ADHI KARYA – JEPOE JOINT OPERATION

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BOILER CHEMICAL CLEANING
PLG-100-COM-PR-001 PROCEDURE Page 3 of 13

TABLE OF CONTENT

1.0 TITLE 4

2.0 SCOPE 4

3.0 REFERENCE 4

4.0 GENERAL DESCRIPTION 4

5.0 WATER CONTENT OF THE SYSTEM 5

6.0 MECHANICAL PREPARATION 5

7.0 OTHER PREPARATION 5

8.0 CHEMICAL TREATMENT AND INSPECTION PROGRAM 6

9.0 DETAIL DESCRIPTION 7

10.0 LIST OF CHEMICAL 12

11.0 PRELIMINARY WATER PROGRAM 12

12.0 SAFETY PRECAUTIONS DURING CHEMICAL CLEANING 13

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COMMISSIONING PROCEDURE
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BOILER CHEMICAL CLEANING
PLG-100-COM-PR-001 PROCEDURE Page 4 of 13

1.0 TITLE
Procedure for boiler chemical cleaning

2.0 SCOPE
This procedure covers the general requirements for boiler acid cleaning based on
chemical to be implemented. The purpose of boiler chemical cleaning is to remove
oil/grease, rust/scaling, which is formed during boiler pressure parts fabrication. Final
step of boiler chemical cleaning is to perform magnetite film layer formation on boiler
tube as an indication boiler is ready to operate.

3.0 REFERENCE
3.1 JINAN BOILER OPERATION MANUAL
3.2 CHEMICAL SUPPLIER DOCUMENT

4.0 GENERAL DESCRIPTION OF THE SYSTEM

4.1 Data of the boiler
Boiler manufacturer : Jinan Boiler
Type of the boiler : CFB
Max steam capacity : 420 t/h
Steam outlet temperature : 540 °C
Steam outlet pressure : 9.8 MPa
Total water volume : 250 m3

4.2 Description of the Cleaning system

4.2.1 Feed water line from the feed water pumps and economizer
4.2.2 Water wall tube
4.2.3 Steam drum ¾ the volume
4.2.4 Super heater area not to be acid cleaning
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5.0 WATER CONTENT OF THE SYSTEM

5.1 Feed water line and economizer banks
5.2 Front, rear and side walls incl. heavy down comers and cyclone including down
comers.
5.3 Steam drum ¾ volume
5.4 Total cleaning volume approximately 1750m3

6.0 MECHANICAL PREPARATIONS

6.1 Temporary filling, draining and circulation system (temporary piping)
6.2 Install the temporary acid solution tank
6.3 Install the additional chemical dosing pump (additional pump)
6.4 Install temporary chemical solution circulation pump
6.5 Install line acid circulation pump to chemical tank
6.6 Install drain line from chemical tank to sewer
6.7 Install drain line from collecting drain front and rear side to sewer
6.8 Remove cyclone separator of the steam drum
6.9 Install temporary low pressure boiler for heating the chemicals solution

7.0 OTHER PREPARATIONS

7.1 Personnel
7.1.1 Personnel to carry out the chemical cleaning will be under GPOS
SUPERVISION.
7.1.2 Boiler operators for handling the feed water pump
7.1.3 Unskilled labor 2-4 peoples per shift for transportation and dosing the
chemicals to circulation tank
7.1.4 Personnel for analyzing feed water will be under GPOS SUPERVISION
7.2 Electric Power
7.2.1 Electrical supply for circulation pump shall be ready, one from PLN, and the
other from genset.
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BOILER CHEMICAL CLEANING
PLG-100-COM-PR-001 PROCEDURE Page 6 of 13

7.3 Boiler System

7.3.1 Demin water specification shall be within the specification mentioned in the
design specification:
- pH at 25°C : 6.5 – 7.0
- conductivity at 25°C : ≤ 0.02 µm/cm
- total Silica as SiO2 : 0,015 mg/l
7.3.2 Chemicalsl circulation piping system shall be tested with the demineralized
water.
7.3.3 Venting and draining system shall be ready.
7.3.4 Chemicals drainage and neutralization pond shall be available.

7.4 Demineralized Water

7.4.1 Demineralized water should be available. Demin water requirement during
boiler acid cleaning estimated 1750 m3.
7.4.2 Demineralized water shall be available in demin storage tank during boiler
chemical cleaning process.

7.5 Safety Precaution

Safety precaution during chemical cleaning following the step at point no. 12.0

7.6 Valve Check List

All valves for chemical cleaning system will be listed in a check list by GPOS.

7.7 Neutralization Pit and Sewer System

Arrangement must be made for proper disposing of spent acid and caustic solution
before sending to waste water treatment plant.
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8.0 CHEMICAL TREATMENT AND INSPECTION PROGRAM

8.1 Pre rinsing of the system.
8.2 Grease removing treatment.
8.3 Rinsing of the system.
8.4 Hydrofluoric acid treatment.
8.5 Flushing to low conductivity.
8.6 Final citric acid treatment, neutralization and passivation.
8.7 Final flushing with ammonia dosed demineralized water pH > 10, 2 if cold water
available.
8.8 Inspection of steam drum and if necessary headers.
8.9 Final installation of the steam drum internal. Leak test of the boiler.
8.10 Magnetite formation treatment at min 2,7 MPa (part of steam blowing)

9.0 DETAILED DESCRIPTION

9.1 Pre Rinsing of the System

9.1.1 Fill water to boiler through feedwater line until level in the steam drum
is below manhole .While filling the water to steam drum, open air vent
on the steam drum, and closed after there is no air comes out from the air
vent. Stop the circulation pump, and drain the water necessary through
bottom header until the water is clean
9.1.2 Fill the water again until level in the steam drum is below manhole.
During water filling to boiler, charging the steam from low pressure
boiler for heating the water in chemical tank (50°C – 60°C)
9.1.3 Continue for circulating the water, open three (3) valve at bottom header,
and maintain drum level below normal level. During this circulation
maintain chemical tank level at 75%.
9.1.4 Stop circulation pump and add hydrazine (75 kg), start again circulation
pump, and continue filling water until main steam line (hydrazine
blanket). Crack open drain valve 2” on main steam line check valve
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BOILER CHEMICAL CLEANING
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blank, if water already comes out, stop circulation pump, and close main
steam line air vent.

9.2 Grease Removing Treatment

9.2.1 Maintain level in steam drum on normal water level and start circulation
pump. While continue circulating ensure water temperature is 60°C.
Stop steam supply from the boiler if temperature already reach 60°C.

9.2.2 Add chemicals to tank alternatively:

- TSP 90% 75 kg (3 sack)
- Detergent 38 kg (2 pails)
- Defoamer 13 kg (1 jerigen)

9.3 Rinsing of the System

9.3.1 After circulating the chemicals solution for four (4) hours, stop
circulation pump.
9.3.2 Drain the boiler until empty.
9.3.3 Fill water to boiler until normal level water, stop the pump and drain the
boiler directly (boiler flushing process).

9.4 Hydrofluoric Acid Treatment

9.4.1 After boiler flushing is finish, fill demin water to chemical tank.
9.4.2 After the level is sufficient start circulation pump, and continue filling
water to boiler until level in the steam drum is below manhole.
9.4.3 Stop the pump and heating the water by using steam from temporary low
pressure boiler until water temperature reaching 50°C. Stop steam supply
from the boiler if temperature already reach 50°C.
9.4.4 Add chemicals to tank alternatively:
- HCl 30% 4500 kg (4 kemps)
- Armohib 28 (2 pail)
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9.4.5 Circulate the chemicals solution for five (5) hours.

9.4.6 Chemical analysis shall be performed every one (1) hour.
9.4.7 Drain the boiler after circulation process.
9.4.8 Add chemicals to pond alternatively, for neutralizing the chemicals pH:
- PAC 100 kg
- NaOH (48%) 2500 kg

9.5 Flushing to Low Conductivity

9.5.1 After draining boiler is finish and chemical tank is empty, fill demin
water to chemical tank. After the level is sufficient, start circulation
pump and continue filling water to boiler until level in the steam drum is
at normal level water.
9.5.2 Circulate the water for two (2) hours, and drain the boiler (1st flushing)
9.5.3 Repeat the process until conductivity of the water is below 20µS/m.

9.6 Final Citric Acid treatment, Neutralization and Passivation

9.6.1 After flushing to low conductivity is complete, fill the boiler again until
level in the steam drum is below manhole.
9.6.2 While continue circulating, heating the water by using steam from
temporary low pressure boiler until water temperature reaching 50°C.
Stop steam supply from the boiler if temperature already reach 60°C.
9.6.3 Add chemicals to tank alternatively for neutralization phase, and
circulate for four (4) hours :
- Citric acid 50% 500 kg (20 sacks)
- Ammonia 1000 kg (7 drum)
9.6.4 Ensure chemical solution pH is 9.6
9.6.5 Add chemicals to tank for passivation phase, and circulate for two (2)
hours :
- Sodium nitrite 388 kg (15 sacks)
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BOILER CHEMICAL CLEANING
PLG-100-COM-PR-001 PROCEDURE Page 10 of 13

9.6.6 After chemical circulation is complete, stop the pump and drain the
boiler.

9.7 Final Rinsing with Ammonia Water

9.7.1 After draining the boiler is complete, fill the water again until level in
the steam drum is below manhole, and stop the circulation pump.
9.7.2 Add ammonia (260 kg or 2 drum) to chemical tank and circulate for four
(4) hours. Ensure chemical solution pH is 10.2
9.7.3 After the circulation is complete, drain the boiler

9.8 Inspection

9.8.1 Inspect steam drum, compare the result by picture (by comparing the
result before and after acid cleaning)
9.8.2 Install the dismounted drum internal parts.
9.8.3 Cut three (3) bottom header cap, and compare the result before and after
acid cleaning (others three bottom header cap already cut off for
temporary pipe connection)

9.9 Hydrostatic (Pressure) Leak Test

9.9.1 Leak test at operating pressure (9.8 MPa).

9.9.2 After leak inspection is complete, temporary piping installation shall to
be removed, and boiler is ready for normal operation.

9.10 Magnetite Formation Treatment (Part of Steam Blowing)

9.10.1 Fill the system with chemical for the start of magnetite film formation,
using ordinary chemical dosing system to the drum.
9.10.2 Considering the service length and the operative capability of the boiler
the presence of homogeneous and pure film of magnetite is a matter of
the greatest importance. After the cleaning part of the pickling is
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finished, the boiler is to be operated under low load. min 2,7 MPa for
about 10 – 24 hour with a dosage in the feed water. During treatment the
boiler is being blown off powerfully. After this time when the boiler
water will be show satisfactory values of chemical analysis, the boiler is
to be set in operation. the purpose of this so called “Protecting Film
Operation” are :
a) Build up a protecting film of magnetite on almost uniform
thickness.
b) Blowing off of finely powdered slug residual
During this magnetite formation the following analysis to be carried out by the
laboratory personnel under GPOS SUPERVISION:

Parameter Units Feedwater Boiler water Steam/Condensate Remarks

- 8.8 – 9.3 9 – 10.5 With Cu system
pH at 25°C
- 9.0 – 9.3 Without Cu system

mg/L 10 – 30 Volatile treatment

N2H4
mg/L 10 – 50

Oil mg/L ≤ 0.3

µmol/
Hardness ≤2
L
Dissolved oxygen mg/L ≤7
Fe mg/L ≤ 30 ≤ 20
Cu mg/L ≤5 ≤3
Na mg/L ≤ 10
SiO2 mg/L ≤2 ≤ 20
Chloride mg/L -
PO4 mg/L ≤ 50
Salinity mg/L ≤ 100
Conductivity µS/m < 150
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PLG-100-COM-PR-001 PROCEDURE Page 12 of 13

10. LIST OF CHEMICALS

Dosage Quantity (kg) Quantity (kg) for
Sequence No. Chemicals
(%) for 2 boiler 1 boiler
1 TSP 90% 0,0286 143 71,5
Degreasing 2 Detergent Liquid 0,01435 72 36
3 Defoamer 0,0036 18 9
4 HCl 30% 1,8572 2286 1143
Acid Cleaning 5 Armohib 28 0,1 500 250
6 Citric Acid 50% 0,2 1000 500
Ammonium
Passivation 7 0,5429 2715 1358
Hydroxide
Neutralization 8 Sodium Nitrite 0,1572 786 393
Preservation 9 Hydrazine 35% 0,1286 643 321.5
10 Cyclohexilamine 0,0428 128 64
Waste
11 NaOH 1,1428 5714 2857
handling
12 PAC 0,0428 214 107

11. PRELIMINARY WATER PROGRAM

Activity m3 of Water Temperature Quality
Day no. 1 Flushing the boiler 30 °C Demin water
Day no. 2 Fill and flush the
30°C Demin water
boiler
Day no. 3 Flush/fill the boiler.
30°C Demin water
flush to low conductivity
Day no. 4 Flushing to low
conductivity. 30 °C Demin water
Final flushing
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Day no. 5
30 °C Demin Water
Final Flushing
Day no. 6 Final flushing 30 °C Demin water
Day no. 7 Filling for
3°C 0 Demin water
Hydrostatic pressure test.
Day no. 8 – 10
30 °C Demin water
Magnetite formation
Total ± 1750

12. SAFETY PRECAUTIONS DURING CHEMICAL CLEANING

12.1 The area where chemicals will be handled to be roped off
12.2 Sign “ Danger” chemical cleaning in progress”, similar warning should be
posted in area where spillage of solution may occur.
12.3 Fire hose should be available at chemical cleaning pump suction level in the
event of solution leak or spillage.
12.4 Rubber gloves, aprons, gas mask and glasses should be provided for the
personnel handling chemical cleaning solution
12.5 Good ventilation should be provided in the steam drum prior to entering the
drum for inspection.
12.6 Safety water shower shall be provided near chemicals tank