POST OPERATIONAL CHEMICAL CLEANING OF BOILER #3

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:

To dislodge / loosening of hard, adherent deposit on the internal surfaces of tube,

alkali boilout is recommended with use of Trisodium phosphate (1000 ppm) and
Disodium phosphate (500 ppm) at minimum ¼ of operating pressure of boiler.
Before the alkali boilout, the boiler drum is cleaned mechanically. All the boiler
instruments leads and sampling lines should be isolated except the drum
sampling line and direct reading level of gauge glass.
Boiler is filled with DM water and subsequently drained to remove any
suspended matter present in the boiler. Boiler is again filled with DM water up to
the bottom level of the drum. The required chemicals are charged in the form of
concentrated solution through drum manhole.
Boiler is lighted up as per the O&M instructions and pressure is raised gradually
up to ¼ of operating pressure. During entire process, normal drum level is to be
maintained to avoid any possibility of carryover in the supper heater. Once the
pressure is attained, held for two hours and blow down is given by operating the
low point drains in sequence each for 30 seconds, after the fire is put out. After
completion of blowing operation, the above process of raising pressure, holding
pressure and blow downs are repeated for six times.
During the process , the samples are analyzed for pH and alkalinity
measurement. The boiler is allowed to cool down gradually. When the drum
pressure drops to 2 Kg/cm2, the entire system is drained hot. On completion of
total draining, the boiler is washed with DM water till the drain sample is free
from phosphate.
After completion of alkali boilout process, the boiler is to be prepared for acid
cleaning which includes the water walls, economizer, drum, down comers and
low point drains. The erection of temporary piping, valves, fittings, circulation
tanks and pump should be completed. The drum internal should be removed and
orifice plate should be installed for all down comers. Plugging the connecting
tubes in main drum should isolate the super heaters.
2. Super Heater Filling:

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. Cold Water Rinse:

Fill the system with DM water and establish circulation by pumps. Circulate for
about ½ an hour and drain.

4. Hot water drain:

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:

The following chemicals are required for acid pickling stage:

1. Acid inhibitor 0.20 % (v/v)
2. Ammonium bifluoride: 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. Citric Acid Rinse:

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 ½ an
hour. Drain the system under N2 capping.

8. Ist DM Water Rinse:

Fill the boiler system with DM water and establish circulation. Raise the
temperature of circulating water up to 50-550 C and circulate ½ an hour. Measure
the iron content in the inlet and return line. Drain the system under N2 capping.

9. IInd DM Water Rinse:

Fill the boiler system with DM water and establish circulation. Raise the
temperature of circulating water up to 50-55 0 C and circulate ½ 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 80-
900 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. Passivation stage – II:

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. Effluent neutralization pit:

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. Inspection of boiler after chemical cleaning:

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.

Actual commencement and follow up:

Check list:-
A check list was prepared with certain check points so as to ensure and assign
various responsibilities to concerned departments.

S.No. Check points Responsibility

01 Lighting EMD
02 Arrangement for testing table Chem
03 Shifting of testing apparatus Chem
04 Stocking of chemicals Chem
05 Arrangement of PPEs BMD/Chem
06 N2 Cylinder Procurement and stocking at site BMD
07 Arrangement of showers BMD
08 Washing hose BMD
09 Presence of Doctors S K Roy/G K Nayak
10 Ambulance BMD
11 Air hose BMD
12 Acid unloading hose BMD
13 Acid tanker arrangement Chem
14 Circulation tank and piping leakage testing BMD
15 Readiness of N Pit Chem
16 Making both KSB ready EMD/OMD
17 One telephone near circulation tank BMD/IT

Details of procedure for chemical analysis :

DETERMINATION OF HCL CONCENTRATION IN PICKLING

SOLUTION :-

REAGENTS -
A.Sodium hydroxide solution , Standard 1.0 N

B.Mixed Indicator

Three parts of Bromo cresol green (0.1 % solution in

alchohol)

One part of Methyl Red (0.2% solution in alchohol)

PROCEDURE-

a. 10 ml of sample

b. 2-3 drops of methyl red indicator

c. Titrate with 1.0 N NaOH solution.

d. End point from grey to blue- green.

CALCULATION –

% HCl = V x 0.36
Where V = Milliliters of 1.0 N NaOH used to obtain end point.
ESTIMATION OF HYDRAZINE:- (Method no. 1)

REAGENTS-
A. Standard 0.1 N Potassium Bromate
(Dissolve 2.7836 g of KBrO3 and 10 g of KBr in DM water and
make up to 1 Litre)
B. 0.1% Methyl Red indicator solution.
C. Conc. HCl Sp. Gr. 1.18

PROCEDURE-

a. 10 ml of sample.
b. Add 10 ml conc. HCl
c. 5-6 drops of methyl red indicator solution.
d. Titrate with standard 0.1N KBrO3 solution.
e. End point yellow colour.

CALCULATION-

Hydrazine as N2H4 (ppm) = Titre value x 80

HYDRAZINE ESTIMATION:- (Method no. 2)

REAGENTS-

a. 0.1N Na2S2O3 ( 24.822 g of Na2S2O3 .5H2O in 1.0 Litre)

b. 0.1 N Iodine solution (12.692 g of I2 + 20 g of KI in 1.0 Litre)
c. 1.0% solution of Starch (1.0 g of starch in 100 ml)
d. 2.0 N NaOH (80.02 g of NaOH in 1.0 Litre)
e. 2.0 N H2SO4 (98 g in 1.0 Litre)
PROCEDURE-
a. 10 ml sample + 100 ml DM water
b. 2.0 ml 2.0 N NaOH + 0.1 N Iodine
c. Stopper the flask + Settle for 3 minutes.
d. Add 2.5 ml of H2SO4 + starch indicator
e. Titrate with 0.1 N Thio (Record end point as ‘Y’)
f. Carry out a blank experiment taking 100 ml DM water only.
(Record end point as ‘X’)

CALCULATION-
Hydrazine as N2H4 (ppm) = (X-Y) x 80

HYDRAZINE ESTIMATION:- (Method no. 3)

REAGENTS-

a. Sodium bicarbonate
b. 0.1 N Iodine Solution
c. Starch Indicator

PROCEDURE-
a. 10 ml sample+ 25 ml DM water
b. Add a pinch of NaHCO3 + starch Indicator
c. Titrate against 0.1 N Iodine Solution.
d. End point gives blue colouration.

Hydrazine as N2H4 (ppm) = Titre Value x 80

CITRIC ACID ESTIMATION:-

REAGENTS-

a. 0.1 N Standard NaOH solution.

b. Mixed indicator solution
c. Phenolphthalein solution

PROCEDURE-

a. 50 ml sample
b. 4-5 drops of mixed indicator
c. Titrate with 0.1 NaOH
d. End point colour changes from red through gray to blue green
(Record the volume A)
e. Take another sample
f. Add 4 drops of phenolphthalein indicator.
g. Titrate again with 0.1 N NaOH
h. End point colour changes to pink colour(Record the volume B)
CALCULATION-

% Citric Acid = (B-A) x 0.0128

ESTIMATION OF ALKALINITY:-

REAGENTS-

1. 0.1 M HCl acid (Standard): Dissolve 3.647 g (or 9 ml)of HCl in 1 litre
and standardize with standard Na2CO3 Solution.
2. Mixed Indicator :
a. Prepare 0.1% Bromocresol green in alchohol
b. Prepare 0.2% Methyl Red in alchohol
Mix 75 c.c. of former with 25 c.c. of later.

PROCEDURE-
A. 10.0 ml sample
B. 2-3 drops mixed indicator
C. Titrate against 0.1N HCl
D. End point colour is slight red.

CALCULATION-

Alkalinity = Titre value x 0.4 g/ L

ESTIMATION OF TOTAL IRON IN PICKLING SOLUTION:-

REAGENTS-

A. Sodium Acetate
B. Chloroacetic Acid
C. Sulphosalicylic Acid
D. Potassium per sulphate (K2S2O8)
E. 0.01M Standard EDTA solution

PROCEDURE-

a. 10.0 ml sample
b. 1 g Sodium acetate + 1 g Chloroacetic acid + Sulphosalicylic Acid
c. Titrate against 0.01 M EDTA
d. End point pink to pale yellow. (Record volume as A)
e. To the same solution add 1 g potassium per sulphate
f. Titrate against 0.01 M EDTA already in the burette.
g. End point is pink to yellow. (Record the volume as B)
CALCULATION-

Ferric Iron (ppm) = A x 0.01 x 56000/10 = A x 56

Total Iron (ppm) = B x 0.01 x 56000/10 = B x 56
Ferrous Iron = Total Iron – Ferric Iron
IRON & COPPER ESTIMATION IN HCl SOLVENT SYSTEM USED
FOR ACID CLEANING:-

REAGENTS-

1. Ammonium bifluoride crystals

2. Hydrazine sulphate solution (15.0 %)
3. Potassium Iodide
4. KMnO4 Solution (5.0 %)
5. 0.1 N Standard sodium thiosulphate solution
6. Starch Indicator
PROCEDURE FOR IRON-

a. 10 ml filtered sample + 25 ml DM water

b. KMnO4 Solution drop wise till permanent pink colour appears
c. Hydrazine solution drop wise till pink colour disappears.
d. Add 2 drops in excess.
e. 5 g KI and stopper the flask. Allow to stand for 5 minutes.
f. Colour changes from yellow to brown.
g. Add starch indicator. Colour changes to blue.
 h. Titrate with 0.1 N Sodium thiosulphate till blue colour disappears.
(Record the volume as A)

PROCEDURE FOR COPPER-

a. 10 ml filtered sample + 25 ml DM water

b. KMnO4 Solution drop wise till permanent pink colour appears
c. Hydrazine solution drop wise till pink colour disappears.
d. Add 2 drops in excess.
e. Add ammonium bifluoride 5 g and mix well.
f. 5 g KI and stopper the flask. Allow to stand for 5 minutes.
g. Colour changes from yellow to brown.
h. Add starch indicator. Colour changes to blue.
i. Titrate with 0.1 N Sodium thiosulphate till blue colour disappears.
(Record the volume as B)

CALCULATION FOR IRON & COPPER-

Iron (ppm) = (A-B) x 558.5

Copper (ppm) = B x 630
A = ml of thiosulphate consumed during iron estimation
B = ml of thiosulphate consumed during copper estimation
TEST PROCEDURE FOR COPPER ESTIMATION IN AMMONICAL
BROMATE SOLVENT SOLUTION DURING BOILER CLEANING

REAGENTS-

1. Saturated sodium sulphite solution (Approx. 200g/Litre)

2. Hydrochloric acid (1:1)
3. Potassium permanganate solution (20 g/Litre)
4. Hydrazine sulphate solution (saturated)
5. Ammonium bifluoride granular
6. KI Crystals
7. 0.1 N standard sodium thiosulphate solution
8. Starch indicator

PROCEDURE-

a. 25ml DM water + 10 ml sample

b. 4 ml of saturated Na2SO3 solution – allow to react for 2-3 min.
c. 5 ml HCl (1:1) drop wise until the colour disappears. Add little excess.
d. Add KMnO4 solution drop wise until permanent pink colour is
obtained.
 e. Add Hydrazine sulphate solution (saturated) until the solution is clear
and then add 1-2 drops in excess.
f. Add 2-3 g of ammonium bifluoride, shake well allow to stand for 2
min.
g. Add 1-2 g of KI to the flask and stopper, mix and allow to stand for 3-5
min.
h. Titrate the solution with the 0.1N Na2S2O3 till the brown colour starts
to disappear.
i. Add starch indicator and continue titration till the blue black colour
disappears.(Record the volume A )

CALCULATION-

Copper (ppm) = A x 1000 x 0.1 x 63/ Vol. of sample

Copper (%) = A x 0.1 x 6.3/ Vol. of sample x sp.
gr. of sample

ANALYSIS OF FERRIC IRON:-

REAGENTS-

1. 1.0N Na2CO3 solution

2. Sulphosalicylic acid solution (%)
 3. 0.01 M EDTA solution

PROCEDURE-

a. 25 ml of sample and adjust pH to 2.5 with 1.0 N Na2CO3 solution

b. Dilute to 100 ml and add 5 drops of sulphosalicylic acid solution
c. Titrate with 0.01 M EDTA until pink just appears
d. Add further five drops of indicator and continue the titration until the
pink colour disappears.

CALCULATION-

Ferric Iron (ppm) = Titre value x 22.3

Event details:

As per R&D recommendation alkali boil out was not done.

Day 1: 14/04/2008

Super Heater Filling :

Chemical Time Addition of Chemicals pH Hydrazine Conc. (ppm)
prep./ Filling Hydrazine Ammonia
(In Liters) (In Liters)

1st batch 16:40 5 5 - -

16:45 - - 10.2 216
16:55 6 5 - -
Filling started 17:00 - - 10.2 416

2nd batch 17:35 1 1 10.2 314

17:50 3 1 10.0 232
18:05 - - - 336
18:10 5 1 - -
Filling started 18:20 - - 10.0 432

3rd batch 19:00 10 10 - -

19:05 - - 10.3 448
Filling started 19:10 - - - -

4th batch 19:40 10 10 - -

20:00 - - 10.2 464
Filling started 20:05 - - - -

5th batch 20:40 10 10 - -

20:50 - - 10.2 496
Filling started 21:10 - - - -
 6th batch 21:40 10 10 - -
21:55 - - 10.2 480
Filling started 22:00 - - - -

7th batch 22:40 10 10 - -

22:50 - - 10.2 504
Filling started 22:55 - - - -

8th batch 23:45 10 10 - -

00:00 - - 10.2 480
Filling started 00:05 - - - -

9th batch 00:50 10 10 - -

01:10 - - 10.2 488
Filling started 01:15 - - 10.2 488

10th batch 02:05 10 10 - -

02:15 - - 10.2 480
Filling started 02:20 - - - -

03:35 - - 10.0 376

(In SH (In SH vent sample)
vent
sample)
04:05 5 - - -
(For
Pressurization)
04:20 Pressure at bottom end = 10.8 Kg/cm2 and at SH top = 6.0 Kg/cm2.

Total Chemical consumption in SH filling :-

• Ammonia = 105 Liters
• Hydrazine = 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 O/L O/L
16:50 40 - -
17:30 45 - -
18:30 52 40 -
19:00 65 40 -
19:30 72 40 -
20:00 80 40 -
20:30 72 40 -
21:00 62 40 -
22:00 70 48 -
22:30 78 50 -
23:00 75 50 -
23:30 75 52 -
00:00 81 59 -
00:30 - - 3.0
01:00 83 62 -
01:30 Steam line isolated

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
 • Completed on 21:00 hrs
• Qty: 14.7 MT
 Third:
• Started at 21:35 hrs
• Completed at 22:00 hrs
• Qty: 3.0MT

o Acid solution started coming from drum vent at 20:50 hrs

o Acid circulation stopped at 00.00 hrs

Acid Pickling Process :-

Time HCl (%) Iron (ppm) Cu (ppm)
I/L O/L I/L O/L I/L O/L
17:00 Chemical addition started
18:30 1.46 - - - - -
18:45 4.28 0.108 - - - -
19:05 4.57 1.0 - - - -
19:20 - - - 3351 - 1006
20:20 4.3 1.9 4635 5138 1134 2268
21:00 4.5 3.7 3462 4244 2931 2520
21:40 4.7 4.6 5138 4244 2331 3150
23:00 4.5 4.5 6925 7372 3654 3276
23:30 3.9 3.88 7260 7986 3654 3087
00:10 Boiler drain started followed with N2 capping (17/04/08)
01:20 Boiler drain completed

Total Acid (HCl) Consumed = 32.000 MT

• Day 4:17-04-08

DM Water Rinse :-
Time Temp pH
 I/L O/L I/L O/L
01:20 Draining completed and system filling started with DM water
04:40 System filling completed and kept under recirculation
05:00 55.7 46.6 1.9 1.7
06:00 59.7 49.1 1.94 1.91
06:50 DM Water draining started followed by N2 capping
08:45 Draining completed

o Citric Acid Rinse

 DM water filling started with steaming at 08:45 hrs
 Citric acid (400 Kg) dosing started 08:50 hrs
 Completed at 09:05 hrs

Citric Acid Rinse:-

Time pH Temp. Citric Acid Total Iron Ammonia
Conc. (ppm) Addition
(%) (in Liter)
I/L O/L I/L O/L I/L O/L I/L O/L
10:30 2.3 2.0 - - - - - - -
10:35 3.1 2.9 - - - - - - -
10:40 5.3 2.4 - - - - - - 40
10:45 8.36 2.07 - - - - - -
10:50 8.57 2.2 - - - - - - 30
10:55 7.8 2.2 - - - - - - 30
11:00 5.3 2.3 65 48 - - - - -
11:05 3.0 2.6 - - 0.0384 0.0077 - - -
11:15 7.9 2.25 - - - - - - -
11:20 2.58 2.0 - - - - - - -
11:30 - - - - 0.041 0.015 - 65
11:35 7.14 2.1 - - - - - - -
11:40 3.0 2.06 - - - - 72.8 112 70
11:50 5.25 2.72 - - - - - - -
12:05 - - - - - - - - 70
12:30 4.6 3.99 80 50 - - - - -
12:40 3.9 3.8 - - - - - - -
14:00 4.5 4.7 - - - - 151 207 -
14:05 Draining started under N2 capping
15:00 Draining completed

Total chemical consumption in citric acid rinse :-

• Ammonia = 305 Liters

First DM Water Rinse :-

Time Temp pH Iron

I/L O/L I/L O/L I/L O/L
15:05 DM water filling started
16:25 Circulation started
17:30 Water started coming out from drum vent
17:45 67 50 6.5 5.0 16.8 28
18:00 69 50 6.0 5.3 33 72
19:00 Draining started under N2 capping.
20:00 Draining completed

DM Water Circulation cum Neutralization :-

o Soda Ash 2000 kg was charged at 00:35 hrs

Time Temp. (0C) pH Iron

I/L O/L I/L O/L I/L O/L
20:10 DM water filling with partial draining started
22:00 Recirculation established
23:00 72 50 5.3 5.5 22.4 33.6
00:30 88 50 4.1 5.0 22.4 11.2
00:35 Soda Ash charging started (18/04/08)
01:00 Soda Ash charging completed .pH(O/L) =6.2
 03:30 85 60 10.8 10.8 - -
04:45 84 62 10.8 10.8 - -
05:00 83 62 10.8 10.8 - -
06:45 82 66 10.8 10.8 - -
07:30 Draining started without N2 capping
09:30 Draining Completed

• Day 5-6: 18-04-08 to 19-04-08

o DM rinse with simultaneous draining started at 09:10 hrs

o DM rinse continued till 17:00 hrs

System Filling with Simultaneous Draining :-

Time Temp. (0C) pH

I/L O/L I/L O/L
11:10 System filling started
13:05 62 49 9.6 9.8
13:20 - - 9.8 10.0
13:25 55 49 9.8 10.0
13:35 - - 9.8 9.9
13:50 55 50 9.8 9.8
14:30 55 50 9.5 9.7
14:45 - - 9.2 9.7
15:15 50 50 8.6 9.4
15:30 - - 8.2 9.3
15:45 - - 7.6 9.2
16:00 50 47 7.2 8.4
16:45 49 46 8.8 9.1
17:00 69 48 9.3 9.0

Passivation Stage-I :-
Time Chemical Temp. pH Hydrazine Conc.
Addition (ppm)
(In Liters)
 Ammo Hyd I/L O/L I/L O/L I/L O/L
17:00 350 200 - - - - - -
18:00 - - 74 50 9.5 9.5 584 880
18:30 105 - - - - - - -
19:00 - - 84 62 9.3 9.4 376 456
19:35 155 - - - - - - -
20:00 - - 85 67 10.06 10.0 360 384
21:00 - - 90 72 10.2 10.2 392 400
22:00 - - 85 75 10.2 10.18 360 368
23:00 - - 90 78 10.18 10.16 352 352
00:00 - - 91 79 10.18 10.17 352 352
(19/05/08)
01:00 90 80 10.16 10.15 336 328
02:00 - - 92 82 10.17 10.17 336 336
03:00 - - 93 83 10.17 10.17 328 328
04:00 - - 93 83 10.18 10.18 320 320
05:00 - - 94 83 10.18 10.18 320 320
06:00 70 10 94 81 10.28 10.28 320 320
07:00 - - 93 83 10.30 10.29 352 360
08:00 - - 94 83 10.20 10.10 336 352
09:00 50 - 85 81 10.20 10.10 320 336
10:00 - - 89 82 10.22 10.16 304 320
11:00 70 20 - - - - - -
11:05 - - 89 81 10.25 10.18 560 336
12:00 - - 90 81 10.24 10.27 468 440
13:10 - - 84 77 10.10 10.12 304 344
13:30 - - 91 80 - - - -
14:00 - - 89 80 10.06 10.14 320 336
14:45 70 10 - - - - - -
15:10 - - 91 79 10.03 10.02 344 336
16:00 - - 89 79 10.03 10.06 320 320
16:05 105 - - - - - - -
17:00 - - 87 78 10.0 9.98 328 344
17:40 - - 88 78 9.9 9.8 336 340
17:40 Recirculation stopped (Stage-I passivation completed)
17:45 Drain started
18:45 Drain of water circuit completed
19:30 SH drain started
Total chemical consumption in citric acid rinse :-
• Ammonia = 975 Liters
• Hydrazine = 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 Feed BW FST Remarks

Addition
(Liters)
N2H4 NH3 pH N2H4 pH N2H4 pH N2H4
(ppm) (ppm) (ppm)
11:00 - - 10.5 240 - - 10.5 80
12:00 - - 10.5 230 10.2 176 10.5 152
12:30 50 35 - - - - - - Added to LP dosing tank
& both LP dosing p/p
taken service
13:00 - - 10.5 240 10.5 210 - -
13:30 - - - - - - - - Boiler Press.= 40 Kg/cm2

14:30 - - 10.2 32 10.2 26 10.5 150

16:00 50 35 - - - - - - Added to HP dosing tank
HP dosing p/p A &B taken
service
16:30 - - 10.5 80 10.1 24 10.2 128
17:00 - - - - 10.2 32 - -
18:00 10 - - - - - - -
19:00 - - 10.2 25 10.2 28 - -
20:00 60 - - - - - - - 40 liters to LP dosing & 20
liters to HP dosing
21:15 - - 10.2 38 10.2 32 - -
22:30 30 - 10.2 40 10.2 28 - - Added to HP dosing tank

00:30 30 - 10.5 64 10.2 32 - - Added to HP dosing

(01/04/08)
tank .HP Dosing p/p 'A'
isolated
02:30 30 - 10.2 56 10.2 28 - - Added to HP dosing
tank .DM water filled in
boiler
04:30 40 - 10.5 70 10.2 28 - - Added to HP dosing tank

06:30 - - 10.5 64 10.2 28 - -

07:00 50 - - - - - Added to HP dosing tank

08:15 - - 10.3 57 10.2 28 - -

08:30 20 - Added to HP dosing tank

09:15 - - 10.3 57 10.2 30 - -

09:30 30 - - - - - - - Added to HP dosing tank

10:15 - - 10.3 56 10.2 28 - -

10:30 50 - - - - - - - Added to HP dosing tank

11:00 - - 10.2 56 10.2 198 - -

11:45 20 - - - - - - - 15 liters added to HP
dosing tank, 5 liters to LP
dosing tank
12:15 - - 10.2 57 10.2 39 - -
12:45 35 - - - - - - - Added to HP dosing tank

01:00 - - 10.2 56 10.2 32 - - -

01:30 - - 10.2 56 10.2 28 - - UCB #3 was informed

about the final result.
02:10 - - - - - - - - LP dosing p/p A &B , HP
dosing p/p B stopped.

o Chemical addition during stage-II passivation-

 Hydrazine = 505 Liter
 Ammonia = 70 Liter

Total Chemical Consumption in Boiler Circulation and SH filling:-

 Chemical
Hydrazine Ammonia HCl Coronil Thiourea ABF Citric Soda
S.No. Process (Ltr) (Ltr) (MT) (Ltr) (Kg) (Kg) Acid(Kg) Ash (Kg)

1 SH Filling 105 93 - - - - - -
Acid
2 Cleaning - - 32 420 2000 500 -

3 Citric Acid - 305 - - - - 400 -

4 Neutralization - - - - - - - 2000

5 Passivation- I 240 975 - - - - - -

Passivation-
6 II 707 320 - - - - - -
Total Amount 1050 1693 32 420 2000 500 400 2000