PROCEDURE OF CHEMICAL CLEANING OF BOILER

FOR
3X660 MW LPGCL LALITPUR PROJECT

DOC NO. :
PN:TSX:670:00:2014

REV NO. : 00

EFF DATE :
09/05/2014

PREPARED BY

REVIEWED BY

APPROVED BY

( B K ROY )

( S Y BHAVE )
ISSUED TO :

( S Y BHAVE )

COPY NO. :

ISSUED BY

DATE OF ISSUE :
( NAME,DESGN./DEPT.)

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR NORTHERN REGION

(SIGN.)

LPGCL LALITPUR BHEL Ref NO. PN:TSX:670:00:2014

3 X 660 MW
PLANT AREA : BOILER

Sheet 1 of 23

PROCEDURE FOR CHEMICAL CLEANING OF BOILER USING EDTA

1.0

PLANT DETAILS

2.0

OBJECTIVE

3.0

PROPOSAL

4.0

SERVICES REQUIRED

5.0

SAFETY PRECAUTIONS

6.0

EMERGENCY PROCEDURES

7.0

STATE OF THE PLANT

8.0

METHOD

9.0

COMPLETION CRITERIA

10.0

WASTE TREATMENT & DISPOSAL

11.0

APPENDICES
LOG SHEET
ANALYTICAL PROCEDURES
DRAWINGS

LPGCL LALITPUR BHEL Ref NO. PN:TSX:670:00:2014

3 X 660 MW
PLANT AREA: BOILER

Sheet 2 of 23

PROCEDURE FOR CHEMICAL CLEANING OF BOILER USING EDTA

1.0

PLANT DETAILS
The Steam Generator is a once through super critical boiler having spiral wall upto
intermediate header. The Boiler has one Boiler circulation Pump for startup and low load
operation purpose.

1.1

1.2

Boiler Design Data

SH outlet Pressure
SH outlet Temperature
Maximum Continuous Rating
Water Holding Capacity
Economiser
Separator
Furnace
Super heaters
Start up system
Total

- 255.0 Kg/cm2(g)
- 568 0 C
- 2110.0 T/h
200 m3
16 m3
125 m3
92 m3
16 m3
449 m3

2.0

OBJECTIVE

2.1

To chemically clean and passivate the internal surfaces of the steam generating section and
Economiser. This will render these surfaces free from mill scale and other deposits and form
uniform & smooth protective layer of magnetite.

3.0

PROPOSAL

3.1

Prior to Alkali flushing and Acid cleaning Cold and Hot water flushing shall be done to
remove loose rust, debris, deposits and other materials lying in the Boiler.

3.2

Alkali flushing and acid cleaning shall then be done to remove patchy mill scale and adherent
rust.

3.3

During Acid cleaning temperature of EDTA solution shall be maintained around 80~90 degree
Celsius by using steam from Auxiliary Boiler in a non-contact type heat exchanger installed in
the temporary system connected between a tap off from BCP discharge to drain from water
wall intermediate header.

3.4

The temporary system shall have suitable arrangement for injection of chemical solutions into
the Boiler for chemical cleaning and heating of solution in a non contact heat exchanger using
steam. The temporary system shall be properly insulated.

LPGCL LALITPUR BHEL Ref NO. PN:TSX:670:00:2014

3 X 660 MW
PLANT AREA: BOILER

Sheet 3 of 23

PROCEDURE FOR CHEMICAL CLEANING OF BOILER USING EDTA

3.5

The acid cleaned surface shall be passivated using an oxidant.

4.0

SERVICES REQUIRED

4.1

Approximately 3500 m3 of DM water is expected to be consumed for the entire chemical

cleaning process. At any point of time, during acid cleaning, a minimum of 1000 m3 of DM
water should be available for flushing of the system in the event of chemistry upset.

4.2

Availability of required quantities of chemicals

Chemicals

Quantity / Boiler

a. Di ammonium EDTA solution

36 tonne
EDTA, 40% wt / wt (min) as active EDTA
ammoniated to a pH of 5.5 to 6.5
(EDTA : Ethylene Diamine Tetra Acetic acid, Density ~1.2)
b. Ammonia solution (20% Min as NH3,
sp gravity ~ 0.91) as per IS 799 / 1990

14500 litre

c. Tri sodium Phosphate (TSP), Na3PO4.12 H2O

As per IS 573: 1992, assay 17.5% as P2O5 min

400 kg

d. Di Sodium Hydrogen Phosphate, Na2HPO4.12H2O

As per IS: 566: 1984, technical grade assay 98% on
Dry basis

200 kg

e. Sodium Nitrite As per IS: 879: 1981

technical grade, assay 97% min

1700 kg

f. Inhibitor (proprietary)
(Coroban SQ7 or Coronil AED)

1100 litre

g. Formic acid, IS: 9908-1981, assay 85% min

500 litre

LPGCL LALITPUR BHEL Ref NO. PN:TSX:670:00:2014

3 X 660 MW
PLANT AREA: BOILER

Sheet 4 of 23

PROCEDURE FOR CHEMICAL CLEANING OF BOILER USING EDTA

4.3

Availability of steam for heating.

4.4

Availability of adequate quantity of LDO.

4.5

Availability of chemical handling, mixing and injection system.

4.6

Availability of HT / LT power supply and control supply.

4.7

Availability of Tygon Tube (Plastic) for connecting to top and wet leg of Separator Storage
Tank (SST) for monitoring level in the SST.

4.8

Availability of Tell Tale level indication lamps in control room and chemical pumping
station area.

4.9

Availability of a positive displacement pump to supply approximately one litre per minute
(1 Lit / Min) purge water for continuous purging of BCP Motor cavity with DM water.

4.10

Availability of back up Emergency supply for continuous running of the positive displacement
pump.

4.11

Availability of Instrument & Service Air.

4.12

Availability of Chemist & Express lab for testing during the process.

4.13

Availability of Test coupons and their fixing arrangement.

4.14

Availability of flood lights, telephones & walkie-talkie.

4.15

Availability of effluent / neutralizing pit having a perforated Carbon Steel / polythene tubing
arrangement.

LPGCL LALITPUR
3 X 660 MW
PLANT AREA: BOILER

BHEL Ref NO. PN:TSX:670:00:2014

Sheet 5 of 23

PROCEDURE FOR CHEMICAL CLEANING OF BOILER USING EDTA

5.0

SAFETY PRECAUTIONS

5.1

Sufficient number of following personal protective equipments should be available :

Gum boots (various sizes)
Rubber hand gloves
Rubber or Polythene aprons
Helmets
Safety goggles of plain glass
Face mask (Transparent plastic)

5.2

First aid box (containing dilute ammonium hydroxide, 50% sodium bicarbonate solution, eye
lotion, bandages, tincture of iodine, cotton, Burnol etc) should be available near the work area.

5.3

Ample supply of water for flushing and washing should be available at all possible points of
discharge, spillage or escape of chemicals.

5.4

Adequate number of eye wash bottles for treatment of eye should be kept at easily
approachable locations where discharge, spillage or escape of chemicals can occur.

5.5

Safety shower should be provided near chemical handling area.

5.6

A suitable first aid room with outside telephone facilities should be provided within a
reasonable distance from the place where chemicals are being handled.

5.7

Protective clothing and apparatus required for emergency use should be available near the
chemical cleaning area.

LPGCL LALITPUR
3 X 660 MW
PLANT AREA: BOILER

BHEL Ref NO. PN:TSX:670:00:2014

Sheet 6 of 23

PROCEDURE FOR CHEMICAL CLEANING OF BOILER USING EDTA

5.8
5.8.1

First Aid
Splash of chemicals in eye

5.8.1.1 Affected eye should be immediately washed / irrigated with plenty of water. To make the
washing effective the eyelids must be kept open. The eyelids should be pushed apart using the
thumb and index finger of one hand. The affected person may not be able to open the eye
himself because of painful spasms.
5.8.1.2 If an eye wash bottle is used, the jet should not be directed to the front of the eye. It should be
directed from the side so that flow is over the surface of the eye.
5.8.1.3 Irrigation should be continued for 5 10 minutes after which the affected person should be
taken to the first aid room.
5.8.1.4 Irrigation should be continued in the first aid room. After thorough irrigation the eye should be
covered with a pad. The patient should then be referred for medical opinion.
5.8.2

Splash of chemicals on skin

5.8.2.1 If skin irritation occurs the persons should be referred for medical opinion.
5.8.2.2 In the event of splashing of chemicals on the skin, the affected area should be washed
thoroughly avoiding spread of chemical on the face and eyes.
5.9

Safety of Plant

5.9.1

Continuous purging of cavity of Motor of BCP with DM water should be ensured.

5.9.2

With BCP running water level in the SST shall never be allowed to go below visible range.

5.9.3

If after completion of chemical cleaning, Boiler light up for subsequent activities is delayed by
more than 4 weeks then the system should be suitably preserved.

5.9.4

Temperature limits specified for various steps should not be exceeded.

LPGCL LALITPUR
BHEL Ref NO. PN:TSX:670:00:2014
3 X 660 MW
PLANT AREA: BOILER

Sheet 7 of 23

PROCEDURE FOR CHEMICAL CLEANING OF BOILER USING EDTA

5.10

General

5.10.1

All temporary connection to Boiler should be of good quality and suitably tested for no leaks.

5.10.2

Test area should be cordoned off and entry of unauthorized persons should be prohibited.
Suitable signboards should be displayed.

5.10.3

Whenever any inspection is made during the cleaning process the location should be
adequately ventilated.

6.0

EMERGENCY PROCEDURES

6.1

The testing team should be aware of the operating procedures of portable fire extinguishers
and permanent fire fighting system installed in and around the boiler for quenching minor or
major fires.

6.2

The testing team should be aware of the procedure to be followed in case of accidents
involving injury to personnel.

6.3

SPILL CONTROL : In case of spillage or leakage in the temporary system, the same may be
isolated by closing
i) isolating valves at Furnace Intermediate Header drains and
ii) isolating valves at Sidestream outlet.
Instruction should be given to stop the pump also.
Any gland leakage in valves in the permanent as well as temporary system observed during
hot water rinsing and Alkali flushing should be attended to before putting EDTA into the
boiler.

LPGCL LALITPUR
BHEL Ref NO. PN:TSX:670:00:2014
3 X 660 MW
PLANT AREA: BOILER

Sheet 8 of 23

PROCEDURE FOR CHEMICAL CLEANING OF BOILER USING EDTA

7.0

STATE OF THE PLANT

7.1

During the acid cleaning process all the pressure and level instruments are isolated. The BCP
dp transmitter will remain in service to provide for Control Room Indication of the Pump dp
throughout the Chemical Cleaning activities. The impulse line tubing for the instruments
should be flushed thoroughly with ammoniated DM water after the final draining of EDTA
solution.

7.2

The Boiler features numerous permanent thermocouples on the spiral evaporator tubes, on the
BCP casing and at the BCP Discharge / Economiser inlet to enable close and accurate
monitoring of the water circuit temperature. The temperature measurements should be
available.

7.3

For continuous purging of BCP motor cavity with DM water, a Positive Displacement Pump to
supply purge water at a nominal flow of 1 litre / minute (one litre per minute) with a Back up
power supply in addition to its normal supply is available. The line from the Positive
Displacement Pump to BCP should be adequately flushed.
Final arrangement for the motor cavity purge can be discussed on site nearer the time and
taking pipe length and equipment location into consideration.

7.4

To get representative samples of the process solution, sampling points with sample coolers
having adequate cooling water arrangement are provided. Samples will normally be collected
from
a. temporary return line from boiler from sidestream circuit to mixing tank at ground
level, as shown in the drawing.
b. recirculation line of temporary chemical injection pumps connected to temporary
mixing tank
However, if required, sample can also be collected from Wet Leg sampling valves
01HAG15AA621 & 01HAG15AA622, as shown in the drawing.

LPGCL LALITPUR
BHEL Ref NO. PN:TSX:670:00:2014
3 X 660 MW
PLANT AREA: BOILER

Sheet 9 of 23

PROCEDURE FOR CHEMICAL CLEANING OF BOILER USING EDTA

7.5

All Auxiliaries required for safe light up of Boiler are made available with their protections,
interlocks, alarms, measurements, annunciations etc., as per mutually agreed list between M/s
LPGCL and BHEL at site.

7.6

Prior to commencement of Alkali flushing of the Boiler, Feed water system is made ready for
quick flushing of Boiler in case of chemistry upset.

7.7

Inhibitor efficiency test is completed before dispatch. Acceptable corrosion rate is less than
0.1mg / sq cm / hr.

7.8

The MEFCV (Minimum Economizer Flow Control Valve) is kept open at an intermediate
position (around 25% so that there is adequate flow during cold condition and the motor
current is also less than the overload setting) throughout the chemical cleaning process.

7.9

A cement plastered neutralizing pit of approximately 1000 m3 capacity with compressed air
scouring arrangement is available for proper treatment of effluent.

7.10

Test coupons (Boiler water wall tube pieces) are placed in the temporary line between BCP
discharge and water wall intermediate header drain with proper fixing arrangement to assess
the effectiveness of cleaning.

7.11

All the safety measures are discussed and implemented in advance with suitable instruction /
caution tags provided at strategic places / equipment.

LPGCL LALITPUR
BHEL Ref NO. PN:TSX:670:00:2014
3 X 660 MW
PLANT AREA: BOILER

Sheet 10 of 23

PROCEDURE FOR CHEMICAL CLEANING OF BOILER USING EDTA

7.12

Minimum Operational Requirements

1. Readiness of the following including their protections, interlocks, measurements, alarms and
annunciations:
One ID Fan
One FD Fan
One Air Pre-Heater with its Soot Blowing arrangement, rotor stoppage alarm, oil carry over
probe, fire fighting system etc. (The other Air Pre-Heater is isolated by keeping the inlet and
outlet dampers tightly closed).
Boiler Circulation Pump with continuous purging of Motor cavity
LDO Firing system
BMS
SADC
Scanner Air System
2. Free expansion of the furnace and ducts with provision of expansion markers.
3. Boiler start up system.
4. Boiler Vents and Drains system.
5. Proper drainage system of Boiler area.
6. Mechanical readiness of at least one pass of ESP.
7. Adequate quantity of LDO & readiness of LDO handling system.
8. Temporary sampling system along with cooling water arrangement.
9. Effluent treatment pit of approximately 1000 m3 capacity.
10. Drain line to effluent treatment pit.
11. DG set, DG switchgear, emergency switch gear and availability of emergency supplies for
Scanner air fan
Emergency lighting
Emergency power source for running positive displacement pump for continuous
purging of BCP motor cavity.
12. UPS
13. Fire fighting system of concerned equipments.
14. Equipment cooling water system.
15. Availability of test coupons & their fixing arrangements.
16. Emergency operating instructions viz. AC power failure, DC power failure, APH fire etc.
17. Adequate lighting in operating areas.
18. Public address system at all operating locations, including telephone & walki-talkies.
19. Readiness of staircases, hand railings and platforms.
20. Easy access and approaches to all the operating equipments.

LPGCL LALITPUR
BHEL Ref NO. PN:TSX:670:00:2014
3 X 660 MW
PLANT AREA: BOILER

Sheet 11 of 23

PROCEDURE FOR CHEMICAL CLEANING OF BOILER USING EDTA

8.0

METHOD

8.1

Cold Water Rinse

8.1.1

Before starting the acid cleaning process, the Boiler is rinsed with cold DM water containing 15
ppm Ammonia to remove loose debris, rust etc.

8.1.2

SH backfilling is done with ammoniated DM water containing 15 ppm Ammonia.

8.2

Hot Water Rinse

8.2.1

Boiler is again filled with ammoniated DM water containing 15 ppm Ammonia at ambient
temperature.

8.2.2

Boiler is lit up as per O&M instructions and Boiler water temperature is gradually raised to 90oC
(SST water temperature is observed).

8.2.3

Boiler is shut down and BCP is stopped.

8.2.4

Boiler is drained in hot condition to the plant water disposal system by keeping the drain valves
wide open.

8.3
8.3.1

Alkali Flushing
The following chemicals are used:
1. Tri Sodium Phosphate
0.1 %
2. Di Sodium Hydrogen Phosphate 0.05%

8.3.2

The chemicals are added in the mixing tank along with DM water and the solution is thoroughly
mixed by running the temporary pumps on recirculation. Boiler is filled with the solution up to
normal working level in the separator.

8.3.3

Boiler is lit up as per O&M instructions and Boiler water temperature is gradually raised to 8590 deg C (SST water temperature is observed). Samples are analyzed for phosphate and pH on
hourly basis. Temperature is maintained for 4 hours and must be closely monitored. Boiler is
then shut down. BCP is kept running.

LPGCL LALITPUR
3 X 660 MW
PLANT AREA: BOILER

BHEL Ref NO. PN:TSX:670:00:2014

Sheet 12 of 23

PROCEDURE FOR CHEMICAL CLEANING OF BOILER USING EDTA

8.3.4

8.4

After about 4 hours the BCP is stopped. Boiler is drained to the plant water disposal system by
keeping the drain valves wide open (i.e., without throttling). The drained solution is diluted with
plenty of service water.
Hot Water Rinse

8.4.1

Once draining of boiler is complete, it is refilled with treated DM water containing 15 ppm
ammonia. BCP is started and Boiler is lit up. Boiler water temperature is raised to 90 deg C and
then Boiler is shut down.

8.4.2

BCP is stopped after 30 minutes and Boiler is drained in hot condition to plant water disposal
system by keeping the drain valves wide open (i.e., without throttling). pH and PO4 are
measured in the drain water.

8.5

Cold Water Rinse

8.5.1

Once the draining is complete the Boiler is again filled with DM water containing 15 ppm
ammonia. BCP is started. BCP is stopped after 30 minutes and Boiler is drained to the plant
water disposal system. pH and PO4 are measured in the drain water.

8.5.2

Cold rinsing is continued till the pH in the drained water is less than 7.5 and phosphate content
is less than 10 ppm.

8.5.3

All sampling and drain lines are also flushed.

8.6

Acid cleaning & Passivation

8.6.1

Boiler is filled with DM water with NO AMMONIA DOSING and lighted up.

8.6.2

Boiler water temperature is raised to 90 deg C. Then Boiler is shut down, FD and ID fans are
stopped and boiler boxed up. BCP is kept running.

8.6.3

In order to accommodate EDTA solution, adequate quantity of hot water from the Boiler is
drained keeping a close watch on the level in the Separator Storage Tank through the temporary
Tygon tube connected suitably to the top and wet leg of the SST. The level in the SST is
monitored manually from local and it should NOT go below the visible range in any case.

LPGCL LALITPUR
3 X 660 MW
PLANT AREA: BOILER

BHEL Ref NO. PN:TSX:670:00:2014

Sheet 13 of 23

PROCEDURE FOR CHEMICAL CLEANING OF BOILER USING EDTA

8.6.4

Required quantity of inhibitor is added in the EDTA storage tank containing concentrated Di
ammonium EDTA. The Inhibitor effectiveness check must be carried out before mixing
them with EDTA. The temporary pumps connected to storage tank are run on recirculation for
proper mixing of inhibitor with EDTA.

8.6.5

The solution is transferred to the mixing tank and then injected into the system so as to achieve
around 4.0 % EDTA concentration in the cleaning solvent in the Boiler.

8.6.6

Depending on the volume of hot water that can be drained in one go and the size of the mixing
tank, two or more batches of EDTA solution injection may be required. It is ensured that with
the BCP running the level in SST should never go below the visible range.

8.6.7

Additional ammonia, if required, may be injected to adjust the pH of the cleaning solvent in the
range of 5.5 to 6.0. If the pH of the solvent goes beyond 6, formic acid can be used to bring the
pH to the desired level. Circulation of the solution is maintained by BCP.

8.6.8

Temperature of the EDTA solution is maintained around 80~90 deg C by controlling the steam
input in the temporary heat exchanger (non contact type) installed in the temporary system.
Temperature is monitored with the help of temperature gauge mounted locally in the temporary
line.

8.6.9

When Boiler is filled with EDTA solution OR pH of the solution in the Boiler is in the acidic
range, Boiler is NOT to be fired.

8.6.10

Counting of time (i.e., T = 0) for the purpose of calculation of minimum contact period will start
only after completion of injection of required quantity of EDTA solution into Boiler.

8.6.11

Concentration of EDTA and iron in the cleaning solvent are analysed every 45 minutes. If
required, additional quantity of EDTA may be injected to maintain 1% residual EDTA.

8.6.12

Circulation is maintained for 4 hours or till the iron concentration equilibrium in three
consecutive samples is reached, whichever is later.

8.6.13

ID / FD Fans are run, if required, to bring down Boiler water temperature to around 70 deg C.

8.6.14

When the temperature comes down to 70 deg C, ID / FD Fans are stopped.

8.6.15

Suitable quantity of the solvent is drained from Boiler to the effluent pit to accommodate
injection of ammonia and oxidant for passivation.

LPGCL LALITPUR
3 X 660 MW
PLANT AREA: BOILER

BHEL Ref NO. PN:TSX:670:00:2014

Sheet 14 of 23

PROCEDURE FOR CHEMICAL CLEANING OF BOILER USING EDTA

8.6.16

Adequate quantity of ammonia is injected to achieve pH of about 9.5.

8.6.17

Concentrated solution of sodium nitrite is prepared in the mixing tank using DM water. The
concentrated solution is injected into the system so as to achieve 0.5% concentration of sodium
nitrite in the passivating solvent. Circulation is continued using BCP for about four (4) hours.
The temperature is maintained around 60 ~ 70 deg C.

8.6.18

BCP is stopped and the solution is drained into the effluent pit by opening all drain valves.

8.6.19

Boiler is refilled with DM water containing 15 ppm ammonia. Circulation is maintained for 30
minutes by running BCP.

8.6.20

After stopping BCP the Boiler is drained. Boiler filling, circulation with BCP and draining is
continued till conductivity of the final rinse is less than 50 S/cm.

8.6.21

After completion of chemical cleaning activity the next start up of the Boiler should be done
within a reasonable duration. If there is going to be a delay of more than 4 weeks, the water
circuits and superheaters should be preserved with DM water containing 10 ppm of ammonia
(pH ~ 10).

9.0

COMPLETION CRITERIA

9.1

Hot / Cold water rinsing after Alkali flushing

pH < 7.5
PO4 < 10 ppm

9.2

Acid cleaning & Passivation

Chemical cleaning process will be declared complete when the Iron concentration in three (03)
consecutive samples stabilizes OR the EDTA contact period (counting started after completion
of EDTA injection into the system) of Four (04) hours is achieved, whichever is later.

9.3

Rinsing after Passivation

Conductivity of the effluent < 50 S/cm

LPGCL LALITPUR
3 X 660 MW
PLANT AREA: BOILER

BHEL Ref NO. PN:TSX:670:00:2014

Sheet 15 of 23

PROCEDURE FOR CHEMICAL CLEANING OF BOILER USING EDTA

10

WASTE TREATMENT & DISPOSAL

10.1

Treatment and disposal of the waste and effluents of the chemical cleaning process shall comply
with the requirements / stipulations of State Pollution Control Board.

10.2

Hot DM water after flushing shall be drained into plant normal drain.

10.3

The organic spent EDTA chemical solution after the cleaning process is drained into the
neutralizing pit. The pH of the effluent will be in the range of 8.5 to 9.0 and hence no treatment
for pH adjustment is required as it would meet the pH requirement for disposal, subject to
verification at site.

10.4

Compressed air shall be used to destroy the organics. The effluent shall be disposed off after
aeration for 10 days or when it has degraded completely, as per State Pollution Control Board
norms.

10.5

EDTA storage tank, pipelines and inhibitor carboys shall be cleaned with water and the effluent
shall be drained into the neutralizing pit.
NOTE

Drains shall be provided at lowest points of temporary piping.

Additional Check lists / Modifications in the layout, if found necessary, shall be made at
site.

APH, which will be in service during chemical cleaning, will be water washed after
completion of Chemical cleaning process

LPGCL LALITPUR
3 X 660 MW
PLANT AREA: BOILER

BHEL Ref NO. PN:TSX:670:00:2014

Sheet 16 of 23

PROCEDURE FOR CHEMICAL CLEANING OF BOILER USING EDTA

LOG SHEET
PROJECT:

DATE:

UNIT No.:
ACTIVITY: BOILER CHEMICAL CLEANING AND PASSIVATION
I.
ADDITION OF CHEMICALS:
____________________________________________________________________________________
S. No. DATE TIME
NAME OF CHEMICAL ADDED
QUANTITY

___________________________________________________________________________________
II.
ANALYTICAL DATA:
___________________________________________________________________________________
S. No.
DATE TIME
SAMPLING POINT
TOTAL EDTA
IRON
pH
1.
2.
3.
4.
5.
6.
7.
8.
9.
___________________________________________________________________________________

LPGCL LALITPUR
BHEL Ref NO. PN:TSX:670:00:2014
3 X 660 MW
PLANT AREA: BOILER

Sheet 17 of 23

PROCEDURE FOR CHEMICAL CLEANING OF BOILER USING EDTA

PROCEDURE FOR DETERMINATION OF TOTAL EDTA CONCENTRATION IN
PROCESS SOLUTION DURING CHEMICAL CLEANING
1. PRINCIPLE
EDTA reacts with Zirconium ions under strong acid conditions to form a chelate. The end
point of the titration is indicated by a Xylenol orange indicator.
2. REAGENTS AND APPARATUS REQUIRED
APPARATUS
1. Erlenmeyer flask 300 ml capacity
2. Pipettes
3. Hot plate
4. Magnetic stirrer
REAGENTS
1. Hydrochloric acid (conc.)
2. Standard Zirconium oxy chloride (ZrOCl2. 8H2O) 0.1 M solution in 1N HCl (Take a 1000
ml volumetric flask. Add 32.23 gram of ZrOCl2.8H2O and add about 500 ml of DM
water. To this add 85 ml of conc. HCl. Make up to 1000 ml mark with DM water and mix
well)
3. Ascorbic acid
4. Xylenol orange indicator.
3. TEST PROCEDURE
1. Pipette out 10 cc of the water sample into a 300 ml Erlenmeyer Flask
2. Add 10 ml of conc. HCl (the pH value is about 1.0)
3. Add a spatula of ascorbic acid.
4. Boil the solvent on the heating plate for about 5 minutes. (The yellow colour of the ferric
ion should disappear due to reduction to ferrous iron).
5. Immediately after the addition of 0.05 ml of 0.05 % xylenol orange indicator the sample
is titrated with 0.1M ZrOCl2 until the colour changes from yellow to red violet. The
colour change shall remain constant for at least 3 min.
4. CALCULATION
The total EDTA concentration (%) = Volume of 0.1M ZrOCl2 consumed x 0.292

LPGCL LALITPUR
3 X 660 MW
PLANT AREA:BOILER

BHEL Ref NO. PN:TSX:670:00:2014

Sheet 18 of 23

PROCEDURE FOR CHEMICAL CLEANING OF BOILER USING EDTA

PROCEDURE FOR DETERMINATION OF TOTAL IRON CONCENTRATION IN
PROCESS SOLUTION DURING CHEMICAL CLEANING

1. APPARATUS REQUIRED

HACH DR/890 COLORIMETER

Volumetric flasks
Pipettes
Measuring cylinders

2. REAGENTS REQUIRED

FerroVer reagent powder pouches (Supplied by HACH)

3. TEST METHOD
1. Sample is diluted with DM water so that the concentration of Iron is less than 3 ppm
in the test solution.
2. 25 ml / 10 ml of the diluted solution is taken in the cuvette. This will be used as a
blank.
3. Place the blank in the cell holder and cover the sample cell with cap.
4. Zero the equipment and display will be showing 0.00 mg/L Fe.
5. Fill another sample cell with 25/10 ml sample
6. Add the contents of one FerroVer Iron Reagent Powder Pillow to the sample cell (the
prepared sample). Cap and invert to dissolve the reagent powder.
7. Start the timer for 3 mts period.
8. Place the prepared sample into the cell holder. Cover the sample cell with the
instrument cap.
9. Press READ
10. The concentration will be displayed
11. Multiply with dilution factor and report the ppm / g/ lit of Fe concentration.

LPGCL LALITPUR
BHEL Ref NO. PN:TSX:670:00:2014
3 X 660 MW
PLANT AREA:BOILER

Sheet 19 of 23

PROCEDURE FOR CHEMICAL CLEANING OF BOILER USING EDTA

ESTIMATION OF HYDRAZINE
1. REAGENTS
a. Standard Potassium bromate 0.1 N
Dissolve 2.7836 gram of Potassium bromate (KBrO3) and 10 gram of Potassium
bromide (KBr) in DM / Distilled water and make up to 1000 ml.
b. 0.1 % Methyl orange indicator solution.
c. Hydrchloric acid (conc.) AR.
2. PROCEDURE
a) Place 10 ml of sample in a titration flask.
b) Add 10 ml of conc. HCl
c) Add about 5 drops of Methyl orange indicator.
d) Titrate with standard KBrO3 titrant till the first appearance of yellow colour.
3. CALCULATION
Hydrazine as N2H4, ppm

= titre value x 80

LPGCL LALITPUR
BHEL Ref NO. PN:TSX:670:00:2014
3 X 660 MW
PLANT AREA:BOILER

Sheet 20 of 23

PROCEDURE FOR CHEMICAL CLEANING OF BOILER USING EDTA

DDCMIS

01HAC20
CT003

TE

ECON MIXING LINE

D 660.00 mm x 80.00 mm

WARM-UP SUPPLY LINE

01HAG15
CT401

D 60.3 MM X 11.07 MM

TW

F-51

WATER STORAGE DOWNCOMER

D 508.00 mm x 65.00 mm

WATER STORAGE DOWNCOMER SAMPLING

01HAG15
CT001

DDCMIS
TE

EF-02

01HAC20
AA602

F-67B

D 508.00 mm x 65.00 mm
F-67C

D 88.90 mm x 15.24 mm
01HAG15
CT502

TI

TI

BALL / PLUG VALVE, OPEN

FLOW NOZZLE

01HAG15
AA411

01HAG15
AA611

01HAC20
AA401

BALL / PLUG VALVE, CLOSED

D 60.30 mm x 11.07 mm

01HAG51
AA401

F-53

FROM: DDCMIS
DDCMIS

DDCMIS

D 48.30 mm x 10.16 mm
01HAC20
CT001

D 508.00 mm x 65.00 mm

01HAG15
CT501

TI

D 33.40 mm x 9.09 mm
D 60.30 mm x 11.07 mm

Chemical
Sampling

01HAC20
CT002

TE

TE

01HAG15
AA614

EF-01

EF-01
450

01HAG15
AA613

D 457.00 mm x 55.00 mm

01HAG15
AA631

01HAG15
AA603

01HAG15
AA604

D 60.30 mm x 11.07 mm

01HAG15
AA633

01HAG15
AA635

01HAG15
AA632

01HAG15
AA634

FROM: DDCMIS

FLOW ELEMENT

BUTTERFLY VALVE, OPEN

FROM: DDCMIS

01HAG15
AA001

01HAG15
AA636

01HAG15
AA002

BUTTERFLY VALVE, CLOSED

D 21.30 mm x 4.78 mm

D 31.8 mm X 6 mm

01HAG15
AA622

F-67A

D 21.30 mm x 4.78 mm

01HAC20
AA001

01HAC20
AA002

01HAG15
CT503

F-52

D 508.00 mm x 65.00 mm

01HAG15
AA621

SAMPLING SYSTEM

ORIFICE PLATE

REDUCER
GATE VALVE, OPEN
SCREWED PIPE CAP

GATE VALVE, CLOSED

GLOBE VALVE, OPEN

STEAM TRAP
GLOBE VALVE, CLOSED

"Y" TYPE STRAINER

01HAG15
AA615

01HAG15
AA003

01HAG15
AA605

FROM: DDCMIS

D 508.00 mm x 65.00 mm
D 33.4mm x9.09 mm

ECON JUNCTION HEADER

ECON JUNCTION HEADER

E-07

E-07

E-07

F-66B

PDT
F-57

DDCMIS

DDCMIS

E-06TO

01LAB96
AA401

E-06U

01HAG15
AA514

E-06LI

01HAG15
AA513

01HAG15
CT002

D 508.00 mm x 65.00 mm

ECON JUNCTION HEADER

E-07

PITOT TUBE OR PITOT VENTURI TUBE

D 48.30 mm x 10.16 mm

ECON JUNCTION HEADER

01HAG15
AA511

DDCMIS

To System drain
ZT

ZT

FY

FY
E/H

E/H

FC

FROM: DDCMIS

D 508.00 mm x 65.00 mm
F-59A

01HAG15
AA624

E-06TI

01HAG15
AA625

E-05

ECONOMIZER INLET HEADER

01HAG15
AA623

THREE WAY VALVE

AA302

01HAG15
AA402

01HAG15
AA602

01HAG15
AA004
01HAG15
CF503

RO

01HAG51
AA501

BWCP INLET DRAIN VLV

01HAG15
CF501

DIAPHRAM, MODULATING

01HAG15
AA503
FP

01HAG15
AA502

01HAG15
CF401

01HAG15
CF502

FE

01HAG51
AA504
WARM UP BRANCH LINE

01HAG25
AA506

01HAG15
AA504

FP

01HAG15
CF402

DIAPHRAM, DOUBLE ACTING

DESUPERHEATER

FE

01HAG15
AA505

01HAG15
AA506

01HAG15
AA507

01HAG15
AA508

D 48.30 mm x 10.16 mm

D 48.30 mm x 10.16 mm
01HAG25
AA502

CC

01HAG51
AT001

01HAG25
CP001

D 114.30 mm x 17.12 mm
01HAC10
AA401

01HAC10
AA601

REFER DRG. NO:

0-00-047-48366

F-61A

01HAC10
AA001

D 323.90 mm x 40.00 mm

F-60

DDCMIS

01HAG25
AP001

SPRING

D 60.3 mm x 11.07 mm
01HAG51
CF503

DDCMIS
PDT

01HAG25
AA504

01HAG51
AA001

RO

HEAT EXCHANGER

WALL BLOWER

REFER DRG. : LOW PRESS BOILER STARTUP SYSTEM

REFER DRG. NO: 0-00-301-31305

REFER DRG. : LOW PRESS BOILER STARTUP SYSTEM

REFER DRG. NO: 0-00-301-31305

FROM: DDCMIS
01HAC10
CT401

01HAG25
AA507

PT

01HAG25
AA508

F
MAIN PROCESS LINE

D 168.30 mm x 27.5 mm

TW

ZT
01HAC10
CT501

01HAG51
AA002

FL

PP

01HAC10
AA507

01HAC10
AA508
01HAC10
CF001

DDCMIS

D 33.40 mm x 9.09 mm

FT

D 33.40 mm x 9.09 mm

D 26.70 mm x 7.82 mm

01HAC19
AA507

01HAC10
AA506

01HAC10
AA505

PI

D 26.70 mm x 7.82 mm

DDCMIS

01HAC10
AA509

01HAC10
CF003

01HAC10
CF002
FT

01HAG31
AA002

FT
DDCMIS

01HAG31
AA001

01HAG31
AA004
DDCMIS

01HAC10
CT002

01HAC10
CT001
TE

01HAC10
AA517

TE

01HAC10
AA518
ECON INLET LINK

01HAC10
CF501

CC

01LAB91
AA601

01LAB91
AA602

NOTES:
01LAB91
AA401

01LAB91
AA402
ECON INLET LINK

D 559.00 mm x 70.00 mm

FROM: DDCMIS

01HAG31
AA003

01HAC10
AA510

01HAC10
AA514

01HAG31
AA606

D 88.90 mm x 15.24 mm
DDCMIS

DDCMIS

01HAC10
AA513

01HAG31
AA602

D 114.30 mm x 17.20 mm

E-04

BOILER FEED WATER

D 559.00 mm x 70.00 mm
BHEL DWG PE-DG-375-100-N105

1. BOILER ISLAND P&IDS ARE TYPICAL FOR UNITS 1,2 & 3. FOR UNIT 2 TAGS
REPLACE TAG PREFIX "01" WITH "02". FOR UNIT 3 TAGS REPLACE TAG
PREFIX "01" WITH "03".

FLUSH CONNECTION

01LAB91
AA002

D 60.30 mm x 11.07 mm
D 60.30 MM X 11.07 MM
01LAB91
AA003

SH / DESH SPRAYWATER

D 168.30 mm x 21.95 mm

NITROGEN GAS FILLING CONNECTOR

CIRCULATING PUMP

D 323.90 mm x 45.00 mm

01HAC10
AA512

01HAG31
AA601

F-61B

01HAC10
AA511

D 33.40 mm x 6.35 mm

D 323.90 mm x 45.00 mm

01HAC10
CP001

01HAC10
AA516

F-61C

01HAC10
AA502

01HAC10
AA501

01HAC10
AA515

F-66

D 33.40 mm x 9.09 mm

MIXING SPHERE

D 31.80 mm x 6.00 mm

01HAC10
CP401

01HAC10
CP501

01HAG51
AA003

01HAG31
AA301

PT

STEAM HEAT TRACED LINE

E/H

FROM: DDCMIS

01HAC10
AA503

01HAC10
AA504

LONG RETRACT SOOTBLOWER

FY

These low point drains

are to be connected to
the system drain

TI

SOLENOID

SILENCER

WARM-UP SUPPLY LINE

01HAG25
CP002

(REF. DWG.
0-00-047-48369)

FROM: DDCMIS

D 60.3 MM X 11.07 MM

PDT

01HAG25
AA503

PNEUMATIC PISTON, ON/OFF

W-01

01HAG25
AA501

MOTOR

W-04

01HAC10
AA002

E-04

FP

RO

HYDRAULIC PISTON, ON/OFF

01HAG51
AA503

01HAG25
AA505

01HAG51
CF401

FE

D 508.00 mm x 65.00 mm

01HAG25
AA602

01HAG15
AA501

W-05

F-59B

01HAG51
CF501

01HAG51
AA502

01HAG15
CF504

RO

W-04

01HAG51
CF502

01HAG25
AA601

CHAIN WHEEL

DIAPHRAM, SINGLE ACTION

D 33.40 mm x 9.09 mm

01LAB91
AA001

To Mixing Tank of Chemical Cleaning External Equipment

Sampling Point

STEAM TRAP ASSEMBLY

SWING CHECK VALVE

LOW PRESS BOILER

STARTUP SYSTEM
0-00-301-31305

01HAG15
AA601

FROM: DDCMIS

SAFETY VALVE, CLOSED

FC 01HAG15

REFER DRG.

01HAG15
AA401

01HAG51
AA601

CONDENSATE HEADER

FLANGE CONNECTION

01LCL10
BB001
01HAG15
AA301

RESERVOIR WITH WEIRS

REGULATING VALVE

FROM: DDCMIS

TE

E-06L

D 508.00 mm x 65.00 mm

01HAG15
AA512

REFER DRG. : LOW PRESS BOILER STARTUP SYSTEM

REFER DRG. NO: 0-00-301-31305

DRAIN FROM LINKS TO HWL1/HWL2 VALVES

01LAB95
AA401

E-08

01HAG15
CP002

FLOW MEASURING DEVICE

W-06

E-09

ECONOMIZER OUTLET HEADER

W-02

F-56

VENT PLUG

CHEMICAL CLEANING CONNCTOR

SH back filling temporary

line connected to
Backpass Lower Header
Drains

From Chemical Cleaning Pump discharge.

These lines are also to be connected to the System drain.

SUCTION LINE
F-59C

01HAG25
CT001
TE

DDCMIS
01HAG25
CT002

TE

DDCMIS

01HAG27
CP502

01HAN13
AA701

DDCMIS

01HAG27
AA502

DWG No.: 0-00-303-31290

01HAG27
AA609

COOLING WATER RETURN LINE

01HAG27
AA403

BWCP
F-60

D 33.40 mm x 9.09 mm

TI

01HAG25
AA603

01HAG27
AA619

01HAG27
AA501

COOLING WATER

SEE NOTE 2

01HAG27
CT502

01HAG27
CF101
FASL

F = 251.00 l/min

DISCHARGE LINE
F-61A

01HAG25
AP001

01HAG27
AA613

D 88.9 mm x5.49 mm
01HAG27
AA610

01HAG27
AA615

TE

01HAG25
AC001

ZSO

01HAG27
AA614

ZSC

DDCMIS
01HAG25
CT004
DDCMIS

TE

PUMP MOTOR COOLER

MOTOR

TERMINAL
BOX

ZYC

TE

D 88.9 mm x5.49 mm

01HAG27
AA201

01HAG25
AA604

01HAG25
CT003

ELECTRICAL
CABLE

DDCMIS

01HAG25
CT005
DDCMIS
01HAG25
CT501

TI

D 33.40 mm x 4.55 mm
01HAG27
AA603
ZSC

ZSO

DDCMIS

ZYC

01HAG27
AA604

01HAG27
CP501

01HAG27
AA605 SEE NOTE 4

EMERGENCY COOLING WATER TANK

DWG NO.: 0-00-303-31290

D 88.9 mm x5.49 mm

FO

01HAG27
AA202

01HAG27
AA504

01HAG27
AA402

01HAG27
CT501
TI

01HAG27
AA503
COOLING WATER
DWG No.: 0-00-303-31290

COOLING WATER SUPPLY LINE

D 88.9 mm x5.49 mm

01HAG27
AA601

D 88.9 mm x5.49 mm
01HAG27
AA401

F = 251.00 l/min

01HAG27
AA606

01LCR25
CP501

01LCR25
CT501
TI

NOTE 6

01LCR25
CP502

(LOCK CLOSED)

01LCR25
AA504

01LCR25
AA503

01LCR25
AA501

01LCR25
AA502

01LCR25
AT001

NOTES:
SEE NOTE 1

1. REMOVE REMOVABLE SECTION - BLANK OFF WITH 2500# BLIND FLANGE

WHILE PUMP IS OPERATING.
2. AIR VENT PLUG TO BE LOCATED AT THE HIGHEST POINT IN THE PUMP COOLER
& THERMAL BARRIER L.P. PIPING SYSTEM.
3. THESE VALVES MUST BE IN LOCKED CLOSED POSITION WHILE PUMP IS OPERATING.
4. FOR SYMBOLS AND LEGENDS SEE DWG NO.0-00-047-48365.
5. REFERENCE DRAWING -0-00-047-48365 FOR PUMP LOCATION IN PROCESS.
6. TERMINAL POINT LOACTED WITHIN 5 METERS OF BOILER WATER CIRC. PUMP.

COOLING WATER
DWG No.: PE-DG-375-100-N-106

BOILER RECIRC PUMP MOTOR LP FILL WATER

D 33.40 mm x 4.55 mm
01LCR25
AA601

01LCR25
AA602

01LCR25
AA603

01LCR25
AA604

01LCR25
AA401

01HAG27
AA608
(LOCK CLOSE)

This valve is to be kept closed

and a blind flange is to be used.
Condensate Quality Water
Positive Displacement Pump
1 lit/ min from secured power supply
and with back up power supply