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A

OBJECTIVE : To remove the grease & protective coating from the boiler tube surface by filling the

boiler with alkaline solution & then lighting up the boiler , raising the pressure to 40 ksc , holding at 40
ksc & giving blow down as per the steps described below . The process is known as the alkali boil out
of new boilers .

COMPLETION CRITERIA :-

RESPONSIBILITY :BHEL/NTPC Commissioning/erection /operation/chemistry group .

Minimum 8 Nos of blow down or the oil level in blow down sample is < 5 ppm .

Rinsing with water , boiler water circuit PO4 < 2ppm.

SH back flushing with N2H4 & NH3 so that PO4 < 2ppm .

CHEMICALS REQUIRED :DISODIUM PHOSPHATE

= 200 KG

TRISODIUM PHOSPHATE = 400 KG


N2H4 & NH3 for back flushing of SH =

SERVICES REQUIRED FOR ALKALI BOIL OUT :-

Sufficient quantity of DM water .


Manpower for manning at various locations boiler , chemical dosing area , Boiler fill pump house.
Fire fighting team shall be available as long as the boiler is in lighted up condition
Shift chemist & staff round the clock .
One Boiler fill pump in service & stand by pump available .
Telephone at boiler drum level / chemical mixing area /lighting at various location s of boiler

/Walky-talkies for control room & other locations .


LDO oil in sufficient quantity .

REQUIREMENTS FOR BOILER ALKALI BOIL OUT :Boiler is ready for light up as per 1 st light up requirement given in annexure - 1 .
Furnace expansion constraints are checked & removed by joint walk down check from boiler top
to Bottom ring header .

Other preparedness checks as per check list in annexure - 2 .


Readiness & availability of operating parameters in CRT as listed in annexure - 3
Readiness of the valves from remote operation as per list annexure - 4
O&M manuals /Operating instructions for various auxiliaries , BCW pumps .
Emergency operating procedures .
Emergency operating procedures in case total power failure .

Page 1 of 7

H-1

PROCEDURES :The total alkali boil out procedure is divided into the following sub procedures as outlined below .
Chemical preparation & boiler filling procedure .
Boiler light up & pressurisation to 40 ksc procedure .
Blow down & sampling procedure .
After completion of blow down boxing up procedure .
Cooling down of boiler & monitoring .
Boiler draining .
Boiler refilling , SH back filling & boiler draining .
Inspection of boiler drum / bottom ring header & cleaning .

Chemical preparation & boiler filling procedure .


Prerequisites :Boiler/economiser are in drained condition .
Bottom drain hdr main drain valve to IBD is closed .
Except the Bottom Ring hdr rear side drain all other drain to bottom drain hdr are closed .
Boiler fill line is also isolated .

Page 2 of 7

H-2

Page 3 of 7

Boiler pressure 10 ksc .


Take one set of expansion readings .
Monitor all the boiler parameters every hr as per the log sheet .
Keep line up the FW LLCV for taking makeup either through IBV or main valve as per requirement .
Monitor D/A level .
Boiler pressure 20 ksc .
Take one set of expansion readings .
Monitor all the boiler parameters every hr as per the log sheet .
Keep line up the FW LLCV for taking makeup either through IBV or main valve as per requirement .
Monitor D/A level .
Boiler pressure 30 ksc .
Take one set of expansion readings .
Monitor all the boiler parameters every hr as per the log sheet .
Keep line up the FW LLCV for taking makeup either through IBV or main valve as per requirement .
Monitor D/A level .
Boiler pressure reached 40 ksc . & maintain for 4 hrs at this pressure .
Take one set of expansion readings .
Monitor all the boiler parameters every hr as per the log sheet .
Check for any abnormality in MS/CRH/HRH hdrs at drum level & below (For hammering etc)
Here reduce the oil pressure to bare minimum i.e 3.5 ksc . Dont allow the pressure to go up .
Monitor the drum metal temp/drum level.

H-3

1 st Blow Down & Sampling procedure .

Once 4 hrs passed at 40 ksc the boiler is ready for its 1 st blow down .
Try to maintain 8-9 ports water level in the drum & make up fully lined up to take level as early as

possible after /during blow down .


People should be ready at boiler 0 mtr along with chemistry group .
Charge the sample cooler .
The bottom drain hdr main isolation valve to IBD tank is fully open .
Open the sample line drain .

Inform control room to Hand trip the boiler .( close the start up vents one valve in each line i.e
S81/S82)

Open the bottom ring header drain valve B-92 electrically from local .(30 sec to full open)

At the expire of one minute close the electrically operated valve B 92 full .
Then collect the sample from sample cooler discharge with care so that it should not fall on hand .
The sample is to be analyzed for alkalinity , Phosphate , silica , oil content .

Once the main valve B - 92 is closed give clearance to start the boiler (light up). Open the start

up vents .
Then close the manual isolation valves in drain line & main drain to IBD . Isolate the sample

Now open the manual valve B 89 up to the 20 % opening mark very fast .
Once it opens 20 % , count 1 minute .

cooler .

Boiler Light up & Raising the Boiler pressure to 40 ksc . & maintain for 2 hrs at this

pressure .
Keep all 4 oil guns in service . Raise the Boiler pressure to 40 Ksc , then reduce oil pressure to
minimum 3.5 ksc to maintain the pressure . Keep it at 40 ksc for 4 Hrs .

H- 4

H-5

2 nd Blow down & Sampling procedure .


Follow the same procedure till the completion criteria achieved .

After completion of blow down boxing up procedure .


Stop the ID/FD fan after reducing the flow .
Create the natural draft flow path by opening the FD fan discharge damper , blade pitch , ID fan

Page 4 of 7

H-6

inlet gate, guide vane , discharge gate all full open . SADC shall be full open .
Close the SH start up vents .
Stop the LDO pump at FOPH .
Isolate the oil valves at all corners & at oil station in firing floor as well .
MDBFP-C shall be in service till boiler pressure drops down as HP purge is in service . This can

only be stopped after switching over to LP purge from boiler fill pump .
Take makeup as per requirement

Fill up the boiler cooling down monitoring log sheet .


At boiler pressure of 5 ksc open the start up vents & SH drains .
Open the drains before MS stop valves LHS/RHS

At drum metal temp of 90 0 C open the drum vents . At this point only one BCW pump can be kept

H-8

Cooling down of boiler & monitoring .

in service .
At BCW pump suction manifold temp of 90 0 C or less stop the BCW pump .
Now the boiler is ready for draining .

Boiler draining .

Before draining the boiler the C row drain & main drain shall be clear .
Dilution water should be arranged by fire hydrant water or # 3,4 side settling bin water can be

continuously overflown to C row .


Chemistry group shall be informed about draining , so that the diluted water pH can be measured

To drain the boiler open the bottom ring header (Rear) drain to drain header full both manula &
MOV B92 .

Open the economiser inlet header drain both manual & MOV E 18 full .
Now slowly open the main drain valve to IBD tank initially 25 % . After measuring the pH & the

drain line margin further opening can be done .


Once the main boiler draining is completed , the drain pipe looping can be drained by opening the
bottom most drain that is the sampling point .

H-9

H-10

Boiler refilling , SH back flushing to drum & boiler draining .

The mixing tank is to be flushed properly .


Tank is to be filled , steam to be charged .

Once temp picked up 80 0 C boiler is to be filled till one port is visible in the drum via both bottom

ring header & economiser .


SH is to be filled with hydrazine & ammonia solution to have a pH of 10 & hydrazine 200 ppm .
Once the drum level starts increasing stop SH filling .
Drain the boiler .

Monitor the drain water for residual PO4 in both boiler & SH water

Inspection of boiler drum / bottom ring header & cleaning .


After complete draining of the boiler /economiser PTW shall be issued to ME for opening the boiler
drum & Bottom Ring Header manholes for inspection & cleaning & temporary pipe lines for acid

cleaning .
Thoroughly clean the boiler drum & bottom ring header .
Boiler drum primary separators are to be removed for Making ready for Acid cleaning .

Page 5 of 7

BOILER ALKALI BOIL OUT PROCEDURE .


1.

2.
3.
4.

The boiler shall be filled with an alkaline solution of


500 ppm

1000 ppm Trisodium Phosphate

Disodium phosphate

Filling shall be done simultaneously with both the Bottom ring header & Economiser .
Boiler will be lighted up & pressurized to 40 ksc
Holding at 40 ksc for 4 hrs
Sample to be taken from CBD sampling point .

5.
6.

Measurement for

Alkalinity

Phosphate

Dissolved Silica

Oil Content

If the phosphate content drops to < 50 % of initial value then dose phosphate again .
Fire out the boiler
Blow down through the bottom drain hdr drain to IBD . Keep open the valve for 1 minute
.

7.
8.

Record the pressure drop , make up the level immediately .


Again light-up & pressurize the boiler to 40 ksc . Hold it f 2 hrs .
Repeat the blow down for 8 times (minimum) or till the oil content reaches < 5 ppm

9.
10.
11.
12.
13.

when it is declared completed .


Box up the boiler & allow natural cooling .
At 2 ksc pressure at least one CC pump shall be in service .
At drum temp. 90 0 C Open the drum vents .(all 4 valves )
Stop the CC pump .
Drain the boiler once the CC pump suction manifold temp < 90 0 C . by opening the

14.
15.

bottom drain hdr valve full to the C: row drain .


Inspect the drum /bottom ring header & clean them .

Page 6 of 7

ANNEXURE - 3
OTHER REQUIREMENTS CHECK LIST.
AA

1.

Boiler roof hdr all hangers are released & all tie rods are in position . Necessary inspection & clearance

2.
3.
4.
5.

w.r.t this by ME/BHEL .


Boiler drum only primary separators are erected ( secondary separators I,e he scrubbers are not erected)
Boiler bottom drum i.e the bottom ring headers the baffle plates are in position , but the orifices are not put .
Boiler drum end points are insulated .
Boiler drum level measurement through gauge glass available with requisite lighting arrangement .

6.

Communication to UCB with lamp arrangement is completed .


All boiler expansion indicators are fixed at drum level L/R / 73 mtr / 45/48 mtr /23 mtr /Bottom ring hdr &

7.

measurement protocol formats are available .


All temporary pipe lines are connected i.e

MAIN BOILER .

From the Mixing tank area pump discharge to the Bottom drain hdr stub provided for alkali boil out .

Drain line from EBD tank to the nearest plant drain where the blowdown as well boiler draining is to
be done after alkali boil out is completed .

8.
9.
10.

Sampling point is provided from the bottom drain hdr . Temporary Sample cooler is erected , cooling

water provided from boiler fill line . Cooler discharge is provided to the nearest plant drain .
LP purge from boiler fill pump is available .
HP purge from BFP discharge is flushed for all 3 BCW pumps & sample result is with in limit .
Boiler is completely drained including economiser , SH/RH etc .All drain valves are in open position &
respective main valves are also open

BB

1.

Mixing tank is filled , leakage checked , if any attended , tank flushed & drained . Tank level monitoring

2.

transparent PVC hose is fixed .


Boiler fill line through to mixing tank , pressure gauge is available in boiler fill line near mixing tank before

3.
4.
5.
6.
7.
8.
9.

the valve to monitor the fill line pressure .


Auxiliary steam is available to the Mixing tank from APRDS .
Power supply from the respective unit to the chemical cleaning area is available
Emergency power supply also available from EMCC .
Availability of recirculation pumps in chemical cleaning area at least 2 pumps out of 5 pumps erected .
Proper lighting/approach in mixing tank area
Clearing of C row drain where the IBD drain is connected .
Clearing of the bottom drain header area .

MIXING TANK AREA :-

Page 7 of 7

Annexure I

Status of equipments for BLU of Unit #5


Sl.
NO
I
1.0
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)

ACTIVITY

Status

BOILER
ID FAN 4A
Lube oil flushing
VFD room A/C plant commissioning.
Cooling water pipe flushing & charging.
VFD panels commissioning.
Charging of VFD transformers.
ID Fan motor trial.
Inlet guide vane calibration and remote operation.
Ducts checking and clearance including air leak test.
ID Fan interlock & protection checking.
ID Fan trial.

2.0
i)
ii)
iii)
iv)
v)

FD FAN 4B
Lube oil flushing.
Motor trail run.
Flushing of cooling water lines and charging.
Interlock & protection checking.
Fan trail run.

3.0
i)
ii)
iii)
iv)
v)
vi)
vii)

CC Pumps
Purge line flushing & Cavity filling
Booster pump motor trail
Booster pump trail
O/H tank with pneumatic control valves auto operation.
Interlock & protection checking.
Pump trail 4C
Pump trail 4B

4.0
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)

SAPH 4B
Lube oil flushing.
Cooling water readiness for lube oil pumps.
Motor trail run.
SAPH trail with air motor
SAPH trail with electric motor
Soot blower commissioning.
Fire fighting system flushing and readiness.
Water washing system flushing and readiness.
Rotor stoppage alarm
Commg of hot spot detection system. (fire sensor)

5.0
i)
ii)
iii)

FURNACE & AIR /FLUE GAS DUCTS


Furnace gas tightness test.
Completion of furnace & duct insulation.
Completion of wall blower internal inspection for nozzle clearance
checking.

Page 8 of 7

iv)
v)

Boiler expansion indicators with initial position punching.


SADC internal inspection after C&I clearance.

6.0

BOTTOM ASH HOPPER


Completion of refractory & dry out.
Fixing and closure of B. A hopper gates.
Sealing and hopper cooling water arrangement and over flow line
connection to drain.

7.0
i)
ii)
iii)
iv)
v)

SCANNER AIR FAN


Discharge dampers operation checking.
Interlocks & protection checking.
Scanner guide pipes fixed at all corners and clearance.
Trial run of AC scanner air fan.
Trial run of DC scanner air fan.

8.0
i)
ii)
iii)
iv)
v)

LIGHT OIL SYSTEM


Air blowing of pipe lines.
Oil flushing.
Motorised / pneumatic valves commissioning from remote.
Commissioning of corner oil /air nozzles valves.
FSSS interlocks readiness, with oil system.

9.0
i)
ii)

FIRE FIGHTING SYSTEM


Charging of boiler fire hydrant system.
Boiler corner stations spray nozzles availability.

10.0
i)
ii)
iii)
iv)
v)
vi)

ALKALI BOIL OUT


Chemicals availability.
DM water availability.
Readiness of DM water pumps and chemical feeding pumps with
mixing tank.
Piping from tank / pumps to boiler.
Removal of separators and internal inspection of drum & ring
headers.
Readiness of blow down tank at boiler 0 meter and its drain
extension.

11.0
i)
ii)
iii)
iv)

C&I SYSTEM
FSSS system readiness.
SADC
DDCMIS
Availability of measurements and alarm pertaining to Secondary
air, Flue gas, Feed water, Steam, Boiler metal temp. points, Drum
level indication and drum pressure indicator at UCB.

12.0
i)
ii)
iii)
iv)

PA SYSTEM
PA system at ID Fan area.
PA system at LHS & RHS at drum level
PA system at FD Fan area.
PA system at operating floors.

Page 9 of 7

13.0

FUEL OIL HANDLING SYSTEM


LDO HANDLING SYSTEM
HFO HANDLING SYSTEM

II
i)
ii)
iii)
iv)

ESP (Pass A)
Mechanical readiness of ESP internals.
Charging of ACP
Commissioning of rapping system.
Completion of insulation.

III
1.0

TG
TG ECW PUMPS
Motor trail
Interlock & protection checking.
ECW tank readiness.
Coupled trial run of TG ECW pumps

2.0

SG ECW PUMPS
Motor trail
Interlock & protection checking.
Coupled trial run of TG ECW pumps

3.0

MDBFP 4C
Lube oil flushing
Motor trial run
Interlock/ protection check of motor & voith coupling
HC scoop commissioning.
Motor + voith coupling trial run
Hydraulic test of feed line.
Deareator readiness with all instrumentation
Interlock/ protection check of pump.
Coupled trial run of MDBFP - 4C

4.0

ACW PUMPS
Motor trail
Interlock & protection checking.
Coupled trial run of ACW pumps

5.0

CW PUMPS
CWP 4A Motor trail
Interlock & protection checking.
Coupled trial run of CW pump 4A

6.0

APRDS
Auxiliary steam

IV

DM PLANT, PT PLANT, RAW WATER SYSTEM.

ELECTRICAL SYSTEM

Page 10 of 7

1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0

11 KV SWITCHGEAR
3.3 KV SWITCHGEAR
415 V SWITCHGEAR
220 V BATTERY & CHARGERS
UPS BATTERY & CHARGERS
24 V BATTERY & CHARGERS
LIGHTING
DG SET

VI
1.0
2.0
3.0

AIR-CONDITIONING
A/C OF CER
A/C OF VFD
A/C OF ESP

VII
1.0
2.0

COOLING TOWERS
CW channel
Cooling tower 4B

VIII
1.0
2.0

COMPRESSED AIR SYSTEM


INSTRUMENT AIR SYSTEM
SERVICE AIR SYSTEM

Page 11 of 7

TURBINE SIDE VALVES FOR BLU


Sl No.

Valve No Valve description

Mechanical
readiness

AS 6

Aux. steam to D/A initial heating

Ready

AS10

Aux. steam to D/A pegging.

Ready

AS114

Ready

CHD 7

CHD 13

FD 6

Aux. steam to D/A pegging line drain


regulating valve.
Hydrazine dosing at MDBFP C
suction
Ammonia dosing at MDBFP C
suction.
MDBFP C discharge valve

FD 11

100% HPH Bypass line.

Ready

FD 12

50% HPH Bypass line.

Ready

FD 13

Feed control station.

Ready

10

FD 16

Feed control station by pass.

Ready

11
12

PGB 391 Motorised valve to MDBFP C motor


AA- 201 cooler / working oil cooler.
ECW - 7 TG - ECW PP # A discharge valve.

Ready
Ready
Ready

Ready
Ready

13

ECW 8

TG - ECW PP # B discharge valve.

Ready

14

ECW 9

TG - ECW PP # C discharge valve.

Ready

15

ECW 83 Boiler ECW PP # A discharge


valve.
ECW - 84 Boiler ECW PP # B discharge
valve.
ECW
ACW PP # A discharge valve.

16
17

Local commg

Ready
Ready
Ready

18

ECW

ACW PP # B discharge valve.

Ready

19

ECW

ACW PP # C discharge valve.

Ready

20

ECW- 64

Emergency make up from DM make


up.

Ready

Page 12 of 7

Remote
commg

Boiler side valves for BLU


Sl

Valve No

Description

No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.

E18
E19
B92
B 86
B 88
E2
E2A
B 21
B 85
B 87
B 81
B 68
B 83
B 82
B 69
B 84
B 72
B 73
B 76
B 77
B 74
B 75
B 78
B 79
S 74

Eco I/l header drain


Eco feed line drain
Bottom Ring header drain
Bottom Ring header steam Blow off
Bottom Ring header steam Blow off
Economiser I/L valve
IBV of E2
Eco Recirculation valve
Emergency drain from Drum.
Emergency drain from Drum.
CBD drain
CBD drain
CBD drain
CBD drain
CBD drain
CBD drain
Vent valve left Drum
Vent valve left Drum
Vent valve left Drum
Vent valve left Drum
Vent valve right Drum
Vent valve right Drum
Vent valve right Drum
Vent valve right Drum
SH DIV panel drain to SH drain

26.

S 75

header (left)
SH DIV panel drain to SH drain

S23
S25
S21
S22
S19
S24
S26
S77
S76
S 11
S12
S 13
S14

header (right)
BP lower rear header Left
BP lower rear header Left
BP lower front header drain
BP lower front header drain
SH roof I/L header drain
BP lower rear header drain right
BP lower rear header drain right
SH platen I/L header drain
Platen SH in let header drain.
SH roof O/C header vent left
SH roof O/C header vent left
SH roof O/C header vent Right
SH roof O/C header vent Right

27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.

Mechanical

Local commg

Page 13 of 7

Remote commg

Sl
No
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.

Valve No

Description

S68
S69
S70

Div panel header vent


Div panel header vent
Div panel to SH platen I/L header

S71

vent
Div panel to SH platen I/L header

S79
S81
S82
S83
S84
MS - 1
MS 3
MS 5
MS 2
MS 4
MS 6
S 85
S 87
S 86
S 88

vent
SH O/L header vent
SH start up vent
SH start up vent
SH start up vent
SH start up vent
MS stop valves (Boiler left)
IBV of MS 1
IBV of MS 1
MS stop valve (Boiler right)
IBV of MS 2
IBV of MS 2
Electromotive relive valve MS left.
IBV to ERV - S 85
Electromotive relive valve MS right.
IBV to ERV - S 86

Mechanical

Local commg

Ready
Ready

Page 14 of 7

Remote commg

Boiler side dampers and gates for BLU


Sl
No

Valve/gate No

1.

Desc
ription
HID fan - B inlet gate.

NC 02AA 201
2.

HID fan - B inlet gate.

3.

HID fan - B discharge gate.

LA 20 AA201
LA 20 AA 202
7.
LA 20 AA 203
8.

HFD fan # B SCAPH Bypass


damper.
HFD fan # B SCAPH I / L
damper.
HFD fan # B SCAPH O / L
damper.
HFD fan B blade pitch control.

Over

R
eady

NA 44AA 202

R
eady

HESP C pass outlet damper


NA 43AA 203

R
eady

HESP C pass outlet damper


NA 43AA 204

R
eady

HESP D pass outlet damper


NA 44AA 203

R
eady

HESP D pass outlet damper


NA 44AA 204

R
eady

HScanner air fan- A discharge


damper.
HScanner air fan- B discharge
HS 12AA 201
damper.
HNA 22 AA 201 SAPH # B flue I/L damper.
HS 11AA 201

20.

Over

HESP D pass inlet damper.

17.

eady

NA 44AA 201

16.

Over

HESP D pass inlet damper.

15.

eady

NA 43AA 202

14.

Over

eady

HESP C pass inlet damper.

13.

R
eady

eady

NA 43AA 201
12.

Over

eady

HESP C pass inlet damper.

11.

eady

LBO 2AA 201

19.

HFD fan B discharge damper.

10.

Over

eady

LBO 2AA 101


9.

R
R

HID fan - B discharge gate.

6.

Over

eady

NC 02AA 204
5.

Over

Over

eady
eady
R
eady

21.

HSAPH # B flue O/L damper.


NA 22 AA101

22.

R
eady

HPAPH # B flue gas I/L damper.


NA 21 AA 201

23.
NA 40 A201,202

R
emote
commg

eady

NC 02AA 203
4.

L
ocal commg

eady

NC 02AA 202

18.

M
echanical

Over

eady
HCommon damper flue gas to
ESP
C& D pass.

R
eady

Page 15 of 7

Over

24.

HSAPH # A flue gas I/L damper.


NA 12 AA 201

25.

HPAPH # A flue gas I/L damper.


NA 11 AA 201

26.
27.

R
eady
R
eady

HSAPH # B air I/L damper.


LA 20 AA204
HLA 20
AA

SAPH # B air I/L damper.


HSAPH # B air O/L damper.

LA 20 AA206
29.

HSAPH # A air O/L damper.

HPAPH #A air I/L damper

R
eady

HPAPH #B air O/L damper


FE40 AA205

R
eady

HPAPH #B air I/L damper


FE40 AA20 4

Over

eady

FE30 AA204
33.

R
R

HPAPH #A air O/L damper

32.

Over

eady

FE30 AA205
31.

eady

LA 10 AA206
30.

Over

eady

205
28.

R
eady

R
eady

Page 16 of 7

NATIONAL THERMAL POWER CORPORATION


TALCHER SUPER THERMAL POWER PROJECT
COMMISIONING DEPARTMENT
Stage II , 4 X 500 MW units
UNIT 5 ACID CLEANING PROCEDURES
A

OBJECTIVE : To remove the patchy mill scale & rust from boiler heat exchanging surface i.e
water wall , boiler drum , down comer pipes ,economiser and excluding the SH /RH circuit by acid
cleaning process after successful alkali boil out is completed .

RESPONSIBILITY :-

COMPLETION CRITERIA :-

BHEL/NTPC Commissioning/erection /operation/chemistry group .

ACID/CHEMICAL REQUIREMENTS :-

SL
NO
1.
2.
3.
4.
5.
6.

ACID
Hydrochloric acid (HCL)
Rodine
Ammonium Bifloride

Blr water

Quantity required

Concentration in %
5 % +/- 1 %
0.20 %
0.25 %

in tons

Ammoniated Citric Acid


Di/Trisodium phosphate

solution

7.

Caustic Soda Lye

8.

Bleaching powder

Acid pickling &


soaking
Ammoniated citric

0.2 %

acid rinse
Neutralization

0.1 % & 0.2 % in the


boiler
250 P pm

Hydrazine/ammonia

Used for Process

process
Passivation process

hydrazine/pH 10
PH 5.5-9.0

For neutralization of

/Floride < 2 ppm

acid
For neutralization of
hydrazine /ammonia

SERVICES REQUIRED FOR ACID CLEANING

:-

Sufficient quantity of DM water .


Boiler fill pump in service & stand by pump available .
Auxiliary steam from APRDS .
Electric power supply to chemical cleaning area from SSS SWGR/ EMCC .
Manpower for manning at various locations
Fire fighting team shall be available as long as the boiler is in lighted up condition
Shift chemist & staff round the clock .
Telephone /lighting/Walky-talkies
LDO oil in sufficient quantity
F

REQUIREMENTS FOR ACID CLEANING

:-

Boiler is ready for light up as per 1 st light up requirement given in annexure - 1 .


Furnace expansion constraints are checked & removed by joint walk down check from boiler top to
Bottom ring header .
Other preparedness checks as per check list in annexure- 2 .
Readiness & availability of operating parameters in CRT as listed in annxure- 3
Readiness of the valves from remote operation as per list annxure- 3
G

PROCEDURES :-

Page 17 of 7

Chemical preparation & boiler filling procedure

H-1

Chemical preparation & boiler filling procedure .

BB

Boiler light up & pressurisation to 40 ksc procedure


Blow down & sampling procedure .
After completion of blow down boxing up procedure .
Cooling down of boiler & monitoring
Boiler draining .
Inspection of boiler drum / bottom ring header & cleaning .

OTHER REQUIREMENTS :Drum internals are removed & inspected after alkali boil out & boxed up.
Bottom ring header manholes are opened for inspection /cleaned / checked for tightness of all
perforated panels & boxed up.
Sample piece is joint tested for inhibiter effectiveness ( RODINE)
Sample piece is made ready to put inside the drum during acid cleaning
Temporary pipe lines are laid as per the scheme attached .
Drum gauge glass to be replaced with a rubber/plastic tube arrangement
Nitrogen cylinder arrangement at 0 mtr for capping after acid cleaning . (during draining process)
Valves to be provided in filling line to suction manifold, economizer, ring header etc
Readiness of temporary system such as
o Boiler filling to be completed with in 1 hr
o LP purge water at 8-10 ksc near the BCW pump on continuous basis .
o Draining of the boiler with in 1 hr
o Telephone connections to the Boiler fill pump area / Acid cleaning area / Drum level
o

CC

DD
D-1.0

/Fuel oil pump house etc .


Readiness of PA system
Readiness of 2 Acid tank / Mixing tank for ammonium bifloride

READINESS / PREPARATION OF CHEMICAL SOLUTIONS :-

Preparation of 30-32 % HCL with Rodine is completed in 2 tanks .


Preparation of ammonium bifloride with DM water is completed in another tank .
Shifting of above bi-floride solution to the 2 acid tanks .
Mixing of inhibited acid with bi-floride solution by running the pups on recirculation
Preparation of ammoniated citric acid with citric acid monohydrate & liquor ammonia .
Preparation of neutralizing solution in mixing tank.(Di-sodium phosphate do deca hydrate / Tri-

sodium phosphate do deca hydrate)( 0.1 % & 0.2 % in the boiler)


Preparation of blended solution of hydrazine/ammonia solution for passivation of boiler .

ACID CLEANING PROCEDURE STEP BY STEP :BOILER FILLING WITH DM WATER & LIGHTING UP THE BOILER TO RAISE THE
TEMP. TO 80 0C BEFORE GOING FOR ACID INJECTION :-

Fill the boiler through the bottom ring header /economizer / up to the bottom gauge glass . Then stop

filling .
Start back filling of the SH at hydrazine 200 pip & pH >10 till it over flows to the drum . stop filling
Light up the boiler as per procedure
EBD/CBD should be full closed & vent valves to be full open .

Stop the boiler once drum metal temp. & BCW pup suction manifold temp. >/ 80 0C . Box up the

boiler by stopping natural air path .


Drain the boiler water circuit . ( CC pump valves keep open )

Page 18 of 7

D-2.0

valve at the acid pump discharge


The sample of the mixed water is to be monitored at pump discharge i.e sample point A as per

drawing at regular interval of 5 min .


The sample result for acid shall be < 5% +/- 1% other wise regulate the acid as desired .

D-3.0

Fill the boiler with 60-70 0C water from the 250 mm temporary header through
WW drain / Eco drain/ BCW pump suction manifold drain ( 2 lines of 120 mm)
Start injection of chemicals at the suction of the filling pump through the acid pump & regulation

D-2.0

FILLING OF BOILER ALONG WITH ACID INJECTION :-

The temp. of the water & acid mixture dosed is to be regulated with in 60-70 0C.
Once the boiler drum level is at the bottom port stop filling through suction manifold .
Fill the boiler up to the drum level is 100 mm above center line .
Start Boiler Water Circulating (BCW) pump B (center pump)

FILLING OF BOILER ALONG WITH ACID INJECTION :Collect sample from BCW pump discharge header & record them as per the annexed log sheet .
After 30 min stop the pump & allow the acid for soaking.
After 30 min again start the BCW pump & run for 5 min & stop .
Take sample at 10 min interval .
Continue this process till the iron content is in equilibrium n for 3 consecutive sample .
The total time allowed for this exercise is 6 hrs including (the filling 1 hr &draining 1 Hr)
Stop BCW pump B .
Then keep the N2 capping system ready .
Start draining the boiler under N2 capping to the neutralization Pit near # 6 .
Maintain the N2 capping pressure at 0.5 ksc to 1.0 ksc

DM WATER RINSE AFTER ACID PICKLING/SOAKING IS COMPLETED ( 6 HRS


ACTIVITY) :-

D-4.0

Refill the boiler with DM water at 60-70 0C.


While filling the drum vent valve are to be operated to maintain the pressure at 0.5 ksc . Fill up to 50

% of the gauge glass .


Then start back flushing of the SH through the LTSH drain till the water level is raised in the drum up

to 8-9 ports .
Run BCW-B for 5 min .
Take sample from BCW discharge & point A
Drain the boiler
Continue this operation till the sample result pH is 4-5 .

AMMONIATED CITRIC ACID RINSE AFTER DM WATER RINSE :Fill the boiler with 60-70 0C water from the 250 mm temporary header through
WW drain / Eco drain/ BCW pump suction manifold drain ( 2 lines of 120 mm)
Start injection of citric acid solution prepared at the suction of the filling pump through the acid

pump & regulation valve at the acid pump discharge


The sample of the mixed water is to be monitored at pump discharge i.e sample point A as per

drawing at regular interval of 5 min . ( 0.2 % concentration at the boiler inlet)


Adjust the pH at the filling point around 3.5-4.0 through sample point -A
Once the boiler drum level is at the bottom port stop filling through suction manifold .
Fill the boiler up to the drum level middle in the gauge glass .
Start Boiler Water Circulating (BCW) pump B (center pump) for 5 min at an interval of 30 min &

stop .
Collect sample from BCW pump discharge header after stopping the pump & record them as per

the annexed log sheet .


Again After 30 min run the pump for 5 min collect the sample after stoppage of the pump .
Continue this operation till 3 consecutive samples read the acid % & iron content are steady .

Page 19 of 7

D-5.0

D-6.0

Fill the boiler with 60-70 0C water from the 250 mm temporary header through
WW drain / Eco drain/ BCW pump suction manifold drain ( 2 lines of 120 mm)
Raise the water level up to +100 mm mark
Operate the BCW pump for 5 min .
Stop the pump & drain the boiler under nitrogen capping .
Continue the boiler filling & draining operation till the sample at pointB is having IRON < 25 ppm .
Maintain the N2 capping pressure at 0.5-1.0 ksc .

NEUTRALISATION OF THE BOILER SYSTEM :U Tube manometer to be replaced with normal gauge glass
Preparation of neutralizing solution & feeding to the boiler along with DM water like acid filling

parallely through Eco /WW/Suc. Manifod drain . Nitrogen capping is to be maintained .


Once boiler filling is complete open the drum vents .
Start the BCW pump-B .
Light up the boiler & raise the pressure to 10 ksc .
Hold the pressure for about 6 hrs .
Blow off all instruments for release of any acid particle .
After 6 hrs kill the fire .
Natural cooling of the boiler .

Drain the boiler after metal temp. < 90 0C


While draining back flushing of SH with DM water conditioned with hydrazine & ammonia .
Boiler is drained with drum vents open to atmosphere & no N2 capping is used .

PASSIVATION OF BOILER :-

Fill the boiler with DM water & inject the prepared blended solution so that the final water having

250 ppm of N2H4 & pH of 10 to the boiler .


Fill through the WW/Eco/Suction manifold drain
Fill up to the normal drum level .
Start the boiler circulation pump-B
Lightup the boiler at slow rate .
Raise the drum pressure to 40 ksc & hold it for 24 hrs .
Feed water to be fed to boiler should have residual N2 H4 25 pip & pH 10
Ammonia & hydrazine to be dosed in the FST to maintain above values .
After 24 hrs shut down the boiler & allow it to cool down slowly .

EE

DEMINERALISED WATER RINSE :-

D-7.0

This operation shall be minimum 4 hrs & maximum 5 hrs duration .


Then drain the boiler under positive nitrogen pressure of 0.5 to 1.0 ksc .

At 95 0C stop the BCW pump & drain the boiler under atmospheric pressure & aerate the system
After cool down open the upper & lower drum for inspection
Manually clean them , refit the drum internals etc .
Restore all temporary connections make the boiler available for steam blowing .

NEUTRALISATION OF BOILER EFFLUENTS

:-

As soon as the acid is drained to the neutralizing pit caustic soda is added to neutralize .
As soon as the citric acid is drained to the neutralizing pit caustic soda is added to neutralize .
Neutralization of Hydrazine & ammonia by bleaching powder .

Page 20 of 7

NATIONAL THERMAL POWER CORPORATION


TALCHER SUPER THERMAL POWER PROJECT
COMMISIONING DEPARTMENT
Stage II , 4 X 500 MW units
UNIT 5 ACID CLEANING LOG SHEETS

PROCESS : BOILER FILLING & ATTAINING 80 0 C BOILER TEMP.


DATE

Sl
no
1.
2.
3.
4.
5.
6.
7.

Activity

Start Time

Complete Time

Boiler Filling through Eco/WW


Super Heater Filling
Starting of BCW pumps
Boiler Light Up
Attaining 80 0 C
Killing of Fire
Boiler Draining

Remarks
( It Should Take 1 Hr)

( It Should Take 1 Hr)

PROCESS : BOILER FILLING & ACID INJECTION WITH ACID PICKLING &
SOAKING

Sl

Activity

no
1.

Boiler Filling through


Eco/WW/BCW suction manifold

2.
3.

along with acid injection


Suction manifold closed
Boiler drum level > 100 mm above

4.
5.

centerline ( 7 ports)
1 st Starting of BCW pump - B
Boiler Draining

Start Time

Complete Time

Remarks
( It Should Take 1 Hr)
Water temp.60-70 0 C
Acid concentration 5 % +/- 1%

( run for 30 min)


( It Should Take 1 Hr)

Page 21 of 7

PROCESS : Chemical sampling during acid injection Sampling interval 5 minutes


Sampling point A ( discharge of fill pump)

Time

Sample no

Sample Result

Remarks

( 5 %+/-1% )
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

Page 22 of 7

PROCESS : Chemical sampling during acid pickling & soaking


Sampling interval 5-10 minutes
Sampling point B ( discharge of BCW pump)

Time

Sample
no
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Note :

Iron Content

Remarks
Starting Of BCW pump for 30 min
Stopping of BCW pump for 30 min
Starting Of BCW pump for 5 min
Stopping of BCW pump for 30 min
Sampling at 10 min interval
Starting Of BCW pump for 5 min
Stopping of BCW pump for 30 min
Starting Of BCW pump for 5 min
Stopping of BCW pump for 30 min
Starting Of BCW pump for 5 min
Stopping of BCW pump for 30 min
Starting Of BCW pump for 5 min
Stopping of BCW pump for 30 min

Total time allowed for acid inside the boiler including filling & draining
should not be more than 6 hrs .

Page 23 of 7


Sl
no
1.

PROCESS : BOILER RINSING BY FILLING DM WATER AT 60-70 0 C

Activity

Start Time

Complete

Remarks

Time
Boiler Filling through

( It Should Take 1 Hr)

Eco/WW/BCW suction

Water temp.60-70 0 C

manifold up to 50 % in the

Drum pressure to be maintained at 0.5 ksc by

gauge glass

regulating the valve

2.
3.

SH back flushing
1 st Starting of BCW

( run for 5 min)

4.

pump B for 5 min


Collect sample from BCW

Sample to be checked for pH it should be > 4-5

5.
6.

discharge hdr.
1 st Boiler Draining
Boiler Filling through

( It Should Take 1 Hr)


( It Should Take 1 Hr)

Eco/WW/BCW suction

Water temp.60-70 0 C

manifold up to 50 % in the

Drum pressure to be maintained at 0.5 ksc by

gauge glass
7.

2nd Starting of BCW

regulating the valve


( run for 5 min)

8.

pump B for 5 min


Collect sample from BCW

Sample to be checked for pH it should be > 4-5

9.

discharge hdr.
2nd t Boiler Draining

( It Should Take 1 Hr) maintain drum pressure 0.5

10.

Boiler Filling through

ksc
( It Should Take 1 Hr)

Eco/WW/BCW suction

Water temp.60-70 0 C

manifold up to 50 % in the

Drum pressure to be maintained at 0.5 ksc by

gauge glass
11.

3rd Starting of BCW pump

regulating the valve


( run for 5 min)

12.

B for 5 min
Collect sample from BCW

Sample to be checked for pH it should be > 4-5

13.

discharge hdr.
3rd Boiler Draining

( It Should Take 1 Hr) maintain drum pressure 0.5


ksc

Time

Sample no

Sample Result

Time

Sample no

PH 4 - 5

1.
3.
5.

Sample Result
PH 4 - 5

2.
4.
6.

Page 24 of 7


Sl
no
1.

PROCESS : BOILER FILLING & AMMONIATED CITRIC ACID INJECTION


Activity

Start Time

Boiler Filling through

Complete
Time

Remarks
( It Should Take 1 Hr)

Eco/WW/BCW suction manifold

Water temp.60-70 0 C

along with CITRIC acid injection


Suction manifold v/v closed
Boiler drum level up to middle of

Acid concentration 0.2 % & pH 3-4

2.
3.
4.
5.

the gauge glass


1 st Starting of BCW pump - B
Sample collection after stopping

6.

BCW pump
Boiler Draining

( run for 5 min) & stop for 30 min

( It Should Take 1 Hr)

PROCESS : Chemical sampling during citric acid injection ,Sampling interval 5


minutes ,Sampling point A ( discharge of fill pump)

Time

Sample no

Sample Result
( 0.2 % )

Remarks

1.
2.
3.
4.
5.

PROCESS : Chemical sampling during citric acid pickling & soaking Sampling
interval 5-10 minutes ,Sampling point B ( discharge of BCW pump)

Time

Note :

Sample
no
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Acid %

Iron Content

Remarks
1 st Starting Of BCW pump for 5 min
Stopping of BCW pump for 30 min
2 nd Starting Of BCW pump for 5 min
Stopping of BCW pump for 30 min
Sampling at 10 min interval
3 rd Starting Of BCW pump for 5 min
Stopping of BCW pump for 30 min
4 th Starting Of BCW pump for 5 min
Stopping of BCW pump for 30 min

Total time allowed for this process is min 4 hrs & max 5 hrs .

Page 25 of 7

PROCESS : BOILER RINSING BY FILLING DM WATER AT 60-70 0 C AFTER CITRIC ACID


SOAKING
Sl
no
1.

Activity

Start

Complete

Time

Time

Remarks

Boiler Filling through Eco/WW/BCW

( It Should Take 1 Hr)

suction manifold up to 100 mm above

Water temp.60-70 0 C

the center line.

Drum pressure to be maintained at


0.5 ksc by regulating the valve
( run for 5 min)

2.

1 st Starting of BCW pump B for 5

3.

min
Collect sample from BCW discharge

4.

hdr.
1 st Boiler Draining

5.

Boiler Filling through Eco/WW/BCW

Under N2 capping 0.5 ksc


( It Should Take 1 Hr)

suction manifold up to 100 mm above

Water temp.60-70 0 C

the center line.

Drum pressure to be maintained at

Sample to be checked for pH it should be


> 4-5
( It Should Take 1 Hr)

0.5 ksc by regulating the valve


( run for 5 min)

6.

2nd Starting of BCW pump B for 5

7.

min
Collect sample from BCW discharge

8.

hdr.
2nd t Boiler Draining

9.

Boiler Filling through Eco/WW/BCW

maintain drum pressure 0.5 ksc


( It Should Take 1 Hr)

suction manifold up to 100 mm above

Water temp.60-70 0 C

the center line.

Drum pressure to be maintained at

> 4-5
( It Should Take 1 Hr)

10.

3rd Starting of BCW pump B for 5

11.

min
Collect sample from BCW discharge

12.

hdr.
3rd Boiler Draining

Time

Sample no

Sample to be checked for pH it should be

0.5 ksc by regulating the valve


( run for 5 min)
Sample to be checked for pH it should be
> 4-5
( It Should Take 1 Hr) maintain drum

Sample Result

Time

Sample no

Iron < 25 ppm


1.
3.
5.

pressure 0.5 ksc


Sample Result
Iron < 25 ppm

2.
4.
6.

Page 26 of 7

PROCESS : NEUTRALISATION OF THE BOILER SYSTEM.

Sl

Activity

no
1.

Boiler Filling through Eco/WW/Suc

( It Should Take 1 Hr)

manifold with neutralizing solution

N2 capping to be maintained at

2.

injection .
After Boiler filled open the drum

3.
4.
5.
6.
7.
8.

vents .
Starting of BCW pump - B
Boiler Light Up
Raising the pressure to 10 ksc
Hold the pressure for 6 hrs .
Blowing off all instruments
Kill the fire after 6 hrs is

9.
10.

complete .
Allow natural cooling of the boiler .
Stop BCW-B after drum metal

11.

temp. is 90 0C .
While draining the boiler back

Start Time

Complete Time

Remarks

0.5 ksc .

( It Should Take 1 Hr)

flushing of the SH with DM water


injected with Hydrazine &
12.

ammonia .
Draining of the boiler with drum
vents open & no N2 capping is
required.

Page 27 of 7

PROCESS : NEUTRALISATION OF THE BOILER SYSTEM.


Sl

Activity

no
1.

Boiler Filling through Eco/WW/Suc

( It Should Take 1 Hr)

manifold with neutralizing solution

N2 capping to be maintained at

2.

injection .
After Boiler filled open the drum

3.
4.
5.
6.
7.
8.

vents .
Starting of BCW pump - B
Boiler Light Up
Raising the pressure to 10 ksc
Hold the pressure for 6 hrs .
Blowing off all instruments
Kill the fire after 6 hrs is

9.
10.

complete .
Allow natural cooling of the boiler .
Stop BCW-B after drum metal

11.

temp. is 90 0C .
While draining the boiler back

Start Time

Complete Time

Remarks

0.5 ksc .

( It Should Take 1 Hr)

flushing of the SH with DM water


injected with Hydrazine &
12.

ammonia .
Draining of the boiler with drum
vents open & no N2 capping is
required.

Page 28 of 7

PROCESS : PASSIVATION OF THE BOILER SYSTEM.


Sl

Activity

Start Time

Complete Time

Remarks

no
1.

Boiler Filling through Eco/WW/Suc

( It Should Take 1 Hr)

manifold with blended solution of

Maintain N2H4 250 p p m

N2H4 & NH3 injection with drum


vent open.
2.
3.
4.
5.
6.

Starting of BCW pump - B


Boiler Light Up at slow rate
Raising the pressure to 40 ksc
Hold the pressure for 24 hrs .
Feed water to boiler should have

7.

N2H4 250 p p m & pH 10


Kill the fire after 24 hrs is complete

8.
9.

& allow slow cooling of the boiler .


Allow natural cooling of the boiler .
Stop BCW-B after drum metal

10.

temp. is 90-95 0C .
Drain the boiler under atmospheric

& pH 10 in the fill water .

Fill up to normal level .

Chemicals to be added to FST


directly through manhole .

No N2 capping is required.

condition .

Page 29 of 7

PROCESS : NEUTRALISATION OF CHEMICALS DRAINED .

Sl
no

CHEMICAL

Draining of chemical
Start
Complete
Time

Time

Neutralisation details
Start
Complete
Time

Time

Neutralisng

Effluent

chemical

result

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

Page 30 of 7

DETAILS OF ACID CLEANING ACTIVITIES


Unit 5 / TSTPP/NTPC /STAGE II /4X500 MW UNITS
Sl

DESCRIPTION

no

Chemical used

Quantity
used

Filling criteria

Boiler light
up required

Pressure

Waiting

/Temp raise

time/approx.

to

time

Completion
criteria.
Drum metal

1.

temp &

Boiler filling with DM water &


lighting up the boiler to raise the

NIL

NIL

temp. To 80 0 C before acid

Only DM
water in 1 hr.

BCW pump
YES

80 C

suction
manifold

injection .

temp. is >
80 0 C

2.
3.

Draining the boiler


Filling of boiler along with acid
injection .

NIL
HCL

NIL

NIL
ACID

NIL

concentratio
n shall be <

DM water rinse after acid


4.

5.
6.
7.
8.

pickling/soaking is completed ( 6
hrs activity) :
Ammoniated citric acid rinse after
DM water rinse :
Demineralised water rinse :
Neutralisation of the boiler
system :
Passivation of boiler :

Page 31 of 7

DETAILS OF ACID CLEANING ACTIVITIES


Unit 4 / TSTPP/NTPC /STAGE II /4X500 MW UNITS
Sl

DESCRIPTION

no

9.

Normal process time

Time of

Time of

Total time

required

start

completion

required

Boiler filling with DM water &


lighting up the boiler to raise the
temp. To 80 0 C before acid

10.
11.

12.

13.
14.
15.
16.

injection .
Draining the boiler
Filling of boiler along with acid
injection .
DM water rinse after acid
pickling/soaking is completed ( 6
hrs activity) :
Ammoniated citric acid rinse after
DM water rinse :
Demineralised water rinse :
Neutralisation of the boiler
system :
Passivation of boiler :

Page 32 of 7

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