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SSTPS, SINGRAULI.
Post operational chemical cleaning of boiler U#3 started on 16th of April, 2008.
This was actually scheduled to be started on 7th of April. The delay was due to
failure of acid inhibitor Rhodine A 213;Henkel ;Mumbai under laboratory
conditions. Which lead to fresh purchase of Coronil 213 special from Arudra
Engineering (Pvt.) Ltd., Chennai. New acid inhibitor was received on the site on
15th of April.
Before the decision of acid cleaning for boiler U#3 was taken, deposit analysis
was carried out in detail at NTPC R & D Center. Findings of R&D and method
of acid cleaning for boiler U#3 was given as follows:-
Introduction:
Internal deposit quantity of water wall tubes of boiler #3 was carried out in R &
D lab. It shows that the presence of 51-64 gm/cm2 on the hot surfaces and 37-47
mg/cm2 on the cold side of surfaces. Platen water wall tubes contain the internal
deposit quantity 161 mg/cm2 at lower side and 48 gm/cm2 at upper side of the
tube Internal deposit analysis consist of Copper 4.5-5.3%, Calcium 2.1-7.7%
and Silica 0.7-0.9% along with Iron oxide. On the basis of internal quantity and
analysis, single stage post operational chemical cleaning is recommended. The
experiments were conducted in laboratory to finalize the chemical cleaning
process. The procedure for chemical cleaning includes the following steps.
1. Alkali Boilout
2. Acid Pickling
3. Neutralization
4. Passivation
1.
Alkali Boilout:
2.
Back flush the super heater with DM water and backfill with treated water
containing 200 ppm hydrazine and ammonia to raise the pH > 10. Plug the super
heater connecting tubes inside the drum. Raise the pressure to 4-5 Kg/cm2 and
isolate super heater.
Suspend the water wall tube sample coupons inside the drum at both the end to
ascertain efficiency of cleaning and passivation before cutting of actual tube
from boiler.
3.
Fill the system with DM water and establish circulation by pumps. Circulate for
about an hour and drain.
4.
Fill the system with DM water and establish circulation by pumps. Raise the
temperature of water to 55-600 C by passing the steam in circulating tank and
drain after circulation of half an hour.
5.
Acid Pickling:
0.25 % (w/v)
3. Thiourea
1.0 % (w/v)
4. Hydrochloric acid
5.0 % (w/v)
Fill the boiler system with DM water and establish circulation with circulation
pumps. Admit steam into mixing tank and raise the temperature of circulating
water to about 65-700 C in return line. Cut off steam and add a small quantity of
HCl and immediately followed by required quantity of acid inhibitor. Keep the
pumps running for thorough mixing. Charge calculated quantity of ammonium
bifluoride in the mixing tank slowly and circulate the system for complete
mixing of chemicals. Add required quantity of HCl in controlled manner so that
acid concentration does not increase more than 6%. Acid concentration is to be
measured at n interval of 10 minutes while the acid is being added. Analyze the
sample from inlet and return line for acid concentration, iron and copper. The
circulation will be terminated once the steady values of iron, copper and acid are
obtained in both inlet and return line or maximum six hours after addition of
chemicals. Drain the system under N2 capping.
6.
DM Water Rinse:
Fill the boiler system with DM water and establish circulation with circulation
pumps. Raise the temperature of circulating water up to 50-60 0 C by injecting
steam and circulate for 30 minutes. Drain the system under N2 capping.
7.
Fill the boiler system with DM water and establish circulation. Raise the
temperature of circulating water up to 50-55 0 C and add 0.2% (w/v) citric acid.
Add liquor ammonia to raise the pH of circulating water to 3.5- 4.0. Circulate for
2 hours. Measure the pH and iron content in the solution at an interval of an
hour. Drain the system under N2 capping.
8.
Fill the boiler system with DM water and establish circulation. Raise the
temperature of circulating water up to 50-550 C and circulate an hour. Measure
the iron content in the inlet and return line. Drain the system under N2 capping.
9.
Fill the boiler system with DM water and establish circulation. Raise the
temperature of circulating water up to 50-55 0 C and circulate an hour. Drain
the system under N2 capping. After measuring the iron content in the inlet and
return line.
11.
Passivation stage I:
Fill the boiler system with DM water and establish circulation. Add hydrazine to
get the concentration of hydrazine from 400- 500 ppm and add ammonia solution
to raise the pH up to 10.0. Raise the temperature of circulating water up to 80900 C by addition of steam circulate for 20 hours. Measure the hydrazine
concentration and pH of circulating water periodically. Add hydrazine into
solution when concentration goes below 200 ppm. Drain the system in hot
condition. Open vent, drum manholes and cut bottom ring headers stubs to cool
down the system in aerated condition.
12.
Restore the boiler after chemical cleaning by putting drum internal and all the
permanent connection. Prepare the boiler for regular operation as per the
guidelines of O&M. Fill the boiler with DM water containing 200 ppm of
hydrazine and ammonia to raise pH 10.0. Light up the boiler and raise the
pressure to 40 Kg/cm2 and maintain the pressure for 24 hours. During the
process, inject hydrazine in the feed water to maintain hydrazine concentration
25 ppm. After completion of II stage passivation, the boiler can be taken for
regular operation.
13.
Effluent Treatment:
The effluent generated after each stage of acid pickling will be treated with
caustic soda flakes or caustic lye to a pH level from 5.5- 8.0 before discharging
from plant. The effluent after first stage passivation will be treated with
bleaching powder.
14.
A neutralization pit should be made available near the site with the holding
capacity of around 400 M3. The pit should have non-corrosive lining, circulating
and discharging pumps capacity.
15.
Drum manhole should be opened and visually inspected the drum internal
surface and water wall coupons placed in the drum for smooth uniform formation
of magnetite coating and effectiveness of cleaning. Arrangement should be made
to cut the water wall tube samples from high heat affected area after chemical
cleaning to calculate quantity of deposit on the internal surface, if any.
Check points
Lighting
Arrangement for testing table
Shifting of testing apparatus
Stocking of chemicals
Arrangement of PPEs
N2 Cylinder Procurement and stocking at site
Arrangement of showers
Washing hose
Presence of Doctors
Ambulance
Air hose
Acid unloading hose
Acid tanker arrangement
Circulation tank and piping leakage testing
Readiness of N Pit
Responsibility
EMD
Chem
Chem
Chem
BMD/Chem
BMD
BMD
BMD
S K Roy/G K Nayak
BMD
BMD
BMD
Chem
BMD
Chem
16
17
EMD/OMD
BMD/IT
= Titre value x 80
= (X-Y) x 80
= Titre Value x 80
Event details:
As per R&D recommendation alkali boil out was not done.
Day 1: 14/04/2008
Time
1st batch
16:40
16:45
16:55
17:00
5
6
-
17:35
17:50
18:05
18:10
18:20
Filling started
2nd batch
Filling started
3rd batch
Filling started
4th batch
Filling started
5th batch
Filling started
Addition of Chemicals
Hydrazine
Ammonia
(In Liters)
(In Liters)
pH
5
5
-
10.2
10.2
216
416
1
3
5
-
1
1
1
-
10.2
10.0
10.0
314
232
336
432
19:00
19:05
19:10
10
-
10
-
10.3
-
448
-
19:40
20:00
20:05
10
-
10
-
10.2
-
464
-
20:40
20:50
21:10
10
-
10
-
10.2
-
496
-
6th batch
Filling started
7th batch
Filling started
8th batch
Filling started
9th batch
Filling started
10th batch
Filling started
21:40
21:55
22:00
10
-
10
-
10.2
-
480
-
22:40
22:50
22:55
10
-
10
-
10.2
-
504
-
23:45
00:00
00:05
10
-
10
-
10.2
-
480
-
00:50
01:10
01:15
10
-
10
-
10.2
10.2
488
488
02:05
02:15
02:20
10
-
10
-
10.2
-
480
-
03:35
10.0
(In SH
vent
sample)
-
376
(In SH vent sample)
04:05
04:20
5
(For
Pressurization)
Pressure at bottom end = 10.8 Kg/cm2 and at SH top = 6.0 Kg/cm2.
105 Liters
93 Liters
Day 2: 15-04-08
o Two acid tankers (29.5 MT) arrived
o Boiler water under recirculation while heating with steam continued.
Time
Temperature ( 0C)
Turbidity
I/L
16:50
17:30
18:30
19:00
19:30
20:00
20:30
21:00
22:00
22:30
23:00
23:30
00:00
00:30
01:00
01:30
40
45
52
65
72
80
72
62
70
78
75
75
81
83
Steam line isolated
O/L
O/L
40
40
40
40
40
40
48
50
50
52
59
62
3.0
-
Day 3: 16-04-08
o Third acid tanker could not reach before 16.30 hrs leading to late
start.
o Drain (equal to three volumes of mixing tank) started at 15:15 hrs
o Chemical addition
started at 17.00 hrs
30 liter HCl + 420 liters Coronil 213 special added at 17:00 hrs
500 Kg Ammonium bifluoride added at 17:30 hrs
2000 Kg Thiourea added at 17:45 hrs
completed at 18:20 hrs
Unloading of acid tanker
First:
Started on 18:30 hrs
Completed on 19:30 hrs
Qty: 14.5 MT
Second:
Started at 19:45 hrs
HCl (%)
Iron (ppm)
I/L
O/L
Cu (ppm)
I/L
O/L
I/L
O/L
Chemical addition started
1.46
4.28
0.108
4.57
1.0
3351
4.3
1.9
4635
5138
1134
4.5
3.7
3462
4244
2931
4.7
4.6
5138
4244
2331
4.5
4.5
6925
7372
3654
3.9
3.88
7260
7986
3654
Boiler drain started followed with N2 capping (17/04/08)
Boiler drain completed
Day 4:17-04-08
Temp
pH
1006
2268
2520
3150
3276
3087
I/L
O/L
I/L
O/L
Draining completed and system filling started with DM water
System filling completed and kept under recirculation
55.7
46.6
1.9
1.7
59.7
49.1
1.94
1.91
DM Water draining started followed by N2 capping
Draining completed
01:20
04:40
05:00
06:00
06:50
08:45
10:30
10:35
10:40
10:45
10:50
10:55
11:00
11:05
11:15
11:20
11:30
11:35
11:40
11:50
12:05
12:30
12:40
pH
I/L
2.3
3.1
5.3
8.36
8.57
7.8
5.3
3.0
7.9
2.58
7.14
3.0
5.25
4.6
3.9
O/L
2.0
2.9
2.4
2.07
2.2
2.2
2.3
2.6
2.25
2.0
2.1
2.06
2.72
3.99
3.8
Temp.
I/L
65
80
-
O/L
48
50
-
Citric Acid
Conc.
(%)
I/L
O/L
0.0384 0.0077
0.041
0.015
-
Total Iron
(ppm)
I/L
72.8
-
Ammonia
Addition
(in Liter)
O/L
112
-
40
30
30
65
70
70
-
14:00 4.5
4.7
14:05 Draining started under N2 capping
15:00 Draining completed
151
207
305 Liters
Temp
I/L
O/L
pH
I/L
O/L
Iron
I/L
O/L
16.8
33
28
72
DM Water Circulation cum Neutralization :o Soda Ash 2000 kg was charged at 00:35 hrs
Time
20:10
22:00
23:00
00:30
00:35
01:00
Temp. (0C)
I/L
O/L
pH
I/L
O/L
Iron
I/L
O/L
22.4
22.4
33.6
11.2
03:30
04:45
05:00
06:45
07:30
09:30
85
60
10.8
10.8
84
62
10.8
10.8
83
62
10.8
10.8
82
66
10.8
10.8
Draining started without N2 capping
Draining Completed
Temp. (0C)
I/L
O/L
System filling started
62
49
55
49
55
50
55
50
50
50
50
47
49
46
69
48
Passivation Stage-I :-
pH
I/L
O/L
9.6
9.8
9.8
9.8
9.8
9.5
9.2
8.6
8.2
7.6
7.2
8.8
9.3
9.8
10.0
10.0
9.9
9.8
9.7
9.7
9.4
9.3
9.2
8.4
9.1
9.0
Time
Chemical
Addition
(In Liters)
Temp.
pH
Hydrazine Conc.
(ppm)
17:00
18:00
18:30
19:00
19:35
20:00
21:00
22:00
23:00
00:00
(19/05/08)
01:00
02:00
03:00
04:00
05:00
06:00
07:00
08:00
09:00
10:00
11:00
11:05
12:00
13:10
13:30
14:00
14:45
15:10
16:00
16:05
17:00
17:40
17:40
17:45
18:45
19:30
Ammo
350
105
155
-
Hyd
200
-
I/L
74
84
85
90
85
90
91
O/L
50
62
67
72
75
78
79
I/L
9.5
9.3
10.06
10.2
10.2
10.18
10.18
O/L
9.5
9.4
10.0
10.2
10.18
10.16
10.17
90
80
10.16
10.15
92
82
10.17
10.17
93
83
10.17
10.17
93
83
10.18
10.18
94
83
10.18
10.18
70
10
94
81
10.28
10.28
93
83
10.30
10.29
94
83
10.20
10.10
50
85
81
10.20
10.10
89
82
10.22
10.16
70
20
89
81
10.25
10.18
90
81
10.24
10.27
84
77
10.10
10.12
91
80
89
80
10.06
10.14
70
10
91
79
10.03
10.02
89
79
10.03
10.06
105
87
78
10.0
9.98
88
78
9.9
9.8
Recirculation stopped (Stage-I passivation completed)
Drain started
Drain of water circuit completed
SH drain started
I/L
584
376
360
392
360
352
352
O/L
880
456
384
400
368
352
352
336
336
328
320
320
320
352
336
320
304
560
468
304
320
344
320
328
336
328
336
328
320
320
320
360
352
336
320
336
440
344
336
336
320
344
340
975 Liters
240 Liters
Day 7: 29-04-08
Passivation Stage-II:
o Deaerator chemical addition
Hydrazine =
200 Liter
Ammonia =
250 Liter
Day 8-9: 30-04-08 to 01-05-08
o Boiler light up at 10:30 hrs (30/04/2008)
Time
Chemical
Addition
(Liters)
Feed
BW
FST
Remarks
N2H4
NH3
pH
N2H4
(ppm)
pH
N2H4
(ppm)
pH
N2H4
(ppm)
11:00
12:00
12:30
50
35
10.5
10.5
-
240
230
-
10.2
-
176
-
10.5
10.5
-
80
152
-
13:00
13:30
14:30
16:00
50
35
10.5
10.2
-
240
32
-
10.5
10.2
-
210
26
-
10.5
-
150
-
16:30
17:00
18:00
19:00
20:00
10
60
10.5
10.2
-
80
25
-
10.1
10.2
10.2
-
24
32
28
-
10.2
-
128
-
21:15
22:30
00:30
30
30
10.2
10.2
10.5
38
40
64
10.2
10.2
10.2
32
28
32
02:30
30
10.2
56
10.2
28
04:30
06:30
07:00
08:15
08:30
09:15
09:30
10:15
10:30
11:00
11:45
40
50
20
30
50
20
10.5
10.5
10.3
70
64
57
10.2
10.2
10.2
28
28
28
10.3
10.3
10.2
-
57
56
56
-
10.2
10.2
10.2
-
30
28
198
-
12:15
12:45
01:00
01:30
35
-
10.2
10.2
10.2
57
56
56
10.2
10.2
10.2
39
32
28
02:10
(01/04/08)
Chemical
Hydrazine
(Ltr)
Ammonia
(Ltr)
105
93
SH Filling
Acid
Cleaning
32
420
Citric Acid
305
Neutralization
Passivation- I
PassivationII
240
S.No.
1
Process
Total Amount
HCl
(MT)
Coronil
(Ltr)
Thiourea
(Kg)
ABF
(Kg)
Citric
Acid(Kg)
Soda
Ash (Kg)
2000
500
400
2000
975
707
320
1050
1693
32
420
2000
500
400
2000