WI / WTP-II / 310

MAHARASHTRA STATE POWER GENERATION COMPANY LIMITED

NASHIK THERMAL POWER STATION
W.T. PLANT -II

BOILER CHEMICAL PASSIVATION PROGRAMME OF UNIT NO. 5

On completion of annual overhaul of Boiler No. 5 the following Alkali Boil out cum Passivation
programme is to be arranged.
(A) Alkali Boil out :-
1) After successful completion of hydraulic test, drain the system completely through headers
including economizer, dearator etc.
2) Fill the system up to normal operating level and inform Senior Chemist on duty during filling of
boiler for chemical dosing. During filling, charge the LP Dosing Tank with 5 liters of Hydrazine and 2 liters of
Ammonia to full level and run the LPHD pumps with full strokes whenever BFP is in service.
Before lighting up of the boiler, please ensure the availability of Boiler water, Steam and Feed water
sampling points.
3) Light up the boiler and raise the pressure up to 10 Kg /cm2
4) After attaining the boiler pressure 3 Kg/cm2, start chemical dosing through HP dosing pumps
(Charge the H.P. dosing tank with 10 Kg. Tri Sodium Phosphate and 1 Kg Sodium Hydroxide pellets to full
level. Dose the complete solution to the boiler so as to attain pH above 10 and M-alkalinity above 300 ppm.
After dosing complete solution, flush the H.P.dosing pipeline with D.M. Water.)
5) Raise the boiler pressure slowly up to 40 Kg/ cm2 and maintain the pressure for 08 hours. During
this period, operate the header blowdowns through all low point headers for 60 seconds after every 4 hours
i.e. two blowdowns in 8 hours.
6) After operation of second blowdown, cool the boiler by force cooling so as to attain metal
temperature 120 degree centigrade as quickly as possible and arrange hot flushing at 120 degree centigrade
through low point headers.
7) Fill the boiler and check the phosphate content and alkalinity of boiler water sample .If the
phosphate content is more than 5 ppm, one more flushing of the system is required, otherwise, boiler is ready
for passivation.

MAHARASHTRA STATE POWER GENERATION COMPANY LIMITED

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 NASHIK THERMAL POWER STATION
W.T. PLANT -II
BOILER CHEMICAL PASSIVATION PROGRAMME OF UNIT NO. 5
FOR SENIOR CHEMIST ON DUTY

On completion of annual overhaul of Boiler No.5, the following Passivation programme is to be

arranged.

Passivation :-
1) Drain the boiler drum and water walls only for filling the passivation chemicals in the system . Fill the
boiler up to normal operating level through UDT. Dosing in uDT may be arranged ( as 10 lit hydrazine + 5 lit
ammonia for every fill of uDT) till boiler is completely filled ( Generally 4 to 5 uDT are required). Inform the
Senior Chemist on duty before starting the Boiler filling to arrange chemical dosing. Charge the LPHD tank
with 10 liters Hydrazine and 5 liters Ammonia . Run the LPHD pumps with full strokes whenever BFP is in
service.
2) Charge H.Pdosing tank with 30 Lit. Hydrazine & 5 Lit Ammonia, 10 Kg Trisodium Phosphate and dose
further as per requirement to maintain residual Hydrazine above 200 ppm.
3) After chemical dosing, light up boiler and raise the pressure slowly up to 40 kg/sq.cm.
4) Flush the Boiler drum sampling point and Steam sampling point thoroughly.
5) Maintain 40 kg/sq.cm pressure for 08 hrs..
6) After 08 hrs, put off the burners. Increase drum level up to 7 bulbs (maximum level) and drain the boiler
through downcomers up to one bulb (first blowdown)
7) Then relight-up the boiler (before lighting up of boiler, charge the HP dosing tank with 30 lit. Hydrazine, 5
lit. Ammonia and dose the complete tank solution, followed by flushing the line with DM water to the boiler)
and raise the pressure up to 40 kg/sq.cm pressure for six hours and again put off burners and increase drum
level up to 7 bulbs and drain the boiler through downcomers up to one bulb.( second blow down).
8) Then arrange steam blowing for 2 hrs.
9) During this period, boiler water pH is to be maintained above 10 and residual Hydrazine above 200 ppm .
10) Inform the Sr.Chemist on duty while running feed pump so as to run LPHD pump with chemical dosing
(5 lit. Hydrazine and 2.5 lit. Ammonia).
11) After completion of second blowdown ,bank the boiler and cool it down as below
a) First 04 hours natural cooling
b) Further cooling for 6 hrs. by running I.D fan and restricted temperature drop to 10-degree
centigrade per hour.
c) Force cooling by running I.D. / F.D. fans till 120 deg. C. temperature.
Then fill the boiler up to top of the drum and drain completely inclusive of economizer and
header.
12) After completion of above draining boiler passivation programme is over.
Boiler may be lighted up taking normal lighting up level in the drum. After lighting up of boiler at
30-kg/sqcm pressure, blow down through downcomers to be given for 30 seconds each.
After this, steam may be blown out sufficiently through HPHT drain after attaining pressure 40
kg/sqcm. The steam clearance may be obtained from Sr. Chemist.
After obtaining the steam clearance from Sr. Chemist, boiler is ready for further normal operation.
Executive Chemist,
WTP-II

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 TIME SCHEDULE OF PASSIVATION OF U - V

S.N. Item No. Description Time Reqd.

1 1 Filling of Boiler (with chemical dosing) 02 Hrs.
2 2 Boiler Light up and raise the Pressure 40 kg/sqcm 06 Hrs.
3 4 Maintain the Pressure 40 kg / sqcm for 08 hrs. 08 Hrs.
4 5 Operate First blow down 01 Hr.
Again Light up the boiler and raise the pressure 40
5 6 kg/sqcm and maintain for 06 hrs. 06 hrs.

6 Operate Second blow down 01 Hr.

7 7 Steam blowing. 02 Hrs.
8 10a) First 02 hrs natural cooling 02 Hrs.
10b)& Force cooling using ID / FD fans to attain normal temp.
9 c) and press. 06 Hrs.
Total : 34 Hrs.

BOILER PASSIVATION PROGRAME OF UNIT - V

MINIMUM TIME REQUIRED = 34 HRS