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CHEMICAL CLEANING OF

PRE-BOILER SYSTEM
OBJECTIVES

To remove dirt ,oil ,grease etc., from Condensate ,Feed


water, Drip and Extraction steam lines of HP and LP
heaters prior to putting these systems in regular service.
This is to ensure flow of clean condensate and feed water
to the boiler.
STATE OF THE PLANT

• Hydro-test of the entire system to be flushed declared


completed.
• All the regenerative equipments are installed in position and
temporary pipeline connection as per scheme is complete.
• The bore of the temporary pipelines should preferably be the
same as that used in permanent system.
• All permanent support are provided for all the pipelines before
flushing.
• Plugs to be provided in the safety valves of LPHs,water seal
inlets in flash tanks and LPH 1 and in C&I tapping.
• Screens to be provided on booster pump suction line and acid
cleaning pump suction line
• Availability of auxiliary steam.
• Reagent preparation plant.
• Sampling points for each circuit.
• Level gauge on tank, pressure gauges and temperature
indicators wherever required.
• All the cutting and welding work on instrument tapping points
are complete upto isolating root valves.
• All the orifices,flow nozzles, control valves and NRV internals
are removed and a checklist is prepared. Spool pieces are
provided wherever required.
• Installation of temporary chemical cleaning pumps(2 nos.) and
connected piping along with required instrumentation is
complete.
• During post mounting cleaning it is proposed to use chemically
clean water from condensate storage tank.
• Readiness of process water supply system,condenser
circulating water system with pump house.
• Availability of compressed air.
• Proximate analysis laboratory facility.
• Power supply to acid cleaning pumps,CEPs,condensate
emergency make up pumps, condensate normal make up
pumps, motor operated valves and lighting.
EQUIPMENTS AND RESOURCES FOR WATER
WASHING

• Condensate storage tanks.


• Condenser of volume 1000m3 as a reservoir for storing the
dematerialized water.
• Turbine condensate pumps (3 nos.).
• Chemical cleaning pumps (q=300t/h,h=80mwg,n=1500rpm)-
2nos.
• Compressor plant and pipeline Dn100 to supply air into the
washing circuit with the parameters not less than
q=20m3/min,p=0.6MPa
• Pipelines and valves Dn 20-300,Pn 1.6MPa
EQUIPMENT AND RESOURCES FOR CHEMICAL
CLEANING AND PASSIVATION
• Deaerator and Feed Water Storage Tank.
• Chemical cleaning pumps (q=300t/h,h=80mwg,n=1500rpm)-
2nos.
• Pipelines and valves Dn 20-300,Pn 1.6MPa
• SG Package neutralizing basin for collecting the spent
solutions.
• Reagent Preparation Plant designed for storage, preparation
and supply of chemical reagents.
• Chemical reagents.
• Washing process controlling instruments (flow elements,
pressure gauges, level gauges, temperature elements)
The pre-boiler system consists of
• Condensate system
• Drip system
• Feed water system
• Extraction steam lines to Regenerative Heaters
→ Condensate system comprises of 3 nos. of Condensate
Extraction Pumps,Low Pressure Heaters, Gland Steam
Cooler,Deaerator,connecting pipelines including excess
condensate line upto Condensate storage tank.
→Feed water system comprises 2 nos. of motor driven boiler
feed pumps,2 nos. of Turbine driven boiler feed pumps ,their
booster pumps and recirculation lines, high pressure heaters, their
connecting pipelines upto econimiser inlet.Reheater and
Superheater spray line are also included for the purpose of
flushing.
→ Drip system comprises of the shell side of all LP and HP
heaters and their normal and emergency drip lines.
→Extraction steam system consists of bled steam lines from
different stages of Turbines (HPT,IPT and LPT) to LP and HP
heaters,Deaerator and TDBFPs.
CLEANING METHOD

• Pre- mounting cleaning.


 Extraction steam lines to regenerative heaters
• Post-mounting cleaning.
 Feed water line,Condendate line and heater drip lines.
• Steam blowing.
 MS line,CRH line , HRH line ,steam line to TDBFPs etc.
METHODS AND SCOPE OF CLEANING

Post Mounting Cleaning

• Main Turbine and BFP Drive Turbine Condenser Cleaning.


• Hydro-pneumatic Washing with Demineralized Water of Unit
Circulating System.
• Chemical Cleaning of Water–Steam path of Heater and
Pipeline with hydrofluoric Acid solution.
• Chemical Passivation of Water-Steam path of Heater and
Pipeline with Hydrogen Peroxide solution added with
Ammonia.
Pre-Mounting Cleaning

• Chemical Cleaning of Pipelines in a bath of Hydrofluoric Acid


solution.
• Spent solution displacement.
• Chemical Passivation of Pipelines with Hydrogen Peroxide
solution added with ammonia.
• Air Blowing of Passivated pipelines for drying.
Main Turbine and BFP Drive Turbine Condenser
Cleaning or Condenser Degreasing.

STEP- I
• The demineralized water is heated upto 700c in the De-aerator
FST.
• The Chemical solution prepared in reagent preparation plant is
mixed with the hot water in the De-aerator FST.
• The hot solution is transferred to Condenser with the help of
temporary chemical cleaning pump through temporary
pipelines connecting pump discharge header to the CEP
discharge header and the cooling device sprayers of
Condenser.
• Circulation is completed by bringing this solution from
condenser to Chemical Cleaning pump suction header through
CEP suction header and temporary pipeline connection.
• Circulation is continued for 4 hrs.
• System is isolated after closing one temporary gate valve
provided in the circuit (refer to scheme.)
DEAERATOR
CHEMICAL

AUX.STEAM

FST

BP BP
BP BP

ACID CLEANING PUMPS

CONDENSERS

CEPS
STEP –II

• CEPs are charged from water side by opening suction valve


and through proper venting, keeping discharge valve in closed
condition and suction strainer in position.

• Flushing started by alternately starting and stopping CEPs and


completing the circulation from CEP discharge to CEP suction
line through recirculation line and condenser.
• Circulation is continued for 4 hrs.

• After cleaning the spent solution is pumped from condenser to


neutralizing basin.

• Water washing of Condenser started and continued for 4 hrs.


using the two circuits already described..
DEAERATOR
CHEMICAL

AUX.STEAM

FST

BP BP
BP BP

ACID CLEANING PUMPS

CONDENSERS

CEPS
Hydro-pneumatic Washing of Unit Circulating System
with Demineralized Water and air.

→ Hydro-pneumatic washing of unit circulating system is carried


out step by step with simultaneous water and air supply.
→ Demineralized water for washing is stored in the De-aerator
FST and Condenser.
→ Hydropneumatic washing is declared completed if suspended
matter content of the washing water reaches no more than
100mg/kg.
→ Hydro-pneumatic washing of unit circulating system is done
using following four circuits.
CIRCUIT 1:

Circuit 1A
De-aerator FST – TDBFP A booster pump suction line –
BP strainers – Temporary header connecting the BP
suction lines downstream of the strainers – Acid cleaning
pumps – Temporary discharge header – Temporary lines
to the discharge gate valves of four feed pumps – Feed
lines to HPH – Bypass line of all HPH – HPH bypass
lines – Water path of HPH 6,7,8 – Feed water line upto
boiler feed control unit – Temporary discharge line to the
circulating water line - De-aerator FST.
Circuit 1B
De-aerator FST – TDBFP B booster pump suction line –
BP strainers – Temporary header connecting the BP
suction lines downstream of the strainers – Acid cleaning
pumps – Temporary discharge header – Temporary lines
to the discharge gate valves of four feed pumps – Feed
lines to HPH – Bypass line of all HPH – HPH bypass
lines – Water path of HPH 6,7,8 – Feed water line upto
boiler feed control unit – Temporary discharge line to the
circulating water line - De-aerator FST.
Circuit 1C
De-aerator FST – MDBFP booster pump suction line –
BP strainers – Temporary header connecting the BP
suction lines downstream of the strainers – Acid cleaning
pumps – Temporary discharge header – Temporary lines
to the discharge gate valves of four feed pumps – Feed
lines to HPH – Bypass line of all HPH – HPH bypass
lines – Water path of HPH 6,7,8 – Feed water line upto
boiler feed control unit – Temporary discharge line to the
circulating water line - De-aerator FST.
Circuit 1D
De-aerator FST – Booster pump suction line – BP
strainers – Temporary header connecting the BP suction
lines downstream of the strainers – Acid cleaning pumps
– Temporary discharge header – Temporary lines to the
discharge gate valves of TDBFP A – Feed lines to HPH –
Bypass line of all HPH – HPH bypass lines – Water path
of HPH 6,7,8 – Feed water line upto boiler feed control
unit – Temporary discharge line to the circulating water
line - De-aerator FST.
Circuit 1E
De-aerator FST – Booster pump suction line – BP
strainers – Temporary header connecting the BP suction
lines downstream of the strainers – Acid cleaning pumps
– Temporary discharge header – Temporary lines to the
discharge gate valves of TDBFP B – Feed lines to HPH
– Bypass line of all HPH – HPH bypass lines – Water
path of HPH 6,7,8 – Feed water line upto boiler feed
control unit – Temporary discharge line to the circulating
water line - De-aerator FST.
Circuit 1F
De-aerator FST – Booster pump suction line – BP
strainers – Temporary header connecting the BP suction
lines downstream of the strainers – Acid cleaning pumps
– Temporary discharge header – Temporary lines to the
discharge gate valves of MDBFP A – Feed lines to HPH
– Bypass line of all HPH – HPH bypass lines – Water
path of HPH 6,7,8 – Feed water line upto boiler feed
control unit – Temporary discharge line to the circulating
water line - De-aerator FST.
Circuit 1G
De-aerator FST – Booster pump suction line – BP
strainers – Temporary header connecting the BP suction
lines downstream of the strainers – Acid cleaning pumps
– Temporary discharge header – Temporary lines to the
discharge gate valves of MDBFP B – Feed lines to HPH
– Bypass line of all HPH – HPH bypass lines – Water
path of HPH 6,7,8 – Feed water line upto boiler feed
control unit – Temporary discharge line to the circulating
water line - De-aerator FST.
Circuit 1H
De-aerator FST – Booster pump suction line – BP
strainers – Temporary header connecting the BP suction
lines downstream of the strainers – Acid cleaning pumps
– Temporary discharge header – Temporary lines to the
discharge gate valves of four feed pumps – Feed lines to
HPH – 50 % bypass line of all HPH– Feed water line
upto boiler feed control unit – Temporary discharge line
to the circulating water line - De-aerator FST.
Circuit 1I
De-aerator FST –Booster pump suction line – BP
strainers – Temporary header connecting the BP suction
lines downstream of the strainers – Acid cleaning pumps
– Temporary discharge header – Temporary lines to the
discharge gate valves of four feed pumps – Feed lines to
HPH – 100 % bypass line of all HPH – Feed water line
upto boiler feed control unit – Temporary discharge line
to the circulating water line - De-aerator FST.
Circuit 1J
De-aerator FST –Booster pump suction line – BP
strainers – Temporary header connecting the BP suction
lines downstream of the strainers – Acid cleaning pumps
– Temporary discharge header – Temporary lines to the
discharge gate valves of four feed pumps – Feed lines to
HPH bypass line for 6A,7A,8A – Feed water line upto
boiler feed control unit – Temporary discharge line to the
circulating water line – De-aerator FST.
Circuit 1K
De-aerator FST –Booster pump suction line – BP
strainers – Temporary header connecting the BP suction
lines downstream of the strainers – Acid cleaning pumps
– Temporary discharge header – Temporary lines to the
discharge gate valves of four feed pumps – Feed lines to
HPH bypass line for 6B,7B,8B – Feed water line upto
boiler feed control unit – Temporary discharge line to the
circulating water line – De-aerator FST.
Circuit 1E
De-aerator FST –Booster pump suction line – BP
strainers – Temporary header connecting the BP suction
lines downstream of the strainers – Acid cleaning pumps
– Temporary discharge header – Temporary lines to the
discharge gate valves of four feed pumps – Feed lines to
HPH – Water path of HPH 6A,7A,8A – Feed water line
upto boiler feed control unit – Temporary discharge line
to the circulating water line – De-aerator FST.
Circuit 1L
De-aerator FST –Booster pump suction line – BP
strainers – Temporary header connecting the BP suction
lines downstream of the strainers – Acid cleaning pumps
– Temporary discharge header – Temporary lines to the
discharge gate valves of four feed pumps – Feed lines to
HPH – Water path of HPH 6B,7B,8B – Feed water line
upto boiler feed control unit – Temporary discharge line
to the circulating water line – De-aerator FST.
CIRCUIT 2:

Circuit 2A
Condenser – CEP suction lines – Acid cleaning pumps –
CEP discharge header – Condensate line bypassing
LPHs – line down stream of LPHs – Temporary
discharge line to the circulating water system – De-
aerator FST

Circuit 2B
Condenser – CEP suction lines – Acid cleaning pumps –
CEP discharge header – Water side of LPHs – Line
down stream of LPHs – Temporary discharge line to the
circulating water system – De-aerator FST
CIRCUIT 3:

Circuit 3A
Condenser – CEP suction lines – Acid cleaning pumps –
CEP discharge header – Condensate line bypassing
LPHs – Temporary header for water supply to the HPH
steam space – Steam side of HPH 6A – HPH discharge
line – Temporary discharge line to the circulating water
system – De-aerator FST
Circuit 3B
Condenser – CEP suction lines – Acid cleaning pumps –
CEP discharge header – Condensate line bypassing
LPHs – Temporary header for water supply to the HPH
steam space – Steam side of HPH 6B – HPH discharge
line – Temporary discharge line to the circulating water
system – De-aerator FST
Circuit 3C
Condenser – CEP suction lines – Acid cleaning pumps –
CEP discharge header – Condensate line bypassing
LPHs – Temporary header for water supply to the HPH
steam space – Steam side of HPH 7A – HPH discharge
line – Temporary discharge line to the circulating water
system – De-aerator FST
Circuit 3D
Condenser – CEP suction lines – Acid cleaning pumps –
CEP discharge header – Condensate line bypassing
LPHs – Temporary header for water supply to the HPH
steam space – Steam side of HPH 7B – HPH discharge
line – Temporary discharge line to the circulating water
system – De-aerator FST
Circuit 3E
Condenser – CEP suction lines – Acid cleaning pumps –
CEP discharge header – Condensate line bypassing
LPHs – Temporary header for water supply to the HPH
steam space – Steam side of HPH 8A – HPH discharge
line – Temporary discharge line to the circulating water
system – De-aerator FST
Circuit 3F
Condenser – CEP suction lines – Acid cleaning pumps –
CEP discharge header – Condensate line bypassing
LPHs – Temporary header for water supply to the HPH
steam space – Steam side of HPH 8B – HPH discharge
line – Temporary discharge line to the circulating water
system – De-aerator FST
CIRCUIT 4:

Circuit 4A
Condenser – CEP suction lines – Acid cleaning pumps –
CEP discharge header – Condensate line bypassing
LPHs – Temporary header for water supply to the LPH
steam space – Steam side of LPH 1A – LPH discharge
line – Temporary discharge line to the circulating water
system – De-aerator FST
Circuit 4B
Condenser – CEP suction lines – Acid cleaning pumps –
CEP discharge header – Condensate line bypassing
LPHs – Temporary header for water supply to the LPH
steam space – Steam side of LPH 1B – LPH discharge
line – Temporary discharge line to the circulating water
system – De-aerator FST
Circuit 4C
Condenser – CEP suction lines – Acid cleaning pumps –
CEP discharge header – Condensate line bypassing
LPHs – Temporary header for water supply to the LPH
steam space – Steam side of LPH 2 – LPH discharge
line – Temporary discharge line to the circulating water
system – De-aerator FST
Circuit 4D
Condenser – CEP suction lines – Acid cleaning pumps –
CEP discharge header – Condensate line bypassing
LPHs – Temporary header for water supply to the LPH
steam space – Steam side of LPH 3 – LPH discharge
line – Temporary discharge line to the circulating water
system – De-aerator FST
Circuit 4E
Condenser – CEP suction lines – Acid cleaning pumps –
CEP discharge header – Condensate line bypassing
LPHs – Temporary header for water supply to the LPH
steam space – Steam side of LPH 4 – LPH discharge
line – Temporary discharge line to the circulating water
system – De-aerator FST
M M

M
BP BP

M
M

M
M
M
M

M
M
M

M
M
M

HPH-6A HPH-6B
M M

M
M
M

HPH-7A HPH-7B

TO ECO
I/L

M M

HPH-8A HPH-8B
M
M

M
M

MAIN MAIN
M M CONDENSER - 1 CONDENSER - 2
M
M

M M

M M M M

M
M

M
CEP-3 CEP-2 CEP-1

LPH-1A
LPH-4 LPH-3 LPH-2
M M
M

M M M
M

M M
CPU

M
M

M
M

M
M

M
M M M
M M

LPH-1B GSC

M DRIP /P-A
M

M DRIP /P-B
M

M
BP BP

M
M

M
M
M
M

M
M
M

M
M
M

HPH-6A HPH-6B

M
M
M

HPH-7A HPH-7B

TO ECO I/L

HPH-8A HPH-8B
M
M

M
M

MAIN MAIN
M M CONDENSER - 1 CONDENSER - 2
M
M

M M

M
M
CEP-3 CEP-2 CEP-1

CPU

M
M

M
M

M
GSC
M
M

M
BP BP

M
M

M
M
M
M

M
M
M

M
M

M
M
M

MAIN MAIN
CONDENSER - 1 CONDENSER - 2

M M M M

M
M

M
CEP-3 CEP-2 CEP-1

LPH-1A
LPH-4 LPH-3 LPH-2
M M
M

M M M
M

M M
CPU

M
M

M
M

M
M

M
M M M

LPH-1B GSC
M M

M
BP BP

M
M

M
M
M
M

M
M
M

M
HPH-6A HPH-6B
M M

M
M
M

HPH-7A HPH-7B

TO ECO
I/L

M M

HPH-8A HPH-8B
M
M

M
M

MAIN MAIN
CONDENSER - 1 CONDENSER - 2
M
M

M
M
CEP-3 CEP-2 CEP-1

M M

M
CPU

M
M

M
M

M
M

M
GSC
M

M
BP BP

M
M

M
M
M
M

M
M
M

M
M

M
M
M

MAIN MAIN
CONDENSER - 1 CONDENSER - 2

M
M

M
CEP-3 CEP-2 CEP-1

LPH-1A
LPH-4 LPH-3 LPH-2
M M

M
CPU

M
M

M
M

M
M

M
M M

LPH-1B GSC

M DRIP /P-A
M

M DRIP /P-B
ACID CLEANING:

→ Acid cleaning is made using the same four circuits on which


water washing is made. To make closed circuit the de-aerator
is included into the scheme, in which cleaning solution can be
heated if required.
→ Reagents in liquid form, each by separate pipeline, are
supplied from reagent preparation plant into suction pipeline
of acid cleaning pump.
→ Minimum Hydrofluoric acid solution temperature is 200C and
optimum temperature is 400 C
→ Acid cleaning phase duration is 4-8 hours at temperature up to
400C
→ Hydrofluoric acid cleaning solution concentration is selected
depending on ferric oxide quantity in the circuit to be washed.
CLEANING SOLUTION DISPLACEMENT:

→ Primary displacement of spent cleaning solution is carried out


by compressed air from the compressor-house ; this allows
saving of water for washing.
→ The final removal of solution is carried out with standard
speed ; in drainable section – not less than 1m/s and in non-
drainable section not less than 2m/s. Solution is removed from
the circuits by hydraulic pneumatic method with water supply
from condensers by acid cleaning pumps.
→ Acid cleaning is declared finished if discharge water
conductivity reaches 20µs/cm.
PASSIVATION:

→ Passivation of acid cleaned surface is carried out with


Hydrogen Peroxide solution added with ammonia.
→ Before passivation the acid cleaned surface is neutralized with
the circulation of ammonia solution.
→ Passivation is carried out with demineralized water under the
following conditions:
• Hydrogen Peroxide concentration is 0.02%.
• Ammonia Concentration is upto 0.8%.
• Solution temperature is 400C.
• Duration 4-6 hours.
• Solution flow velocity is 0.3 to 0.5 m/s
→ Metal surface treatment with oxidant solution permits to form
thin protective ferric oxide film.

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