TCPL-1X63.
75 MW POWER PLANT, GUMMIDIPOONDI
Doc. Ref : LMI/OPR/25 Date of issue : 24/02/06 Rev : 0 Page 1 of 3
PROCEDURE FOR APH WATER WASHING
1.INTRODUCTION:
When accumulated fly ash deposit on APH heating surface cannot be removed
readily by soot blowing, it is sometimes necessary to water wash the heating surface to
maintain acceptable draft loss through the air heater. These losses should never exceed
50% of normal value measured with clean heater. It is observed that normal value of
flue gas p across the APH is 100 mmwcl. It is therefore recommended, that a
periodical record of draft losses be kept during operation of the heater to determine the
need of washing. (Which is already being recorded in Boiler log sheet)
Frequency of washing is depending upon variables such as quality of fuel
burned, firing conditions, boiler operations etc. Most deposit accumulations forming on
the air heater elements are highly soluble in water and therefore easily removed by
washing provided that a sufficient quantity of water is used. APH Washing is
accomplished when the boiler is shutdown. Yearly or as warranted APH chemical
washing is carried out to remove sulphur born corrosion products from APH heating
surface.
2. AIR HEATER WATER WASHING SYSTEM:
The APH water washing plant consists of: - (refer attached P& I diagram)
One 100 m3 tank to store the water
One centrifuge pump- capacity 145 t/hr, discharge pressure 12 ksc.
Piping connection and valves from air heaters hopper to drain wash water to
sewer.
Air heater water washing device consisting of two stationary multi-nozzle
pipes facing the upper and lower end of rotor in the gas side.
One caustic soda dosing plant for water conditioning consisting of: -
One 80 liters NAOH tank with manual mixer
Issued by works manager
TCPL-1X63.75 MW POWER PLANT, GUMMIDIPOONDI
Doc. Ref : LMI/OPR/25 Date of issue : 24/02/06 Rev : 0 Page 2 of 3
One motor operated NAOH dosing pump with suction filter.
3.PROCEDURE:
APH water washing is to be done after boiler shutdown and when the APH flue
gas inlet temperature reaches around 120 0 c.
1. Before washing inspect the ash hoppers, pipes and valves to ensure that the outlet
flow passage is not plugged.
2. The ash evacuation pipe connected to the APH hoppers should be disconnected. Open
FD & PA fan duct drains.
3. Check whether APH water-washing pump is available.
4. Fill storage tank by deaerator water as the temperature of wash water is to be
maintained above 60 0 c by mixing with service water.
5. The APH is to be kept running and the ID; FD fans are to be stopped.
6. When the APH flue gas inlet temperature is around 120 0 c, start APH water
washing pump for doing hot water washing.
7. Open Inlet valves to top and bottom multi nozzle pipes of APH and maintain the
pump discharge pressure 10 ksc by adjusting re- circulation valve.
8. Do hot water washing till outlet water is fairly clear.
9. Stop hot water washing. Fill storage tank with service water up to 50% level.
Issued by works manager
TCPL-1X63.75 MW POWER PLANT, GUMMIDIPOONDI
Doc. Ref : LMI/OPR/25 Date of issue : 24/02/06 Rev : 0 Page 3 of 3
10.Add chemicals (caustic soda) directly into the tank. Make up the tank with service
/deaerator water to maintain water temperature around 50 to 60 0c. Run APH washing
pump on recirculation for ½ hour. Maintain pH of solution of 10.5 to 11.5.
11.Admit the chemical water in APH at top and bottom till the inlet and out let pH of
water are almost close or APH outlet pH > 9. Stop the APH washing pump.
12.Drain the APH water wash tank and fill it with service water.
13.Start the APH pump and rinse the APH.
14.Check pH every ½ hour and continue rinsing till the outlet pH is almost close to inlet
pH.
15.Run ID FAN with minimum damper opening to dry the APH for 1 hour.
4. RESPONSIBILITY:
It is the responsibility of the Unit Control engineer that the procedure for APH
Water washing is followed during APH water washing with the assistance of station
chemist.
5. Any review of this document will be with the approval of works manager. The next
review will be after one year.
Issued by works manager
