FOR INFORMATION

2009.05.19

S.W.KANG

J.W.LEE

S.C.SONG

First Issued

Rev.

Date

Prepared

Checked

Approved

Details of Revision

Client:

COASTAL GUJARAT POWER LIMITED

A TATA POWER COMPANY
Engineer:

Contractor:

Sub supplier:

Orig-Pc

Project Title:

4000 MW ULTRA MEGA POWER PROJECT

AT MUNDRA, GUJARAT, INDIA
Prepared

Date

Name

09.05.19

S.W.Kang

Scale

Pc

T07073

N/A
Code

DOC. TITLE

LBH

Coordinated
Checked

09.05.19

J.W.Lee

Approved

09.05.19

S.C.Song

Dept.

BOILER BASIC
DESIGN TEAM

Doosan Heavy Industries &

Construction Co.Ltd.
Document No.:
Owner Document No.:

GUIDELINE FOR
PRESERVATION OF BOILER

Reg.No.

M005
Dept

UNID

Rev

Version

P
T07073-LBH-SY-M005
TCE.5146A-510-00-5411

Page-No.

1/6

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Record of Revisions

Rev
A

Date
2009.05.19

Page affected

Description of Revision
First Issue

This Document is the property of Doosan Heavy Industries and Construction Co., Ltd., Chang-won, KOREA,
and is to be used only for the purpose of the agreement with Doosan pursuant to which it is furnished.

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GUIDELINE OF PRESERVATION OF BOILER AFTER CHEMICAL

CLEANING AND HYDRAULIC TEST

TABLE OF CONTENTS

TITLE

PAGE NO.

PRE-OPERATIONAL PERIOD ...................................................................................... 4

Post Hydraulic test ................................................................................................... 4
Post Chemical Cleaning........................................................................................... 4
SHORT OUTAGE........................................................................................................... 5
4 Days or Less .......................................................................................................... 5
4 DAYS OR LESS - UNIT PARTIALLY DRAINED FOR REPAIRS .............................. 5

LONG OUTAGE ............................................................................................................. 5

Longer than 4 Days .................................................................................................. 5
Longer than 4 Days - Unit Partially Drained for Repairs....................................... 5

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PRESERVATION OF BOILER AFTER CHEMICAL CLEANING AND HYDRAULIC TEST

PRE-OPERATIONAL PERIOD
Post Hydraulic test

1. Normally the boiler is kept full of treated water after completion of the initial hydraulic test
(refer to Guideline of Boiler Hydraulic Test). If waters in the drainable sections of heating
surface in the boiler were drained, for repairs or other reasons, they should be refilled with
demineralized or condensate quality water containing 10 ppm ammonia and 200 ppm
hydrazine. This should produce a solution pH of approximately 10. The superheater
should be filled first to overflow. Then, the economizer and waterwalls can be filled
through normal fill connections (See Note 1) with demineralized or condensate quality
water, or if not available, any source of clean, filtered water may be used. This water
should also contain 10 ppm ammonia and 200 ppm hydrazine.

NOTE 1: Hydrazine and ammonia should be added in a manner that

results in a uniform concentration throughout. They may be added to
the system in several ways, for example:
a. By pumping concentrated solutions through the chemical feed
equipment and blend filling to achieve the desired concentrations.
b. If condenser leakage is not a cause for shutdown, concentrated
solutions can be introduced directly into the hot well where they can be
mixed to achieve the desired concentrations. If condensate
demineralizers are employed, they must be bypassed during this
operation.
Fluid temperature in the cycle must be below 400F (204C) before
addition of hydrazine. If this temperature is exceeded, the hydrazine will
decompose.

2. With the economizer, waterwalls, superheater, and reheater filled to overflowing,

pressurize the unit with nitrogen to 0.35 kg/cm2g (See Notes 2).

NOTE 2: The tube side of copper alloy feedwater heaters should be filled
with demineralized water containing 0.5 ppm ammonia and 50 ppm
hydrazine.

Post Chemical Cleaning

1. Introduce demineralized or condensate quality water containing 10 ppm ammonia and 200
ppm hydrazine into the superheater, reheater, the tube side of the feedwater heaters and
associated piping, economizer, and waterwalls (Refer to Notes 2).
2. Nitrogen cap the superheater and the shell side of the feedwater heaters. Maintain 0.35
kg/cm2g nitrogen pressure (See Note 3).
4

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PRESERVATION OF BOILER AFTER CHEMICAL CLEANING AND HYDRAULIC TEST

NOTE 3: Nitrogen cap should be applied through the superheater outlet

header drain/vent, and reheater outlet header drain/vent, as the unit is
cooled, when pressure drops to 0.35 kg/cm2g. Admission of air through
atmospheric vents should be avoided.

SHORT OUTAGE
4 Days or Less
1. Maintain hydrazine and ammonia concentrations at the levels present during normal
operation.
2. Establish and maintain a 0.35 kg/cm2g nitrogen cap on the superheater (See Note 3).
3. Nitrogen cap the shell side of the feedwater heaters.
4 Days or Less - Unit Partially Drained for Repairs
1. Drain and open only those sections requiring repairs.
2. Isolate remainder of unit under 0.35 kg/cm2g nitrogen pressure, where possible (See Note
3).
3. Maintain hydrazine and ammonia concentrations for water remaining in the cycle at the
level present during normal operation.
4. Nitrogen cap the shell side of the feedwater heaters.

LONG OUTAGE
Longer than 4 Days
1. Fill the superheater and reheater with demineralized or condensate quality water
containing 10 ppm ammonia and 200 ppm hydrazine. The pH of the solution should be
approximately 10. Add the fill water to the outlet of the non-drainable sections.
2. Increase the hydrazine and ammonia concentration in the waterwalls, economizer and the
tube side of the feedwater heaters and associated piping to 200 ppm hydrazine and 10
ppm ammonia (See Notes 1, and 2).
3. Establish and maintain a 0.35 kg/cm2g nitrogen cap on the superheater (See Note 3).
4. Nitrogen cap the shell side of the feedwater heaters.
Longer than 4 Days - Unit Partially Drained for Repairs
1.

Drain and open only those sections requiring repairs.

5

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PRESERVATION OF BOILER AFTER CHEMICAL CLEANING AND HYDRAULIC TEST

2.

Fill the superheater and reheater (if not drained for repairs) with demineralized or
condensate quality water containing 10 ppm of ammonia and 200 ppm hydrazine. The
pH of the solution should be approximately 10. Add the fill water to the outlet of the nondrainable sections.

3.

Increase the hydrazine and ammonia concentrations in the tube side of the feedwater
heaters and the undrained circuits of the economizer and waterwalls to 200 ppm
hydrazine and 10 ppm ammonia (See Notes 1, and 2).

4.

Establish and maintain a 0.35 kg/cm2g nitrogen cap on the undrained sections of the unit,
where possible (See Note 3).

5.

Nitrogen cap the shell side of the feedwater heaters.

6.

After completion of the repairs, fill the drained sections with demineralized or condensate
quality water containing 10 ppm hydrazine. Cap with nitrogen (See Notes 1, and 2).

The static wet preservation period is recommended within two months. If the wet
preservation period is extended over two months dry preservation is recommended.
If it is very difficult situation to change from wet to dry preservation, the preserved water
quality should be checked carefully at several points and it should be circulated periodically.
If chemical density is lower than above mentioned value, chemical mixed water should be
injected in the preserved water.

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