JINDAL URBAN WASTE MANAGEMENT (GUNTUR) LTD

PROCEDURE FOR ALKALI BOIL OUT

OBJECTIVE

The purpose of alkali boil out is to remove the deposits like oil, grease, mill scale etc from boiler
internals, which was resulting out of manufacturing, fabrication and erection. Such deposits in the boiler
tube walls will restrict heat transfer and will result in failure due to overheating.

PRE-REQUISITES
In order to commence alkali, boil out of the boiler, the following prerequisites /inputs have to be ensured.

• Ensure the Mechanical completion of boiler including auxiliaries and piping.

• Ensure the completion of hydraulic test activities and refractory dry out.

• Ensure the readiness of electrical and instrumentation controls.

• Ensure that adequate illumination is available in and around boiler house.

• Ensure that electrical power is available for motorized valves and gauge glass illuminator.

• Ensure the availability of DM water through boiler feed pumps.

• Ensure the readiness of sample collection system.

• Ensure the availability of required chemicals for the alkali boil out.

• Ensure that the boiler is fully ready for light up with thermal expansion provisions.

• Ensure the availability of lab facilities to test the water. (PH and oil deduction)

• Ensure the readiness of chemical dosing system.

• Ensure that all the debris is removed from Boiler.

• Ensure that the drum internals are removed from steam drum and match marking is given.

• Ensure that all the access doors in the boiler are closed.
Ensure the availability of the following.

1. Good working drum level gauge glass with illuminator assembly.

2. Boiler drum pressure gauge.

3. Safety /relief valves with gags or hydrostatic plugs are removed.

4. CBD, IBD and all drain valves in good working conditions.

5. Water level control and associated alarms

6. Cooling water piping and air piping

7. Furnace pressure gauge

8. Temperature indications for flue gas feed water and steam line.

• Ensure that during alkali boil out, transmitters connected to steam drum and steam piping is isolated
to avoid any damages to transmitters due to alkali.

• Ensure that blow down and drain connections are terminated to safe location.

• Ensure that feed water pump operates satisfactorily.

• Ensure that all dampers are in good working condition and ‘OPEN’ ‘CLOSE, positions are marked
correctly.

st
PROCEDURE FOR 1 STAGE BOIL OUT (At 20 kg/cm²(g) pressure)

1. Fill the specified quality feed water 50mm below the steam drum manhole rim.

2. Exact quantity of chemicals ( Tri sodium phosphate Na3 PO4 12 H2O and Di sodium phosphate Na2
HPO4 -7H2O) is to be carried in dry form up to the drum level platform. The chemicals are to be
dissolved in DM water externally in a container near the drum manhole in batches. The concentrated
solutions so prepared are to be poured in to the drum through the manholes. When entire quantity of
chemical has been dissolved and poured in to the drum. Close the manhole and fill the drum to the
normal level.

3. Increase slowly the heat input to boiler to raise pressure.

4. At a pressure of approximately 30 psi (2.1 kg/cm² (g)) a good flow of steam from air release valves will
be noticed. Up on seeing this close the air release valve.

5. Continue increasing the pressure to 20 kg/cm²(g) .

6. Maintain pressure at 20 kg/cm²(g) for a period of 12 hours. This will ensure rapid circulation of water
through boiler.

7. Give blow down at every 2 hours interval from water wall drains for one minute each,

8. Extinguish the fire and blow down boiler manifolds individually by giving blow down for a period of 2-3
minutes each.

9. Allow boiler to cool down naturally when pressure comes to 2.5 kg/cm²with manifolds closed; blow down
steam drum until water level falls below gauge glass.
10. Following this entire boiler can be blown down as quickly as possible using all manifold and drum blow
down and drains.
This way evacuates the water before any dirt or oil has time to settle down.

Note: When blowing down through all drains and blow downs simultaneously, due regard must
be exercised for the capacity of the blow down system.

• When pressure falls to 30 psi (2.1 kg/cm²) open air release valves.
• With blow down and drain valves still open, wash through drums,Manifolds,and tubes with high
pressure clean water to wash out any remaining sediment.
• After every blow down operation collect drum water sample and analyze for phosphate and oil content.
Replenish phosphate concentration through HP dosing system as and when the residual value goes less
than half of the concentration maintained at the start of the process.
• Continue the boil out operation till the oil content in the sample collected does show less than 5ppm or till
the eight blow downs are completed whichever is later. If this parameter is not achieved in 1 st stage than 2nd
stage boil out to be carried out..

ND
PROCEDURE FOR 2 STAGE BOIL OUT

• At a pressure of approximately 30 psi (2.1 kg/cm²(g)) a good flow of steam from air release valves will be
noticed. Up on seeing this close the air release valve
• Raise the boiler pressure to 35kg/cm²(g) and carry out boil out operation by maintaining this pressure for
a period of 12 hours. This will ensure rapid circulation of water through boiler. The pressure is to be
maintained by controlling the fuel firing and modulation of the start-up vent. During this process normal
drum level is to be ensured.
• After every blow down operation collect drum water sample and analyze for phosphate and oil content.
Replenish phosphate concentration through HP dosing system as and when the residual value goes less
than half of the concentration maintained at the start of the process.
• Continue the boil out operation till the oil content in the sample collected does show less than 5ppm or till
the eight blow downs are completed whichever is later.

COMPLETION OF BOIL OUT

• When analysis confirms the oil presence in the samples is equal to or less than 5 ppm the boil out
operations treated as completed.
• For confirmation it is suggested to collect 3 samples within 5 minutes of each other and check the
consistency of the results.
POST BOIL OUT OPERATION

• Operate each blow down and drain valve successively for a few seconds to discharge any accumulated
sludge. Repeat several times meanwhile maintain drum level.
• Allow the boiler to cool down naturally. When the drum pressure comes to 2 kg/cm² (g) open the all air
release valves.
• When the drum pressure drops to atmospheric, drain the boiler by opening all valves on drain headers.
• Fill the boiler up to the drum to the required level and back flush the super heaters into the drum till the
sample collected from super heater off take tube mouth in the drum shows a low conductivity and high
clarity.

BOILER RINSING

After completion of Alkali boil out and boiler is considerably cooled, flush the boiler with DM water till the
system is free from alkali solution. i.e. Ph value of effluent should be equal to that the DM water used for
flushing
FINAL INSPECTION
• After draining the boiler cut the inspection caps in headers to inspect for any sediment, cleaning and
flushing.
• After boiler has cooled down completely, open all manhole doors and remove all manifold inspection
caps to inspect the internal surfaces.
• Re-weld the end caps on headers as per recommended procedures and carry out necessary NDT and
stress reliving as applicable.
• Accumulated dirt and sludge should be scrapped out in drum, manifolds and tubes washed through high
pressure clean water.
• Examine all heating surfaces and gas passes of boiler for excessive soot deposits resulting from low
firing rates employed in Boil out. Clean manually the soot deposits.
• Check all refractory for any cracks.
• Check for any ash accumulation in any area.
• Check that expansion joints are set correctly and that expansion clearances are adequate.

NOTE
Boiler water contains chemicals, which are hazardous for human safety and hence safe disposal is
necessary.