Boiler Chemical Cleaning

Bharat Heavy Electricals Limited
Power Sector: Technical Services

Advance Techniques in Boiler Chemical Cleaning
Chemical Cleaning of Boilers with EDTA
1
By:
HC Madan
SS Chauhan
Dhruv Garg
Agenda
Need for Chemical Cleaning of Boilers
1
What is EDTA Cleaning?
BHELs Experience with EDTA Cleaning
EDTA Cleaning Process
EDTA vis--vis HCl Cleaning Advantages
2
3
4
5
6
Conclusion
2
Need for Chemical Cleaning of Boilers
Need for Chemical Cleaning of Boilers?
4
Pre-operative
Maintaining steam quality at the turbine inlet.
Minimizing corrosion of the metal surface of
boiler.
Post-operative
Improving heat transfer in the system.
Enhancing efficiency of the power plant.
Minimizing under-deposit corrosion of the metal
surface of boiler.
Minimizing plant outage due to boiler tube
failures.
Pre-operative Chemical Cleaning System
Evaporator System
Economizer
Downcomers
Bottom Ring Headers
Water Walls
Boiler Drum (Only water touched surface)
5
6
Iron metal surface with corrosion layers
What is EDTA Cleaning?
7
8
What is EDTA?
EDTA or Ethylene Di-amine Tetra acetic Acid is a strong
chelating agent having ability to form stable complexes
with transition metal ions present in boiler such as of Iron
and Copper etc.
EDTA and EDTA-Fe Complex Structure
9
EDTA EDTA-Fe Complex
EDTA Pickling & its Reaction
10
Magnetite Layer
11
A protective layer of Magnetite (Fe
3
O
4
) is formed
on the water touched metal surfaces in the
steam generator.
Magnetite layer acts as a coherent media that
stops further corrosion of the base metal.
Magnetite is a combination of FeO and Fe
2
O
3
.
BHELs Experience with EDTA Cleaning
12
13
EDTA process is at present executed by :
Dow chemical Co USA
Halliburton Services UK
Alstom, MHI, & Siemens
Process details & chemical formulations
especially inhibitor for the process are being
held under proprietary rights by these
companies.
EDTA Process - World Scenario
14
BHEL has joined the select band of few
companies in the world to possess &
establish this advanced cleaning process.
BHEL has marked the giant leap by
developing its own inhibitors and chemical
formulations for EDTA Cleaning Process.
EDTA Process - World Scenario
15
EDTA Process developed by R&D Centre of
BHEL-Trichy; involved in-house development of
inhibitors:
BHEL MAX
BHEL SOL
These inhibitors are patented by BHEL:
Patent Nos.: 177 & 332 / 2004
These inhibitors act by forming an invariable
layer between the base metal surface and the
chemical solution as the deposits are removed.
Inhibitors
16
EDTA Cleaning Process was introduced in BHEL in
2003-2004.
Chemical cleaning of boilers with EDTA completed in 43
projects of different ratings, till Feb 2009.
Year No. of Projects
2003 2004 1
2004 2005 3
2005 2006 3
2006 2007 7
2007 - 2008 13
2008 - 2009 16
Total 43
Experience with EDTA Cleaning
17
Experience with EDTA Cleaning
Rating No. of Projects
500 MW 4
250 MW 22
210 MW 9
75 / 120 / 125 MW 8
Total 43
Rating wise
2003-04 to 2008-09 (upto Feb 2009)
18
Exceptions during reigns of EDTA Process
Besides EDTA Cleaning, BHEL has also conducted HCl
cleaning at following 7 projects during the same period.
Rihand # 4 (500 MW)
Vindhyachal # 9 (500 MW)
Vindhyachal # 10 (500 MW)
Sipat # 4 (500 MW)
Sipat # 5 (500 MW)
Kahalgaon # 6 (500 MW)
Kahalgaon # 7 (500 MW)
19
Projects expected in 2009-10
Rating No. of Projects
500 MW 9
250 MW 11
210 MW 1
125 MW 6
Total 27
20
21
Alkali Flushing
Alkali Flushing
Hot Water Flushing
Cold Water Rinse
EDTA Cleaning
EDTA Pickling & Passivation
Treated DM Water Rinsing
Inspection
SH Back Flushing
22
Alkali Flushing - Purpose
Alkali Flushing
Removes polar organic materials such as oil,
grease etc. from the metal surface.
Alkali reacts with polar organic materials to form
soluble glycerols and salts.
Loose deposits, dust etc. are also removed.
TSP and DSP is used as alkali.
Hot Water Flushing
Cold Water Rinse
23
Alkali Flushing- Procedure
Alkali Flushing
Alkali solution made by adding TSP(0.1%) & DSP
(0.05%) with DM water.
Solution is filled into boiler through bottom ring
header & economizer drains up to NWL.
Boiler is fired. Water temperature is raised to 140C
and boiler tripped.
Solution is allowed to cool till 95C and then drained.
24
Alkali Flushing- Procedure (Contd..)
Hot Water Flushing
System is filled with DM water and temperature
raised to 1400C and allowed to cool to 950C and
drained subsequently.
Cold Water Rinse
System is filled with DM water and drained. The
process is repeated till phosphate level is less than
10 ppm.
25
Preparing EDTA Solution
EDTA solution is prepared for total boiler volume by
mixing.
1.EDTA Ammoniated (40%) : 4%
2.BHEL MAX (inhibitor) : 0.15-0.2% w/v
3.BHEL SOL (inhibitor) : 0.15-0.2% v/v
4.Hydrazine hydrate : 1000 ppm
5.Ammonia : for setting pH as 9.5-9.8
26
EDTA Pickling and Passivation
The system is filled with EDTA solution upto drum NWL
The boiler is lighted up and temperature raised to 140
0
C
and maintained for 4 hours and sample solution
checked for iron, pH and EDTA concentration every
an hour.
The boiler is tripped on achieving 3 consecutive
readings of iron concentration.
The solution is allowed to cool till 95
0
C and drained.
27
Treated DM Water Rinsing
A solution of hydrazine (0.01-0.02%) and ammonia
with DM water is prepared (pH 9.5 9.8) and the
system is filled with this solution.
Boiler is fired and temperature raised to 120C.
Boiler is tripped and allowed to cool. When the
temperature comes down to 95C, the solution is
drained.
28
Inspection
Boiler drum
Bottom ring headers
Water wall tubes
Super heater back flushing
Super heater is filled with a solution of hydrazine
(N
2
H
4
>50 ppm) & Ammonia (pH>9.5) in DM water
through SH drain header. When the solution comes
through SH openings in the drum, the back flushing is
continued for 10-30 minutes and drained.
29
EDTA Cleaning Results
30
31
EDTA vis--vis HCl Cleaning-Advantages
32
33
EDTA vis--vis HCl CleaningAdvantages
HCl Cleaning Process
Preliminary Cleaning Alkali Cleaning
Hot Water Flushing
Alkali Boil-out
Cold Water Rinsing
Acid Cleaning
HCl Cleaning
DM Water Rinsing
Citric Acid Rinsing
DM Water Rinsing
Neutralization
Passivation (1
st
and 2
nd
Stage)
Inspection
34
EDTA vis--vis HCl CleaningAdvantages
Disadvantages of HCl Cleaning Process
Lot of temporary piping required.
More number of chemicals (12 Nos.) required.
Nitrogen gas in huge volume & its piping system required.
Auxiliary steam required in huge quantity, which is a problem in
green field projects.
DM water and fuel consumption is very high.
Process handling is difficult and hazardous due to corrosive nature
of chemicals.
Large cycle time (17 days).
Effluent treatment & disposal requires huge investments.
35
EDTA Cleaning Advantages
Technological advantages
EDTA is a strong chelating agent with transition metal ions
and hence has an efficient action as metal remover.
Process advantages
Use of Nitrogen & its system is eliminated.
Auxiliary steam is not required at all.
DM water and fuel consumption is less.
Shorter cycle time (5 days).
36
EDTA Cleaning Advantages
Process advantages (contd.)
Less temporary piping required
Less number of chemicals required.
Ease of handling.
Effluent treatment easy.
Other advantages
Economical.
Conclusion
37
38
EDTA cleaning process ensures efficient cleaning and
passivation of boiler internal surfaces.
Inhibitor for EDTA cleaning process being used has been
developed by BHEL. Inhibitors are patented as BHEL
MAX and BHEL SOL.
EDTA Cleaning has obvious advantages over conventional
HCl Cleaning with minimum effect on the base metal
surface.
Conclusion
Thank you
39

Boiler Chemical Cleaning

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Power Sector: Technical Services

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