reheat drain isolation valves 40LBB61AA851 and 40LBB62AA851 shall be
closed.
• Auxiliary Steam isolation valves 40LBG24AA201 (a.k.a. 40MAA20AA201) and
40LBG12AA501 shall be closed.
• HP Extraction isolation valve 40LBQ20AA201 shall be closed.
• Temporary drain valves 40LBK13AA801, 40LBK14AA801, 40LBK25AA801,
40LBK26AA801, 40LBK33AA801, 40LBK34AA801, 40LBK40AA001,
40LBK40AA003, and 40LBK40AA851 shall be opened periodically to drain
condensate as necessary.
• Temporary bypass valve 40LBK21AA501 shall be open.
• AST valve 40LBK41AA002 shall be closed

6.3 Main Boiler #C: Cold Reheat / Reheater / Hot Reheat / LP Bypass
• Install blow kits in each of the MSV/CV’s, MS-01 & MS-02, and connect to
temporary blow piping
• Install blow kits in each HRH throttle valve, HR-01 & HR-02 and connect to
temporary piping
• Remove the internals from the CRH non-return valve, 40LBC10AA701
• Install temporary Blanking plates at the two Main Turbine HP Exhaust
connections to Cold Reheat, 40LBC11BLNK001 and 40LBC12BLNK001.
• Return HP Bypass Valve 40MAN10AA001 to its normal configuration and close
the valve.
• Remove the blind from 40LBK20BLNK001
• Remove the blind from 40LBK23BLNK001
• Remove the blind from 40LBK40BLNK001
• Remove the blind from 40LBK40BLNK004
• Install the blind for 40LBK20BLNK002
• Install the blind for 40LBK22BLNK001
• Install the blind for 40LBK50BLNK001
• Remove the blind for 40LBK35BLNK001 for the initial blows in this sequence, and
then install it for the target blows.
• Isolation valves for pressure instruments shall be open if needed for control of
the process. Otherwise the valves shall be closed.
• Isolation valves for PTC connections shall be closed (LBA, LBB, and LBC systems.)
• Safety valves shall be open and operable (LBA, LBB, and LBC systems.)
• Cold Reheat Level Switch Isolation Valves shall be closed (40LBC10AA903,
40LBC10AA905, 40LBC10AA907, 40LBC10AA909, 40LBC10AA911,
40LBC10AA913, 40LBC10AA915, 40LBC10AA917)
• HP Bypass Valve 40MAN10AA001 shall be closed.
• HP Bypass attemperating spray isolation valve 40LAE10AA502 shall be closed.
• Main Steam drain isolation valves 40LBA61AA851 and 40LBA62AA851 shall be
closed.
• Main Steam sampling isolation valve 40LBA60AA501 shall be closed.
• Cold Reheat drain isolation valves 40LBC10AA851 and 40LBC10AA861 shall be
closed.
• Cold Reheat isolation valve 40LBC50AA201 shall be closed.

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• Hot Reheat sampling isolation valve 40LBB60AA501 shall be closed.

• Hot Reheat drain isolation valves 40LBB61AA851 and 40LBB62AA851 Shall be
closed.
• Auxiliary Steam isolation valves 40LBG24AA201 (a.k.a. 40MAA20AA201) and
40LBG12AA501 shall be closed.
• HP Extraction isolation valve 40LBQ20AA201 shall be closed.
• Temporary drain valves 40LBK13AA801, 40LBK14AA801, 40LBK25AA801,
40LBK26AA801, 40LBK33AA801, 40LBK34AA801, 40LBK40AA001,
40LBK40AA003, and 40LBK40AA851 shall be opened periodically to drain
condensate as necessary.
• Temporary bypass valve 40LBK21AA501 shall be open.
• AST valve 40LBK41AA002 shall be closed.

7.0 PROCEDURE
7.1 Overall Steam Blow Sequence:
Main Boiler #A: Main Steam (targeted)
Main Boiler #B: Main Steam Bypass and Cold Reheat (targeted)
Main Boiler #C: Cold Reheat / Reheater / Hot Reheat / LP Bypass (targeted)

7.2 Overall Process Conditions:

The calculated steam blow flow rates, pressures, temperatures, CFR’s, and boiler
operating conditions required for the steam and service blows are provided in Table 1
and Table 2 in Section 8 References.

The tables should be referred to during the steam blow process to assist in determining
the Disturbance Factor. The Cleaning Force Charts provided in the tables are based on
temporary pipe configurations and boiler steam production capabilities. Since the
boiler performance may be different than the design basis of this procedure, the
achievement of Disturbance Factors greater than 1.05 may occur at different boiler
loads than indicated.

7.3 Final Acceptance of Steam Blow:

Refer to the Steam Blow Acceptance Sheets in the Appendix for details of final
acceptance.

7.4 Main Boiler Steam Blow Procedure

7.4.1 Limitations:
Operation during the steam blow process should be monitored closely to
ensure that the original equipment manufacturer’s operating procedures are
followed and no operational limits are exceeded. Prior to conducting this
steam blow, the references identified in this procedure should be carefully
reviewed. Listed here are some, but not all, equipment and project
limitations that shall be followed:

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a) Furnace exit gas temperature shall be monitored to assure the boiler

temperature limits are not exceeded.
b) Do not exceed the superheater tube design temperature or reheater
tube design temperature specified in the boiler manufacturer’s
operating instructions.
c) Dirty steam should not be allowed to pass through the startup vents
or reheater.
d) Boiler burner rates should be monitored to ensure the boiler has
been properly tuned and authorized for loads higher than this limit.
e) During the HP Bypass Piping steam blow care must be taken to
assure the Cold Reheat piping design pressure is not exceeded when
building up boiler pressure prior to opening the temporary steam
blow valve.

7.4.2 General Notes on Steam Blows:

a) Temporary steam blow desuperheaters shall be OFF at all steam
temperatures below 315°C. Otherwise, operate the desuperheaters
to quench to saturation in order to mitigate noise. (If necessary.)
b) The Hot Reheat bypass piping between the LP bypass valve and the
condenser will not be steam blown. Instead, this piping will be
cleaned under a separate procedure.
c) The HP to CRH bypass piping will be steam blown after the Main
Steam blows.
d) All branch lines not being blown during a steam blow shall be
isolated in order to avoid creating “dead-legs” which will collect
debris and cause targets to fail. The Startup Manager shall identify
all potential “dead-legs” of the steam systems being blown.
e) The MS, CRH, HRH, Auxiliary Steam, and temporary piping drains
shall be opened at the early stages of steam blow to prevent the
accumulation of condensate.
f) Drip legs shall have temporary field-routed piping connections
installed to allow blowing each drip leg. While blowing each system,
periodically blowdown all drip legs in the flow path and laterals for
ten (10) minutes each. All drip legs shall be cleaned out after
completion of steam blowout operations by cutting off the
temporary blow piping and manually removing any accumulated
debris. A permanent cap shall then be welded in place.
g) All systems required for the steam blows shall be operated in
accordance with the normal operating procedures. Deviations from
the normal operating procedures will be identified by the Startup
Manager or his designee.
h) The condenser hotwell water level during each steam blow shall be
closely monitored by operating personnel to insure adequate water
level is properly maintained. Elevated hotwell level should be
maintained to ensure adequate reserve. Level indications or alarms
by the DCS should be verified manually. The water level in the
hotwell must take into account, and not cover any steam drains that
may be directed to the condenser during steam blow operations.

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i) A temporary demineralized water storage tank (if required) and the

condenser hotwell will be filled prior to initiating the steam blow.
The condenser makeup water supply system shall be configured to
maintain adequate makeup water flow rate to the condenser.
j) The permanent and temporary steam piping systems and equipment
shall be monitored during steam blow to ensure safe practices are
maintained. Check for steam leaks and expansion problems in the
temporary piping during all steam blows. Repair leaks as required.
Pipe supports shall be inspected to insure that they are within the
design travel limits, but not necessarily at their design hot
condition.
k) The Startup Manager or his designee shall walk down all systems
prior to steam blows. The walkdowns will review permanent and
temporary piping, flow paths, equipment, piping supports,
scaffolding, barricades, silencer placement, target bar inserter
operation, and hose connectors. Any remaining safety issues should
be identified and resolved prior to the start of steam blows.
l) Upon completion of the final steam blow, all temporary piping and
equipment shall be removed and the plant restored to its
permanent plant operating configuration.
m) All manufacturers’ recommended startup procedures and allowable
temperature soak periods and ramp rates shall be followed for the
boiler.
n) The pressure and temperatures in all permanent steam piping shall
be continuously monitored by the plant DCS and local
instrumentation to ensure that it does not exceed the desired levels.
Excessively high conditions may cause the design conditions for the
temporary steam blow piping to be exceeded. If the condition in the
temporary piping exceeds its design values, corrective measures
shall be taken. If the excessive conditions cannot be reduced, the
boiler may need to be shut down.
o) If provided, portable demineralized water trailers will be connected
to the temporary demineralized water storage tank(s) and from the
storage tank(s) directly to the cycle make-up and supply system
pipe connections.
p) Boiler water pH shall be closely monitored during steam blow. The
boiler and feedwater shall be maintained at a pH acceptable to the
boiler supplier.
q) Boiler feedwater flow instrumentation and controls shall be
complete and operational from the control room. The permanent
steam flow nozzles and orifices will not be used to measure steam
flow unless otherwise noted (i.e. their calibration would need to be
adjusted for the expected conditions during steam blow). It is
anticipated that the boiler feedwater and condensate flow orifices
and nozzles will be used for steam flow determination.
r) The plant DCS may be temporarily configured to calculate
Disturbance Factors.

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s) A log book shall be maintained of all modifications made to DCS

programming, jumpers, and any other modifications that are made.
Each item shall be noted with the date/time it is made, and the
date/time it is cleared and restored to normal operation.

7.4.3 Condensate and Feedwater Configuration

During the Main Steam, HP Bypass, and Reheat steam blows, the condensate
and feedwater systems will be in operation as described below.
Note: During the Auxiliary Steam System blows, steam will be supplied from
the Auxiliary Boiler and the main plant condensate and feedwater systems
will be out of service.

For main steam and reheat blows, the condensate system shall be
configured with one condensate pump, the condensate polisher and the
gland steam condenser in service. LP Heaters 5, 6, 7 and 8 and the Drain
Cooler shall be bypassed. The LP System Bypass Desuperheater Sprays,
Auxiliary Steam System Attemperator Sprays, and Generator Cooling Water
Supplemental Supply shall be isolated. Instrumentation and controls
associated with the in service condensate components shall also be in
service. Normal operating procedures shall be followed for the in service
components.

The feedwater system shall be configured with one boiler feed pump and
associated strainers in service. HP Heaters 1, 2 and 3 shall be bypassed. The
HP Attemperators, Reheat Desuperheaters, Water Collecting Tank and
associated instrumentation shall be in service. Instrumentation and controls
associated with the in service feedwater components shall also be in service.
Normal operating procedures shall be followed for the in service
components.

7.4.4 Steam Blow Control Configuration

Prior to the steam blow activities, temporary modifications to the DCS
configuration may be required. These are to be implemented in the field.
Programming of Disturbance Factor for each piping section cleaned. A log
book shall be maintained of all modifications made to DCS programming,
jumpers, and any other modifications that are made. Each item shall be
noted with the date/time it is made, and the date/time it is cleared and
restored to normal operation.

7.5 Main Boiler #A: Main Steam

Pipe Cleaned: High Pressure Steam Pipe (Target Blow).

Drawings: Main Boiler #A Steam Blow Package (Appendix 1)

Reheater: The Auxiliary boiler will supply cooling steam to the reheater via the
Cold Reheat piping, and will vent through the boiler vent valves
and/or drains in the HRH piping

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7.5.1 Instrumentation
Instrumentation to be used for calculating the Disturbance Factors in the HP
steam piping.
Pressure: 40LBA60CP001 (HP Superheater Outlet pressure
transmitter) Temperature: 40LBA60CT001 (HP Superheater Outlet
temperature transmitter)
Flow: 40LAB50CF601 (Economizer Inlet flow transmitter)
7.5.2 Procedure
The HP Steam blow will consist of cyclic pressure targeted blows.

Initially, the boiler will be fired with the TSB gate valve closed and the warm
up valves open to the silencer. During this period, all of the drip legs and low
point drains in the system will be opened to purge any condensate.
Once the system has reached 150°C, the warm up valves will be closed and
the boiler temperature and pressure allowed to build up to those specified
in Table 1.

Once the boiler conditions reach the Initial Cleaning Steam Conditions
specified in Table 1, the TSB valve is opened as quickly as possible to blow
steam through the main steam blow path to the silencer.

Continue blowing until either the pressure drops below the Final Cleaning
Steam Conditions or the water level drops below the sight glass in the
collection tank, then close the TSB valve and repeat the process of Firing to
the Initial Cleaning Steam Conditions, then blowing to atmosphere.

When the steam blow plume is clear of visible dirt and debris, generally after
10 to 15 blows, begin inserting targets into the blow path to monitor the
pipe cleanliness.

Once the target conditions meet the Acceptance Criteria outlined in Section
5.0, pull the boiler fire and allow the temporary piping to cool, then
reconfigure the piping and blinds in the temporary piping to perform the
HP Bypass piping blows.

7.6 Main Boiler #B: Main Steam Bypass to Cold Reheat

Pipe Cleaned: P Steam Bypass & Cold Reheat Inlet piping (Service Blow).

Drawings: in Boiler #B Steam Blow Package (Appendix 1)

Reheater: Cooling steam for the reheater during HP Bypass blows will be
provided from the Main Steam circuit through the bypass valve and
will vent through the boiler vent valves and/or drains in the HRH
piping.

7.6.1 Instrumentation

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Instrumentation to be used for calculating the Disturbance Factors in the HP

Bypass and Cold Reheat inlet piping.
Pressure: 40LBA60CP001 (HP Superheater Outlet pressure
Transmitter)
Temperature: 40LBA60CT001 (HP Superheater Outlet temperature
transmitter)
Flow: 40LAB50CF601 (Economizer Inlet flow transmitter)

7.6.2 Procedure
The HP Bypass and CRH blow will consist of continuous pressure service
blows.

Initially, the boiler will be fired with the TSB valve closed and the warm up
valves open to the silencer. During this period, all of the drip legs and low
point drains in the system will be opened to purge any condensate.

Once the system has reached the 150°C, the warm up valves will be closed
and the boiler temperature and pressure allowed to build up to the Initial
Cleaning Steam Conditions specified in Table 1. Care must be taken to avoid
building up pressure higher than the Cold Reheat piping design pressure.

Once the boiler conditions reach the Initial Cleaning Steam Conditions
specified in Table 1, the TSB valve is opened as quickly as possible to blow
steam through the cold reheat steam blow path to the silencer.

Continue blowing until either the pressure drops below the Final Cleaning
Steam Conditions or the water level drops below the sight glass in the
collection tank, then close the TSB valve and repeat the process of firing up
to the Initial Cleaning Steam Conditions, then blowing to atmosphere.

When the steam blow plume is clear of visible dirt and debris, pull the boiler
fire and allow the temporary piping to cool, then reconfigure the blinds in
the temporary piping to perform the HRH blows.

7.7 Main Boiler #C: Cold Reheat / Reheater / Hot Reheat / LP Bypass

Pipe Cleaned: Cold Reheat Piping / Reheater / Hot Reheat Piping / LP Bypass
(Target Blow).

Drawings: Main Boiler #C Steam Blow Package (Appendix 1)

7.7.1 Instrumentation
Instrumentation to be used for calculating the Disturbance Factor through
the reheater and piping.
Pressure: 40LBB60CP001 (HRH Outlet pressure transmitter)
Temperature: 40LBB60CT601 (HP Superheater Outlet temperature
transmitter)
Flow: 40LAB50CF601 (Economize Inlet flow transmitter)

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7.7.2 Procedure
The HRH/CRH blow will consist of cyclic pressure targeted blows.

Initially, the boiler will be fired with the TSB gate valve closed and the warm
up valves open to the silencer. During this period, all of the drip legs and low
point drains in the system will be opened to purge any condensate.

Once the system has reached 150 °C, the warm up valves will be closed and
the boiler temperature and pressure allowed to build up to those specified
in Table 1.

Once the boiler conditions reach the Initial Cleaning Steam Conditions
specified in Table 1, the TSB valve is opened as quickly as possible to blow
steam through the hot reheat steam blow path to the silencer.

Continue blowing until either the pressure drops below the Final Cleaning
Steam Conditions or the water level drops below the sight glass in the
collection tank, then close the TSB valve and repeat the process of firing to
the Initial Cleaning Steam Conditions, then blowing to atmosphere.
During the initial (non-targeted) blows, the temporary piping from the LP
Bypass valve will be open allowing the piping from the HRH main header to
the LP Bypass valve inlet to be cleaned.

When the steam blow plume is clear of visible dirt and debris, allow the
piping to cool down, and insert a spectacle blind in the temporary piping
from the LP Bypass valve blowout kit nozzle.

Once the spectacle blind is installed blocking the steam pathway to the LP
Bypass valve, restart the boiler and begin inserting targets into the blow
path to monitor the pipe cleanliness.

When two consecutive targets meet the acceptance criteria outlined in

section 5, shut down at least one overnight shift and force cool the steam
generator. Restart the boiler and resume blows until two consecutive
acceptable targets are met.

Note that since the Hot Reheat circuit encompasses the normal steam path
(i.e. Main Steam, Cold Reheat, Reheater, and Hot Reheat), and thermal
cooldown will be performed between circuits to reconfigure temporary
piping blinds, the cooldown is required only for the Hot Reheat circuit.

8.0 REFERENCES
The following documents define the routing, configuration, equipment, operating, and design
criteria of the steam blow and related systems.

8.1 Steam Condition Requirements

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a) Table 1 – Main Steam, Cold Reheat, and Hot Reheat Blow Conditions

8.2 Project P&ID’s:

a) 189963-4LBA-M2587
b) 189963-4LBB-M2590
c) 189963-4LBC-M2591
d) 189963-4LBG-M2061A
e) 189963-4LBG-M2061B
f) 189963-4LBG-M2061C
g) 189963-4LBS-M2602A
h) 189963-4MAW-M2623A

8.3 Supplier Drawings:

a) IHI P&ID’s K600-311

b) Siemens BFPT P&ID 620P42253_U1_64304030, AS SB
c) Siemens BFPT P&ID P189963-620P42253_U2_64304030, AS SB
d) Toshiba Steam Seal P&ID 0KS002730
e) Toshiba Seal Steam Piping Isometric Drawings DDKW26726
f) Toshiba CRH Check Valve Isolation Device DDKW26410 Page 5 of 7
g) Entropie Veolia P&ID 16003-PD-0023

8.4 Project Isometric Drawings:

a) 189963-09-40LBA-01 (Main Steam System Isometric)

b) 189963-09-40LBC-01 (Cold Reheat System Isometric)
c) 189963-09-40LBB-01 (Hot Reheat System Isometric)
d) 189963-08-40LBG-01 (Auxiliary Steam System Isometric)
e) 189963-02-40LBK80BR001-1
f) 189963-02-40LBK80BR002-1
g) 189963-02-40LBK80BR003-1
h) 189963-08-40LBK81BR001-1
i) 189963-09-40LBK11BR001-1
j) 189963-09-40LBK12BR001-1
k) 189963-09-40LBK20BR001-1
l) 189963-09-40LBK20BR003-1
m) 189963-09-40LBK20BR004-1
n) 189963-09-40LBK21BR001-1
o) 189963-09-40LBK22BR001-1
p) 189963-09-40LBK23BR001-1
q) 189963-09-40LBK23BR001-2
r) 189963-09-40LBK23BR001-3
s) 189963-09-40LBK31BR001-1
t) 189963-09-40LBK32BR001-1
u) 189963-09-40LBK33BR001-1
v) 189963-09-40LBK40BR001-1

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w) 189963-09-40LBK50BR001-1
x) 189963-09-40LBK50BR001-2
y) 189963-09-40LBK50BR001-3
z) 189963-09-40LBK51BR001-1
aa) 189963-09-40LBK52BR001-1
bb) 189963-09-40LBK90BR002-1
cc) 189963-09-40LBK90BR003-1
dd) 189963-09-40LBK90BR004-1
ee) 189963-09-40LBK90BR005-1
ff) 189963-09-40LBK90BR006-1
gg) 189963-09-40LBK90BR006-2
hh) 189963-09-40LBK90BR007-1

8.5 Steam Blow System (LBK) P&ID’s:

a) 189963-4LBK-M2594A
b) 189963-4LBK-M2594B
c) 189963-4LBK-M2594C
d) 189963-4LBK-M2594D
e) 189963-4LBK-M2594E

8.6 Piping Isometric Drawings

a) TBA

8.7 Supplier Documents

a) E097-918 IHI Boiler Steam Blow Procedure (Typical)
b) 2CWN002896 (Siemens)

APPENDICES:

1) Steam Blow Valve List

2) Steam Blow Acceptance Sheets
3) Annotated Steam Path P&ID Markup Set - Attached

i. Main Boiler #A Steam Blow Package

ii. Main Boiler #B Steam Blow Package
iii. Main Boiler #C Steam Blow Package

ATTACHMENTS:

a) Steam Blow P&ID's

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Table 1 – Lontar Unit 4 Steam Blow Conditions

Main Steam HP Bypass Cold Reheat
(LBA) (MAN) (LBC)
Boiler Load % 100 70 100
Pipe ID mm 292 210 373
Blow Type Target Service Target
Heat Balance Case TMCR HLO TMCR
Reference Steam Conditions
Flow kg/hr 944716 623078 439848
Pressure MPa 25.8 25.57 5.73
Temperature °C 585 582 352.58
Density kg/m3 76.36 75.22 22.401
Initial Cleaning Steam
Conditions
Flow kg/hr 473339 609334
Pressure MPa 3.5 2.136
Temperature °C 345 344
Density kg/m3 13.096 7.90
CFR >1 >1
Final Cleaning Steam Conditions
Flow kg/hr 348530 501187
Pressure MPa 2.5 1.69
Temperature °C 305 304.35
Density kg/m3 9.948 6.72
CFR >1 >1

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Table 2 – Lontar Unit 4 Auxiliary Steam Blow Conditions

1 2 3 4 5 6 7 8 9 10
Auxiliary Steam Auxiliary Auxiliary Auxiliary CRH Steam Auxiliary Steam to Auxiliary LP Extraction LP Extraction LP Extraction
to Thermal Steam to Steam to Steam to Supply Piping CRH Deaerator Steam Supply to Supply to the to CRH
Desalination Soot Blowing CRH via Gland to Auxiliary Supply Header via Supply Auxiliary BFP Turbines Deaerator
Plant via Pipeline Pipeline Seals Steam Pipelines 40LBG22 Piping to the Steam Header Header
40LBG52 40LBG24 Header and 40LBC50 BFP Turbines

Pipe ID mm 305 438 305

Blow Type Service Service Service Service Service Service Target Target Target Service
Reference Steam Conditions
Flow kg/hr * * * * * * 25888 88412 25888 *
Pressure MPa (a) 1.092 1.13 1.092
Temperature °C 366 366.2 366

Density kg/m3 3.77 3.84 3.77

Cleaning Steam Conditions
Flow kg/hr 40000 40000 40000
Pressure MPa (a) 0.527 0.531 0.553
Temperature °C 256.7 256.9 257.3

Density kg/m3 2.07 2.09 2.19

CFR >1 >1** >1**

* Auxiliary Steam Blows 1, 2, 3, 4, 5, 6, and 10 are service blows. As such, the only requirement is to maintain the AST valve throttled to achieve the optimum
pressure in the Auxiliary Boiler Drum of 11.7 bar (g) (170 psig), and visually confirm the pipe cleanliness by observation of the steam discharging the exit location.

** Pipe Segment from IP Exhaust steam header to BFPT's and Deaerator Pegging having CFR less than 1 will be hydrolased in lieu of, or in addition to, steam
blow.

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Table 9.5.3 Completion Value of Boiler Hot Clean-up (Preconditions for Pressure Rise)
Items Required value Target Value Remark
Treatment All Volatile Treatment
Dissolved Oxygen(O2) < 10 ppb at ECO Inlet
Cation Conductivity at < 1 µS/cm at ECO Inlet
25deg.C
Iron(Fe) < 50 ppb at ECO Inlet
Silica(SiO2) < 30 ppb at ECO Inlet
pH at 25deg.C 9.3 – 9.5 at ECO Inlet
Hydrazine (N2H4) >20 at ECO Inlet
Copper(Cu) < 2 ppb at ECO Inlet

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b) Valve Technical Specification

c) Target plate

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d) IHI guidelines Table 9.5.2 Completion Value of Boiler Cold Clean-up (Preconditions
for Light off)
Items Required value Target Remark
Value
Treatment All Volatile
Treatment
Dissolved < 10 ppb at ECO Inlet
Oxygen(O2)
Cation < 1 µS/cm at ECO Inlet
Conductivity at
25deg.C
Iron(Fe) < 100 ppb at ECO Inlet

Silica(SiO2) < 30 ppb at ECO Inlet

pH at 25deg.C 9.3 – 9.5 at ECO Inlet

Hydrazine (N2H4) >20 at ECO Inlet

Iron(Fe) < 150 ppb at Separator

Drain Tank
Outlet

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REVISION HISTORY

Revision
Number Revision History Effective Date
0 Initial Issue as a Site Document 07/04/2019

1 Incorporated PLN Comments 22/04/2020

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