ACID CLEANING : CFBC BOILER No # 3

Step – 1
After done the complete mechanical arrangements , the system will fill up with DM water and start
steam purging for maintain the temperature upto 60 deg of the cleaning solution.

Step – 2
After acheiving the 60 Deg temperature of the recirculating cleaning water solution , start adding
the chemical as listed below:
The volume of cleaning solution is approximately 105 – 110 M3
Corroban (Corrosion Inhibitor) – 210 Kgs ( 2 % of the Volume of cleaning solution)
Hcl Acid – 19 MT : to maintain the 5% Hcl strength of the solution

After the 1 Hrs circulation the parameters of circulating cleaning solution are:
Iron – 2140 ppm
Silica – 111 ppm
Calcium Hardness - < 1.0 ppm
Temp of the solution is 60 Deg C.

Step – 3
After 4 Hrs circulation , adding 105 Kgs Ammonium Bi Flouride (1% of the Volume of cleaning
solution). On that time the parameters of circulating cleaning solution is
Iron – 7680 ppm
SiO2 – 286 ppm
Cacium Hardness - < 1.0 ppm
Temp of the solution is 60 Deg C.

Step – 4
After the 6 Hrs circulation the parameters of circulating cleaning solution are:
Iron – 8740 ppm
Silica – 248 ppm
Calcium Hardness - < 1.0 ppm
Temp of the solution is 60 Deg C.

Step – 5
After the 7 Hrs circulation the parameters of the circulating cleaning solution almost same. Thus the
circulation will be stopped and start it to drained out. The drained acid solution is neutralzed with
lime & caustic Soda lye.
Qty of Lime – 5 MT
Caustic soda lye – 2 MT (48%)

Step – 6
After complete drained out of the cleaning solution, the nitrogen purging will start to complete
flushed out.

Step – 7
After the completion of nitrogen flushing , the system will again flush out with DM water.

Step – 8
After the 12 Hrs flushing with DM water, the flushing will stopped. Againg system will
completelety drained out and fill with fresh DM water for start up the mild cleaning process.
Step – 9
Start the mild cleaning process.

Step – 10
Increase the temperature of recirculating cleaning solution with steam upto 60 Deg. Adding the
chemicals as listed below:
Citric Acid – 850 Kgs (0.8 % of the Volume of cleaning solution)
Corrosion Inhitor – 30 Kgs

Step – 11
After 3 Hrs circulation , adding the following chemings for creating the soft passivation layer of
nitrite.
Anhydrous Ammonia – 210 Kgs (2% of the volume of cleaning solution)
Sodium Nitrite – 550 Kgs (0.5 % of the volume of Cleaning solution)
Temp of the solution is 60 Deg C.

Step – 12
After 8 Hrs circulation with ammonia & Sodium nitrite, the 1st the circulation is stop & start
flushing with DM water.

Step – 13
The flushing will be stopped after 3 Hrs & the system is completely drained out. The process of
mild cleaning is now complete & ready for passivation with Hydrazine & Ammonia after physical
inspection of boiler.

Step – 14
After the physical inspection of boiler, all the temporary arrangements & piping is removed & done
the as it is original. Again the system is fill up by DM water for hydro test.

Step – 15
After the Hydro test, the boiler is ready for 2nd stage passivation with hydrazine & ammonia.

Step – 16
Added the following quantities of Hydrazine hydrate & Ammonia in boiler drum to maintain upto
200 ppm of hydrazine level in 2nd Stage passivation. Start the lite up process build up the
temperature & pressure upto 40 Kgs of the boiler.
Hydrazine hydrate – 22 Kgs (0.2 % of the volume of system)
Ammonia – 22 Ltrs (0.2 % of the volume of system)

Step – 17
After 4-5 hrs under the 40 Kg/Cm2 pressure , the fire is kill out & the pressure is reduced upto 20
Kg/Cm2 for 16 Hrs. Thus the 2nd stage passivation is completely done.

Step – 18
After the 2nd stage passivation the boiler is completely drained out & it is ready for regular normal
operation.