M33-Chemical Cleaning of Utility Boiler

LARSEN & TOUBRO
LTD.
O&M POWER
SUBJECT
238.5MW CAPTIVE POWER PLANT

PANIPAT NAPTHA CRAKER PROJECT,
INDIAN OIL CORPORATION LTD.
PMC-EIL
Pre Commissioning Procedure for

Chemical Cleaning of Utility Boiler
DATE:
Page 1 of 24
DOC No.:
6556-EPCC4-52-O-M-0M33
Chemical Cleaning of Utility

Boiler
Procedure No. : LNT/POWER/IOCL/M/CC-UB/COMM
LARSEN & TOUBRO LIMITED

L&T Energy Centre,
Near Channi Jakatnaka
Baroda 390002
________________________________________________________________________________
LARSEN & TOUBRO

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O&M POWER

SUBJECT
Revision
No.

PMC-EIL
Date
Description
Author
DATE:
Page 2 of 24
DOC No.:
6556-EPCC4-52-O-M-0M33
Reviewed By
Approved By
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LTD.
O&M POWER
SUBJECT

PMC-EIL

DATE:
Page 3 of 24
DOC No.:
6556-EPCC4-52-O-M-0M33
Contents
Sr. No.
1
2
3
4
5
6
7
8
9
10
11
12
Title
Cover Page
Revision Status
Contents
Record Of Revision
Chapter -1: Objective
Chapter-2 : Reference
Chapter-3 : Pre-Requisites
Chapter-4 : Precautions and Notes
Chapter-5 : Acceptance Criteria
Chapter-6 : Test Equipment
Chapter-7 : Pre Commissioning Activity Plan
List Of Checklists and Annexures
Page No.
1
2
3
4
5
6
7
8
9
10
12
19
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O&M POWER
SUBJECT

PMC-EIL

DATE:
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DOC No.:
6556-EPCC4-52-O-M-0M33
Revision Record Sheet
Chapter No.
Section No.
Remarks
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O&M POWER
SUBJECT

PMC-EIL

DATE:
Page 5 of 24
DOC No.:
6556-EPCC4-52-O-M-0M33
1.Objective
The objective of this procedure is to provide guidelines for CHEMICAL CLEANING OF
UTILITY BOILER.
Chemical Cleaning of Utility Boiler includes the following activities :
( a ) Preliminary Flushing
( b ) Hot Alkali Flushing
( c ) Inhibited Inorganic Acid Cleaning
( d ) Neutralisation and Passivation
( e ) Final In-Service Passivation
The Chemical Cleaning activity shall be facilitated by the following external equipments
installed temporarily for the cleaning operation.
-
Temporary Tanks ( for mixing the chemicals & preparation of the cleaning solution )
Circulation Pumps ( for transfer of chemicals from the tank to the system piping
which are to be cleaned and circulating the cleaning solution)
External Heat Source (for raising the temperature of the circulating solution during
the cleaning process)
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SUBJECT

PMC-EIL

DATE:
Page 6 of 24
DOC No.:
6556-EPCC4-52-O-M-0M33
2.References
Sr.No
1
2
3
4
5
6
Drawing /Documents
P & ID of BOILER WATER AND
STEAM SYSTEM DRUM AND
FURNACE
OEMs CHEMICAL CLEANING
PRESCRIPTIONS ( ANSALDO )
Applicable Standards and Codes
OEMs O&M Manuals
MSDS of Chemicals
Chemical Cleaning Schemes /
Loops
Diagram No and revision

6556 EPCC4 PI P 52 1B - 1101
6556 EPCC 4 52 1B SPM - 3008
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PMC-EIL

DATE:
Page 7 of 24
DOC No.:
6556-EPCC4-52-O-M-0M33
3.Pre Requisites
Sl.No
1
2
3
6
7
8
9
10
11
12
13
14
Job Description
Remarks
Records
Completion of Civil construction,

Availability of Lighting in UTILITY
BOILER area.
Installation of Equipments, Piping,
Valves and Instruments as per P&I
diagram.
Availability of Electric Power &
Emergency DG Power
Availability of required manpower with
required Tools and Tackles.
Chemists required for analysing samples
taken during various stages of Cleaning
Process.
Availability of P&I Diagrams, GA
Drawings, List of Chemicals & Reagents
and O&M Manuals listed in the
Reference.
Availability of First Fill of Lubricants
required during Start up, PreCommissioning & Commissioning
Provision for proper approach to
equipment.
Preparation of Erection Punch List and
jointly signing of the same.
Availability of Instrument and Service Air
Format III / IV Clearance from EIL /
IOCL
Availability of required DM Water for
flushing and rinsing operations
Installation and Testing of Temporary
Cleaning Circuit including equipments
and associated Piping .
Neutralisation Pit ready for safe disposal
of treated effluents
Availability of Chemicals , Nitrogen , Acid,
Inhibitors , Diesel and other Reagents
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16

PMC-EIL

DATE:
Page 8 of 24
DOC No.:
6556-EPCC4-52-O-M-0M33
required for the Chemical Cleaning

process.
Temporary Laboratory Set up for
analysing the samples taken during the
course of Chemical Cleaning.
Availability of Personnel Protective
Equipments Rubber Gloves , Apron ,
Gum Boots , Safety Goggles , Nose
masks etc.
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PMC-EIL

DATE:
Page 9 of 24
DOC No.:
6556-EPCC4-52-O-M-0M33
4.Precaution and Notes

Sr.No
Pre-cautions
Yes/No
Area under commissioning should be completely tagged and

barricaded and only authorised persons should be permitted to
enter in this area.
To protect personnel and the equipment, barriers, danger signs,

safety tags, area restrictions, etc. should be displayed. A safety
check shall be carried out before pre-commissioning
/commissioning activity.
The equipment should be stopped if unusual sound or excessive

vibration is observed.
Proper communication should be established between the UB

area and the control room.
Prior to the commencement of the Chemical Cleaning of UB ,

equipment and the operational area should be thoroughly cleaned.
Line up of equipment /system (interconnected) & settings are

checked before any trial run/charging to avoid potential safety /fire
hazards/accident to equipment and /or human being arising out of
open connections / blanks, leaks, grounding , inadvertent charging
etc. Removal of Blanks in the piping to / from the equipment shall
be ensured except if specifically required.
Applicable MSDS should be displayed nearby the equipment.
Based on the site conditions, minor changes to the procedure may

be incorporated at site. OEMs Instructions/Guidelines shall be
followed.
Commissioning Engineer
Site Safety In-Charge
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DATE:
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DOC No.:
6556-EPCC4-52-O-M-0M33
5.Acceptance Criteria
Sr.
No
1.
Criteria
(a)
The Chemical Cleaning must be able to achieve :

Removal of organic products used for preservation
(b)
Absence of mud and foreign matter.
(c)
Removal of oxides and scaling from all wetted surfaces of

the boiler.
Formation of a compact and adherent magnetite layer.
(d)
Format
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DATE:
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DOC No.:
6556-EPCC4-52-O-M-0M33
6.Test Equipments
Sr.
No.
Pre Commissioning /
Commissioning tests
1.
Chemical Cleaning
2.
Testing Kit for analyzing samples
Test equipments list
Remark
Instruments Pressure
Gauges , Temperature
Gauges and Flow meters
installed in the Temporary
Cleaning Circuit
PH Meter , Specific
Conductivity Analyser ,
Turbidity meter etc.
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DATE:
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DOC No.:
6556-EPCC4-52-O-M-0M33
7.Pre Commissioning Activity Plan

Inspection
Agent
Sr.
No
Activity
Record
L&T
1.
System Identification , Isolation and Tagging
2.
Safety Precautions
3
3.1
Chemical Cleaning Operations

Flushing
3.2
Hot Alkali Flushing
3.3
Acid Cleaning
3.4
Neutralization and Temporary Passivation
3.5
Final In-service Passivation
3.6
Controls
3.7
Cleanliness Evaluation
Restoration of System
HP - Hold Point.
RW - Review of contractor documents.
Owner/PMC.
WC - 100% inspection by Contractor
Remark
EIL
W- Witness by owner/PMC.
S- Surveillance inspection by
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Sr.
No
1.0
1
2
3
4
5
6
7
8
10
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14
15

PMC-EIL

DATE:
Page 13 of 24
DOC No.:
6556-EPCC4-52-O-M-0M33
Steps to be carried out
Remarks
System Identification , Isolation and Tagging

Identify each system to be cleaned and clearly define the
extent of cleaning.
Prepare Schematic diagrams to define the pre boiler system,
boiler system and piping to be cleaned.
Identify branch lines , bypasses , instrument connections
and parallel circuits of various sizes and configurations.
Design temporary piping to include all system piping and
equipment to be cleaned and flushed.
Establish temporary connections in the pre boiler system to
create a once through system for flushing.
Minimise non flushing area.
Block spring supported piping to prevent spring damage
during chemical cleaning.
Keep dead legs and by pass lengths as short as possible.
Wherever possible , Make provisions to drain or blowdown
legs. Consideration must be given to branch lines and dead
legs to ensure an adequately cleaned system.
After installing all temporary piping and circulation
equipment , the system should be hydrostatically tested at
1.5 times the expected cleaning pressure to identify any
leaks prior to introducing chemicals. Pressurize to identify
any leaks prior to introducing chemicals .
Include all piping to be used to transport solvent and other
chemical agents.
Isolations required to be done on the boiler , removal of
internals of valves , flow meters etc. shall be as per OEM 's
recommendations.
All required preparations and provisions must be done as
follows :
Any permanent flowmeter 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 to be removed.
Instruments in the permanent piping shall be installed after
completion of Cleaning process.
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O&M POWER
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16
17
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2.0
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3.0

PMC-EIL

DATE:
Page 14 of 24
DOC No.:
6556-EPCC4-52-O-M-0M33
Any part of under cleaning circuit and / or piping not

compatible with acid solution must be suitably protected , for
instance by counter filling with DM water
All temporary installation required for Chemical Cleaning
must be erected according to good engineering practice ,
such as sample connections for chemical analysis,
temporary levels , flowmeter and temporary valves, vents
and drains , tanks ,pumps , heaters, instrumentation and all
other necessary equipment
All the required laboratory facilities must be operational and
available.
Safety Precautions
All personnel involved in the cleaning operation must be
informed of all required safety precautions
Provide temporary showers and eyewash stations , if
required , along with other safety equipment.
Schedule the Cleaning Operation in such a way that there
will be no power supply cut during the process.
Adhere to all safety aspects in handling of chemicals during
Chemical cleaning.
Corden off the surrounding area and post appropriate
warning signs.
All required safety procedures must be applied and working
areas must be restricted to operating personnel only.
Note : Considering that once started , Acid Cleaning phase
must continue without interruption until upon the completion
of the same.
Pre Operational Chemical Cleaning
Boiler Chemical Cleaning is required to remove eventual

tube working residuals , oxide formation , due to possible
bad material preservation , oil substances used during
( a ) 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.
Velocities : Successful Cleaning requires solvent velocities
( b ) in the range of 0.2 to 1.2 m/sec through boiler sections
depending on type of acid used.
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(c)
(d)
(e)

PMC-EIL

DATE:
Page 15 of 24
DOC No.:
6556-EPCC4-52-O-M-0M33
Conceptual Design : 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 economiser and furnace waterwall
tubes.
Accomplish the above step by feeding economiser by
external pumping station , cleaning furnace walls by nitrogen
recirculation at downcomers bottom and by solution return to
pumping station.
Provide Flowmeter and valves on the temporary piping to
economiser.
Chemical Cleaning operations
3.1
1
2
3
3.2
1
2
3
4
5
6
7
Flushing
Carry out the Flushing operation just before Chemical
Cleaning
To accomplish an effective Flush , Flow rates should be as
high as possible and circulating pumps shall be used.
Flushing shall be done using DM water and shall be
continued until water going to waste is observed to be clear
and after filtration without appreciable suspended solids
from any boiler section.
Alkaline Cleaning ( Hot Alkali Flushing )
Carry out the Alkaline Cleaning by injecting an alkaline
solution in order to remove oils and rust inhibitors which are
applied to internal tube surfaces.
Prepare an alkaline solution containing 2000 ppm Tri
Sodium Phosphate , 1000 ppm Di Sodium Phosphate and a
compatible wetting agent.
Heat the circulating water to bring its temperature to about
90 deg.C. Heating shall be done by the heating station
placed in the temporary circuit.
Continue the circulation at 90 deg.C for atleast 18 to 24
hours after the alkaline chemicals have been injected.
Perform periodical Checks
When the circulation has been stopped , Displace the
alkaline solution by draining and rinsing with DM water.
Maintain the system in the same condition until acid
cleaning.
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8
3.3
1
2
3
4
5
8
9
10
11
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PMC-EIL

DATE:
Page 16 of 24
DOC No.:
6556-EPCC4-52-O-M-0M33
Note : If several days will elapse before acid cleaning , it is

recommended that ammonia and hydrazine (10 ppm and
200 ppm respectively ) are used in water.
Inhibited Inorganic Acid Cleaning
Carry out the Acid Cleaning to remove oxides , scales ,
siliceous substances from inside the pressure parts.
Acid solution shall be inhibited by suitable and reliable
inhibitor in order to keep the corrosion rate lower than
allowed value.
Establish the rated circulation in the circuit. Control the
solution flow to achieve and maintain suggested velocities in
every section of pressure parts which are under cleaning.
Ensure that the Superheaters backflushing is in operation.
During Cleaning of Economiser and Furnace walls , an extra
circulation may be installed by injection of Nitrogen at
downcomers bottom through installed special nozzles , in
addition to the temporary pumping station.
Maintain the Temperature at specified value during acid
cleaning by very good and uniform warming of all the circuit
under cleaning before chemical injection.
Note : After Chemical injection , it is forbidden to light up
boiler and the only way to heat the circulating solution is by
means of an external heat source (could be thermic fluid
heat exchanger) at very low heating rate, to compensate
heat dispersion.
Inject the required quantity of Corrosion Inhibitor ( Rodine
213 or equivalent) into the system.
Gradually Add Hydrochloric acid and Initiate Circulation of
the solution , Maintain the operating temperature within 60
70 deg.C
Initially , Open all the vents in the cleaning circuit to allow
escape of Hydrogen generated by the acid reaction.
Continue the Circulation for 4 5 hours and Perform
periodic sampling.
Complete the activity when the acid concentration gets
stabilized and Iron content determinations becomes
constant.
Drain the acid solution under Nitrogen blanketing.
Carry out Rinses to wash carefully all sections of the circuit ,
including temporary piping with all involved equipments.
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3.4
1
2
3
4
3.5

PMC-EIL

DATE:
Page 17 of 24
DOC No.:
6556-EPCC4-52-O-M-0M33
Pay special attention to wash and clean by draining and / or

back filling all dead pipes and connections of the circuit by
operating section by section and by checking the resultant
outgoing conductivity.
Neutralization and Temporary Passivation
Carry out the Neutralization of eventual iron and / or acid
traces that could be still in the boiler tubes.
It is performed in two steps as below :
Firstly an acid phase to be obtained 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.
Final In Service Passivation
11
Flush the boiler sections until the effluent conductivity is not

more than 20 S / cm.
Fill the boiler completely (including Superheater) with DM
water added with Hydrazine and Ammonia.
Fire the boiler and Raise the pressure to 5 bar in about 3
hours.
Starting from the pressure of 2 bar , Perform quick
discharges by operating boiler drains.
Check at the end of this operation , the Hydrazine content
should be about 70 100 ppm.
Raise the pressure to 10 bar in about 2 hours , and Perform
the discharges as above.
Maintain the boiler at this value for 3 hours and Note the
Hydrazine content will be about 50 70 ppm.
Operate the boiler in this fashion as shown in the
Passivation Curve (LNT/POWER/IOCL/M/CC-UB/4)
Finally Raise the Pressure to 45 bar in about 3 hours. Note
the hydrazine content will be 1 5 ppm.
This activity completes the Boiler Chemical Cleaning
operation.
Release the boiler for further operation.
3.6
Controls
1
2
3
4
5
6
7
8
9
10
Perform the Checks of the control parameters during the

various stages of chemical Cleaning and Record the
Observations as per
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1
4.0

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DATE:
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DOC No.:
6556-EPCC4-52-O-M-0M33
Cleanliness Evaluation
Carry out the evaluation of the cleanliness degree obtained
by chemical cleaning by direct control of atleast three
representative samples taken from the boiler after the
cleaning operation.
Restoration of System
Restore the Boiler and Preserve the Boiler for further
operation.
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DATE:
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DOC No.:
6556-EPCC4-52-O-M-0M33
List of Check Lists & Annexures

Sl.
No
1.
2.
3.
4.
Description
Check List for
Format
Temporary Chemical
LNT/POWER/IOCL/M/CC
Cleaning of Circuit
-UB/1
Format for recording Data of Chemical
LNT/POWER/IOCL/M/CC
Cleaning of Utility Boiler
-UB/2
Lay out of Temporary Chemical Cleaning
LNT/POWER/IOCL/M/CC
Circuit
-UB/3
Final In service Passivation - Curve
LNT/POWER/IOCL/M/CC
-UB/4
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Pre Commissioning Formats for

Page 20 of 24
Format No. :
L&T/POWER/IOCL/M/CCUB/1
DOC No.:
6556-EPCC4-52-O-M-0M33
CHECK LIST -1
CHECK LIST FOR TEMPORARY CHEMICAL CLEANING CIRCUIT
Sl
No
Description
Result
1.
Check for the installation of temporary

cleaning equipments wit respect to the
cleaning schemes/loops
2.
Check for the cleanliness of the equipment

and associated piping
3.
Check the valves in the system for correct

open/close operation.
4.
Check for the availability of electrical supply

for the temporary circulation pumps
5.
Check if the temporary pumps trial run is

completed
6.
Check if the instruments installed are

calibrated and functionally tested
7.
Check for the installation of special devices

orifices, flowmeters, plugs if any
8.
Check for the availability of list of blanks

installed , if any
9.
Check if the installation is tested for leakage
10.
Check for the provision of sampling points

in the temporary circuit
11.
Check for the provision of proper supports

for the temporary piping
12.
Check if the drains , vents if any are routed

properly to the nearby drains
Tested by
Larsen & Toubro Ltd.
Name:
Witness By
Name:
Name:
Signature
Signature
Signature
Remarks
Witness By
DATE:
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Page 21of 24
Format No. :
DOC No.:
6556-EPCC4-52-O-M-0M33
ANNEXURE 1
FORMAT FOR RECORDING DATA OF UB - CHEMICAL CLEANING
Date
Time
Cleaning
Process
Process Parameter
Item
Value
Chemicals
Used
Flushing
pH
Total Alkalinity
Oil Content
Alkaline
Cleaning
Grease
Content
Temperature
Drum Level
pH
Total Iron
Trivalent Iron
Acid Conc.
Acid
Cleaning
Instantaneous
Velocity
Temperature
Corrosion rate
Inhibitor
Efficiency
pH
Neutralisation Iron
Temperature
pH
Rinses
Conductivity
Final Check
Pickling grade
Tested by
Name:
Witness By
Witness By
Name:
Name:
Signature
Signature
Signature
Quantity
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Page 21of 24
Format No. :
DOC No.:
6556-EPCC4-52-O-M-0M33
Eventual mud
presence
pH
Residual
Hydrazine
Passivation
Filtration
Conservation
Nitrogen
Pressure
Tested by
Name:
Witness By
Witness By
Name:
Name:
Signature
Signature
Signature
DATE:
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Page 23of 24
Format No. :
DOC No.:
6556-EPCC4-52-O-M-0M33
ANNEXURE 2
LAY OUT OF CHEMICAL CLEANING CIRCUIT
Tested by
Name:
Witness By
Witness By
Name:
Name:
Signature
Signature
Signature
DATE:
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Page 24 of 24
Format No. :
DOC No.:
6556-EPCC4-52-O-M-0M33
ANNEXURE 3
FINAL PASSIVATION CURVE
Tested by
Name:
Witness By
Witness By
Name:
Name:
Signature
Signature
Signature

M33-Chemical Cleaning of Utility Boiler

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LARSEN & TOUBRO

238.5MW CAPTIVE POWER PLANT

Pre Commissioning Procedure for

Chemical Cleaning of Utility

LARSEN & TOUBRO LIMITED

LARSEN & TOUBRO

Pre Commissioning Procedure for

238.5MW CAPTIVE POWER PLANT

LARSEN & TOUBRO

238.5MW CAPTIVE POWER PLANT

Pre Commissioning Procedure for

LARSEN & TOUBRO

238.5MW CAPTIVE POWER PLANT

Pre Commissioning Procedure for

Revision Record Sheet

LARSEN & TOUBRO

238.5MW CAPTIVE POWER PLANT

Pre Commissioning Procedure for

LARSEN & TOUBRO

238.5MW CAPTIVE POWER PLANT

Pre Commissioning Procedure for

Diagram No and revision

LARSEN & TOUBRO

238.5MW CAPTIVE POWER PLANT

Pre Commissioning Procedure for

Completion of Civil construction,

LARSEN & TOUBRO

238.5MW CAPTIVE POWER PLANT

Pre Commissioning Procedure for

required for the Chemical Cleaning

LARSEN & TOUBRO

238.5MW CAPTIVE POWER PLANT

Pre Commissioning Procedure for

4.Precaution and Notes

Area under commissioning should be completely tagged and

To protect personnel and the equipment, barriers, danger signs,

The equipment should be stopped if unusual sound or excessive

Proper communication should be established between the UB

Prior to the commencement of the Chemical Cleaning of UB ,

Line up of equipment /system (interconnected) & settings are

Applicable MSDS should be displayed nearby the equipment.

Based on the site conditions, minor changes to the procedure may

Site Safety In-Charge

LARSEN & TOUBRO

238.5MW CAPTIVE POWER PLANT

Pre Commissioning Procedure for

The Chemical Cleaning must be able to achieve :

Absence of mud and foreign matter.

Removal of oxides and scaling from all wetted surfaces of

LARSEN & TOUBRO

238.5MW CAPTIVE POWER PLANT

Pre Commissioning Procedure for

Testing Kit for analyzing samples

Test equipments list

LARSEN & TOUBRO

238.5MW CAPTIVE POWER PLANT

Pre Commissioning Procedure for

7.Pre Commissioning Activity Plan

System Identification , Isolation and Tagging

Chemical Cleaning Operations

Hot Alkali Flushing

Neutralization and Temporary Passivation

Final In-service Passivation