RECOMMENDED PROCEDURE FOR ALKALI BOIL OUT 1X120 TPH STOKER FIRED BOILER BANNERI AMMAN SUGARS LIMITED,

SATYAMANGALAM RECOMMENDED PROCEDURE FOR ALKALI BOIL OUT 1.0 INTRODUCTION:

Alkal !" l "#$ "% $&' !" l'( ) *a(( '+ "#$ a) a,a($ "% ,('-*".. )) "/ /0 ",'(a$ "/) / "(+'( $" ('."1' " l, 0('a)' a/+ "$&'( .,#( $ ') a+&'( /0 $" $&' /$'( "( ,('))#(' ,a($) "% $&' !" l'(.T& ) *l'a/ /0 ) *a(( '+ "#$ a%$'( $&' $"$al *".,l'$ "/ "% $&' !" l'( '('*$ "/. 2.0 SCOPE : G'/'(a$ /0 )#(%a*'), +(#. a/+ '*"/". )'( a(' *"1'('+ #/+'( $&' *&'. *al *l'a/ /0 )*",'. 2.0 TECHNI3UE : F"( *a((4 /0 "#$ $&' alkal !" l "#$ , 1000 ,,. "% T( )"+ #. P&"),&a$' a/+ 500 ,,. "% D )"+ #. P&"),&a$' a(' #)'+ a) *&'. *al a0'/$).Alkal !" l "#$ ) *a(( '+ "#$ a$ +(#. ,('))#(' "% 60 K07*.2. 6.0 PREPARATIONS: E/)#(' $&' %"ll"8 /0 :-B" l'( '('*$ "/ $" !' *".,l'$'+ / all ('),'*$) 8 $& ('9# ('+ *"/$("l a/+ /)$(#.'/$a$ "/. -B" l'( a#: l a( ') )#*& a) %a/),%''+ ,#.,) , )$"k'( 8 $& $ ) a))"* a$'+ )4)$'.) a/+ "$&'( *"//'*$'+ .a*& /'( ') a(' $( al (#/ a/+ $&' ( ",'(a$ "/ %#ll4 ,("1'+ / all ('),'*$). -D'a(a$"( a/+ $&' %''+ $a/k a(' ('a+4 / all ('),'*$). -B" l'( /)$(#.'/$a$ "/ *"/$"l ,a/'l .a+' ('a+4 %"( ('0#la( ",'(a$ "/. -R'%(a*$"(4 a/+ /)#la$ "/ 8"(k "% $&' !" l'( ) *".,l'$'+.All )*a%%"l+ /0, $'.,"(a(4 )#,,"($) a/+ a/4 )#,,"($) ,('1'/$ /0 !" l'( ':,a/) "/ ) ('."1'+. -A((a/0'.'/$) a(' .a+' %"( ,'(.a/'/$ l 0&$ /0 %a* l $ ') a$ all",'(a$ /0 %l""( l'1'l). -T(a /'+ ",'(a$ /0 ,'()"//'l %"( $ak /0 *a(' "% !" l'( ",'(a$ "/. -F (' % 0&$ /0 '9# ,.'/$) ,("1 +'+ a$ all 1a/$a0' ," /$) / $&' !" l'( &"#)' a/+ ,'()"/) 8"(k /0 / $&' #/ $ !' *"/1'()a/$ 8 $& $&' #)a0' "% $&' % (' % 0&$ /0 '9# ,.'/$).

-D(#. /$'(/al) ('.a / / ,") $ "/ +#( /0 !" l "#$. -C&'. *al 9#a/$ $ ') ('9# ('+ %"( $&' !" l "#$ $" !' '/)#('+. -H4+(a#ll * $')$ "% $&' !" l'( ) *".,l'$'+ $" $&' ('9# ('+ ,a(a.'$'( !'%"(' $&' *"..'/*'.'/$ "% alkal !" l "#$. -P(' ;!" l'( )4)$'. )&"#l+ !' %l#)&'+ 8 $& alkal )"l#$ "/ -HP7LP +"< /0 )4)$'. )&"#l+ !' .a+' ('a+4 %"( +"< /0 "% *&'. *al) +#( /0 !" l "#$ a*$ 1 $4. -C&'. *al la! %a* l $ ') %"( $')$ /0 "% )a.,l'). -F ()$ a + !": a/+ )a%'$4 a,,l a/*') )&"#l+ !' .a+' a1a la!l'. 5.0 PROCESS :-

-B" l'( ) % ll'+ 8 $& D M 8a$'( = +(a /'+ a) %a)$ a) ,")) !l' $" ('."1' )#),'/+'+ .a$$'( $" $&' ':$'/$ ,")) !l' .T& ) ",'(a$ "/ ) (','a$'+ "/' "( $8" $ .') $ ll $&' +(a / /0 8a$'( a,,'a() *l'a(. -O/*' $&' a!"1' ",'(a$ "/ ) *".,l'$'+, % ll #, $&' !" l'( 8 $& DM 8a$'( #/$ l $&' 8a$'( ) )''/ l $$l' a!"1' $&' !"$$". "% $&' )$'a. +(#..K'', $&' .a/&"l' *"1'( ",'/. -P(',a(' a )"l#$ "/ "% $( -)"+ #. ,&"),&a$' a/+ + -)"+ #. ,&"),&a$' a) ,'( +")a0' .'/$ "/'+ / DM 8a$'( a/+ *&a(0' $&' *&'. *al) / $" $&' !" l'( +(#. $&("#0& $&' .a/&"l' !4 )'1'(al /*('.'/$).T&' '/$ (' 9#a/$ $4 "% $&' *&'. *al) ) +")'+ / $" $&' !" l'(. -Cl")' $&' .a/&"l' *"1'( a/+ l 0&$ #, $&' !" l'( a) ,'( O=M /)$(#*$ "/).Ra )' $&' )$'a. ,('))#(' 0(a+#all4 $" 60 k07*.2 . B" l'( ':,a/) "/ ('a+ /0) )&"#l+ !' ('*"(+'+ a$ 10, 20, 20 a/+ 60 k07*.2 = #/ %"(. $4 .#)$ !' '/)#('+.Ma /$a / $&' ,('))#(' %"( 12 &(). -Ma /$a / $&' !" l'( ,('))#(' a$ 25 $" 60 k07*.2. Bl"8 +"8/ $&("#0& $&' !"$$". &'a+'( +(a / 1al1') / "(+'( $" '/)#(' ('."1al "% .#*k a/+ "$&'( .,#( $ ') *"ll'*$'+ a$ $&' !"$$"..T&' ",'/ /0 a/+ *l") /0 "% $&' +(a / 1al1') )&"#l+ !' +"/' 1'(4 9# *kl4 a/+ /"$ ':*''+ /0 "/' . /#$' ",'(a$ "/ ,'( 1al1'.I$ ) '9#all4 .,"($a/$, +#( /0 $&' '/$ (' ",'(a$ "/ $" .a /$a / $&' +(#. l'1'l. -T&' l"8 ," /$ !l"8 +"8/) a(' $" !' ",'(a$'+ "/*' / $8" &"#() a/+ ) : )#*& !l"8 +"8/) a(' 0 1'/ +#( /0 $&' 12 &"#() ",'(a$ "0/ "% !" l "#$. -B" l'( 8a$'( )a.,l' ) *"ll'*$'+ a%$'( '1'(4 !l"8 +"8/ a/+ a/al4)'+ %"( ,H a/+ alkal / $4. -A%$'( $&' *".,l'$ "/ "% 12 &"#() "% !" l "#$ ",'(a$ "/, $&' !" l'( ) !":'+ #, a/+ all"8'+ $" *""l /a$#(all4, )" $&a$ $&' ,('))#(' ) +(",,'+ $" 1 k07*.2.A$ 1 k07*.2 . ,('))#(', $&' !" l'( ) +(a /'+ $&("#0& l"8 ," /$ +(a /).T&' )#,'(&'a$'() a(' !a*k %l#)&'+ $&"("#0&l4.T&' !" l'( ) % ll'+ a/+ +(a /'+ 2 "( 2 $ .') #) /0 DM 8a$'( $ ll $&' ,H "% $&' %l#)& /0 8a$'( a,,("a*&') $" $&a$ "% DM

8a$'(.T&' +(#.) a(' /),'*$'+ a/+ a/4 +'!( ) *"ll'*$'+ a$ $&' !"$$". +(#. ('."1'+ .a/#all4. D#( /0 alkal !" l "#$ ",'(a$ "/ , .,"($a/$ ,a(a.'$'() l k' ,('))#(', %''+ /0 (a$' ,$'.,'(a$#(' a/+ 8a$'( a/al4) ) '$*. a(' )4)$'.a$ *all4 l"00'+. T&' !" l'( ) $&'/ ,(',a('+ %"( )$'a. !l"8 /0 ",'(a$ "/). A/"$&'( M'$&"+-2 RECOMMENDED PROCEDURE FOR ALKALI BOIL OUT 1.0 O!>'*$ 1': Once the boiler light up is carried out, preoperational cleaning is taken up in which alkali boil out forms the first activity. Alkali Boil out at an elevated pressure of 40 Kg cm ! "#rum $ressure% is carried out prior to acid cleaning to meet the following ob&ective' ( ( )t prepares the surfaces for ensuring acid cleaning. )t mostly converts the entire interior scale to magnetic o*ide that could be easily dissolved by acid solvents used during acid cleaning. ( ( )t loosens the binding or the scale to parent metal. +oose metal o*ides are removed from the system leaving a lesser ,uality of o*ides for acid digestion. ( -urface cracks are developed over the scale layer, benefiting better acid penetration and effective cleaning in shorter time. ( As the total time for acid in&ection, retention and draining is restricted to a ma*imum of . hours, partial removal of o*ides and better surface preparation help in achieving the pickling operation in the recommended time limit. ( /emoval of oil, greases, dirt and any preservative organic coating is ensured. 0his helps in accomplishing effective acid cleaning and surface e*posure. 2.0 P("*'+#(' 2.1 S*",'

0he scope of cleaning during this operation includes a portion of feed line, entire evaporative system of the boiler and the economi1er. 2.2 T'*&/ 9#'

Alkali boil out at a pressure of 40 Kg cm ! is carried out using a combination of 0ri2 sodium $hosphate "concentration 3000 ppm as 4a5 $O4 3!6!O% and #i -odium $hosphate 6epta 6ydrate "concentration 700 ppm as 4a! 6$O4286!O%.

2.2 (

P(',a(a$ "/ Boiler should be ready in all respects for light up and raising the drum pressure to 40 Kg cm!. All the drum internals including the secondary steam separators are in position as per the drawings. Boiler drain header may be connected to storm water drain suitably with temporary line and well supported. $ermanent gauge glass is to be replaced by a temporary gauge glass. Ade,uate #9 water and specified chemicals as per the re,uirement should be made available after ensuring their ,uality by testing of samples. 6$ dosing system should be operational with concentration boiler chemicals charged into the supply tank. -ampling points for drum water samples should be made available. :uantity of #.9. water ;00 90 to be made available. <ollowing chemicals to be made available' 0$- 500 Kg= #-$ 370 Kg. P("*'))

( (

( ( ( 2.6

3. <ill the boiler with demateriali1ed water upto the bottom of the drum. !. 9i* the re,uired ,uantity of 4a5 $O4 > 4a! 6$O4 with #9 water in small increments and prepare a homogeneous solution in a !002liter drum. 5. Add the total ,uantity of chemicals into the steam drum through the drum manhole, close the manhole and raise the water level to minimum visibility in the gauge glass. 4. +ight up the Boiler as per O > 9 instructions and slowly raise the drum pressure in increments of 7, 30, !0, !7, 50 > 40 Kg cm !. 9onitor and record the e*pansion movement of the boiler by the e*pansion markers already provided at different locations. )f any obstruction is noticed stop increasing boiler pressure and remove the obstruction. 7. 9aintain the drum pressure at 40 Kg cm !, with minimum possible firing rate ad&usted and with boiler startup vent valve full open, for two hours for better digestion of the impurities by the chemicals. .. $ut out the fire and issue blow down through low point drain by opening the valve, for one2minute duration. ?nsure that the drum level does not fall below the visibility limit of the gauge glass.

8. 9ake up the drum level and again light up the boiler to raise the pressure to 40 Kg cm! with the same firing rate for ne*t two hours. 0he blow down as described earlier is repeated. @. After every blow down operation, collect drum water sample and analy1e for phosphate, p6 value and oil level content. /eplenish phosphate concentration through 6$ do1ing system as much as possible to maintain half of the initial sample result. ;. 0he process of boiling out for two hours and blowing down is repeated till the oil content in drain sample shall be Ano longer detectedB "C 7 ppm or traces% in two consecutive samples or till @ blow down are completed, whichever is later. A minimum of 3! hours of boil out is a must in any case. /epeat the boil out with additional chemicals, if oil level is found high. 30. Kill the boiler fire after the completion of boil out operations and allow for natural cooling. 6ot drain the boiler when the drum pressure touches !.0 Kg cm !. 33. <ill the boiler upto the minimum drum level and back flush the super heaters into the drum, raising level up to normal. #rain the boiler continuing the super heater back flushing with hydra1ine #9 water with p6 30 and hydra1ine !00 ppm. -imilarly fill and drain the boiler several times till the alkalinity in super heater and boiler drain water is less than !7 ppm. 3!. 0he hand hole pipes in the ring header are cut as a preparatory work for acid cleaning. Dlean the ring header through these connections with a high2pressure water &et.

Another method:
STANDARD PROCEDURE FOR CHEMICAL CLEANING ?DRUM TYPE NATURAL CIRCULATION BOILER@ 1.01 I/$("+#*$ "/: Advanced steam, data in modern power stations demand high purity of steam in order to prevent fouling of the turbine and safe operation of the power plant. 6igh purity of steam depends on the cleanliness of the waterside of the Boiler. Boiler components during manufacture in shop from raw material to final shape and during erection at site undergo both physical and chemical changes. 0hese include rust due to atmospheric corrosion and formation of o*ides of iron due to the heat treatment at shop. 0he other common impurities found are lubricants, grease, silica in the form of silicates, etc.

Dhemical cleaning, apart from imparting cleanliness of waterside surfaces, leaves behind a thin uniform protective layer of magnetic o*ide of iron "called magnetite%. 1.02 Ba) * T'*&/ 9#': Dhemical cleaning of the boiler will be carried out by a pickling solution of 4E inhibited 6ydrochloric Acid by circulation method. 0o intensify the action of 6ydrochloric Acid and to dissolve silicious impurities, Ammonium Bi <luoride of 0.3E concentration after mi*ing is added to the cleaning solution. 0o lessen the action of acid on parent metal suitable inhibitor is added to the pickling solution. )n the final phase of cleaning the freshly pickled surfaces are protected from corrosion by a passivity layer of magnetite formed chemically by the addition of 6ydra1ine and Ammonia. 0he above layer is reinforced further by the process of second stage passivation, at a later stage, at a drum pressure of 40 kg cmF. )n the above process, the chlorides formed during the process are easily soluble and go readily into solution. Dleaning time for the process is less compared to any other cleaning solvent even at low cleaning solution velocities. 1.02 S*",' "% Cl'a/ /0: 0he scope of cleaning includes a portion of the feed line and complete evaporative system of the Boiler. -uperheater and reheaters are e*cluded from the cleaning circuit. #uring pickling the superheater connecting tubes will be plugged suitably from inside the drum and remain filled and pressuri1ed with Ammoniated 6ydra1ene water confirming to p6 30.0 and 6ydra1ene content not less than !00 ppm. 0he reheaters will remain dry through out the process. Dheck that the plugs can hold more than 7 kg cmF pressure before closing the drum manhole. 0o facilitate fi*ing the plugs the drier assemblies are removed and for fi*ing orifice plate on down comers the primary and secondary separators are removed. 0he pressuri1ation of superheater system will be done by pressuri1ing pump as shown in schematic drawing on page 35 of 35. 1.06 P("1 ) "/al E9# ,.'/$ %"( C&'. *al Cl'a/ /0: 0he provisional pickling e,uipment is designed for the GD)/DH+A0)O4 9?06O#I of chemical cleaning and consists of a dissolving tank. Dirculating pumps and connecting piping and valves. Besides pickling e,uipments, valves and fitting for the supply of water, acid, heating steam to the dissolving tank and fittings for 4itrogen capping has also been made. #ue to the chemical reaction of the 6ydrochloric Acid solution during the pickling process hydrogen gas evolves in large ,uantities and being lighter than air, it gets collected at the

highest spots of the system forming undesirable gas cushions. 0hese are continuously taken out through drum air vents. /epresentative water wall tube samples are hung inside the drum as well as in the dissolving tank to ascertain ,uality of cleaning. 2.06.01 A* + C (*#la$ "/ P#., 8 $& M"$"( = S$a($'( Acid circulation pumps of 370 to !00 t hr with a pressure head of 370 to !00 9JD are used for the purpose. 0he pumps shall preferably be of single stage, centrifugal, back pull out design with hori1ontal or vertical casing type coupled to a suitable 440 K AD motor. 0he gland packings shall be of pure 0eflon make to have better resistance to corrosive chemicals. 0he pumps are to be provided with suction and delivery piping of all the pumps are connected to a distributor from which supply piping is lead to individual connections. 0he pumps shall be erected on firm foundations giving sufficient clearances between them for ease of operation and maintenance. 2.06.02 D ))"l1 /0 Ta/k 9ild steel tank of !0 m5 capacity is fabricated and provided with the following fittings. $rovision for overflow, level indication, a perforated header for heating steam, supply lines from #9 water, steam, acid, return piping from the system, suction pipe with wire mesh at the entry, drain connections to atmosphere with valves. 0he tank shall be provided on the top with walkway along with handrails around for handling of chemicals. 0he tank shall be welded by approved ,uality welders and insulated. 2.06.02 L"*a$ "/ "% T'.,"(a(4 E9# ,.'/$) 0he location of the temporary e,uipments may be decided based upon the following considerations' 2 i% 0he dissolving tank shall be elevated to suitable height to provide the 4$-6 specified for the acid circulation pumps. A suitable location in the boiler floor area can preferably be looked for. Otherwise the tank has to be supported e*ternally on temporary structures. ii% -ufficient care should be taken to locate the dissolving tank at a place where damage to the nearby e,uipment are avoided due to possible spillage of chemical solutions from the tank by overflowing.

iii%

-ufficient space should be provided between the pumps to have access for safe operation.

iv%

Dirculating pump and starters should be separated to have safety and ease of operation.

v%

)t is preferable to locate the e,uipment nearer to waste disposal point such as main station drain, etc. if possible.

vi%

0he main controlling valves such as recalculating valves, valves for make up water, steam, system return, and system drain etc. are located near the circulating pump at convenient accessible location for effective control of the process.

2.06.06

E%%l#'/$ D ),")al

?ffluent disposed after completing each activity of the chemical cleaning is to be neutrali1ed for 3. !. 5. 4. /emnant phosphates, after alkali boil out process. /emnant hydrochloric acid and fluoride content after pickling process. /emnant citric acid, ammonia after citric rinse. /emnant hydra1ine L ammonia after passivation.

0reatment of effluents 3, 5, 4 and #.9. water rinse drains can be either in waste water treatment plant "if provided% or #.9. water plant neutrali1ing pit. $hosphates are neutrali1ed with hydrochloric acid, hydra1ine and ammonia with bleaching powder and ade,uately diluted with water. Dustomer has to decide based on the capability of the wastewater treatment plant to recover #. 9. water from the final product. 6owever for the picking process "effluent !% it is preferable to dig an eathern pit of 500 m5 and the entire boiler drain be dumped in it. 4ecessary temporary drain lines, raw waterlines to neutrali1ation pit has to be laid accordingly. Ade,uate lime has to be dosed and mi*ed to raise the p6 to @.0. Agitate the solution with compressed air. a% Add fly ash and e*pose the solution to solution to sunlight. #ilute the solution and check for fluoride content to be within local pollution control limits "M ! ppm%. +ater on the remnants are buried with mud. b% Alternatively the solution may be slowly pumped out with a 302m5 pump into the plant drain canals, flooding with raw water to limit fluoride content to less than ! ppm. A typical pollution control board re,uirement in )ndia is given below'

Pa(a.'$'( 3. $6 !. 0emperature ND 5. 0otal solids mg 3 4. 0otal dissolved solids mg 3 7. -uspended solids mg 3 .. Oil > grease mg 3 8. Dhlorides mg 3 @. -ulphates mg 3 ;. <luorides mg 3 30. -ulphides mg 3 33. $henolic mg 3 3!. Ammonical 4itrogen mg 3 35. Dyanide mg hr 34. 0otal Dhromium mg 3 37. Dhromium 6e*avalent mg 3 3.. Dopper mg 3 38. +ead mg 3 3@. 4ickel mg 3 3;. Oinc mg 3 !0. Organic mg 3 !3. 9ercury mg 3 2.06.05 N $("0'/ Ca,, /0 0.! 0.3

Ma: .#. L . $ 7.0 to ;.00 47 2 !300 300 30 .00 3000 3.7 ! 3 70 0.! 0.3

5 7 5 3

0.03

4itrogen capping is done during operations to protect the freshly e*posed metal surfaces after pickling from being corroded due to e*posure to atmospheric air, upto neutrali1ing boil out. A scheme of connections of 4! cylinders to the boiler system is shown in the figure on page 35 of 35. /e,uired number of cylinders of suitable capacity is connected to the bus, which in turn is connected to the drum air vents through a stop valve and a non2return

valve. )n case the smaller cylinders are envisaged for the capping, ! nos. of manifold systems to accommodate 37 cylinders each connected through two nos. of heavy duty regulators may be employed. 0he stop valve in the 4itrogen line and the air vent valve nearer the drum are kept open and the other air vent valve on drum is kept closed. All other air vents in the system are kept closed to prevent ingress of air into the system. As the dumping of the system starts nitrogen enters through the non2return valve into the system and offers effective blanketing. Jhen the system is completely drained and filled with nitrogen, the stop valve in the nitrogen line shall be closed. 0he pressure of nitrogen in the system is to be maintained slightly above atmospheric pressure, say about 7230 $-) control draining operation accordingly. Jhen the system is getting filled for ne*t operation, the nitrogen in the system is vented through the airline prevents entry of water or chemical solution to nitrogen piping system. 2.06.0A a@ P("*'+#(' A* + P *kl /0: i% <ill the entire system with #9 water establish appro*imate 470 t hr flow by running 5 nos, circulating pumps. 9aintain 5 to 7 kg cmF pressure in the drum. ii% ?nsure that water flows from the drum vents to the collecting tank and to the mi*ing tank. iii% Admit steam into the mi*ing tank and raise the temperature of circulating water to .0ND as measured in return line. Dontinue circulation for eight hours for the purpose of hot flushing and drain the system completely. iv% 0ake fresh #9 water into the tank and establish circulation as per steps i P ii and raise the temperature of water to .0ND. v% Dut off steam and add re,uired ,uantity of inhibitor, with the pumps running to achieve through mi*ing. vi% Add re,uired ,uantity of 5025!E 6ydrochloric acid in a controlled manner so that acid concentration as measured in the sample from pump discharge does not e*ceed .E. 0his sample is to be collected at intervals of 30 minutes.

vii%

0otal ,uantity of acid re,uired to achieve acid concentration of 4E in the circulating solution is to be added in one hour. -imultaneously charge calculated ,uantity of ammonia bifluoride into the mi*ing tank by several increments.

viii%

Dollect sample from circulating solution, at an interval of 37 minutes, at the pump discharge and return line and analy1e for acid strength and iron concentration.

i*%

-top circulation once three consecutive samples show almost same values of acid and iron concentration of if the circulation is done for ma*imum of 4 hours. "0otal acid contact time to be less than . hours%.

*%

#rain the system under nitrogen blanket. 4eutrali1e the spent acidic solution with line, at convenience.

!@

D. M. Ba$'( R /)' i% On completion of draining of acidic solution, fill the system with plain #9 water and establish circulation. ii% /aise the temperature of water to .02.7Q3R ND and circulate for one hour. iii% Dollect samples from pump discharge and return line and analy1e for acid and iron concentration. iv% #rain the system under nitrogen blanket.

*@

C $( * A* + R /)' i% On completion of draining, fill the system with #9 water and establish circulation. ii% /aise the temperature to .02.7ND and add 0.!E J v citric acid monohydrate. iii% Add li,uid ammonia to raise the p6 of the solution to 5.7 to 4.0 and circulate for ! hours. iv% Dollect samples and analy1e for p6 and iron content, drain the system under nitrogen cover when values stabili1e.

+@

DM Ba$'( R /)' i% water. On completion of draining rinse the system with plain #9

ii% absent. iii%

One or two rinsing operation is to be done till the iron content drop down to 70 ppm "preferably !7 ppm% and acidity is

All the draining operations are to be done under nitrogen blanket.

'@

N'#$(al <a$ "/ i% <ill the system with plain #9 water, raise the temperature to ;0ND2;7ND after establishing circulation. ii% Add re,uired ,uantity of 0.3E. #isodium $hosphate 4a! 6$O4 86!O and 0.!E trisodium $hosphate 4a5 $O4 3!6!O and maintain circulation for . hours. iii% 6ot drain the system under atmospheric air by keeping the drum vents open.

%@

Pa)) 1a$ "/ 0he ob&ective of passivation is to prevent corrosion since the cleaned surfaces are more susceptible for corrosion at a very fast rate. 0he corrosion is prevented by providing a thin layer of magnetite "first stage%, which gets strengthened in the subse,uent firing of the boiler "second stage%. @ F ()$ S$a0' Pa)) 1a$ "/ 0he system is filled with #9 water and ad&ust for circulation. 0he temperature of water is raised and maintained at @7ND by e*ternal steam heating. $6 of #9 water is raised to ;.7 by adding ammonia and hydra1ine is charged to get a concentration of !00 ppm. 0he solution is left to circulate for about !0 hours at a temperature of ;02;7ND. 0he hydra1ine concentration is maintained at !00 ppm through out the operation. After !0 hours, the solution is drained hot from the system and left aerated by natural draft. @ I/),'*$ "/ "% ,(',a(a$"(4 8"(k %"( S'*"/+ S$a0' Pa)) 1a$ "/ 0he drum is inspected thoroughly and all loose debris cleaned manually. /ing header hand hole pipe connections are removed and the header cleaned with water. /ing header is to be inspected by bulb and mirror arrangement or boroscope. 0he super heater plugs and down comer orifice plates are removed and drum internals are refitted. All the provisional e,uipments are dismantled and original fittings and mounting are installed back. 0he boiler should be prepared for regular operation, upon completion of hydraulic test at working pressure.

S'*"/+ S$a0' Pa)) 1a$ "/ 0he chemicals vi1. Ammonia li,uor, for raising the p6 to ;.. and hydra1ene, to get a concentration of !00 ppm are charged in the operating feed water tank. 0he boiler is filled by feed pump upto normal operating level in drum and lighted up with one or two oil burners. 0he steam pressure in drum is gradually raised to 40 kg cmF and maintained at that value. Jater samples are taken from feed line to find out hydra1ine concentration and p6 value. 0he boiler is kept in service for !4 hours maintaining the hydra1ine concentration not less than !02!7 ppm in feed water. At the end of the process, the boiler is bo*ed up and allowed for natural cooling. At 3 or ! kg cmF the superheater air vents are opened and at about ;0ND "#rum temperature% the water in the system is drained and the system is left aerated. 0he second stage passivation marks the end of the chemical cleaning process.

S,'* % *a$ "/ "% C&'. *al a/+ 3#al $4 Sl. N". 3.0 !.0 Na.' "% C&'. *al #isodium $hosphate 4a!6pO4 86!O 0risodium $hosphate 4a5$O43!6!O ")-' 785' 3;85% 5.0 6ydrochloric Acid' 50E ")-' !.7' 3;8.% 4.0 /odine' !35 -pecial 9 s Agromore +td., Bangalore 7.0 Ditric Acid ")-' 74.4' 3;80% ..0 8.0 @.0 Ammonia' !7E 6ydra1ine 6ydrate' @0E 4itrogen Dylinders "..! m5 each, )-' 3848' 3;8!% ;.0 30.0 33.0 Ammonium Bifluoride 6ydrated +ime Bleaching $owder 3370 kg. !7 0ones 7 0ones 3.7 +trs 7.0 +trs. !00 4os. 7!0 kg !.0 +trs. 57 0ones 3$4. 587 kg 870 kg

N"$': 10C ':$(a 9#a/$ $4 "% *&'. *al) $" !' ,("*#('+ %"( a/4 #/%"(')''/ /'*')) $4. 0hroughout the process, commencing from pickling to first stage passivation, steam at the rate of 30 to 37 0 hr. at 30 3! kg cmF, !70ND temp. -hould be made available at the inlet of the dissolving tank. Ba$'( 1"l#.' ?T4, *al@ a. Jater walls b. #rum c. ?conomi1er d. -uperheater e. /eheater Sl. N". 3. $)$? DESCRIPTION #)A !85 S ..!7 30@ 4@ 3UANTITY 500 9?0?// M2 350 54 50

!. $)$? 5. $)$? 4. $)$? 7. $)$? .. /?#HD?/ 8. /?#HD?/ @. /?#HD?/ ;. /?#HD?/ 30. /?#HD?/ 33. /?#HD?/ 3!. /?#HD?/ 35. B?4# 34. B?4# 37. B?4# 3.. B?4# 38. /?#HD?/ 3@. /?#HD?/

#)A !3; S ..57 #)A 3.@.5 S 8.33 #)A 5!5.; S ..57 #)A 4@.5 S 7.0@ !85 S ..57 0O 334.5 S ..0! 5!5 S ..57 0O 334.5 S ..0! 5!5 S ..57 0O !85 S ..57 !85 S ..57 0O !3;.3 S ..57 !85 S ..57 0O 3.@.5 S 8.33 5!5 S ..57 0O !85 S ..57 !85 S ..57 0O !3; S ..57 #)A !85 S ..57 ";0N% #)A !3;.3 S ..57 ";0N% #)A 3.@.5 S 8.33 ";0N% #)A 5!5.; S ..57 ";0N% 5!5 S ..57 0O 3.@.5 S 8.33 !85 S ..57 0O 334.5 S ..0!

70 9?0?/500 9?0?/40 9?0?/500 9?0?/03 4O. 03 4O. 03 4O. 05 4O-. 03 4O. 03 4O. 03 4O. 50 4O-. 0; 4O-. 50 4O-. 0@ 4O-. 07 4O-. 07 4O-.

LIST OF DALDES RE3UIRED FOR ALKALI FLUSHING AND ACID CLEANING SIEE 3% !% 5% 4B 500 "TA0?% 4B !70 "T+OB?% 4B !70 "TA0?% NO. RE3UIRED 7 7 3! UTILITY $H9$ -HD0)O4 $H9$ #)-D6A/T? -U-0?9 -H$$+U $)0 $H9$ 4% 7% .% 8% 4/K "4B !70% 4B !00 "TA0?% 4B 370 "TA0?% 4B 370 "T+OB?% 7 ! 5 4 #)-D6A/T? 4/K 0A4K #/A)4 > -U-0?9 KA+K? -U-0?9 KA+K?#9 JA0?/, -0?A9 $H9$ /?D?)K? "!% @% ;% 4B 300 "TA0?% 4B 40 "TA0?% 5 37 37 30 -U-0?9 KA+K? -A9$+)4T #/A)4, K?40$/. TAHT? )-O+A0)O4 T+A4# DOO+)4T > B/T. 6OH-)4T NITROGEN CAPPING DALDES 3. !. 5. 4. 7. 4! DA$$)4T +)4? 0O #/H9 K?40- 4/K24B 40 #/H9 K?40- )-O+A0)O4 L 4B 40 4! 9A4)<O+# )-O+A0)O4 KA+K?- L 4B 37 4! -H$$+U +)4? )-O+A0)O4 L 4B 40 $/. TAHT?- )-O+A0)O4 L 4B 37 ! !0 ! 4 ! /?0H/4

KA+K?- P -U-0?9 #/A)4 0O

30% 4B !7 "TA0?% 33% 4B !7 "T+OB?%

NITROGEN CAPPING DALDES 3. !. 5. 0.!7 KT D9F 0.!0 KT D9F 0.300ND 8 4O 4 4O . 4O . 4O $H9$ #)-D6. -U-0?9 -U-0?9 )4 OH0

06?/9OJ?++-