Titolo Identificativo Rev. Pag.

Di
title document no. rev. Page Of

CHEMICAL CLEANING PRESCRIPTIONS 6556-EPCC4-52-1B-SP-M-3008

1 1 14

Volume N. Prodotto/Struttura
Volume no. product/structure

Tipo doc. Emittente Edizione in lingua Derivato da Rev.

doc. type issued by language derived from rev.

AC ENGLISH
Job no Progetto Cliente
project client
3034 IOCL PANIPAT NAPHTHA L&T
CRACKER
Rev. Descrizione
rev. kind of revision

1 P I A. COLOMBO R. ORSARIA R.SARDANO 27.02.2007

0 P I A. COLOMBO R. ORSARIA R.SARDANO 22.11.2006

Rev St. Sc. Preparato Controllato Verificato Verificato Verificato Approvato Data
Rev. st. sc. Prepared checked checked checked checked approved date

nformazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
Confidential informations, property of Ansaldo Caldaie S.p.A., not to be used for any purpose other than that for which they are supplied.
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IOCL PANIPAT NAPHTHA CRACKER 6556 – EPCC4 –52-1B-SP-M-3008

1 GENERAL CONSIDERATIONS............................................................................... 3

1.1 RELIABILITY OF THE OPERATION ...............................................................................................3

1.2 UNITS DESCRIPTION ......................................................................................................................3

2 BOILER CHEMICAL CLEANING ............................................................................ 4

2.1 PREOPERATIONAL CHEMICAL CLEANING.................................................................................4

2.2 PERIODICAL CLEANING ................................................................................................................4

2.3 VELOCITIES .....................................................................................................................................4

3 CONCEPTUAL DESIGN.......................................................................................... 4

4 CHEMICAL CLEANING OPERATIONS .................................................................. 5

4.1 PRELIMINARY STEP .......................................................................................................................5

4.2 PREPARATION ................................................................................................................................6

4.3 OPERATIONS DESCRIPTION.........................................................................................................6

4.3.1 FLUSHING............................................................................................................................................. 6
4.3.2 ALKALINE CLEANING ....................................................................................................................... 7
4.3.3 ACID CLEANING ................................................................................................................................. 7
4.3.4 NEUTRALIZATION AND TEMPORARY PASSIVATION ............................................................... 8
4.3.5 FINAL IN SERVICE PASSIVATION................................................................................................... 8

4.4 CONTROLS ......................................................................................................................................9

4.5 CLEANLINESS EVALUATION ......................................................................................................10

5 TECHNICAL PRESCRIPTIONS AND GUARANTEES .......................................... 10

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
Confidential informations, property of Ansaldo Caldaie S.p.A., not to be used for any purpose other than that for which they are supplied.
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IOCL PANIPAT NAPHTHA CRACKER 6556 – EPCC4 –52-1B-SP-M-3008

1. GENERAL CONSIDERATIONS:

This document deals with the prescriptions for the chemical cleaning of PANIPAT
boilers.
Boilers preoperational chemical cleaning involves economizer and furnace sections.With
reference to boiler pressure parts organic or inorganic acid should be used; a typical
formulation is total 5% of hydrocloridric acid.
The choice of cleaning acid must be done by Cleaning Company under its own
responsibility holding in due consideration final arrangement of cleaning circuit, operating
procedure, chemicals availability and waste disposal facilities on the basis of its
consolidated experience.
In any case Boiler operations can start only after thermal cycle has been successfully
and properly cleaned and it is ready for normal operation.
Except the supply of chemicals, all hardwares, systems, logistics etc. shall be included in
L&T’s scope.

1.1 RELIABILITY OF THE OPERATION

Due to the high costs of the plant and to the eventual further outages caused by a not
fully successful cleaning that could occur during operation, operating procedure should
be fully tested and performed by a qualified Company.

1.2 UNITS DESCRIPTION

These units are box type boiler, that means fully drainable pressure parts. Boiler
characteristics at MCR are:

- boiler design pressure 152 kg/cm^2g

- feedwater temperature economizer 133 °C;
- steam flow SH-2 outlet 406,5 t/h;
- steam pressure at SH-2 outlet 132 kg/cm^2g
- temperature at SH-2 outlet 529 °C;

These units are suitable to fire HSD light oil, BFO heavy oil and RLNG gas with burners
on front and rear wall.

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
Confidential informations, property of Ansaldo Caldaie S.p.A., not to be used for any purpose other than that for which they are supplied.
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IOCL PANIPAT NAPHTHA CRACKER 6556 – EPCC4 –52-1B-SP-M-3008

2. BOILER CHEMICAL CLEANING

Boiler chemical cleaning may be of two different kinds: preoperational

andperiodicalchemical cleaning.

Based on the different aim they have, in general different procedures could be applied,
with some differences as shown hereafter.

2.1 PREOPERATIONAL CHEMICAL CLEANING

Boiler initial chemical cleaning is required to remove eventual tube working residuals,
oxide formation due to possible bad material preservation, oil substances used during
manufacturing and preservation, weld spatter, rust, oxide scales, in order to have a good
active metallic surface to get strong, thin and uniform magnetite layer inside boiler
pressure parts.

2.2 PERIODICAL CLEANING

This operation is required to remove periodically internal oxide deposits formed, during
plant operation, inside the boiling area, i.e. economizer and furnace tubes.
Detailed discussion about this item is not the object of this document, expressly written
for Boiler preoperational cleaning.

2.3 VELOCITIES

A successful cleaning requires solvent velocities in the range of 0.2 to 1.2 m/sec through
boiler sections depending on type of acid used. This will require correct sizing of pumping
station and temporary piping to control chemicals flow rates in the range of rated
velocities.

In the following, suggestions for conceptual design and general chemical cleaning
recommendations are provided.

3. CONCEPTUAL DESIGN

Suggested boiler cleaning circuit is based on obtaining and maintaining the required
velocities, with an acceptable cleaning solvent, to adequately remove oxide scale from
the internal surfaces of economizer and furnace (attachment 3).
This step should be accomplished feeding economiser by pumping station, cleaning
furnace walls by nitrogen recirculation at downcomers bottom and by solution return to
pumping station.

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
Confidential informations, property of Ansaldo Caldaie S.p.A., not to be used for any purpose other than that for which they are supplied.
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IOCL PANIPAT NAPHTHA CRACKER 6556 – EPCC4 –52-1B-SP-M-3008

Samplings are carried out before heating station and after chemical injection; flowmeter
and valves are provided on the temporary piping to economizer; furnace walls are fed
counter current. Suitable position of instruments and equipments is shown on same
attachments 1 as above.

Considering that once started, the acid phase must continue without interruption up to
the successful completion of the same, enough spare parts (instrumentation, valves .....)
are very recommended especially for pumping and heating station where 100%
redundancy is practical common value.

4. CHEMICAL CLEANING OPERATIONS

The success of a chemical cleaning depends largely on a good planning and a detailed
step by step procedure.
Developing a good planning and a good procedure requires close interfaces and
cooperation with all subjects involved.

4.1 PRELIMINARY STEP

This step is required for erection of temporary portion of cleaning circuit.

At the mean time all required preparations and provisions must be done as follows:

- any permanent flow meter must be removed from the circuit under cleaning;
- valves and instruments must be protected by suitable temporary preparation, isolation
or removal, i.e. internals of non return valves must be removed;
- in case previous precautions are not sufficiently reliable, instruments connections must
be cut off on temporary basis;
- any part of under cleaning circuit and/or piping not compatible with acid solution must
suitably protected, for instance by counter filling with demi water;
- all temporary installation required for chemical cleaning must be erected according
good standard practice, such as sample connections for chemical analysis, temporary
levels, flow meter and temporary valves, vents and drains, tanks, pumps, heaters,
instrumentation and all other necessary equipment;
- all required safety procedures must be applied and working areas must be restricted to
operating personnel only;
- all the required laboratory facilities must be operational and available.

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
Confidential informations, property of Ansaldo Caldaie S.p.A., not to be used for any purpose other than that for which they are supplied.
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IOCL PANIPAT NAPHTHA CRACKER 6556 – EPCC4 –52-1B-SP-M-3008

4.2 PREPARATION

Demineralized water or good quality condensate in any case according boiler feedwater
requirements will be used for all stages of the chemical cleaning requiring water.

Water needed for the cleaning will be taken either from the condensate storage tanks or
from the condenser provided that no contamination from external sources is possible.

Tanks and condenser must be filled up before starting and must be maintained as full as
possible during chemical cleaning.

Temporary level indication should be installed on the condenser and on the drum, if not
already available.

Superheaters must be protected by back flushing.

A suitable heating station should be placed on the temporary line.

Fill up the boiler and the cleaning system with demineralized water and then do the
hydrostatic test on the entire system.
Once hydrotest has been successfully run, circulation test must be performed with
demineralized water in order to check operating performance of all the involved
equipment, especially pumps, heaters, valves, and instrumentation, taking particular care
to the flowmeter.
At least two or three operating points must be checked in order to know the pumping
station capability and hence to be sure about the rated flows required in the different
phases of cleaning to control velocities at the specified values.
Superheaters backflushing test should be accomplished by checking drum level.
Neutralization basin must be available to treat acid water discharged from boiler.

4.3 OPERATIONS DESCRIPTION

4.3.1 FLUSHING

This operation shall be carried out just before chemical cleaning.

To accomplish an effective flush, flow rates should be as high as possible and
condensate or circulating pumps should be used.

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
Confidential informations, property of Ansaldo Caldaie S.p.A., not to be used for any purpose other than that for which they are supplied.
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IOCL PANIPAT NAPHTHA CRACKER 6556 – EPCC4 –52-1B-SP-M-3008

Flushing should be done using demineralized water and should continue until water
going to waste is observed to be clear and after filtration without appreciable suspended
solids from any boiler section.

4.3.2 ALKALINE CLEANING

Alkaline cleaning should be accomplished by injecting an alkaline solution in order to

remove oils and rust inhibitors which are applied to internal tube surfaces.

An alkaline solution containing 2000 ppm trisodium phosphate ( 2000 ppm Na3PO4 ),
1000 ppm disodium phosphate or equivalent, and a compatible wetting agent should be
used.
Circulating water will be heated to bring its temperature to about 90°C.
Heating may be done by direct ignition of lighters and/or by heating station on the
temporary circuit: this is a critical step that needs some operating precautions and very
strict Boiler control.
Circulation at 90°C should continue for at least 18 to 24 hrs after the alkaline chemicals
have been injected.
This time may be computed also on non continuous basis: it means that overnight
stopping are allowed. In such a case the circulation may be stopped and temperature will
drop down. When starting again with circulation, the operating temperature must be
controlled at the rated value again.
Periodical checks should be done according to following Point 4.4.
When the circulation has been stopped, the alkaline solution should be displaced to
waste by draining and rinsing with demineralized water, either with condensate or
circulating pumps.
The system should be maintained like this until acid cleaning. If several days will elapse
before acid cleaning, it is recommended that ammonia and hydrazine (10 ppm and 200
ppm, respectively), are used in the water.

4.3.3 ACID CLEANING

Acid cleaning should be carried out to remove oxides, scales and siliceous substances
from inside the pressure parts.
Acid solution should be inhibited by suitable and reliable inhibitor in order to keep the
corrosion rate lower than allowed value as specified at Point 5.0.
Rated circulation should be established in the circuit. However it is recommended to
control cleaning solution flow in order to achieve and maintain suggested velocities in
every section of under cleaning pressure parts.
Superheaters backflushing should be in operation.

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
Confidential informations, property of Ansaldo Caldaie S.p.A., not to be used for any purpose other than that for which they are supplied.
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IOCL PANIPAT NAPHTHA CRACKER 6556 – EPCC4 –52-1B-SP-M-3008

In addition to temporary pumping station when running the eco and furnace walls
cleaning an extra circulation may be installed as already discussed above by injection of
N2 at downcomers bottom through installed special nozzles.
Temperature should be maintained at specified value for during all acid phase by
very good and uniform warming of all the circuit under cleaning before chemical dosing:
in fact after chemical injection it is forbidden to light-up boiler and the only way to heat
circulating solution is by mean of shell and tube heat exchanger at very low heating rate,
just to compensate heat dispersion.

Recommended operating temperature:

a) Inhibited organic acid 90 ÷ 95 °C

b) Inhibited inorganic acid 60 ÷ 70 °C

During first hours, all vents in the cleaning circuit should be opened to allow escape of
the hydrogen generated by the acid reaction.
Circulation should continue for 4 -5 hrs and periodical sampling should be taken to
perform specified checks according to Point 4.4. However, when iron content
determinations become constant, this step is accomplished.
Acid should be displaced under nitrogen pressure, even if boiler is of drainable type.
Rinses should be carried out taking care to wash carefully all sections of the circuit,
including temporary piping with all involved equipments.
Special attention must be payed to wash and to clean by draining and/or backfilling all
dead pipes and connections of the circuit by operating section by section and by
checking the resultant outgoing conductivity.

4.3.4 NEUTRALIZATION AND TEMPORARY PASSIVATION

This step should achieve neutralization of eventual iron and/or acid traces that could be
still in the boiler tubes.
Usually it is performed in two steps :
- firstly an acid phase to neutralise iron (a correct PH value could be 4.5);
- secondly a basic phase to be obtained by recirculating a basic solution (
PH 9.5-10 ) to neutralise acid traces.
Checks and analysis will be in accordance with point 4.4

4.3.5 FINAL IN SERVICE PASSIVATION

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
Confidential informations, property of Ansaldo Caldaie S.p.A., not to be used for any purpose other than that for which they are supplied.
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IOCL PANIPAT NAPHTHA CRACKER 6556 – EPCC4 –52-1B-SP-M-3008

This step is the final one of boiler chemical cleaning, nevertheless it is very important for
safe and reliable future boiler operation. This step requires obviously the involvement of
very experienced and entrained personnel:

the current practice is to involve in such an operation Boiler Manufacturer and Cleaning
Company specialists.
This operation will be accomplished according the following:
It is necessary to flush until the effluent conductivity is not more than 20 µS/cm.
The boiler is then completely filled up (including superheater) with water added with
hydrazine and ammonia.
Boiler pressure should be raised to 5 bar in about 3 hrs (by firing the burners or the
ignitors) starting from the pressure of 2 bar, quick discharges should be performed by
operative boiler drains.
At the end the hydrazine content should be 70-100 ppm.
In about 2 hrs the pressure should be raised to 10 bar, discharges as above.
This value should be maintained for 3 hrs and the hydrazine content will be about 50-70
ppm.
Go on operating in this way as shown on passivation curves, (Attachment 2 and 3).
Finally the pressure is increased to 45 barg in about 3 hours, with hydrazine content is
1-5 ppm. Checks will be as specified in Point 4.4.
Steam blowing now can start.

4.4 CONTROLS

During the chemical cleanings the following checks must be carried out:

Alkaline treatment:
- pH;
- total alkalinity titre;
- oil and grease content;
- temperature control;
- drum level.
Acid treatment:
- pH;
- acid titre;
- total Fe in solution;
- trivalent Fe in solution;
- inhibitor efficiency;

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
Confidential informations, property of Ansaldo Caldaie S.p.A., not to be used for any purpose other than that for which they are supplied.
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IOCL PANIPAT NAPHTHA CRACKER 6556 – EPCC4 –52-1B-SP-M-3008

- instantaneous velocity control;

- temperature control;
- corrosion rate control.

Neutralization treatment:
- pH;
- Fe;
- temperature control.

Rinses:
- pH;
- conductivity.

Final check:
- pickling grade control;
- control for eventual mud presence.
Passivation:
- pH;
- residual hydrazine;
- filtration.

4.5 CLEANLINESS EVALUATION

The evaluation of the cleanliness degree obtained by cleaning shall be carried out
bydirect control of at least three representative samples taken from the boiler after the
operation.
The sampling location has to be agreed with the boiler supplier.

5. TECHNICAL PRESCRIPTIONS AND GUARANTEES

The cleaning must be able to guarantee:

-total removal of organic products used for preservation;
-total absence of muds and foreign matters;
- total removal of oxides and scaling from all interested surfaces;
- corrosion rate lower than 0.1 mg/cm²h: localized corrosions, that could compromise
the thermal and mechanical resistance of the steam generator, are not allowed;
- formation of a compact and adherent magnetite layer.

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
Confidential informations, property of Ansaldo Caldaie S.p.A., not to be used for any purpose other than that for which they are supplied.
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IOCL PANIPAT NAPHTHA CRACKER 6556 – EPCC4 –52-1B-SP-M-3008

In any case it is advisable to carry out, by suitable planning, the blowing operations
immediately after the chemical cleanings, to have and stabilize good magnetite layer
before any boiler light-up and BMCR operation.

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
Confidential informations, property of Ansaldo Caldaie S.p.A., not to be used for any purpose other than that for which they are supplied.
 DOCUMENT:
IOC Ltd. – PANIPAT Naphtha Cracker 6556 – EPCC4 –52-1B-SP-M-3008

Chemical Cleaning Prescriptions REV. 1 PAGE. 12 OF 14

A1

PASSIVATION CURVE

45

40

35

30
PRESSURE (bar)

25

20

15

10

0
10

12

14

16

18

20

22

24

26

28

30

32

34

36
0

TIME (h)

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
Confidential informations, property of Ansaldo Caldaie S.p.A., not to be used for any purpose other than that for which they are supplied.
 DOCUMENT:
IOC Ltd. – PANIPAT Naphtha Cracker 6556 – EPCC4 –52-1B-SP-M-3008

Chemical Cleaning Prescriptions REV.1 PAGE. 13 OF 14

A 2

PASSIVATION CURVE

100

90

80

70

60
HYDRAZINE (ppm)

50

40

30

20

10

0
10

12

14

16

18

20

22

24

26

28

30

32

34

36
0

TIME (h)

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
Confidential informations, property of Ansaldo Caldaie S.p.A., not to be used for any purpose other than that for which they are supplied.
 DOCUMENT:
IOC Ltd. – PANIPAT Naphtha Cracker 6556 – EPCC4 –52-1B-SP-M-3008

Chemical Cleaning Prescriptions REV. 1 PAGE. 14 OF 14

A3
ROOF
DRUM
UPPER REAR SH 1 SH2
WALL

Boiler Stop Valve

ECONOMIZER

LEFT SIDE RIGHT SIDE

FRONT REAR
WALL WALL
WALL WALL

ECO INLET

NITROGEN
INJECTION CHEMICAL
INJECTION

WASTE

SAMPLING POINT

HEATING

DEMI WATER

WASTE

SAMPLING POINT
CIRCULATING PUMPS DOSING PUMP

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
Confidential informations, property of Ansaldo Caldaie S.p.A., not to be used for any purpose other than that for which they are supplied.