ABO & Acid Cleaning

Station: NTPCBHEL Ref No.
PS-DC-202-500-0002
Sheet 1 of 36
Ramagundam
NTPC Ref no RGM /1/TS/1/005
Plant area: BOILER
PROCEDURE FOR BOILER ALAKALI BOIL OUT AND ACID CLEANING
SLNO
STATUS
LIST OF CONTENTS
1.0
PLANT DETAILS
2.0
OBJECTIVES
3.0
PROPOSALS
4.0
SERVICES REQUIRED
5.0
SAFETY PRECAUTIONS
6.0
EMERGENCY PROCEDURES
7.0
STATE OF THE PLANT
8.0
METHOD
9.0
COMPLETION CRITERIA
10.0
APPENDICES
a) DRAWING
b) LOG SHEETS.
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Station: NTPCBHEL Ref No. PS-DC-202-500-0002

Sheet 2 of 36
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1.0
PLANT DETAIL
The steam Generator is a controlled circulation plus Radiant
Reheat (Type CC+RR) boiler. Firing equipment consists of five
elevation of remotely controllable high energy arc Ignitors, five
elevations of air cooled, non-retractable steam automizing oil Gun
and nine elevations of pulverized coal nozzles. The nine
elevations of pulverized coal nozzles are supplied with coal from
nine numbers of type XRP 1003 Bowl mills, which form the load
carrying fuel for the boiler.
Control equipment provided consists of furnace safeguard
supervisory system, scanner air control system and a secondary
air control system.
Major auxiliary equipment provided consists of pulverizers,
feeders, fans and miscellaneous valves. Three number of boiler
circulating pumps are provided to ensure proper circulation of
water in the furnace wall circuits.
2.0
OBJECTIVE
2.1
The objective of this procedure is to clean the internal surface of

the steam generating portion and heating surface (Economiser)
using specified chemicals.
3.0
TESTING PROPOSAL
3.1
The objectives are achieved by carrying out the following testing

proposals.
3.2
By carrying out an effective boil-out, grease and any protective

coatings applied are removed.
3.3
Then, it is subjected to acid cleaning for the removal of patchy

mill scale and rust.
3.4
Finally, the acid pickled surface is passivated for the formation of

uniform and coherent magnetite layer.
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Sheet 3 of 36
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4.0
SERVICES REQUIRED.
4.1
Prior to the commencement of chemical cleaning, all the

de-mineralized water storage tanks should be kept full and the
de-mineralizing
units
kept
in
regenerated
condition.
3
Approximately, 6000 m of de-mineralized water will be consumed
for the entire process. At any time of acid cleaning, a minimum of
two boiler volumes (app. 1400 m 3 ) of de-mineralized water
should be available in ready stock to facilitate rapid flushing of the
system in the event of chemistry upset.
4.2
All the required quantities of chemicals as given below should be

made available prior to the commencement of the process.
SPECIFICATION OF CHEMICALS & QUANTITY
NAME OF CHEMICALS
QTY/Each Boiler
1.
Na2 HPO4 12 H2O DISODIUM HYDROGEN

PHOSPHATE
800 Kg.
1S 566 1991
2.
Na3 PO4 12 H2O TRISODIUM PHOSPHATE

IS:573:1992
1500 Kg.
3.
HYDROCHLORIC ACID : 30% MIN

IS:265:1993
60 Tonnes.
4.
RODINE : 213 SPECIAL

(PROPRIETORY ITEM)
Mfd. by Agromore, (Bangalore)
800 Ltrs.
OR
CORONIL : 213 SPECIAL
(PROPERIETORY ITEM)
Mfd. by Arudra Engineers Pvt. Ltd., (Chennai)
5.
CITRIC ACID
IS:5464:1995
1200 Ltrs.
800 Kgs.
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Sheet 4 of 36
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6.
AMMONIA : 25%
1000 Ltrs.
IS: 799-1990
7.
HYDRAZINE HYDRATE: 80%

IS:12086 1992
1000 Ltrs
8.
NITROGEN CYLINDERS: 6.2 mm3 each

IS:1747:1991 OR
(NITROGEN FROM CRYOGENIC TANKER)
AMMONIUM BIFLUORIDE ; 97%
IS:13119 1991
500 Nos.
9.
1000 kg.
10.
HYDRATED LIME : Grade A

IS:1540:1990 (Part II)
05 Tonnes.
11.
BLEACHING POWDER : Grade I

IS:1065 1989
02 Tonnes.
12.
CAUSTIC SODA LYE (50%)
60 Tonnes.
4.3
For acid pickling, temporary polythene U tube should be used for

drum level.
4.4
6.6 KV, 415V Supply available.
4.5
220 AC/DC, 110V AC control supply available.
4.6
Instrument/service Air available.
4.7
Chemist/Express lab available
4.8
Auxiliary steam available. (Approx: 15 TPH at 12 kg/cm 2 & 250

deg C.
4.9
Boiler pressurising pump available for use
4.10
Boiler fill pump available for use.
4.11
Flood lights / telephones / walkie-talkie are available.
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Sheet 5 of 36
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4.12
In the acid tank, only hydrochloric acid and inhibitor should be
mixed. Ammonium bi-fluoride shall be prepared in the chemical
tank. This will be mixed with the acid solution about a couple of
hours prior to the commencement of acid injection.
4.13
Two independent sources of purge water is made available for

boiler circulating water pumps.
4.14
Temporary switch board meant for the pump of chemical cleaning

process should be fed from two sources of AC supplies i.e. one
from station switchgear & other from DG sets.
4.15
Corrosion Rate (Metal Loss in grams / m2 / hr. test of Inhibitor
shall be carried out as per NACE standard before start of Acid
cleaning activity.
Necessary First Aid facilities shall be available near the test area
including first aid box (containing dilute ammonium hydroxide,
50% sodium bicarbonate solution, eye lotion, bandages, tincture
of iodine, cotton, burnol etc)
5.0
SAFETY PRECAUTIONS :
5.1
SAFETY EQUIPMENTS: M/s. BHEL will ensure the availability of

1. GUM BOOTS (Various sizes)
6 Pairs
2. Rubber gloves
6 Pairs
3. Rubber or Polythne aprons

4. Helmets
6 Nos.
12 Nos.
5. Safety goggles plain glass
6 Nos.
6. Face mask (Transparent , plastic)
4 Nos.
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Sheet 6 of 36
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5.2
EMERGENCY PROVISIONS
5.2.1
Flushing and washing water supplies
5.2.2
Ample supplies of tepid flushing and washing water supplies shall

be provided at all possible points of discharge, spillage or escape
of chemicals.
5.2.3
Adequate provisions shall be made for emergency treatment of

the eyes, comprising eye wash bottles, located conveniently to
places where discharge, spillage or escape of chemicals can
occur.
5.2.4
Safety shower shall be provided.
5.2.5
A suitable first aid treatment room with outside telephone facilities

shall be provided within a reasonable distance of the place where
chemicals are being used.
5.2.6
A suitable room shall be provided for housing the protective

clothing and apparatus required for emergency use.
5.3
FIRST AID TREATMENT
5.3.1
Splashes of the eye
5.3.1.1
Immediately flood the eye with water. To be effective the eyelids

must be opened. The eyelids should be pushed apart using the
thumb and index finger of the left hand. The casualty will probably
not be able to open the eye himself because of painful spasms.
5.3.1.2
If an eye wash bottle is used the jet should not be directed at the
front of the eye. It should be directed in from the side, so that flow
is over the surface of the eye.
5.3.1.3
Irrigation should be continued for 5 10 minutes after which the

casualty should be taken to the first aid room.
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Sheet 7 of 36
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5.3.1.4
Irrigation should be continued in the first aid room. Remember

vision is saved by thorough irrigation, no other treatment can
prevent damage if this is omitted.
5.3.1.5
After thorough irrigation the eye should be covered with a pad;

the patient should be referred for medical opinion.
5.3.2
Irritation of the skin
5.3.2.1
5.4
If signs of skin irritation occur the persons should be removed

from contact and referred for medical opinion. In the event of the
splashing of the skin with chemicals the effected area should be
washed thoroughly avoiding spreading contamination to the face
and eyes.
Pipe Insulation
5.4.1
All temporary / Permanent pipelines carrying steam / hot water

and coming in contact with personal will be insulated.
5.4.2
Test area will be cordoned off and unauthorized persons entry

shall be prohibited .Suitable signboard shall be displayed.
5.4.3
Whenever any inspection in made during the cleaning process,

the location should be adequately ventilated.
5.5
SAFETY OF PLANT:
A) If the light up after cleaning could not be done within 3
weeks after completion of cleaning, the system will be
suitably preserved.
B) Temperature limitation specified for various steps should
not be exceeded.
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Sheet 8 of 36
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6.0
EMERGENCY PROCEDURES :
6.1
The testing team should be aware of the operating procedures of

fire extinguishers to be used for quenching minor or major fires.
6.2
The testing team should be aware of the procedure to be followed

in case of accident involving personnel injury .
6.3
In case of failure of running circulating pump the stand by pump

should be started immediately without delay.
6.4
An operator posted at the pump area, should be instructed to

stop the pumps and properly isolate the system in the event of
emergency. Emergency operating instructions, in this record
should be prepared at site. All the test team members should be
well conversant with the emergency operating instructions.
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Sheet 9 of 36
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7.0
STATE OF THE PLANT

Readiness of the following is to be ensured.
7.1
During the acid cleaning process, all the permanent boiler

instruments are isolated except providing a temporary pressure
gauge of 0 to 5 kg/ cm 2 in the drum for monitoring nitrogen
pressure in the drum during nitrogen capping.
7.2
For alkali boilout, neutralizing and passivation processes,

essential control and instruments viz. Protections, interlock,
alarms, measurement, annunciation etc. required for safe lightup
of boiler are made available, as per mutually agreed list between
site NTPC and BHEL.
7.3
Boiler is flushed thoroughly including the temporary pipe lines

and system. This should be done prior to the connection of
temporary acid cleaning system to the main boiler.
7.4
For chemical cleaning process, the internals of the non-return

valve provided in the economiser recirculation line is removed in
order to facilitate fast filling and draining of the boiler.
7.5
All the boiler auxiliaries are made ready and available for boiler
light up. This includes Auxiliary steam, chemical dozing pumps,
tanks, all boiler circulating pumps, fans, oil pumps etc. A
checklist, containing minimum requirements to be made ready
prior to commencement of Chemical cleaning is enclosed at 7.20.
7.6
Drum vent lines, Nitrogen capping lines are properly tagged and
taken to suitable location for easy operation.
7.7
Prior to the commencement of alkali boilout, alkali flushing

(detergent flushing) of preboiler system is completed.
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Sheet 10 of 36
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7.8
For ABO, only Primary Separators are erected in upper drum and
baffle plates are erected in lower drum. Secondary separators
and Driers not erected in the upper Drum and orifices not erected
in the lower drum for ABO.
7.9
For Acid cleaning, Primary separators erected for ABO are also
removed.
7.10
After completing acid cleaning, all the internals of upper and

lower drum are installed back and both drums are normalized.
(Please note that, baffle plates are already in erected condition in
the lower drum).
7.11
In addition to the metal temperature in the drum, additional

temperature points with penning type temporary thermocouple
are provided in the ring header (bottom drum) at minimum 4
locations at equal distances. Provision made for monitoring
temperature in the control room.
7.12
O & M instruction for the boiler and other auxiliaries including

circulating pumps are available well in advance of the
commencement of the cleaning process.
7.13
The pressure and temperature gauges and the flowmeter

installed as per the scheme.
7.14
All the safety measures discussed and implemented in advance

with suitable instruction/caution tags provided at strategic places/
equipment.
7.15
Various drainings from the system at different operations during

the process is provisioned with adequate neutralisation prior to
final disposal.
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Sheet 11 of 36
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7.16
Boiler tube coupons placed at two ends inside the drum and
bottom ring beader to see the effectiveness of the cleaning.
7.17
Proper neutralising arrangement is available at site to neutralize

and dispose off the effluent in line with A.P. pollution control board
norms.
7.18
Chemical dosing system is ready.
7.19
All Boiler circulating water pumps are ready.
7.20
MINIMUM REQUIREMENTS
1. ENSURE THE COMMISSIONING OF THE FOLLOWING
INCLUDING THEIR PROTECTIONS, INTERLOCKS,
MEASUREMENTS, ALARMS AND ANNUNCIATIONA: ONE ID FAN
ONE FD FAN
ONE SEC. AIR PRE-HEATER ALONG WITH ITS
SOOT BLOWING SYSTEM
FIRE DETECTION AND FIRE FIGHTING SYSTEM
ROTOR STOPPAGE ALARM
OIL CARRY OVER PROBE
AIR MOTOR
(PROPER ISOLATION OF THE OTHER SAPH, IN CASE
IT IS NOT AVAILABLE, SHOULD BE ENSURED)
STEAM COIL AIR PRE-HEATER
LIGHT OIL FIRING SYSTEM
ELEVATION OF LIGHT DIESEL OIL FIRING
EQUIPMENTS
FSSS
SADC
DDCMIS
MMIPS
SCANNER AIR SYSTEM
HP DOZING SYSTEM
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Sheet 12 of 36
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CC PUMPS
MEASUREMENTS, ALARMS, ANNUNCIATIONS
PERTAINING TO SECONDARY AIR, FLUE GAS FEED
WATER, STEAM & BOILER METAL TEMP.
BOILER BOTTOM HOPPERS WITH FURNACE BOTTOM
SEALING SYSTEM AND PROPER MAKE UP & OVER
FLOW ARRANGEMENTS.
COMPLETION OF GAS TIGHTNESS TEST OF FURNACE
AND COMPLETION OF ITS INSULATION.
2. COMPLETION OF AIR TIGHTNESS TEST OF AIR AND FLUE
GAS DUCTS AND COMPLETION OF THEIR INSULATION
3. ENSURE FREE EXPANSION OF THE FURNACE AND
DUCTS AND PROVISION OF EXPANSION MARKERS,
ALONG WITH PUNCHING OF INITIAL POSITION.
4. BLOWDOWN SYSTEM OF BOILER
5. PROPER DRAINAGE SYSTEM OF BOILER AREA.
6. AIR IN LEAK TEST OF MIN. TWO PASSES OF ESP &
COMPLETION OF THEIR INSULATION.
7. READINESS OF TWO PASSES OF ESP IN ALL RESPECTS
INCLUDING MECHANICAL, ELECTRICAL & PEMS.
8. ADEQUATE QUANTITY OF LIGHT OIL STOCK.
READINESS OF LIGHT OIL HANDLING SYSTEM.
9. COMPLETION OF PRE-BOILER SYSTEM ALKALI
FLUSHING.
10. READINESS OF N2 CAPING SYSTEM.
11. READINESS OF MDBFP AND FEED SYSTEM.
12. BOILER WATER SAMPLING SYSTEM ALONG WITH SAMPLE
COOLERS (AS PER MUTUALLY AGREED BETWEEN NTPC &
BHEL SITE)
13. AVAILABILITY OF AUXILIARY STEAM SYSTEM FOR
HFO SYSTEM (FO TANKS HEATING, FO HEATERS,

DRAIN OIL SYSTEM ETC.)
FUEL OIL FIRING EQUIPMENT AT BOILER FRONT
STEAM TRACING
SCAPHs
SOOT BLOWING SYSTEM OF SEC. APHs.
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Sheet 13 of 36
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14. DC BATTERIES, CHARGERS AND DCDBs.
15. DG SET, DG SWITCHGEAR, EMERGENCY SWITCH GEAR AND
AVAILABILITY OF EMERGENCY SUPPLIES FOR
SCANNER AIR FAN
EMERGENCY LIGHTING
16. UPS
17. FIRE FIGHTING SYSTEM OF CONCERNED EQUIPMENTS.
18. AIR CONDITIONING SYSTEM OF UCB, VFD ROOM AND ESP
CONTROL ROOM
19. EQUIPMENT COOLING SYSTEM VIZ.
DMCW SYSTEM ALONG WITH PLATE-HEAT

EXCHANGERS AND ALKALI DOZING SYSTEM.
CLCW SYSTEM.
20. AVAILABILITY OF ADEQUATE QUANTITY OF DM WATER.
21. ADEQUATE CAPACITY OF INSTRUMENT AIR AND SERVICE AIR
SYSTEM
22. EMERGENCY OPERATING INSTRUCTIONS VIZ. AC POWER
FAILURE, D.C.POWER FAILURE, APH FIRE ETC
23. ADEQUATE LIGHTING IN OPERATING AREAS.
24. PUBLIC ADDRESS SYSTEM AT ALL OPERATING LOCATIONS,
INCLUDING TELEPHONE & WALKI TALKIES AT ALL AFFECTED
AREAS
25. READINESS OF STAIRCASES, HANDRAILINGS AND PLATFORMS.
26. PERSONAL SAFETY EQUIPMENT.
27. READINESS OF DRAINAGE SYSTEM OF BOILER AND TURBINE
ZERO METRE ELEVATIONS.
28. EASY ACCESS AND APPROACHES TO ALL THE OPERATING
EQUIPMENTS.
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Sheet 14 of 36
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8.0
TEST METHOD :
8.1
ALKALI BOIL OUT

The boiler (steam generating surfaces and economiser) is filled
with an alkaline solution containing 500 ppm of di-sodium
phosphate dodeca hydrate, and 1000 ppm of Tri sodium
phosphate do deca hydrate and then fired to raise the pressure to
40 kg/ cm2, following the specified operational procedures. During
the process, rotation of boiler circulating water pumps should be
done as per operating instructions.
8.1.1
Procedure
Prepare the boil out chemical solution in hot demineralized water
in the chemical mixing tank. The solution is formulated by
dissolving the following proportionate quantities of chemicals,
depending on the volume of the system to be cleaned.
1.
0.05% Na2 HPO4
2.
0.1 % Na3 PO4
12 H2O
12 H2O
8.1.2
Hold the solution prepared as above in the tank and homogenise

the same by recirculating the solution by operating temporary DM
water pumps.
8.1.3
Start filling the boiler with de-mineralized water, with

simultaneous blend filling of already prepared boil out chemical
solution.
8.1.4
Light up the boiler as per O & M instructions and gradually raise

the pressure to 40 kg/ cm2 . Hold the pressure for four hours.
Obtain boiler water sample from CBD sampling point and analyse
for alkalinity, phosphate content, dissolved silica and oil content.
Prescribe blow down every 2 Hrs. once, after killing the fire;
Duration of the blow down shall be for one minute Ensure that
the drum level does not go out of gauge glass vision. Repeat the
operation of raising the pressure to 40 kg/ cm 2 after each blow
down.
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Sheet 15 of 36
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During the process if the phosphate concentration drops to half of
the initial values maintained, dose additional chemicals through
phosphate dosing system to restore original concentration.
NOTE: All the testing will be done as per the mutually agreed
standard procedure. However, inhibitor efficiency test will be done
as per NACE standard.
8.1.5
The boil out is declared completed when the oil value is less then
5 ppm or minimum eight blow downs are completed whichever is
later.
8.1.6
Drain the boiler, when it is cooled, as per O & M instructions.

Once the draining is completed, fill the boiler with demineralised
water, heated to 80 deg C, through Temp. DM water pumps. Back
flush the super-heaters with DM water containing 200 ppm
hydrazine and pH raised to 10.0 with NH 3 till it overflows into the
drum. Drain the boiler to the waste disposal system. Inspect the
lower and upper drums and manually clean them.
8.2
NOTE
8.2.1
To speedup economiser filling and draining operation, the

isolating valve in the economiser recirculation line is to be kept
opened and the internals are to be removed from the non-return
valve provided in the economiser recirculation line.
8.2.2
As far as possible, all the boiler circulating pumps should be kept

running on rotation during alkali boil out. However, if due to any
unforeseen reasons, any of the pumps remains out of service, the
non-running pumps are also to be kept under continuous purging.
8.2.3
Whenever, boiler is to be filled with chemical solution and if the

procedure calls for boiler light up, the following guide lines should
be followed besides O & M instructions.
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Sheet 16 of 36
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8.3.0
FILLING UP OPERATION:
The chemical solution should be filled up simultaneously
parallely through the bottom drum and economiser till the water
level is seen at the lower most portion of the level gauge.
8.4.0
LIGHTING UP
Besides following the O & M instructions the following points are
to be taken care of.
8.4.1
Drum air vents are to be opened before lighting up the boiler.
8.4.2
The drum level has to be brought to the top port of the gauge
glass. This would provide the necessary water for filling the
headers and tubing above the normal water level.
8.4.3
Start the / one boiler circulating pumps in accordance with the

boiler circulating pump operating instructions.
8.4.4
After commissioning two pumps, take out or add water to

establish 100mm above normal level indicated in the gauge
glass.
8.4.5
Initiate boiler light up as per O & M instructions.
8.4.6
Place further boiler water circulating pumps in operation when the

drum pressure reaches 5 to 7 kg/ cm 2 and gradually bring the
drum level to normal level as the pressure increases. Pumps
should not be started during rapid boiler temperature changes.
(More than 100 deg C / per hour).
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8.5
SHUTTING DOWN
8.5.1
When ABO is declared completed, box up the boiler keeping the

boiler circulating water pumps in operation.
8.5.2
Allow the boiler to under go natural cooling by keeping open all

the dampers / gates in the flue gas system.
8.5.3
Keep at least one pump running at drum pressures below

2 kg/ cm2 and bring the water level to normal.
8.5.4
Open drum vent when the drum temperature is around 90 deg C

to 100 deg C.
8.5.5
Bring the water level in the drum to the lower most visible point in
the gauge glass and stop the last boiler circulating water pump as
per O & M instruction.
8.5.6
Drain the unit after attaining the desired cooling at the down
comer and suction manifold.
8.5.6.1
By following the above procedure, pump vibrations are

maintained and air ingress also averted.
8.5.6.2
Chemical feeding pumps and temporary DM water pumps should

be started simultaneously to achieve the controlled feeding of
chemicals for uniform concentration of the solution being fed to
the boiler. Boiler filling should be done through water walls and
economizer simultaneously. Uniform and required concentration
can be obtained by throttling respective control valves.
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Sheet 18 of 36
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8.6
ACID CLEANING
8.6.1
Acid cleaning is carried out by adopting soaking technique, using
hydrochloric acid of 5% + 1%, 0.2% V/V inhibitor Rodine 213
Special or 0.3% V/V of inhibitor Coronil 213 Special and 0.25%
ammonium bi-fluoride. Pickling by acid is followed by plain demineralized water rinse, ammoniated citric rinse (0.2%), plain demineralized water rinse and neutralization of the pickled surfaces
with a mild alkaline solution containing a mixture of di and tri
sodium
phosphate. Finally, the entire cleaned and neutralised
surfaces are passivated with ammoniated hydrazined solution at
an elevated temperature and pressure. All the draining operations
prior to the neutralisation step are to be done under nitrogen
capping. The gauge glass used for alkali boil out is to be replaced
by a polythene tube.
8.6.2
MOCK TRIAL:
A mock trial should be conducted prior to the commencement of
the pickling operation to check the healthiness of the temporary
system erected and to acquire an idea of operations of various
valves, pumps and other connected system, so that actual
operation is carried out to the nearest accuracy. The boiler filling in
approximately 1 hour and draining in approximately 1 hour are to
be achieved.
8.6.3
PROCEDURE:
Fill the boiler parallely through water wall and economizer with
plain de-mineralized water up-to the bottom gauge glass. Stop
filling though water wall and economizer. Now, back fill the superheaters with de-meneralized water containing a min. of 200 ppm
hydrazine with solution pH raised to 10.0 using ammonia. Back
flush the super heater till the drum level rises to normal operating
level. Having ensured that the superheaters are filled, light up the
boiler as per the O & M instructions and raise the metal
temperature both at the drum and suction manifold to 80 deg. C
with boiler circulating pumps in service. Once the temperature is
reached, shut down the unit and drain water from boiler to the
waste disposal system. Close all the furnace openings to retain the
heat in the boiler.
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Sheet 19 of 36
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8.6.3.1
Mix the required quantities of 30 32% Hydrochloric acid and
inhibitor Rodine 213 Special or Coronil 213 special, and keep it
ready in the acid tanks (2 Nos.). Dissolve required quantity of
ammonium bi-fluoride in D.M water and keep it ready in the
chemical mixing tank. Transfer the ammonium bi-fluoride solution
equally into the two acid tanks. Thoroughly mix the inhibited acid
and transferred ammonium bi-fluoride solution by running the
chemical injection pump on re-circulation for a minimum of one
hour, particularly prior to the commencement of chemical injection
into the boiler.
8.6.3.2
Keep all the boiler blow down valves shut and drum vent valves
open to facilitate escape of gases generated during pickling
process.
8.6.3.3
Keep the nitrogen capping

commencement of acid filling.
8.6.3.4
Choose the centrally located boiler circulating pump for operation

to circulate the chemical solution during soaking/pickling time.
Keep a continuous supply of purge water to all the boiler
circulating pumps.
8.6.3.5
Start filling the boiler parallely through water wall, suction header
of boiler circulating pumps and economiser with heated demineralised water, temperature restricted to 65 deg C 70 deg C.
Simultaneously start injecting the chemical solution already kept
prepared in the acid tanks (mixture of inhibited hydrochloric acid
and ammonium bi-fluoride) along with the fill water. Suitably
control the opening of the control valves to achieve a uniform acid
concentration of 5% + 1% in the water being filled in the boiler.
The regulation of uniform acid concentration is done by very
frequent sampling, from point 'A as shown in the scheme, testing
and suitably adjusting the opening of the chemical injection
control valves. The temperature of the chemical mixed water
should not exceed 650 C to 700 C at any point of time. Stop filling
through suction header of Boiler circulating pump, when the level
in the drum is at the bottom of the gauges glass. But continue
filling through the bottom drum and economizer till the level in the
drum touches 100 mm above the center line of the gauge glass.
system
ready
prior
to
the
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Sheet 20 of 36
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This will ensure complete filling of ECO links to the drum and the
water wall riser tubes. Do not permit the level to go out of sight in
the gauge glass.
8.6.3.6
Once the filling is completed, start the selected boiler circulating

pump and collect samples at every 5 minutes interval from
discharge of boiler circulating pump and analyse for acid strength
and iron concentration. At the end of 30 mts. Period stop the
pump and allow the chemical solution to soak. Operate the same
boiler circulating pump, that was in service earlier for 5 minutes at
an interval of 30 minutes each. Carry out the sampling at every
10 minutes interval and analyse for iron concentration. Acid
pickling / soaking process is to be continued till iron concentration
in three consecutive samples show equilibrium status. If the iron
concentration values do not level out and attain equilibrium
status, regardless of analytical results, the total acid contact time
will not be allowed to exceed 6 hours including the time for filling
and draining.
8.6.3.7
Declare the completion of pickling process once the acid strength

and iron concentration level out and reach equilibrium. Now,
operate the same Boiler circulating pump, that remained in
service earlier for 5 minutes. Stop the pump and drain the unit as
fast as possible, under Nitrogen Capping, maintaining the
nitrogen pressure in the drum around 0.5 to 1 kg/ cm 2 .
8.7
DM RINSE
8.7.1
Re-fill the boiler by running the temporary DM water pumps with

demineralised water heated to a temperature of 60 deg C 65
deg C taking care of the operation of the drum vent valves to
maintain 0.5 kg/ cm2 . Nitrogen pressure in the drum. Fill the
water up to the centre of the gauge glass. Further raise the level
in the drum by 100 mm, by back flushing the superheaters with
treated water.
Signatures
NTPC
BHEL

Sheet 21 of 36
Ramagundam
Plant area: BOILER
STATUS
SLNO
This will also remove, if any trace of acid vapours lodged in the
connecting links to the superheaters. Now run the same boiler
circulating water pump, which was operated earlier till the uniform
concentrations of acid and iron or attained, in the system as
indicated by analysis of the same taken from the discharge of the
boiler circulating pump at sample point A. Analyse the sample for
pH, the pH of the DM rinse should not be allowed to go above 4.0
Drain the boiler under nitrogen capping as practised earlier.
8.8
AMMONIATED CITRIC ACID RINSE
8.8.1
Prepare a solution of ammoniated citric acid with the required

quantity of citric acid mono-hydrate and liquor ammonia in the
chemical mixing tank, equivalent to get a concentration of 0.2%
acid in the water entering into the boiler (as stipulated in clause
8.8.3). Keep the solution under re-circulation to maintain
homogeneity.
8.8.2
Start filling the boiler parallely through the Boiler circulating pump
suction header, water wall and the economiser with hot demineralised water restricted to a temperature of 60 0 to 650 deg. C.
Simultaneously start injecting ammoniated citric acid solution.
8.8.3
Maintain a uniform strength of 0.2% acid in the water taken into

the boiler. Adjust the pH. of the final solution entering the boiler at
sampling point A, between 3.5 and 4.0. Continue the filling
operation, till the level in the upper drum is close to the bottom of
the gauge glass. Now close the valve in boiler circulating pump
suction header & further raise the level in the drum up to middle
of the gauge glass by filling through the economiser & water wall
so as to fill economiser and water wall connecting links.
8.8.4
Start the same boiler water circulating pump that remained in

operation earlier, run it for 5 minutes at an interval of every 30
minutes and collect the sample from CC pump discharge after
stoppage of CC pump. Check for acid % and iron concentration.
Signatures
NTPC
BHEL

Sheet 22 of 36
Ramagundam
Plant area: BOILER
STATUS
SLNO
When lron concentration attains a steady state value for 3
consecutive readings, declare citric acid rinsing is completed. In
any case it will not be completed in less than 4 Hrs. or more than
5 Hrs. Drain the boiler under a positive nitrogen pressure as
practiced earlier.
8.9
DEMINERALISED WATER RINSE
8.9.1
After draining the citric acid solution, start filling the boiler with demineralized water heated to 60 deg 65 deg C. parallely through
the boiler circulating pump suction header, water valve and the
economizer. Raise the level in the drum upto + 100 mm mark.
Operate the boiler circulating water pump for 5 minutes. Stop the
pump and drain the boiler under nitrogen capping as practised
earlier. Repeat the filling and the dumping operation under
Nitrogen Capping till the iron content in the sample collected at
sampling point B is less than 25 ppm.
8.9.2
Maintain the nitrogen atmosphere in the system by maintaining a

pressure of 0.5 to 1.0 kg/ cm2 till the next process of
neutralisation is started.
8.10
NEUTRALISATION
8.10.1
This process is employed to neutralise any acid/acidic pocket

remaining in the system and also to mildly passivate the acid
pickled surface. This prepares the base for achieving an effective
final passivation. For this process, the boiler system and the
necessary instrumentation should be made ready to make firing
feasible. The U tube manometer provided for the acid pickling in
the drum shall be replaced by the gauge glass. All the boiler
water circulating pumps should be made ready for operation.
8.10.2
Prepare the neutralising solution in the chemical mixing tank or

with approximate quantities of di-sodium phosphate do-deca
hydrate and tri-sodium phosphate do-deca hydrate to get a
concentration of 0.1% and 0.2% respectively in the boiler.
Signatures
NTPC
BHEL

Sheet 23 of 36
Ramagundam
Plant area: BOILER
STATUS
SLNO
8.10.3
Recirculate the solution in the tank to homogenise the mixture.

Start filling the boiler with demineralised water, parallely through
the boiler circulating pump suction header water wall and
economiczer with simultaneous injection of phosphate solution,
maintaining uniform concentration throughout the filing period,
under the nitrogen capping as practiced earlier. Regulate the
drum vents. Start the boiler water circulating pumps as per the
O & M instructions. Fire the boiler and gradually raise the
pressure to 10kg/ cm2 .
8.10.4
Follow the precautions as detailed out for alkali boil out. Hold the
pressure at 10 kg/ cm 2 for about 4 hrs. Utilise this opportunity to
blow off all the instrument lines that might have come into contact
during acid pickling time, for better neutralisation of those lines.
After 6 hours, kill the fire, the natural cooling of the boiler be done
and sub-sequently drain the boiler as per procedure explained
earlier and O & M instructions. While draining backflush the
superheaters with de-mineralized water conditioned with
hydrazine and ammonia. The boiler is drained with the drum
vents open to the atmosphere. Allow the system to aerate.
Prepare the boiler for passivation.
8.11
PASSIVATION
8.11.1
The underlined idea is to form a protective magnetite coating on

the steam generating and water touched surfaces that were
exposed to the pickling process.
8.11.2
Prepare a blended solution of hydrazine and ammonia with

calculated quantities in the chemical mixing tank in order to finally
achieve a minimum residual amount of 200 ppm hydrazine and a
solution pH. of 10.0 when filled in the boiler.
8.11.3
Fill the boiler with de-minerallsed water, with simultaneous

injection of hydrazine ammonia mixture. Fill the boiler through
bottom and economiser parellely as practised earlier, upto the
operating level in the drum gauge glass.
Signatures
NTPC
BHEL

Sheet 24 of 36
Ramagundam
Plant area: BOILER
STATUS
SLNO
8.11.4
Prepare the boiler for firing as per O&M instructions. Start the
boiler water circulating pumps as per O & M instructions and fire
the boiler at a slow rate. Raise the drum pressure to 40 kg/ cm 2
and hold it for 24 hrs and maintain a residual hydrazine content of
25 ppm & a solution PH. 10.0 in the feed water being fed into the
boiler during the entire passivation operation. Dose, hydrazine
ammonia mixture in the feed water in the feed storage tank.
8.11.5
After 24 hours of operation, shut down the boiler and allow it to

cool slowly. Keep the boiler water circulating pumps in service as
per the O&M instructions. Shut down the pumps when the metal
temperature drops to 95 deg C.
8.11.6
Drain the boiler under atmospheric pressure and aerate the

system.
8.11.7
Open the upper and lower drums for inspection. Manually clean
them. Refit the drum internals and restore the boiler and prepare
it for regular operation for steam blowing, safety valve floating
etc.
8.12
NEUTRALISATION OF EFFLUENTS
8.12.1
Effluents generated during following activities will be neutralised

and disposed in line with ORISSA Pollution control board norms.
Alkali Boil Out & Neutralisation of pickled surface:
PH of the solution is lowered to less than 9.0 by sufficient dilution
with raw / fire water.
Prepare the boiler for firing as per O&M instructions. Start the
boiler water circulating pumps as per O & M instructions and fire
the boiler at a slow rate. Raise the drum pressure to 40 kg/ cm 2
and hold it for 24 hrs and maintain a residual hydrazine content of
250 ppm & a solution PH. 10.0 in the feed water being fed into
the boiler during the entire passivation operation. Dose,
hydrazine ammonia mixture in the feed water at the suction
point of the feed pump through L.P dosing system / directly
pouring in the feed storage tank.
Signatures
NTPC
BHEL

Sheet 25 of 36
Ramagundam
Plant area: BOILER
STATUS
SLNO
8.12.2
Acid pickling
Effluent is neutralised with caustic soda Lye & Lime Powder. pH
of disposed effluent be maintained between 5.5 to 9.0 and
fluoride less than 2.0 ppm.
8.12.3
Citric Rinse
Effluent is neutralised with caustic soda Lye pH of disposed
effluent to be maintained between 5.5 to 9.0.
8.12.4
Passivation
Hydrazine & Ammonia will be neutralised with bleaching powder.
8.12.5
The cleaning activity should be done with a planning that the

boiler start up could be possible immediately after completion of
cleaning process.
9.0
COMPLETION CRITERIA:
9.1
The test coupons placed at identified locations will be taken out in

the presence of NTPC and all coupons will have uniform
cleaning.
9.2
The drum surface will be visually inspected for uniform smooth

coating of magnetite.
9.3
The low point headers will be inspected and loose debris if any,
will be removed.
Signatures
NTPC
BHEL

Sheet 26 of 36
Ramagundam
Plant area: BOILER
STATUS
SLNO
9.4
Termination Criteria for each step will be as follows:
9.4.1
Alkali Boil out :
(Ref.8.1.5)
9.4.2
(Ref.8.1.6)
9.4.3
(Ref.8.1.6)
9.4.4
Rinsing (Water circuit)
[ oil ] < 5 ppm or minimum 8 blow

downs, which even is latter
:
[ PO4 ] < 2 ppm.
Super heater back-flushing : :
[ PO4 ] < 2 ppm.
Acid Cleaning :
Fe (ppm) value of the sample should

be stable at least for three readings
and time should not be more than six
hours. (including filling and draining.)
DM Rinse :
After circulation, the system drained

under nitrogen blanketing. ( pH shall
be up to 4.0)
(Ref.8.8.4)
Citric Rinse:
Same as acid pickling except the time

should not be more than 5 hours.
9.4.7
DM Rinse :
[ Fe ] < 25 ppm
(Ref.8.1.3.6)
9.4.5
(Ref.8.7.1)
9.4.6
(Ref.8.9.1)
9.4.8
(Ref.8.10.3/4)
9.4.9
Neutralization:
Hold the Boiler pressure for 10 kg/c m 2

for 6 hours.
Passivation :
Coupon inspection to be carried out

after passivation
(Ref.8.11)
Signatures
NTPC
BHEL

Sheet 27 of 36
Ramagundam
Plant area: BOILER
STATUS
SLNO
NOTE (Refer Drg.No. 4:PS:TSX:137:00
1.
Drains to be provided at lowest points of temporary piping.
2.
Sampling point to be provided atleast 5 metres away from the

acid mixing point.
Second sampling point at the tail (farthest end from acid mixing
point of the circuit.
3.
Temporary lines connecting main boiler up to first isolating valve

should withstand 40 Kg/Cu.Cm. Accordingly, the pipe selection to
be made.
4.
Rubber lined valves should be provided in the entire chemical

injection system upto the final injection point in the main feeding
line. The regulating valves should be of bottom diaphragm type.
5.
Pressure gauges in the chemical injection system should be of

diaphragm type.
6.
Rubber lining provided in the various valves and pipe lines should
be resistant to heat, acid and alkali.
7.
15 Cu.M. tank to be epoxy coated internally and leak test to be

done before insulating the tank.
8.
All temporary connections to Boiler should be of radiographic

quality.
9.
40 Cu.M. tank to be leak tested before insulation.
10.
2 Nos. of Acid Storage Tank to be spark tested (By the vendor).
11.
Small drains not connected to neutrallsing pit to be neutralissed

locally with lime power and let into storm water canal.
12.
Service water supply should be available near the pump

operating areas.
13.
Additional Checklists/Modifications in the lay-out, if found

necessary, to be made at site in consultation with site
Commissioning Incharge.
Signatures
NTPC
BHEL
SHEET 29 of 36
10.f
ALKALI BOIL OUT

LOG SHEET NO. 1
DATE:
PROJECT:
UNIT
:
I.
ADDITION OF CHEMICALS:
DATE
II.
TIME (HRS)
NAME OF CHEMICAL
ADDED.
QUANTITY
ANALYTICAL DATA:
Sl. No.
Date
Time
(HRS)
Total
Alkalinity
as
CaCO3
(PPM)
Total
Phosphate
(PPM)
Silica
(PPM)
Oil
(PPM)
Signatures
BHEL
NTPC
SHEET 30 of 36
10.f
BOILER CHEMICAL CLEANING

LOG SHEET NO. 2
DATE:
PROJECT:
UNIT
:
ACTIVITY : SUPER HEATER BACK FLUSHING & FILLING
ANALYTICAL DATA:
Sl. No.
DATE
TIME
(HRS)
PH
HYDRAZINE
PPM
REMARKS.
Signatures
BHEL
NTPC
SHEET 31 of 36
10.f

LOG SHEET NO. 3
DATE:
PROJECT:
UNIT
:
ACTIVITY : ACID PICKLING.

I.
DATE
III.
TIME (HRS)
NAME OF CHEMICAL
ADDED.
QUANTITY
ANALYTICAL DATA:
Sl. No.
DATE
TIME
(HRS)
ACID
STRENGTH %
TOTAL
IRON
(PPM)
REMARKS
Signatures
BHEL
NTPC
SHEET 32 of 35
10.f

LOG SHEET NO. 4
DATE:
PROJECT:
UNIT
:
ACTIVITY: DM WATER RINSE
ANALYTICAL DATA:
SL. NO
DATE
TIME
(HRS)
ACID %
IRON
(PPM)
REMARKS
Signatures
BHEL
NTPC
SHEET 33 of 36
10.f

LOG SHEET NO. 5
DATE:
PROJECT:
UNIT
:
ACTIVITY : CITRIC ACID RINSE

I.
DATE
II.
TIME (HRS)
NAME OF CHEMICAL
ADDED.
QUANTITY
ANALYTICAL DATA:
Sl. No.
DATE
TIME
(HRS)
PH
CITRIC
ACID %
IRON
PPM
Signatures
BHEL
NTPC
SHEET 34 of 36
10.f

LOG SHEET NO. 6
DATE:
PROJECT:
UNIT
:
ACTIVITY : DM WATER RINSE.
ANALYTICAL DATA:
Sl. No.
DATE
TIME
(HRS)
PH
IRON
(PPM)
REMARKS
Signatures
BHEL
NTPC
SHEET 35 of 36
10.f

LOG SHEET NO. 7
DATE:
PROJECT:
UNIT
:
ACTIVITY : NEUTRALISATION:
I.
DATE
II.
TIME (HRS)
NAME OF CHEMICAL
ADDED.
QUANTITY
ANALYTICAL DATA:
Sl. No.
DATE
TIME
(HRS)
PH
TOTAL
ALKALINITY
AS CaCO3
REMARKS
Signatures
BHEL
NTPC
SHEET 36 of 36
10.f

LOG SHEET NO. 8
DATE:
PROJECT:
UNIT
:
ACTIVITY : PASSIVATION.
I.
DATE
II.
TIME (HRS)
NAME OF CHEMICAL
ADDED.
QUANTITY
ANALYTICAL DATA:
Sl. No.
DATE
TIME
(HRS)
PH
HYDRAZINE
(PPM)
REMARKS
Signatures
BHEL
NTPC
BOILER ALKALI BOIL OUT AND ACID CLEANING
PS:TSX:160:00:03
PROJECT : RAMAGUNDAM 500MW
TECHNICAL SERVICES DEPARTMENT
BHARAT HEAVY ELECTRICALS LIMITED

(A Government of India Undertaking)
Power Sector Southern Region
474, Anna Salai, Nandanam, Chennai 600 035.
PROJECT
RAMAGUNDAM 500MW
PROCEDURE
BOILER ALKALI BOIL OUT AND ACID CLEANING
PURPOSE OF
DOCUMENT
FOR EXECUTION / INFORMATION
DOCUMENT NO.
PS:TSX:160 :00:03
COPY NO:
ISSUED TO:
00
Rev. No.
KJ
MJH
RVS
14.05.2003
Prepared by
Reviewed by
Approved by
Date
TECHNICAL SERVICES DEPARTMENT
BHARAT HEAVY ELECTRICALS LIMITED

(A Government of India Undertaking)
Power Sector Southern Region
474, Anna Salai, Nandanam, Chennai 600 035.
ACID CLEANING OF BOILER RAMAGUNDAM 500 MW

DRG. NO: 4 PS. TSX. 0137 :00
DRAWN CHECKED APPROVED DATE
KJ
MJH
RVS
14.05.03
ACID CLEANING SCHEME FOR RAMAGUNDAM 500 MW

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Station: NTPCBHEL Ref No.

STATE OF THE PLANT

Station: NTPCBHEL Ref No. PS-DC-202-500-0002

The objective of this procedure is to clean the internal surface of

The objectives are achieved by carrying out the following testing

By carrying out an effective boil-out, grease and any protective

Then, it is subjected to acid cleaning for the removal of patchy

Finally, the acid pickled surface is passivated for the formation of

Station: NTPCBHEL Ref No. PS-DC-202-500-0002

Prior to the commencement of chemical cleaning, all the

All the required quantities of chemicals as given below should be

Na2 HPO4 12 H2O DISODIUM HYDROGEN

Na3 PO4 12 H2O TRISODIUM PHOSPHATE

HYDROCHLORIC ACID : 30% MIN

RODINE : 213 SPECIAL

Station: NTPCBHEL Ref No. PS-DC-202-500-0002

HYDRAZINE HYDRATE: 80%

NITROGEN CYLINDERS: 6.2 mm3 each

HYDRATED LIME : Grade A

BLEACHING POWDER : Grade I

CAUSTIC SODA LYE (50%)

For acid pickling, temporary polythene U tube should be used for

6.6 KV, 415V Supply available.

220 AC/DC, 110V AC control supply available.

Instrument/service Air available.

Chemist/Express lab available

Auxiliary steam available. (Approx: 15 TPH at 12 kg/cm 2 & 250

Boiler pressurising pump available for use

Boiler fill pump available for use.

Station: NTPCBHEL Ref No. PS-DC-202-500-0002

Two independent sources of purge water is made available for

Temporary switch board meant for the pump of chemical cleaning

SAFETY EQUIPMENTS: M/s. BHEL will ensure the availability of

3. Rubber or Polythne aprons

5. Safety goggles plain glass

6. Face mask (Transparent , plastic)

Station: NTPCBHEL Ref No. PS-DC-202-500-0002

Flushing and washing water supplies

Ample supplies of tepid flushing and washing water supplies shall

Adequate provisions shall be made for emergency treatment of

Safety shower shall be provided.

A suitable first aid treatment room with outside telephone facilities

A suitable room shall be provided for housing the protective

FIRST AID TREATMENT

Splashes of the eye

Immediately flood the eye with water. To be effective the eyelids

Irrigation should be continued for 5 10 minutes after which the

Station: NTPCBHEL Ref No. PS-DC-202-500-0002

Irrigation should be continued in the first aid room. Remember

After thorough irrigation the eye should be covered with a pad;

Irritation of the skin

If signs of skin irritation occur the persons should be removed

All temporary / Permanent pipelines carrying steam / hot water

Test area will be cordoned off and unauthorized persons entry

Whenever any inspection in made during the cleaning process,

Station: NTPCBHEL Ref No. PS-DC-202-500-0002

The testing team should be aware of the operating procedures of

The testing team should be aware of the procedure to be followed

In case of failure of running circulating pump the stand by pump