PRESERVATION CONCEPT
for HRSG after erection completion till start of
pre-commissioning
OWNER:
PROJECT TITLE:
ALBA PS5
MAIN CONTRACTOR:
Revision History
Rev. Revision Date Created by Checked by Approved by Description
Description latest Revision:
Cross checked
Department Name Date Signature
Main Contractor
Replaces
Responsible dept. Created by Checked by Approved by Format
. . A4
Originator Document Type Document Status
- Electronically released
Title, Subtitle Identification number
PRESERVATION CONCEPT For
HRSG after erection completion till start of Rev. Date Lang. Sheet
pre-commissioning A 07-Sep-18 en 1/9
Template No.: GGG/00/-/EQA---/FT/302D (released with Work Instruction GGG/00/-/EQA---/WI/306)
Table of Contents:
1. Aim ......................................................................................................................................................................... 3
2. Scope ..................................................................................................................................................................... 3
3. General Method .................................................................................................................................................... 3
3.1. Dry lay-up method ............................................................................................................................................ 4
4. Lay-up Procedure ................................................................................................................................................ 5
4.1. Prerequisites ..................................................................................................................................................... 5
4.2. Protected components/systems ...................................................................................................................... 5
5. Principles of start-up of the dry air preservation ........................................................................................... 6
6. Principles of control measurements ................................................................................................................ 7
6.1. Relative humidity............................................................................................................................................... 7
6.2. Impurity level ..................................................................................................................................................... 7
7. Supply of dry air................................................................................................................................................... 8
8. Enclosures ............................................................................................................................................................ 8
Originator Identification number Rev. Date Lang. Sheet
A en 2/9
1. AIM
This specification describes the preservation concept to prevent standstill corrosion in the
water/steam cycle for the time after acid cleaning completion of the HRSG until the
commissioning start. To achieve a non-corrosive environment a dry preservation concept must
be applied.
The general method as well as the procedures for the lay-up of the concerned
components/systems are described.
2. SCOPE
The general method for dry air preservation and their procedures for the preservation are
given. The components involved are parts of the HRSG.
This specification has to be treated as a general guideline for the HRSG system, but not as a
binding and entire documentation.
The instruction for preservation in the operational & maintenance manuals of relevant equipment
must be adhered, too.
It is necessary that the conservation methods are understood by the user and that the
preservation is organized and controlled by educated staff.
Note that this dry method preservation does not include the use of nitrogen during that pre-
operational phase.
The concept specification is only valid for the preoperational phase.
In order to avoid casualties, dry lay-up with nitrogen should be avoided!
3. GENERAL METHOD
Aim of the preservation is to prevent corrosion of the materials during the standstills. In general
corrosion attack is due to oxygen and carbon dioxide being present in case the components are
exposed to moist atmosphere. Hereby the corrosion risk increases with air humidity. The
corrosion risk is eliminated by introduction of dry air.
The principle is a flow of dehumidified (dry) air through the component/systems.
3.1. Dry lay-up method
3.1.1. Concept of dry lay-up with Instrument air
Dry air has a relative humidity of ≤30% for the expecting exposure temperature.
Using Instrument air is the preferred method for the pre-operational phase between completion of
acid cleaning and start of commissioning. Generally, the systems are pre-passivated as final step
of the acid cleaning and can withstand humid conditions for a certain time, up to 4 weeks.
Nevertheless, as precautious manner a dry preservation should be adopted as soon as possible to
avoid unforeseeable disturbance of the protective surface layer, e.g. due to excess water
condensation onto the passive layer.
Basically, the component/system must be checked at least once per week for proper humidity
levels.
3.1.2. BASIC DESCRIPTION OF PROCEDURES
Component Method Type Outline of procedure
HRSG incl. Dry lay-up with The boiler is emptied and drained.
feedwater piping Instrument (dry) air Instrument air shall be blown through the various HRSG
system. A relative moisture < 30% is maintained in the
system.
4. LAY-UP PROCEDURE
4.1. Prerequisites
The HRSG system will be acid cleaned to remove impurities. After the cleaning a passivation
step is applied to provide a passivation layer onto the bare metal surface, which already protects
the system from atmospheric attack to a certain degree.
As all steps are performed with chemical conditioned, respectively high purity water at relative
low temperature it cannot be ensured that the surfaces will dry completely and that some smaller
water puddles remain after drainage.
According to the experience from boiler manufacturer and acid cleaning company, the passivated
system can withstand up to four weeks without any special further preservation considerations, as
the remaining water film or smaller water puddles are high alkaline water, so that the corrosion
attack under atmospheric condition will be minor, if present at all.
Nevertheless, as a precautious manner it is recommended to start the dry preservation as soon as
possible within this 4 weeks as remaining moisture must be removed before final dry air
preservation method is applied. It is suggested that the drying process should not start later than 2
weeks after the drainage of the HRSG.
The initial drying process is done by forced air introduction. Humidity checks and inspections
of components may have to be included for confirmation of the dry condition of the metal
surfaces.
4.2. Protected components/systems
4.2.1. HRSG`s dry layup with Dry Air
Dry air shall be introduced through Nitrogen distribution system to each drum and continuously
distributed to the whole HRSG system.
5. DRY AIR PRESERVATION
Make sure that the component/systems are drained out after the acid cleaning and completion of
passivation.
Install temporal connecting piping to existing HRSG Nitrogen system header with a suitable air regulator (0-3 barg).
Start blowing Dry air through the system as per below steps to remove humidity through the drain systems into the
Blowdown tank, keep running approx. 12 hours for each cycle. Refer enclosed marked up flow diagram.
5.1 Dry-Up of LP System
Phase 1 - Red Layer- LP Drum, deaerator, Feed Water Suction and LP Evaporator Dry up
- Dry air will be feed from existing LP drum N2 line.
- LP Superheated steam line isolation valve (LBA10AA051), LP Drum level control isolation valves
(HAC22AA051-HAC22AA061), LP Eco vent line isolation valve and all other vent lines in the
corresponding system shall be closed.
- All LP Evap and feed water suction drain lines shall be kept open around 12 hours. After completion,
follow Phase 2.
Phase 2- Blue Layer- LP Eco and rec. lines dry up
- LP Evap and Feedwater suction drains will be closed.
- LP Drum level control valve isolation valves and LP eco vent valve will be opened. All corresponding
vent lines will be kept closed
- LP eco drain valves will be kept open around 12 Hours. After completion, follow Phase 3.
Phase 3- Green Layer – LP Superheater Line dry up
- LP Eco, LP Evap and Feedwater Suction Line drains will be closed.
- LP Drum level control valve isolation valves and LP eco vent valve will be closed. All corresponding
vent lines will be kept closed.
- Superheater Drains and steam line drains will be kept open around 12 Hours.
5.2 Dry Preservation of LP System
- After completion of these 3 Phase for LP system, air pressure to be set to 05-1 barg and boiler to be
pressured around 1 barg. All Drain lines shall be barely opened, Ensure air flows from all the drain
valves.
5.3 Dry-Up of IP System
Phase 4 – Dark Red Layer IP Drum, deaerator, IP Feed Water and LP Evaporator Dry up
- Dry air will be feed from existing IP drum N2 line.
- IP Superheated steam line isolation valves (LBA30AA003/004), IP Drum level control isolation
valves (HAC25AA051-HAC25AA061), IP Eco vent line isolation valve and all other vent lines in
the corresponding system shall be closed.
- All IP Evap and feed water suction drain lines shall be kept open around 12 hours. After
completion, follow Phase 5.
Phase 5- Light Orange Layer- IP Eco and IP Feed Water Discharge Lines Dry up
- IP Evap drains will be closed.
- IP Drum level control valve isolation valves and IP eco vent valve will be opened. All other relevant
vent lines will be kept closed.
- IP eco drain valves and IP Feedwater Discharge valve will be kept open around 12 Hours. After
completion, follow Phase 6.
Phase 6- Aqua Layer – IP Superheater Line dry up
- IP Eco, IP Evap and Feedwater Discharge Line drains will be closed.
- IP Drum level control valve isolation valves and IP eco vent valve will be Closed.
-All corresponding vent lines will be kept closed.
- IP Superheater Drains and IP steam line drain valves (LBA30AA207/208) will be kept open
around 12 Hours.
5.4 Dry Preservation of LP System
- After completion of these 3 Phase for IP system, IP Drum Level Control Isolation valves, IP Eco
vent valve will be fully opened. Air pressure regulator to be set to 05-1 barg and boiler to be
pressured around 1 barg. All Drain lines on the system shall be barely opened. Ensure air flows from
all the drain valves
5.5 Dry-Up of HP System
Phase 7– Purple Layer HP Drum, HP Feed Water and HP Evaporator Dry up
- Dry air will be feed from existing IP drum N2 line.
- HP Superheated steam line isolation valves (LBA50AA051/51A), HP Drum level control isolation
valves (LAB96AA051-LAB96AA061), HP Eco vent line isolation valve and all other vent lines in
the corresponding system shall be closed.
- All HP Evap drain lines shall be kept open around 12 hours. After completion, follow Phase 5.
Phase 8- Pink Layer- HP Eco and HP Feed Water Discharge Lines Dry up
- HP Evap drains will be closed.
- HP Drum level control valve isolation valves and HP eco vent valve will be opened. All other relevant
vent lines remain closed.
- HP eco drain valves and HP Feedwater Discharge valve will be kept open around 12 Hours. After
completion, follow Phase 9.
Phase 9- Orange Layer – HP Superheater Line dry up
- HP Eco, HP Evap and Feedwater Discharge Line drains will be closed.
- HP Drum level control isolation valves and HP eco vent valve will be Closed.
-All corresponding vent lines will remain closed.
- HP Superheater Drains and HP steam line drain valves (LBA30AA207/208) will be kept open around
12 Hours.
5.6 Dry Preservation of HP System
- After completion of these 3 Phase for HP system, HP Drum Level Control Isolation valves, HP Eco
vent valve will be fully opened. Air pressure regulator to be set to 05-1 barg and boiler to be pressured
around 1 barg. All Drain lines on the system shall be barely opened, Ensure air flows from all the drain
valves.
6. PRINCIPLES OF CONTROL MEASUREMENTS
6.1. Relative humidity
The check of the rH has to be done with potable rH analyzers, which include a temperature
measurement. Simple household weather station may be used for coarse checks.
7. SUPPLY OF DRY AIR
Dry air supply should have a capacity of approx. 200 m3 dry air per hour for each system.
8. ENCLOSURES
Enclosure 1 : Flow diagram
