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6.4.2.2 Liquid Fuel.

Liquid Fuel supply system piping to boiler fuel skid needs also to be inspected and cleaned if required
by means of blowing (dry air or N2 can be used).
During blowing it’s recommended to remove control valve and install temporary spool.

6.4.2.3 Instrument Air.

To have normal function of pneumatic devices such as control valves it is mandatory that instrument air
is very clean and without any condensate.
To achieve this purpose, it is necessary to carefully clean all new pipe erected from Instrument network
to Package boiler header and from there to individual pneumatic devices.
All connection of each pneumatic valve to be disconnected and by manual valves arrange the blowing
air to clean and dry them one by one.

Cleaning check list.

Verify that flushing of the feed water system completed.

Verify that flushing of the boiler completed.

Verify that flushing of the cooling water lines completed.

Verify that flushing of the Lube oil system piping is completed.

Verify that blowing of the instrument pipes and tubes completed.

Verify that blowing of the fuel gas piping completed.

Verify that blowing of the Liquid fuel piping completed.

6.5 BOILER CHEMICAL CLEANING.

Chemical cleaning method is depended on steam nominal pressure, Boiler pressure part internal
surfaces condition, piping and drum manufacturing method could be done by only Boiling out or by
Alkaline and acid cleaning.
Later, at site and based on internal surfaces condition, Client with our TA will decide how to perform
chemical cleaning.
By the way following procedure could be used as recommended method, if client has his own standard
and procedure, it will be reviewed by our TA at site and final decision will be made by client.

6.5.1 OBJETIVE
Preoperational pickling procedure with a soft acid is recommended to eliminate greases, oils, oxides
and other residue generated in the assembly of pressure parts of the boiler.

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Based on ASTM 2866, the recommended corrosion rate is 100 MPY.

The feed water must be confirmed to be enough and uninterrupted prior to chemical cleaning (feed
pumps, valves and piping thoroughly checked out).

6.5.2 APPLICATION FIELD

This procedure affects the Chemical Cleaning operative process during the pre-commissioning phase.

6.5.3 CHEMICAL CLEANING PRODUCTS

The chemical products usually used for the cleaning treatment are as follow. Their concentrations are
defined in the different stages of the procedure described below.
► Wetting agent

► Caustic soda (liquid)

► Corrosion inhibitor

► Citric acid

► Ammonia bifluoride

► Ammonia

► Sodium nitrite.

6.5.4 SUBSYSTEMS TO CLEAN

The different boiler sections to clean are:
► Economizer included in the P&ID Boiler feed water inlet and economizer P&I C-002995-PL-IP100-
001.
► Evaporator banks included in the P&ID steam drum P&I C-002995-PL-IP100-003.

► Steam drum included in the P&ID steam drum P&I C-002995-PL-IP100-003.

► Mud drum P&ID steam drum P&I C-002995-PL-IP100-003.

6.5.5 WASHING CIRCUIT

The subsystems mentioned above will be washed in only one circuit.
Reference drawings:
► Boiler feed water inlet and economizer P&I C-002995-PL-IP100-001

► Main steam P&I C-002995-PL-IP100-002

► Steam drum P&I C-002995-PL-IP100-003

► Blow down system P&I C-002995-PL-IP100-031

Chemical products will be mixed in a mixing tank and be circulated by means of two (2) 100% capacity
pumps (one working and the other in stand-by) through the pipe connections specifically provided for
chemical cleaning by the chemical cleaning company.
Chemical solution shall be heated up until reach 75-80 ºC, it can be done using hot condensate from
another process or using an external heating source.

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The chemical solution will be introduced through the 4” connection located at the feed water pipe to the
economizer, after economizer inlet manual valve, and continue to the economizer up to the steam drum.
From the steam drum will descend through the tubes of water walls: front, rear and sides walls to the
lower drum.
Some temporary hoses should be introduced from the top of steam drum to the lower to introduce air or
N2 (Valves HSD-117 and HSD-118) to facilitate the good circulation of the chemicals into the water
walls and drums.
The chemical solution will be returned to the mixing tank through the 2” connection located at the lower
drum drain and trough the temporary connection for rear and front wall drains located just before the
atmospheric tank.
From the mixing tank, the chemical solution will be reintroduced to the economizer to close the circuit.

SUPERHEATER IS EXCLUDED FROM THE CLEANING CIRCUIT BECAUSE IT’S MADE

OF ALLOY MATERIAL. THE SUPERHEATER MUST BE FILLED WITH DEMI WATER
FORMING A SEAL TO PREVENT THE INGRESS OF THE CHEMICAL SOLUTION
DURING THE PROCESS.

6.5.6 EXECUTION
► Temporary activities.

► Water leaks and circulation testing.

► Chemical cleaning stages.

► Alkaline cleaning

► Acid cleaning
► NEutralisation and temporary pasivation.

6.5.6.1 Temporary Activities

In the following pictures the washing circuits have been marked in the P&ID´s:

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solution inlet in the Economizer.

Solution and Air Path in Drum.

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Blowdown tank solution path and return.

Before proceeding with the boiler cleaning treatment, the following operations must be prepared.
► Steam and water drum manholes will require a new set of gaskets to replace after the chemical
cleaning. For the chemical cleaning process, a rubber gasket can be used.
► Dismantle chevron dryers of steam drum and lay down inside of drum in order them be covered by
chemical solution during the chemical cleaning. Please refer to the drawing C-002995-PL-IP020-
1005 Steam drum internal general arrangement.
► Blowdown tank: close valve to LP steam BDT-102, root valves for instrumentation and level gauge
BDT-108/109/111/112/113/114, and valves to intermittent blowdown tank BDT-105/106 and BDT-
107.

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► Install a blind disc on the steam drum safety valves PSV P-BX6101-A and PSV P-BX6101-B to
avoid contact of internals with chemical solution.
► Superheater must be filled with demi water before closing the manholes of the drum as described
in the below picture.

► Close the outlet steam valves BX6111 and BX6110.

► Connect a temporary hose by removing the thermocouple BX6109 in order to fill the superheater
from the steam outlet to the steam inlet (drum outlet).
► Confirm superheater is filled when the water gets into the drum by the outlet pipe (line HHST-
010).
► Install the temporary connections for cleaning in feedwater line, circuit inlet.
► Install temporary connection to drain economizer after cleaning finish as well as temporary
connections on water drum and wall headers drains to return the chemical solution to the mixing
tank.
► Install temporary connection in blowdown tank drain for solution return.
► Install a temporary transparent hose in parallel with the level transmitters of the steam drum to
monitor the level during the cleaning circuit.
► Install a temporary hose from the steam drum vent valve HSD-125 to the mixing tank. This is to
avoid external leaks in case of very high level during the cleaning process.

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► Close instruments root and end valves for all PI´s, PT´s, LT´s, and FE´s to avoid contact with
chemical solution.
► Economizer and feedwater (P&ID C-002995-PL-IP100-001): Confirm closed root valves HFW-
110/111/112113, HFW-114/115, HFW-116/117, HFD-101/102, HFD-105/106.
► Attemperator line (P&ID C-002995-PL-IP100-001): Confirm closed root valves HTW-
113/114/115/116.
► Steam drum (P&ID C-002995-PL-IP100-003): Confirm closed root valves HSD-
101/102/103/104/105/106/107/108/109/110/111/112, HSD-119/120/121/122/123/124, HSD-
128/129, HSD-130/131/132/133.
► Mud drum (P&ID C-002995-PL-IP100-003): Confirm closed root valves HS-135/136.
► Blowdown system (P&ID C-002995-PL-IP100-003): Confirm closed root valves BDT-
108/109/113/114.
► Install cleaning equipment and make connections to inlet and returns.
► Install connection for treated water to fill the boiler. Customer shall assure that the feedwater quality
shall meet the following requirement:
Feedwater quality

pH @ 25ºC 9.2 – 9.5

Conductivity (µs/cm) 4.3 – 8.6

Acid Conductivity @ 25ºC (µs/cm) <0.2

Total Hardness (mg/kgCaCO3) Not detectable

O2 (µg/kg) 5 – 20

Silica SiO2 (µg/kg) <20

Na (µg/kg) <10

Iron Fe (µg/kg) <20

Cupper Cu (µg/kg) <3

Organic matter (µg/kg) <200

Other elements or substances (µg/kg) Not detectable

► Determine the effluents drainage system, neutralization pit or trucks.

6.5.6.2 Water leaks and circulation testing

After completed the temporary connections:
► Check water flow path through the circuit.

► Fill the boiler up to 50% drum level (Approx. 30m3).

► Start one pump and circulate water through all the circuit.

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► Monitor the level in the temporary hose installed in the steam drum.

► In this phase all leaks found must be corrected and the pumping skid tested.

6.5.6.3 Chemical Cleaning Procedure

The cleaning will be carried out with the procedure named “One Phase clean” that means that only one
boiler filling for the chemical cleaning is required.
Proceed as follow:
Alkaline cleaning
► Fill the boiler with the cleaning auxiliary equipment until reaching the 50 % of steam drum level if it
has not been filled before and start to circulate. During this circulation, the speed solution stablished
will be between 0.2 – 1.2 ms-1.
► Start to heat the water with the external heating source.

► When the temperature reached 45ºC in the return, the wetting agent shall be dosed in the
recirculation tank at a concentration of 0,05 % and caustic soda at 0,25 %. The dosage must be
made in slow way to the mixing tank.
► The wetting agent works as penetrating and grease remover agent together with the soda, giving to
the surfaces a hydrophilic character.
► Heat the solution until reach a temperature of 70ºC-75ºC in the return and keep circulating during
six (6) hours approx.
Acid Cleaning
Without empty the solution, dose the following products:
► Corrosion inhibitor at 0,05 %

► Citric acid at 3 %

► Ammonium bifluoride at 0,3 %

During this phase the personnel the following analytical control should be done every 30 minutes:
► Temperature (impulsion/return)

► % of acidity (3% maximum in return)

► PH (1 - 4)

► Fe3+ and total Fe

► Inhibitor efficiency

► The recirculation of the chemical solutions must continue until the total Fe dissolved content in the
samples taken in the return stay stable during three consecutive values.
Neutralization and temporary passivation
► With the solved total Fe at a constant value, increase slowly the pH of solution dosing ammonia until
it becomes slightly alkaline (7,5-8,5), checking that is maintained stable
► With the chemical solution neutralized, dose sodium nitrite at a 0,3 % to passive the pickling metallic
surfaces, keep circulating for a period not less than four hours.

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► Stop chemical pumps, chemical cleaning is over. Drain the boiler to neutralization basin.

► Open the drums manholes and ventilate for a while.

► Inspect the accessible parts to see the results of cleaning.

6.5.6.4 Final flushing
Once the boiler is emptied and given the work approval, proceed to rinse the boiler. Given the passive
character of the residual solutions in the boiler, is suggested to do the rinse treated water with 50 ppm
of ammonium and 250 ppm of sodium nitrite.

6.5.6.5 Duration
The estimated time to complete the present chemical cleaning activities is five days.

6.5.6.6 Inspection
After the chemical cleaning is completed, a visual inspection should be done on the accessible parts to
confirm the cleanliness.
Dismount all the temporary equipment and replace drum internals.
After the inspection, boiler should be preserved depended on idling period and climate either by dry
preservation or wet preservation explained in chapter 10 of the present document.

6.5.6.7 Waste treatment

If near the boiler is not available a neutralization basin, shall be necessary to arrange tankers with
enough capacity to collect the complete volume of effluents.
It is recommended to empty the boiler within two hours after the cleaning completion to avoid solids
precipitation.

6.5.7 Restoring
Remove all temporary connections and hoses and reinstall all safety valves, control valves, internal
devices of check valves, level glasses, steam drum internal devices, etc.

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