Boiler Chemical Cleaning

WORK PROCEDURE
FOR
Boiler Chemical Cleaning
Pf: Doasan Hrtavy Industries Indonesia
CIREBON COAL FIRED POWER PLANT

PROJECT
Document IVo : TO71 19-DM01-PI HA-740033

WP NO : WP-M-033
1 04. Nov. 2010 Eunpa Bang I Ohsung Kim
1 Date Prepared by
Reviewed by
Mech. General Manager
Approved by
Site Representative
Cirebon Coal Fired Power Plant Project

WP N O : WP-M-033
PT. Doosan Heavy Industries REVNO: 0
Indonesia
WORK PROCEDURE DATE : 1R4m311
PAGE : 2d 19
BOILER CHEMICAL CLEANING PROCEDURE
Table of Contents
1.0 Object
2.0 Application Range
3.0 Guideline

WP NO : WP-M-033
PT. Doosan Heay Industries REVNO: 0
WORK PROCEDURE DATE : 1D4/m11
Indonesia
1 I PAGE : 3d 19
1. Object
The object of this work procedure is aimed to secure quality by remove remaining foreign
materials such as scale, rust, dirt, oil before the start-up and is eventually to enhance
maximum protectionism of the relevant systems in accordance with specifications and
codes during the construction in the Cirebon 660MW CFPP Project.
2. Application Range
'This work procedure plan will be applied for the Chemical Cleaning work on the boiler area
in the Cirebon 660MW CFPP Project.
3. Guideline
The Chemical Cleaning work on the boiler area will be done by this procedure.
4. Procedure
4.1 The progress of work
1) STEP1: Flushing
2) STEP2: Acid cleaning (Possible Degreasing+ Descaling)
3) STEP3: Rinsing
4) STEP4: IVeutralizing, Passivation
4.2 Range of Cleaning
Range of Chemical Cleaning and Volume (Unit)
Economizer 180 m'
Furnace 65 m'
Feed Water Piping 24 cn3
Start-up system 40 m3
Temporary Piping 30 m'
Total 339 m3

WP NO : WPM033
REVNO: o
PT. Doosan Heavy industries
Indonesia
WORK PROCEDURE DATE : 1R4/2011
PAGE : 4af 19
B0:ILER CHEMICAL CLEANING PROCEDURE
4.3 Chemical
4.3.1 Chemical Requirement for progress
Concentration
Progress chemical cleansing condition analysis point criterion
(%)
Flushing N2H4 0.01 Turbidity Turbidity : Below 10 IVTU
perform until Fe++,oil

Fe++-Fe+++, Fe++, Oil concentration:
concentration be
Acid Cleaning AX-3903-A 10.00 PH, Oil Fixed Value(3Analysis Value
stabilized in 80°C +
concentration of Cleaner)
5°C
Turbidity: below 5.0 NTU
PH, Oil
Perform in above 40 - concentration,
Oil concentration: Trace
Rinsing N2H4 0.01
60°C Hot water (below 0.5 ppm)
Turbidity
T-Fe: 100 pprn
Fe++ in above 7WC, T-Fe : Fixed Value

Pre- Fe++.Fe+++,
Citric Acid 0.1 Perform until i t will be (Fixed Value more than 3
Neutralization PH
stabilized Times)
2-3Cycle Circulation in
Neutralization Ammonia 0.075 PH: 9-10
above 80 + 5°C
2-3Cycle Circulation in Remained NzH4: Above

PH, N2H4
above 80 + 5°C 500ppm
''II

WP NO : WP-M-033
Pf. Doosan Heavy Industries REVNO: 0
lndonesla
1 PAGE : 5d 19
4.3.2 Requirement of Chen-~ical
1 ) For Cleansing Boiler Area
I
-
Citric Acid
I
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g8 I
I
350 1
I
Pre-Neutralization
3 Ammonia 25 0.075 1,020 Neutralization

1 1 4 Hydrazine 1 50 1 Passivation
1 5 1 Hydrazine 50 1 1,200 1 Flushing & Rinsing 1
50 Leak Treatment
4.4 Temporary Equipment
1 ) Pump
IV 0. Temp. Equipment Flux Amount Remark
1 Temp. Circulation Pump 250 m3/HR 1EA Pump head : 170M

2 Temp. Circulation Pump 250 m3/HR 1EA
3 Chemical Injection Pump 200 m3/HR 1EA

4 Water Pump 10 m3/HR 2 EA Drain Waste Water

WP NO : W p m
PT. Ooosan Heavy Industries REVNO: 0
Indonesia WORK PROCEDURE DATE : 1124/2011
I
I
I
PAGE : 6 6 19
2) Tank
Requirement
110. Name Volume Amount Remark
(kg)
Circulation Tank 25 rn3 I 1 1 Circulation I
4.5 Installing Equipments
No. Name Amount Requirement Remark

Measuring
Level Gauge 1Sets
1 Chemical Tank Level I
2 Pressure Gauge 5 Sets Measuring Pressure
3 Temp. Gauge Measuring Temperature
4 Pipe & Fitting titer

-
5 Valve titer
6 Communication and Lighting
Removal of Pump Suction

7 Strainer 4 Sets
Foreign materials
4.6 Sampling Point
1) Chemical Cleaning Circulation Pump Inlet Piping

2) Chemical Cleaning Liquid Outlet Piping
4.7 Test Piece and Tube
1) Boiler Tube Material: SA-213T12 :2EA (1EA each 2point) (confirmation)

WP NO : WP-M-033
Indonesia
WORK PROCEDURE DATE : 1~4/2011
BO:[LERCHEMICAL CLEAN:ING PROCEDURE
2) Pipe and Economizer Material: SA-1O6C : 2EA ('I EA each 2point)
% 1. Piece size: 2.5cmx3cmx0.3cm (width x length x thickness)

2. Tube standard: each Tube Size x 5cm- L x 0.3cm th'k
3. Test Piece shall be installed at Circulation Purr~pInlet and Outlet.
4. Test Piece and Tube material shall be equal to material of Cleansing part.
4.8 corr~murricationsystem
Headquarter
CCR
Seperator
(Temp. Pump)
Level gauge
20 kg/cm3
Steam Header
4.9 Installation Position for communication
1) Cleaning headquarter (Temp. Pump)

2) Central Control Room
3) 2 0 ~ ~ 1 cSteani
m ~ Header
4) Leak Observer
4.10 Preparation for Cleaning
1) Temporary and Chemical Tank Flushing shall be operated.

2) Connection between Temporary Equipment and Main Equipment
- Uninstall check valve in the front of Econom'izer and separate from Flipper, and
then connecting the Teliiporary Flange arid temporary piping.
- Temporary Piping shall be connected in back part of BW-LCV-52 which is
located on Separator Storage Tank to Flash Tank line.
- Temporary Level Gauge should be installed and It shall be checked whether
cleaner is possible to enter the SH system or not.
- Cutting the Cap of Ring Header Drain and connect the Temporary pipe.

WP NO : WP-M033
PT, Doosan Heavy Industries REYNO: o
Indonesia
WORK PROCEDURE DATE : IR4i2011
PAGE : 8af 19
- Temporary Pipe should be connected in circulation Tank as extending

connection Line of Vent Station Drip pot Upper Blind and Drip pot.
- Temporary Pipe should be connected in each Boiler Drain Header around Flash
Tank.
- Temporary Pipe should be connected in SIH Spray water Line (Ist12nd De-
superheater).
4.11 Preservation Main Equipment and Operating Valve
1) Before cleaning, for protecting from foreign substance in Boiler Recirculation

Pump, Pump internal shall be filled with water and closed inlet, outlet Valve and
attached Red Tag issued.
2) Motor Valve isolated from cleaning scope and non cleaning scope shall be
separated from power source for Protecting Operation and Red Tag issued
should be attached after Closing Passive Valve.
3) Drain Valve in non cleansing scope Line nearing cleansing scope should be
Opened and checked if the cleanser put into non cleansing scope during cleaning.
4.12 Main Equipment Measuring instrument removal
Orifice, Separation of Flow Nozzle, Isolation Block Valve of Impulse Line should be
protected in accordance with main equipment Instrument including cleaning scope,
4.1315-20 kg/cmZAux. Steam Supply Status shall be checked.
4.14Operating Status of Waste Liquid treatment Equipment should be checked.
4.15 Movement status should be checked by Operating Temporary Equipment like a

Pump.
4.16 Superheater system filling water and rinsing

WP NO : WPM033
PT. Doasan Heavy lndtlstries REVNO: 0
Indonesia
WORK PROCEDURE DATE : lE4/X)11
BOILER CHEMICAL CLEAN:ING PROCEDLIRE
1) After filling Demi. Water Tank treated with 200ppm hydrazine (PHIO) to
superheater using non-cleansing part filling water pump, cleansing superheater.
At this time, cleansing water discharged from superheater should be analysis as
sampling.
2) Filling water should be finished Before Acid washing and While Passivation and
Rinsing for Furnace system, Back wash shall be continued until increase
Separator Storage Tank water level.
3) Discharge pipe connecting from superheater to Flash Tank should be closed for
preventing pollution from cleanser.
4.17 Furnace System Cleaning
4.17.1 Boiler Filling Water, Flushing and Leak Test
- After Filling DEMl Water in DEMl Tank using Temporary Circulation Pump Eco.
Check V N ---> Econorr~izer---> Furnace Wall Tube ---> Separator ---> Separator
Storage Tank ---> BW-LCV52 (Flash Tank) ---> Circulation Pump, Cleaning the
Boiler Area.
- Open the Boiler Vent Valve for Full Filling Water.
- For inject lV2H4to system during filling water to Boiler, Metering Pump shall be
installed at DElVll Tank and then inject N2H4above 100 ppm.
4.1 7.2 Flushing
If finish the filling water, Circula.tionand Blow-out shall be operated until turbidity
reaches the 10.0 NTU using Temporary circulation Pump.
* Analysis contents:
Turbidity: Below 10.0 IVTU
N2H4:Below IOOPPM
* Analysis Period: Each 60 minute

WP NO : WPM033
PT. Doosan Heay Industries WNO: 0
Indonesia
WORK PROCEDURE DA-TE : 1R4M)Il
- Temporary Pipe shol-~ldbe connected in circulation Tank as extending

connection Line of Vent Station Drip pot Upper Blind and Drip pot.
- Temporary Pipe should be connected in each Boiler Drain Header around Flash
Tank.
- Temporary Pipe should be connected in S/H Spray water Line ( I stl2nd De-
superheater).
4.1 1 Preservation Main Equipment and Operatiug Valve
1) Before cleaning, for protecting from foreign substance in Boiler Recirculation

Pump, Pump internal shall be filled with water and closed inlet, outlet Valve and
attached Red Tag issued.
2) Motor Valve isolated from cleaning scope and non cleaning scope shall be
separated from power source for Protecting Operation and Red Tag issued
should be attached after Closing Passive Valve.
3) Drain Valve in non cleansing scope I-ine nearing cleansing scope should be
Opened and checked if the cleanser put into non cleansing scope during cleaning.
4.12 Main Equipment Measuring instrument removal
Orifice, Separation of Flow Nozzle, Isola.tion Block Valve of Impulse Line should be
protected in accordance with main equipment Instrument including cleaning scope.
4.1 3 15-20kg/cm2 Aux. Steam Supply Status shall be checked.
4.14 Operating Status of Waste Liquid treatment Equipment should be checked.
4.1 5 Movement status s h o ~ ~be

l d checked by Operating Temporary Equipment like a
Pump.
4.16 Superheater system filling water and rinsing

WP NO : WPM033
Indonesia WORK PROCEDURE DATE : 1R4/2011
B0:ILER CHEMICAL CLEANING PROCEDURE
4.1 7.3 Leak Test
After Flushing Work, Temporary piping Leak Test should be checked and Operate
repeatedly until It has no Leak Point.
For safety cleaning during chemical cleaning, After Flushing process, leak of
Temporary pipe should be checked and performed repeatedly until it has no leak point.
4.1 8 Cleaning Operation Rehearsal
4.18.1 If finish the Leak Test, Chemical injection Status shall be checked as operating
Temporary Circulation Pump and Chemical lnjection Pump.
4.18.2 All the problem should be prevented and checked previously as circulating
water.
4.1 8.3 During the Rehearsal process, Valve for Aux. Steam Header shall be opened
for supply steam from temporary heat exchanger, and then check the Heating status.
4.1 9 Boiler Chemical Clearling
4.1 9.1 Water Heating

Filling Water in Boiler shall be circulated using temporary circulation Pump, and Aux.
Steam shall be provided to Temporary Heat Exchanger and then heating up to
802~5°C.
4.1 9.2 lnjection Chemical

- Water heating up to 80 +
5°C shall be circulated by temporary circulation Pump
and main cleanser AX-3903-A preserved in Chemical Tank shall be injected by 1
Cycle Chemical lnjection Pump for diluting in to whole cleanser equipment.

WP NO : WP-rVF033
Indonesia
I I
4.1 9.3 Cleanser Circulation
- If finishing injection of cleaner, circulation should be performed repeatedly as

maintaining Return terr~peratureabove 80f 5 "C .
- Operate as controlling the pressure for circulate the cleanser up to height of Vent
Valve Station by over-flow.
- Operate as checking the circulation of cleanser in Main Equipment Branch Line
like an SIH Spray Line.
- If finish the injection of cleaner, Fe++, Fe+++, acid concentration, fat and oil, PH,
temperature should be analyzed each 1 hour, when the Oil and steel gush are
saturated, cleaning finish point shall be decided if the each 3times analysis value
are about the same after analyzing at 30 minute intervals.
4.19.4 Cleanser Discharge

If finish the acid cleaning process, stop the pump and handling temporary Valve, and
then drain water as inject the N2 Gas (0.3-0.5 Kglcaf).
4.19.5 Rinse
- If finish drain cleanser, Demi. Water preserved in Demi. Tank filling in Boiler after
treated by N2H4100 PPM and Drain to waste water treatment plant after circulating
2-3 Cycle operating temporary circulation pump.
- Rinsing should be done by same procedure at 2-3 times until Turbidity reach the
below 5NTU and Oil Concentration reach the below 0.5ppni.
4.20 Neutralization, Passivation
4.20.1 Preparation for Neutralization
1) Heating
If finish I-insing,Aux. Steam shall be supplied from Aux. Steam Header to Temporary
Heat Exchanger and increased circulation water temperature until 80+5"C as
circulation last rinsing water.

WP NO : WPN1033
Pl. Doosan Heavy Industries REVNO: 0
Indonesia
WORK PROCEDURE DATE : 1~4LXl11
- - - -
2) lnjection Chemical
If circulation water temperature reach above 80°C, Citric Acid (0.1 %) solute and
preserved in chemical storage tank shall be injected by same procedure like acid
injection.
3) Circulation and complete

After Citric Acid injection, Water shall be continued to circulate until fixing T-Fe value
over 3 times as sampling and analyzing each 30 minute.
* Analysis point: PH, Fe++, Fe+++
4.20.2 Neutralization
I ) lnjection Chemical
Ammonia Water (0.075%) should be injected by same procedure of acid injection as

maintaining liquid prepared neutralization temperature at 80 k 5 "C .
2) Circulation
Sample of each part should be extracted and checked as maintaining temperature at

80 +5°C and circulating 2-3 Cycle whether if neutralization proceed evenly.
4.20.3 Passivation
I) lnjection Chemical
Hydrazine (0.05%) shall be injected by same procedure of Acid injection as cherr~ical
prepared Passivation keeping 80 5 "C . +
2) Circulation
If finish the chemical injection, Circulation shall be continued 2-3 Cycle as maintaining
Temperature above 80 +
5°C and Concen.tration of Hydrazine above 500.
Sample should be extracted, analyzed and checked if Passivation proceeds in each
equipment cleansing part evenly.
4.21 preservation
Cirebon Coal Fired Power Plant hoject

WP NO : WPM033
Indonesia
WORK PROCEDURE DATE : 1L?412011
PAGE : 13cf19
4.21.1 Preservation for Wet corrosion
Preserve as Full Filling Demi Water Including 200 PPM
4.22 Test and Restoration
4.22.1 Test
Corrosion Rate of Test Piece should be the below 1.0 mgla~l'lhr,And Passivation of
inner Test Tube shall be made 95 % membrane.
4.22.2 Restoration
- Piping Installed Temporary for Cleaning Work should be Uninstalled and Restoring
the Main Equipment.
4.22.3 Waste water treatnient
- After chemical cleaning, Alkali cleaning waste water shall be treated by consigned
sub-vender which have required license and the other waste water shall be
collected in waste water treatment plant. The waste water collected WWTP will be
treated to meet effluent limitation required by local environmental regulation.

Attachment #I
CHEMICAL CLEANING LOG SHEET( 1

TEMPERATURE('C) Dis. CHEMICAL IRON(PPm)
STEP PH Remark Recorder
SUP. RET. Press. Acidity Concentration Fe2+ Fe3+ T-Fe

Attachment #2
TEST Record
(Chemical Cleaning TEST)
Result
Progress
Cleansing
medium
(
1
Analysis Point ~ Result
Chemical Requirement
Rinsing Cold Water

Turbidity
Maintaining
~
I
L
concentration
Acid
concentration AX-3903-A :
Acid
Acid
Cleaning
Reducing Agent :
Pre
Citric Acid PH Citric Acid :
Neutralization
Neutralization
-
Passivation Hydrazine N2H4 N2H4 :
Preservation Nitrogen Pressure IU2 Gas :
Date Doosan CEP

Attachment #3
Chemical Cleaning Check Sheet
1. Corrosion Rate for Test Piece
1) Average Corrosion Rate
2) Passivation Rate
2. Amount of Steel Eruption and Removal Oil
1) Amount of Steel Eruption
2) Amount of Removal Oil
Date Doosan CEP

Attachment #4
SITE INSPECTION
Inspection Point Result
- -
1. Check if the system is .filled with water
2. Check the valve opening and closing if the water entering only cleaning pipe
3. Check if the suction filtering instrument is installed to whole pump
4. Check if it is possible to drain for a moment
5. Check if it is possible to out whole foreign materials out of system
6. Check whole exhaust Valve operation status in system
7. Check if it is possible to control pump pressure

and Test is Operated after opening pump inlet/outlet Valve
I 8. Check packing and bearing in each pump if they will over heating
9. Check if the suction net is inspected frequently for Test and housekeeping
after circulation, stopping and draining
10. Check if the Rinsing is performed until there are no foreign materials
11. Check Uninstall Temp. piping and Extra Equipment after Rinsing, Acid Cleaning and Passivation
Date Doosan CEP

Inspection and Test Plan l-4 ITP NO. ITP-M-034
'
1
Project : CIREBON COAL FIRED POWER PLANT
Customer : PT CIREBON ELECTRIC POWER
r - Inspection Item & Component / System : Chemical Cleaning
Prepared by
I Review by
I
Date Approved By CEP
PT Doosan Mech. PT Doosan QC

1 1 SIH BACK FLUSHING SYSTEM 1
Power
1 BOILER FLUSHING SYSTEM 1
CHMICAL CLEANING SYSTEM
i----------- -1
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r--+--I
CHEMICAL JNJECTICIN P/P

WATERWPlLL TUBE
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1 8"
I I
r er
@ PT. Cirebon Electric Power

Boiler Chemical Cleaning

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Boiler Chemical Cleaning

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WORK PROCEDURE

Pf: Doasan Hrtavy Industries Indonesia

CIREBON COAL FIRED POWER PLANT

Document IVo : TO71 19-DM01-PI HA-740033

1 04. Nov. 2010 Eunpa Bang I Ohsung Kim

Cirebon Coal Fired Power Plant Project