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Bin Qasim 560MW CCPP Karachi Pakistan

HRSG Chemical Cleaning


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Content
1. Purpose................................................................................................................................................................. 2. Reference ............................................................................................................................................................. 3. Condition............................................................................................................................................................. 4. Safety..................................................................................................................................................................... 5. Dosing ................................................................................................................................................................. 6. Chemical cleaning procedure................................................................................................................................. 6.1 Start..................................................................................................................................................................... 7. Appendix1 Chemical cleaning water quality record............................................................................................ 8. Appendix 2 HRSG pressurization curve................................................................................................................. 9. Appendix 3 HRSG chemical cleaning technical data record................................................................................ 3 3 3 3 4 4 4 7 8 9

1. Purpose
HRSG alkali chemical cleaning is injecting NaOH and Na3PO4 into drums and tubes to clean oiland rust inside drums and tubes, and passivation coat would be formed on inner surface after chemical cleaning.

2. Reference
HRSG operation and maintenance manual YL57 SM.2 Chemical cleaning guide for thermal power plant DL/T 794-2001

3. Condition
3.1 Chemical cleaning should be carried out after hydraulic test completed. 3.2 Feed water pipeline and de-superheat water pipeline should be flushed in order to clean impurity and rust. Flow orifice would be installed after feed water pipe and de-superheat water pipe flushed. 3.3 Deminerlized water is available, during chemical cleaning de-mi water pump could be used to feed water to deaerator system. De-mi water common pipe and condensate water common pipe would be connected with temporary pipe on pipe rack. 3.4 Temporary sampling device would be installed at 0m on HRSG drain system. 3.5 For initial start-up of HRSG, three-way damper would be used to control GT exhaust flow rate in order to maintain HRSG system temperature and pressure, steam would be vent via super-heater vent line. During HRSG chemical cleaning GT load should be controlled around 25%. 3.6 HRSG feed water system, motorized valves such as feed water valve, drain valve, feed water control valve, emergency drain valve and vent valve should be commissioned. 3.7 Double-color level gauge of drums are commissioned and put into operation. 3.8 One piece of check plate should be put into HP and LP drum in order to check cleaning result.

4. Safety
4.1 Site operator should know well about HRSG operation guide and specification of chemical, self protection and emergency cure. 4.2 Site operator should wear special mark, non-related persons should be isolated. 4.3 Enough lights, fire fighting, communication devices, medicine and protection should be arranged at site. 4.4 Caution plates should be displayed at site. 4.5 Proper treatment should be arranged for ladders, holes, covers and scaffold. 4.6 Naked fire working and similar work should be forbidden during chemical cleaning. Authorized operators should check system in time and repair any trouble. 3/6

4.7 Operator should wear protection clothes and glassed during chemical transportation. 4.8 Clean water, towel, absorbent cotton, 0.2% boric acid solution would be prepared at mixing and dosing point.

5. Dosing
5.1 Dosing amount According to HRSG operation manual, dosing amount would be NaOH and Na3PO4.12H2O 3-5 kg/m3 , HP system volume is 33m3, dosing amount is 135kg; LP system volume is 14m3, dosing amount is 60kg; DA system volume is 28m3, dosing amount is 115kg. Total dosing amount is 310kg. In consideration of leakage and volatilize, certain quantity chemical would be stored at site. 5.2 Dosing method One 6m3 steel tank would be placed beside HRSG, put solid chemical and calculated water into the tank, mix chemical and demi-water, the dosing solution would be put into bottle cleaned by de-mi water and lifted to drums platform. Dosing solution would be pumped into drums from manhole with electrical dosing pump. After dosing manhole should be closed and sealed, feed water to drums and the level should be 50-100mm below normal level. During chemical cleaning dosing solution would be pumped into DA tank N2 interface with electrical pump.

6. Chemical cleaning procedure


6.1 Start Start GT and open three-way damper, check system and carried bolts hot tightening when HP system pressure rise to 0.3-0.5Mpa(g), LP system pressure rise to 0.2Mpa. 6.2 HP system After dosing HP system would be pressurized to 0.1-0.8Mpa. Drain 1 minute after 8 hours. (Which drain should be open, EBD, IBD ,CBD?) HP system pressurize to 1-1.5Mpa. Drain 1 minute after 8 hours. (Which drain should be open, EBD, IBD, CBD?) HP system pressurize to 2-2.5Mpa. Release pressure and temperature after 8 hours, flushing the system and drain. Empty all system after temperature is 70-80 (Which Temperature? Main Steam Temp or drum Temp?) What about the HP drum replacement with demi water will not be carried out? 6.3 LP system After dosing LP system would be pressurized to 01.-0.4Mpa.(How you prepare the chemical

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solution) Do chemical cleaning for 26 hours continually.(Please mention the time for HP also) Drain 1 minute every 8 hours. (Which drain should be open, IBD, CBD?) After 28 hours cleaning flushing the system and drain. Feed de-mi water into LP system to replace water. Maintain LP system pressure at 0.1-0.4Mpa until HP system cleaning completed. LP system water PH should be maintained more than 9 during this period. 6.4 DA system After dosing DA system would be pressurized to 0.1Mpa. Drain 1 minute after 8 hours. (which Drain?) Drain and flush system after 8 hours, feed de-mi water into DA system to replace dosing water. Maintain DA system pressure at 0.1Mpa until HP system chemical cleaning completed, during this period DA system water PH should be more than 9. Note: Detail chemical cleaning time would be depend on sampling results. 6.5 Caution Taking samples every 2 hours, analysis alkalinity and PH, if alkalinity is too low due to leakage, NaOH or Na3PO4 solution should be added to system. Control drums water level to make sure no liquid would flow into super-heater system. During de-pressurization period, control drums water level at 50-100mm below normal water level, temperature difference should be no more than 50 between up and down side of drums. After chemical cleaning, drums should be flushed and samples should be taken every 15 minutes. Stop flushing after water PH confirmed below 11, and empty system. 6.6 Waste water disposal Waste water would be drained to HRSG flash tanks and flow into blow-down pit, after temperature is lower than 70 and impurity is settled, water would be pumped into chemical neutralization pit with temporary pump. After PH is adjusted to 5.5-9, water would be disposed. (SS and pH and 400C Temp) Proper amount acid would be prepared before waste water treatment. 6.7 Checking and acceptance Checking and photos inside drums should be taken before and after chemical cleaning. One carbon steel plate would be put into each drum in order to confirm cleaning quality. Checking water PH and alkalinity maintain alkalinity stable before flushing and drain, record the data

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every 2 hours. Visual inspection would be carried out to confirm no oil on drum inner surface. Visual inspection would be carried out to confirm no new rust point on drum inner surface. Clean impurity inside drums and take photos for record. NOTE: Please mention the boiler operation, how you would maintain the pressure and temperature. Normally Super heater is not used in chemical cleaning but as per your P&ID you are venting the steam through LP and HP super heaters vents

HP and LP feed water pumps cannot be used during chemical cleaning to avoid dirty water gets in the Impeller. If use the HP and LP Feed water Pump, then what about the Motor testing.. How we make sure proper mixing of chemical in HP and LP drums Chemical Injection point is not mentioned in the procedure Initial stage and during chemical cleaning how would you maintain Chemical levels. Control Philosophy of Drum Levels. List of Isolation valves. Provide List.
The function Test must be done HP/LP Feed water. HPFWP Temperature/ Vibration/ Cooling water side/ Motor side/ etc. Lube Oil Skid Function Test Lube oil Low Pressure cut in Cut out/ High Temperature Alarm/ Low Flow alarm/ Tank Level Low/ High alarm etc. Flushing of Line before HPFWP or LPFWP put in service. Line Hydro Test and Pump Solo run test.

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7. Appendix1 Chemical cleaning water quality record

Time 8:00 10:00 12:00 14:00 16:00 18:00 20:00 22:00 24:00 2:00 4:00 6:00 8:00 10:00 12:00 14:00 16:00 18:00 20:00

Alkalinity

PH

Color

Pressure

Drain times

De-mi water

Quantity: conductivity : SiO2:

8. Appendix 2 HRSG pressurization curve 8.1 HP system

8.2 LP & DA system

9. Appendix 3 HRSG chemical cleaning technical data record


. . . Item Time GT load MW GT exhaust temperature Three way damper opening () HP drum pressure Mpa HP drum water level (mm) Drum wall temperature up/down LP drum pressure Mpa LP drum water level (mm)