BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR WESTERN REGION

RECOMMENDED PROCEDURE FOR ALKALI BOIL OUT OF 2 X 165
TPH AFBC BOILERS AT JSL, RAIGARH
A INTRODUCTION!
The alkali boil out of a boiler is carried out in order to clean the internal
surfaces of the water-touched parts from oil, grease, rust, silica and other
adhered impurities
B SCOPE!
The scope of cleaning during this operation includes a portion of feed line,
entire evaporative system of boiler and economizer.
C TECHNI"UE!
For carrying out the alkali boil out, 1000 ppm of Trisodium hosphate and
ppm of !isodium hosphate are used as cleaning agents. The alkali boil out is
carried out in one stage at drum pressure of "0 #g$cm%.
D PREPARATIONS!
1. re-boiler system should be flushed with alkali solution and & nos. 'F
should be made ready for regular operation from control room.
&. (ll the drum internals including the secondary steam separators are erected
in position as per drawings.
). 'oiler should be made ready in all respects for regular operation upto
drum pressure of "0 #g$cm%. For carrying out alkali boil out, e*ternal
combustor will be utilized for raising bed material temperature of 1
st
compartment. Further parameters will be raised by coal firing in 1
st
compartment.
". +$, !ozing system should be made ready for dozing of chemicals
during boil out activity.
-. 'oiler drum level g$g should be commissioned with lighting arrangement.
.. Feed water and /'! sampling lines should be ready for taking samples.
0. 1e2uired chemicals should be checked for 2uality and 2uantity.
(rrangements for mi*ing of chemicals with !3 water at drum level
should be made. ,ab facilities should be ensured for testing of samples.
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BHARAT HEAVY ELECTRICALS LIMITED
POWER SECTOR WESTERN REGION
4. 5*pansion constraints should be identified and removed. 5*pansion trams
should be installed to monitor the movement of pressure parts.
6. ermanent lighting and communication facilities should be ensured at all
working locations.
10. 7upply of ade2uate 2uantity of !3 water should be ensured before start of
operation.
11. First aid bo* and safety appliances 89um boots, +and gloves, Face 3asks
and (prons: should be made available.
E PROCESS!
1. !rum manhole door should be opened and water should be filled upto
feet below manhole door bottom level. 1e2uired 2uantity of chemicals
should be mi*ed in a separate &00-liter drum and dozed slowly in
boiler through manhole door.
(fter closing manhole door, boiler parameters should be slowly raised
upto drum pressure of "0 #g$cm%. 5*pansion readings should be
recorded at 10, &0 ; "0 #g$cm% drum pressure and uniformity must be
ensured.
&. 'oiler drum pressure will be maintained for & hrs. For proper digestion
of chemicals. /'! sample should be analysed for phosphate and oil
level content.
). ut out the coal firing and issue below down through low point drains
by opening each drain valve for one minute duration. 5nsure that the
drum level does not fall below visibility limits. (fter every blow down,
drain sample to be analysed for phosphate and oil content.
". <f phosphate content drops below half the initial value, further dozing
should be done through phosphate dozing pumps.
-. 3ake up the drum level and again light up the boiler to raise pressure
to "0 #g$cm% for ne*t two hours. The blow down activity is repeated
every two hours as per above procedure.
.. (lkali boil out is declared completed after oil content in sample
collected shows less than - ppm or till 4 blow are completed,
whichever is later. ( minimum of 1& hours boil out is a must.
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BHARAT HEAVY ELECTRICALS LIMITED
POWER SECTOR WESTERN REGION
0. (fter completion of alkali boil out, 'oiler is bo*ed-up and allowed for
natural cooling. =hen drum pressure reaches &.0 #g$cm%, open the
drum vents. +ot drain the boiler when drum temperature is about 60
deg c.
4. Fill the boiler upto minimum level of drum and back flush the
superheater into the drum, raising level upto normal. Then drain the
boiler and analyse drain sample for phosphate. 1epeat this activity till
phosphate content drops below &- ppm.
(fter completion of alkali boil out, drum manhole doors should be opened
and checked for any loose debris and the same should be cleaned.
Thereafter, boiler is released for acid cleaning operation.
)
BHARAT HEAVY ELECTRICALS LIMITED
POWER SECTOR WESTERN REGION
PROCEDURE FOR ACID CLEANING OF 2 X 165 TPH AFBC BOILERS
AT JSL, RAIGARH
A INTRODUCTION!
3odern power stations demand high purity of steam in order to prevent
fouling of the turbine and safe operation of the power plant. +igh purity of
steam depends on the cleanliness of the waterside of the boiler.
'oiler components during manufacture in shop from raw material to final
shape and during erection at site undergo both physical and chemical changes.
These include rust due to atmospheric corrosion and formation of o*ides of
iron due to the heat treatment at shop.
/hemical cleaning, apart from imparting cleanliness of waterside surfaces,
leaves behind a thin uniform protective layer of magnetic o*ides of iron
8called magnetite:.
B SCOPE!
The scope of cleaning includes a portion of the feed line complete evaporative
system of the boiler. !uring pickling the superheater connecting tubes will be
plugged suitability from inside the drum and remain filled and pressurized
with (mmoniated +ydrazine water confirming to p+ 10.0 and +ydrazine
content not less than &00 ppm.
C TECHNI"UE!
/hemical cleaning of the boiler will be carried out by a pickling solution of
"> inhibited +ydrochloric (cid by circulation method. To intensify the action
of +ydrochloric (cid and to dissolve siliceous impurities, (mmonium 'i
Fluoride is added to the cleaning solution. To lessen the action of acid on
parent metal suitable inhibitor is added to the picking solution. <n the final
phase of cleaning the freshly pickled surfaces are protected from corrosion by
a passivated layer of magnetic formed chemically by the addition of
+ydrazine and ammonia. The above layer is reinforced further by the process
of second stage passivation, at a later stage, at a drum pressure of "0 #g$cm%.
D PREPARATIONS!
1# (lkali boil out of water-touched parts should be completed as per
procedure.
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BHARAT HEAVY ELECTRICALS LIMITED
POWER SECTOR WESTERN REGION
2# The scheme of connecting the boiler and pipelines including
provisional e2uipment is attached 8the provisional e2uipments are
designed to achieve circulation of chemicals in ==$5co tubes and
consist of dissolving tank, circulating pumps 8) nos. of 1-0 3
)
$+r, 1&
#g$cm%:, connecting pipes and valves.
$# (rrangements should be made for continuous supply of !3 water and
heating steam to the dissolving tank 8as re2uired for the process: with
valves and fittings as per scheme. 7team should be made available at
the rate of 10 T+ at 10 #g$cm%, &-0?/ at inlet of dissolving tank.
7ufficient storage of !3 water must also be ensured before start of
process.
%# (rrangements should be made for nitrogen capping during the process
of pickling. 1e2uired number of nitrogen cylinders should be made
available before start of pickling process.
5# 1epresentative water wall tube sample should be hung inside the drum
as well as dissolving tank.
6# <nhibitor should be tested before use for its efficiency.
&# For neutralization of acid, it@s preferable to dig an earthen pit of &00
3
)
. Aecessary temporary drain lines and raw water lines should be laid
accordingly. (rrangement should be made for pumping out of
neutralized solution into the plant drain canals.
'# Fire fighting arrangement, first aid and safety appliances should be
kept ready before start of the process. 7ervice water facility should be
arranged near tank area for the purpose of getting water bath in case of
contact with chemicals.
(# 'efore charging chemicals, circulating water pumps must be trial run
and system should be ensured leak proof.
1)# ,ab facilities including services of chemist must be ensured for
analyzing the samples as per the re2uirement of the process.
11# 1emove all the drum internals.
12# Fi*ing of down comer orifice
1$# <solate all the instrument tapping, gauge glasses,
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BHARAT HEAVY ELECTRICALS LIMITED
POWER SECTOR WESTERN REGION
1%# 7+ drain ; fill connections from ,! header should be
disconnected$isolated.
PROCESS!
* A+,- P,+./,01!
i: Fill the entire system with !3 water. 5stablish circulation in the
system by running circulating pumps. 3aintain ) to - #g$cm% pressure
in the drum.
ii: 5nsure that water flows from the drum vents to the collecting tank and
to the mi*ing tank.
iii: (dmit steam into the mi*ing tank and raise the temperature of
circulating water to .0?/ as measured in return line. /ontinue
circulating for four hours for the purpose of hot flushing and drain the
system completely.
iv: Take fresh !3 water into the tank and establish circulation as per steps
i B ii and raise the temperature of water to .0?/.
v: /ut off steam and add re2uired 2uantity of inhibitor, with the pumps
running to achieve through mi*ing.
vi: (dd re2uired 2uantity of )0-)&> +ydraulic acid in a controlled
manner so that acid concentration as measured in the sample from
pump discharge does not e*ceed .>. This sample is to be collected at
intervals of 10 minutes.
vii: Total 2uantity of acid re2uired to achieve acid concentration of "> in
the circulating solution is to be added in one hour. 7imultaneously
charge calculated 2uantity of ammonium bifluoride into the mi*ing
tank by several increments.
viii: /ollect sample from circulating solution, at an interval of 1- minutes,
at the pump discharge and return line and analyse for acid strength and
iron concentration.
i*: 7top circulation once three consecutive samples show almost same
values of acid and iron concentration or if the circulation is done for
ma*imum of " hours 8total acid contact time to be less than . hours:.
*: !rain the system under A& blanking
.
BHARAT HEAVY ELECTRICALS LIMITED
POWER SECTOR WESTERN REGION
2 D# M# W*345 R,064
i: Cn completion of draining of acidic solution, fill the system with plain !.
3. water and establish circulation.
ii: /ollect samples from pump discharge and return line and analyse for
acid and iron concentration.
iii: !rain the system under nitrogen blanket.
+ C,35,+ A+,- R,064
i: Cn completion of draining, fill the system with !3 water and establish
circulation.
ii: 1aise the temperature to --?/ and add 0.&> =$v citric acid
monohydrate.
iii: (dd li2uid ammonia to raise the p+ of the solution to ).- to ".0 and
circulate for & hours.
iv: /ollect samples and analyse for p+ and iron content, drain the system
under nitrogen cover when the values stabilize.
- D# M# W*345 R,064
i: Cn completion of draining rinse the system with plain !3 water.
ii: Cne or two rinsing operations are to be done till the iron content drops
down to -0 ppm and acidity is absent.
iii: (ll the draining operations are to be done under nitrogen blanket.
4 N4735*/,8*3,90
i: Fill the system with plain !.3. waterD raise the temperature to 4--60?/
after establishing circulation.
ii: (dd re2uired 2uantity of 0.1> !isodium phosphate Aa& +0" 0+&C
and 0.&> Trisodium phosphate Aa) C" 1&+&C and maintain
circulation for . hours.
iii: +ot drain the system under atmospheric air by keeping the drum vents
open.
: P*66,;*3,90
0
BHARAT HEAVY ELECTRICALS LIMITED
POWER SECTOR WESTERN REGION
The obEective of passivation is to prevent corrosion since the cleaned
surfaces are more susceptible for corrosion at a very fast rate. The
corrosion is prevented by providing a thin of magnetite 8first stage:, which
gets strengthened in the subse2uent firing of the boiler 8second stage:.
, F,563 S3*14 P*66,;*3,90
The system is filled with !3 water and adEusted for circulation. The
temperature of water is raised and maintained at 4-?/ by e*ternal
steam heating. + of !3 water is raised to 6.- by adding ammonia
and hydrazine is changed to get a connection of &00 ppm. The solution
is left to circulate for about &0 hours at a temperature of 4- F 60?/.
The hydrazine concentration is maintained at &00 ppm through out the
operation.
(fter &0 hours, the solution is drained hot from the system and left
aerated by natural draft.
,, I06<4+3,90 9: <54<*5*395= >95. :95 64+90- 63*14 <*66,;*3,90
The drum is inspected thoroughly and all loose debris cleaned
manually. 'ottom headers hand hole pipe connections are removed and
the headers are cleaned with water.
The super heater plugs and down comer orifice plates are removed and
drum internals are refitted. 7+ connections to be normalized .(ll the
provisional e2uipments are dismantled and original fittings and
mounting are installed back. The boiler should be prepared for regular
operation, upon completion of hydraulic test at working pressure.
,,, S4+90- S3*14 P*66,;*3,90
The chemicals viz. ammonia li2uor, raising the p+ to 6.- and
hydrazine, to get a concentration of &00 ppm are charged in the
operating level in drum and lighted up. The steam pressure in drum is
gradually raised to "0 #g$cm% and maintained at that value. =ater
samples are taken from feed line to find out hydrazine concentration
and p+ value. The boiler is kept in service for &" hours maintaining the
hydrazine concentration not less than &0-&- ppm in feed water.
(t the end of the process, the boiler is bo*ed up and allowed for
natural cooling. (t & #g$cm% drum pressure, all vents are opened and at
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BHARAT HEAVY ELECTRICALS LIMITED
POWER SECTOR WESTERN REGION
about 60?/ drum temperature, the water in the system is drained and
the system is left aerated.
The second stage passivation marks the end of the chemical cleaning
process. Thereafter boiler is released for steam blowing operations.
6
BHARAT HEAVY ELECTRICALS LIMITED
POWER SECTOR WESTERN REGION

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BHARAT HEAVY ELECTRICALS LIMITED
POWER SECTOR WESTERN REGION
SPECIFICATION OF CHEMICAL AND "UALITY
FOR
ALKALI BOIL OUT AND ACID CLEANING ACTIVITIES
OF
2 X 126 TPH AFBC BOILERS AT JSL, RAIGARH
?FOR ONE BOILER ONLY
SL# NO# NAME OF CHEMICAL "UALITY
1. !isodium hosphate Aa
&
+pC
"
0+
&
C &-0 #g.
&. Trisodium hosphate Aa
)
C
"
1&+
&
C
8<7G -0)G 160):
-00 #g.
). +ydrochloric (cidG )0>
8<7G &.-G 160.:
&0 Tons
". /oronilG &1) 7pecial 1-0 ,iters.
-. /itric (cid
8<7G -"."G 1600:
)00 #g.
.. (mmoniaG &-> 1&0 ,iters.
0. +ydrazine +ydrateG 40> "00 ,iters.
4. Aitrogen /ylinders
8..& m
)
each, <7G 10"0G 160&:
1&0 Aos.
6. (mmonium 'ifluoride .00 #g
10. +ydrated ,ime 1- Tons
11. 'eaching owder ) Tons
11