ACID CLEANING PROCEDURE SUBMITTED BY WRIGHT & COMPANY

1.0 PROCESS CIRCUIT

A temporary set-up comprising of acid circulation/mixing tank, suction header, pump

motor sets, discharge header, connecting the discharge to the NRV ( by temporary
removing NRV flap) on BFP discharge line shall be established.

Arrangement shall also be made to establish circulation from bottom water wall
header nipples and other section like Evaporator, Screen tubes etc. leading back to the
circulation tank. Thus a closed loop circulation system shall be established.

In case of acid cleaning of superheater section separate line also to be laid.

Arrangement shall be maid from pump discharge to the inlet of bottom most header of
superheater & outlet from saturated steam header leading back to the circulating tank.

The down comers shall be suitably orificed to prevent short-circuiting. In case of

isolating the superheater from acid cleaning saturated steam outlet tubes from steam
drum shall be plugged to prevent entry of chemical solution into the superheater
section during cleaning.

Lines of DM water overflow effluent disposal etc. so shall also be laid.

2.0 PROCEDURE

A SUPERHEATER BACK FILLING (In case of SH section not taken for

acid cleaning.)

The superheater section shall be back filled with DM water treated with 200 ppm
Hydrazine & ammonia to give pH 10.0 to protect the superheater section from
accidental ingress of chemical solution into it.

B COLD WATER FLUSHING

The boiler system shall be flushed with DM water to remove loose particles,dirt etc as
far as practicable and also to check for leakage, if any.

C ALKALI FLUSHING

System shall be filled with DM water, temperature raised to about 600 C, chemicals
like Tri sodium phosphate, 12H2O – 2500 ppm and caustic soda – 500 ppm and a
surfactant 20 ppm shall be added and circulated for 4 – 6 hrs. Then the system is
drained and rinsed with DM water. This is prelude to a good chemical cleaning.

D ACID PICKLING

System shall be circulated at about 600 C, containing 4 – 5% HCL acid, inhibitor

Nevamine 6120 HPJ – 0.2% and Ammonium bi fluoride – 0.2% shall be added at
later stage. Samples shall be collected to check for iron pick up. When the iron pick
up values become almost steady, it marks the end of pickling step. Then the system is
drained under nitrogen, rinsed and drained again under nitrogen capping. ( Fe
stabilised at 3600 ppm after 5 hrs. )

E CITRIC ACID RINSING

System is filled with 0.2% Citric acid, ammoniated to pH – 3.5, circulated for 2 (two)
hours and then drained under nitrogen capping. Thereafter the system is rinsed and
drained under nitrogen.

F NEUTRALISATION

Then the system shall be neutralized with a solution containing Soda ash at an
elevated temperature for 4 – 6 hrs. Then the system shall be drained and rinsed.

G 1ST STAGE PASSIVATION

System shall be filled with 200 – ppm Hydrazine and ammonia to give pH 10.0 and
circulated at about 700 C. Hydrazine & Ammonia are added intermittently to replenish
looses and then hot drained. The system is drained after 20 hrs. of circulation.

3.0 INSPECTION

The boiler shall be visually inspected jointly after 1st stage passivation. A brownish
black temporary passivated layer of magnetite shall be formed on boiler water
touched surfaces which can be seen inside the boiler drum.

4.0 BOILER RESTORATION

All the temporary pipe lines connected with various header will be cut, All original
header caps, spool pieces will be welded back by high pressure welder then Hydrotest
will be taken.

5.0 2ND STAGE PASSIVATION

After restoration, boiler is initially filled up with DM water containing 200 ppm
Hydrazine and 50 ppm ammonia. Boiler is lighted up and pressure raised to 50% of
working pressure or maximum pressure up to 40 Kg/cm2 gradually and maintained for
24 hrs. Make – up water treated with Hydrazine and Ammonia shall be used.

6.0 BOILER STEAM GENERATION

After water chemistry of boiler blow down is stabilized the boiler will be put in
operation.