OBJECTIVE

THE OBJECTIVE OF THIS PROCEDURE IS TO CLEAN THE INTERNAL SURFACE OF STEAM GENERATING PORTION AND HEATING SURFACE(ECONOMISER) USING SPECIFIED CHEMICALS.BY CARRYING OUT AN EFFECTIVE ALKALI BOIL-0UT GREASE AND ANY OTHER PROTECTIVE COATING APPPLIED ON THE INNER SURFACES OF PRESSURE PARTS ARE REMOVED.THEN IT IS SUBJECTED TO ACID CLEANING FOR THE REMOVAL PATCHY MILL SCALE AND RUST.FINALLY THE ACID PICKLED SURFACE IS PASSIVATED FOR THE FORMATION OF UNIFORM AND COHERENT MAGNETITE LAYER

STATE OF PLANT
THE FLAP OF NRV PROVIDED IN ECONOMIZER FILLING LINE IS REMOVED TO FACILITAE FAST FILING AND DRANING. ALL THE AUXILLARIES ARE MADE READY AND AVAILABLE FOR BOILER LIGHT UP.THIS INCLUDES AUXILLARY STEAM,CHEMICAL DOZING PUMPS,TANKS CC PUMPS,FANS OIL PUMP ETC. NITROGEN CAPING SYSTEM AT SUITABLE LOCATION FOR EASE OF PPERATION. PROPER NEUTRALIZATIN ARRANGEMENT TO NEUTRALIZE EFFLUENT BEFORE DISPOSAL

FOR ABO ONLY PRIMARY SEPARATOR ARE ERECTED IN UPPER DRUM AND BAFFLE PLATE IN LOWER DRUM.SECONDARY SEPARATORS AND DRYER NOT ERECTED IN THE UPPER DRUM AND ORIFICE NOT ERECTED IN LOWER DRUM.FOR ACID CLEANING PRIMARY SEPARATOR IS ALSO REMOVED.
BOILER TUBE COUPONS ARE TO BE PLACED AT TWO ENDS INSIDE BOILER UPPER AND LOWER DRUMS TO EFFECTIVENESS OF CLEANING.

MINIMUM REQUIREMENT ONE SET ID,FD FAN,ONE SAPH ALONG WITH OIL CARRY OVER PROBE,SOOT BLOWING SYSTEM,FIRE DETECTION SYSTEM,ROTOR STOPPAGE ALARMAND AIR MOTOR,LDO,SCANNER FAN,HP DOSING AND LP DOSING SYSTEM,ALL BCW PUMP,BAH,COMPLETION OF ATT FOR URNACE. PROVISION FOR FREE EXPANSION OF BOILER AND EXPANSION MARKER.BLOW DOWN SYSTEM. PERSONAL SAFETY EQUIPMENTS. PURGE WATER FOR CC PUMP.

READINESS OF TWO ESP PASS IN ALL RESPECT. EYE WASH BOTTLE AND EYE SHOWER.

SL NO

ACID

Blr water Concentr Quantity ation in required %

CHEMICAL USED

Used for SL NO Process

ACID

Blr water Concentr ation in %

Hydrochl oric acid 5 % + 1 % 70 tons (HCL) Rodine 0.20 % Ammoniu m 0.25 % Bifloride 800 lts 1000 kg

Acid pickling & soaking

Hydrochl oric acid 5 % + 1 % (HCL) Rodine 0.20 % Ammoniu m 0.25 % Bifloride

Ammonia ted Citric 0.2 % Acid

800 kg

Ammonia ted citric acid rinse

Ammonia ted Citric 0.2 % Acid

Di/Trisod 0.1 % & ium 0.2 % in phosphat the boiler e

Di/Trisod 0.1 % & Neutraliz ium 800 & 0.2 % in ation phosphat 1500 kgs the boiler process e

STEPS FOR ABO Prepare chemical water in chemical preparation tank of 60 m3 DM water through boiler fill pump ,add TSP 60 kg ,add DSP 30 kg ,start heating through steam from aux PRDS and run chemical pumps on recirculation till a temp of 50 deg is achieved. Check the chemical solution concentration of 500 ppm of DSP and 1000 ppm of TSP is achieved.

Fill the boiler through bottom ring header drain, eco line drain ,eco inlet header drain, BCW suction lines ,( BCW discharge valve closed ) by chemical dosing pump till the minimum level of tank as marked at view glass of tank . Raise the drum pressure up to 40 ksc in steps of 10ksc and take expansion readings,maintain it at 40 ksc , take boiler expansion reading, hold 40 ksc for 4 hrs.Collect water samples from CBD sample point for analysis of alkalinity ,phosphate content ,dissolved silica and oil content

Kill the fire in the boiler ,give blow down of 1 minute through bottom ring header drain to IBD(front).Ensure drum level does not go out of vision in gauge glass.(DWLG at drum)
Raise the drum level through MDBFP, Repeat the operation of raising the drum pressure to 40 ksc ,then hold it for 2 hrs.give blow down through bottom ring header drain to water wall drain header, for 1 minute after killing fire Repeat the same procedure and give blow down through ECO line drains & ECO inlet header drain

During this process if phosphate concentration drops to half of the initial value, dose additional chemicals through phosphate dosing system to achieve original concentration. The boil out is declared complete when the oil contained in analyzed sample is less than 5 PPM or minimum eight blow downs (in same sequence) are completed whichever is latter. Box up the boiler keeping BCW pumps in service. Allow the boiler to go under natural cooling ( ID suction & FD discharge open.).

Fill the boiler with hot 80 deg DM water through chemical feeding pump upto lowest port of drum. Back flush the S/H with DM water containing 200ppm hydrazine and PH raised to 10 with ammonia till it overflows into drum. Collect the sample from the sampling points of S/H Header and low point drains for testing. Drain the boiler through IBD.

Continue the filling & draining for rinsing till the phosphate contain in sample is less than 2 ppm.

Steps for acid cleaning

MOCK TRIAL: Mock trial is to be conducted one day in advance so as to check the healthiness of various pumps, valves and other connected system. Boiler filling in 1 hr (approx) and draining in 1 hr(approx) are to be achieved. Boiler filling with DM water & lighting up the boiler to raise the temp. to 80 0c before going for acid injection.

Filling of Boiler along with Acid injection (Picking/Soaking) Fill the boiler with 60-70 0C water from the 250 mm temporary header through water walls low point drain hdr. / Eco filling line/ BCW pump sunction manifold) Once the boiler drum level is at the bottom port stop filling through BCW suction manifold Continue filling through other sources. Fill the boiler up to the drum level is 100 mm above center line. Start Boiler Water Circulating (BCW) pump B ,center pump.

Take sample at every 10 min interval. Continue this process till the iron content is in equilibrium for 3 consecutive sample . Start draining the boiler under N2 capping to the neutralization Pit DM water rinse, after Acid pickling/Soaking is completed: Refill the boiler with DM water at 6070 0C. Fill up to 50 % of the gauge glass .Then start back flushing of the SH through the LTSH drain till the water level is raised in the drum up to 8-9 ports. Continue this operation till the sample result pH is upto 4.0

Ammoniated Citric Acid rinse after DM water rinse: Start injection of citric acid solution prepared at temporary DM filling pump discharge through the acid injection pump & regulation valve at the acid pump discharge Adjust the pH at the filling point around 3.5-4.0 . Collect sample from BCW pump discharge header after stopping the pump & analyze for acid strength & iron concentration . Continue this operation till 3 consecutive samples read the acid % & iron content are steady . This operation shall be minimum 4 hrs & maximum 5 hrs duration .

Demineralised water rinse: Continue the boiler filling & draining operation till the sample at point B is having IRON < 25 ppm

Neutralisation of the boiler system:To remove acid pockets and neutralized acid. Fill the boiler with TSP AND DSP Solun. Light up the boiler & raise the pressure to 10 ksc . Hold the pressure for about 6 hrs. After 6 hrs kill the fire . Allow the boiler to cool naturally . Drain the boiler after metal temperature of < 90 0C is achieved Boiler is drained with drum vents open to atmosphere & no N2 capping is used .

Passivation of Boiler :TO MAKE A LAYER OF MAGNETITE COATING ON PICKLED SURFACE Fill the boiler with DM water & inject the prepared blended solution so that the final water having 200 ppm of N2H4 & pH of 10 is feed to the boiler . Lightup the boiler at slow rate . Raise the drum pressure to 40 ksc & hold it for 24 hrs After 24 hrs shut down the boiler & allow it to cool down slowly . Neutralisation of boiler effluents As soon as the acid is drained to the neutralizing pit caustic soda is added to neutralize . As soon as the citric acid is drained to the neutralizing pit caustic soda is added to neutralize .