BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR WESTERN REGION

RECOMMENDED PROCEDURE FOR ALKALI BOIL OUT

OF 2 X 165
TPH AFBC BOILERS AT JSL, RAIGARH
A) INTRODUCTION:
The alkali boil out of a boiler is carried out in order to clean the internal
surfaces of the water-touched parts from oil, grease, rust, silica and other
adhered impurities
B) SCOPE:
The scope of cleaning during this operation includes a portion of feed line,
entire evaporative system of boiler and economizer.
C) TECHNIQUE:
For carrying out the alkali boil out, 1000 ppm of Trisodium Phosphate and
ppm of Disodium Phosphate are used as cleaning agents. The alkali boil out is
carried out in one stage at drum pressure of 40 Kg/cm.
D) PREPARATIONS:
1. Pre-boiler system should be flushed with alkali solution and 2 nos. BFP
should be made ready for regular operation from control room.
2. All the drum internals including the secondary steam separators are erected
in position as per drawings.
3. Boiler should be made ready in all respects for regular operation upto
drum pressure of 40 Kg/cm. For carrying out alkali boil out, external
combustor will be utilized for raising bed material temperature of 1 st
compartment. Further parameters will be raised by coal firing in 1 st
compartment.
4. HP/LP Dozing system should be made ready for dozing of chemicals
during boil out activity.
5. Boiler drum level g/g should be commissioned with lighting arrangement.
6. Feed water and CBD sampling lines should be ready for taking samples.
7. Required chemicals should be checked for quality and quantity.
Arrangements for mixing of chemicals with DM water at drum level
should be made. Lab facilities should be ensured for testing of samples.

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR WESTERN REGION

8. Expansion constraints should be identified and removed.

Expansion trams should be installed to monitor the movement of pressure
parts.
9. Permanent lighting and communication facilities should be ensured at all
working locations.
10. Supply of adequate quantity of DM water should be ensured before start of
operation.
11. First aid box and safety appliances (Gum boots, Hand gloves, Face Masks
and Aprons) should be made available.
E) PROCESS:
1. Drum manhole door should be opened and water should be filled upto
feet below manhole door bottom level. Required quantity of chemicals
should be mixed in a separate 200-liter drum and dozed slowly in
boiler through manhole door.
After closing manhole door, boiler parameters should be slowly raised
upto drum pressure of 40 Kg/cm. Expansion readings should be
recorded at 10, 20 & 40 Kg/cm drum pressure and uniformity must be
ensured.
2. Boiler drum pressure will be maintained for 2 hrs. For proper digestion
of chemicals. CBD sample should be analysed for phosphate and oil
level content.
3. Put out the coal firing and issue below down through low point drains
by opening each drain valve for one minute duration. Ensure that the
drum level does not fall below visibility limits. After every blow down,
drain sample to be analysed for phosphate and oil content.
4. If phosphate content drops below half the initial value, further dozing
should be done through phosphate dozing pumps.
5. Make up the drum level and again light up the boiler to raise pressure
to 40 Kg/cm for next two hours. The blow down activity is repeated
every two hours as per above procedure.
6. Alkali boil out is declared completed after oil content in sample
collected shows less than 5 ppm or till 8 blow are completed,
whichever is later. A minimum of 12 hours boil out is a must.

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR WESTERN REGION

7. After completion of alkali boil out, Boiler is boxed-up

and allowed for natural cooling. When drum pressure reaches 2.0
Kg/cm, open the drum vents. Hot drain the boiler when drum
temperature is about 90 deg c.
8. Fill the boiler upto minimum level of drum and back flush the
superheater into the drum, raising level upto normal. Then drain the
boiler and analyse drain sample for phosphate. Repeat this activity till
phosphate content drops below 25 ppm.
After completion of alkali boil out, drum manhole doors should be opened
and checked for any loose debris and the same should be cleaned.
Thereafter, boiler is released for acid cleaning operation.

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR WESTERN REGION

PROCEDURE FOR ACID CLEANING OF 2 X 165 TPH AFBC

BOILERS
AT JSL, RAIGARH
A) INTRODUCTION:
Modern power stations demand high purity of steam in order to prevent
fouling of the turbine and safe operation of the power plant. High 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.
These include rust due to atmospheric corrosion and formation of oxides of
iron due to the heat treatment at shop.
Chemical cleaning, apart from imparting cleanliness of waterside surfaces,
leaves behind a thin uniform protective layer of magnetic oxides of iron
(called magnetite).
B) SCOPE:
The scope of cleaning includes a portion of the feed line complete evaporative
system of the boiler. During pickling the superheater connecting tubes will be
plugged suitability from inside the drum and remain filled and pressurized
with Ammoniated Hydrazine water confirming to pH 10.0 and Hydrazine
content not less than 200 ppm.
C) TECHNIQUE:
Chemical cleaning of the boiler will be carried out by a pickling solution of
4% inhibited Hydrochloric Acid by circulation method. To intensify the action
of Hydrochloric Acid and to dissolve siliceous impurities, Ammonium Bi
Fluoride is added to the cleaning solution. To lessen the action of acid on
parent metal suitable inhibitor is added to the picking solution. In the final
phase of cleaning the freshly pickled surfaces are protected from corrosion by
a passivated layer of magnetic formed chemically by the addition of
Hydrazine and ammonia. The above layer is reinforced further by the process
of second stage passivation, at a later stage, at a drum pressure of 40 Kg/cm.
D) PREPARATIONS:
1. Alkali boil out of water-touched parts should be completed as per
procedure.

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR WESTERN REGION

2. The scheme of connecting the boiler and pipelines

including provisional equipment is attached (the provisional
equipments are designed to achieve circulation of chemicals in
WW/Eco tubes and consist of dissolving tank, circulating pumps (3
nos. of 150 M3/Hr, 12 Kg/cm), connecting pipes and valves.
3. Arrangements should be made for continuous supply of DM water and
heating steam to the dissolving tank (as required for the process) with
valves and fittings as per scheme. Steam should be made available at
the rate of 10 TPH at 10 Kg/cm, 250C at inlet of dissolving tank.
Sufficient storage of DM water must also be ensured before start of
process.
4. Arrangements should be made for nitrogen capping during the process
of pickling. Required number of nitrogen cylinders should be made
available before start of pickling process.
5. Representative water wall tube sample should be hung inside the drum
as well as dissolving tank.
6. Inhibitor should be tested before use for its efficiency.
7. For neutralization of acid, its preferable to dig an earthen pit of 200
M3. Necessary temporary drain lines and raw water lines should be laid
accordingly. Arrangement should be made for pumping out of
neutralized solution into the plant drain canals.
8. Fire fighting arrangement, first aid and safety appliances should be
kept ready before start of the process. Service water facility should be
arranged near tank area for the purpose of getting water bath in case of
contact with chemicals.
9. Before charging chemicals, circulating water pumps must be trial run
and system should be ensured leak proof.
10. Lab facilities including services of chemist must be ensured for
analyzing the samples as per the requirement of the process.
11. Remove all the drum internals.
12. Fixing of down comer orifice
13. Isolate all the instrument tapping, gauge glasses,

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR WESTERN REGION

14. SH drain & fill connections from LPD header should

be disconnected/isolated.
PROCESS:
a) Acid Pickling:
i)

Fill the entire system with DM water. Establish circulation in the

system by running circulating pumps. Maintain 3 to 5 Kg/cm pressure
in the drum.

ii)

Ensure that water flows from the drum vents to the collecting tank and
to the mixing tank.

iii)

Admit steam into the mixing tank and raise the temperature of
circulating water to 60C as measured in return line. Continue
circulating for four hours for the purpose of hot flushing and drain the
system completely.

iv)

Take fresh DM water into the tank and establish circulation as per steps
i + ii and raise the temperature of water to 60C.

v)

Cut off steam and add required quantity of inhibitor, with the pumps
running to achieve through mixing.

vi)

Add required quantity of 30-32% Hydraulic acid in a controlled

manner so that acid concentration as measured in the sample from
pump discharge does not exceed 6%. This sample is to be collected at
intervals of 10 minutes.

vii)

Total quantity of acid required to achieve acid concentration of 4% in

the circulating solution is to be added in one hour. Simultaneously
charge calculated quantity of ammonium bifluoride into the mixing
tank by several increments.

viii)

Collect sample from circulating solution, at an interval of 15 minutes,

at the pump discharge and return line and analyse for acid strength and
iron concentration.

ix)

Stop circulation once three consecutive samples show almost same

values of acid and iron concentration or if the circulation is done for
maximum of 4 hours (total acid contact time to be less than 6 hours).

x)

Drain the system under N2 blanking

b) D. M. Water Rinse

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR WESTERN REGION

i)
On completion of draining of acidic solution, fill the
system with plain D. M. water and establish circulation.
ii)

Collect samples from pump discharge and return line and analyse for
acid and iron concentration.

iii)

Drain the system under nitrogen blanket.

c) Citric Acid Rinse

i)

On completion of draining, fill the system with DM water and establish

circulation.

ii)

Raise the temperature to 55C and add 0.2% W/v citric acid
monohydrate.

iii)

Add liquid ammonia to raise the pH of the solution to 3.5 to 4.0 and
circulate for 2 hours.

iv)

Collect samples and analyse for pH and iron content, drain the system
under nitrogen cover when the values stabilize.

d) D. M. Water Rinse
i)

On completion of draining rinse the system with plain DM water.

ii)

One or two rinsing operations are to be done till the iron content drops
down to 50 ppm and acidity is absent.

iii)

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

e) Neutralization
i)

Fill the system with plain D.M. water; raise the temperature to 85-90C
after establishing circulation.

ii)

Add required quantity of 0.1% Disodium phosphate Na2 HP04 7H2O

and 0.2% Trisodium phosphate Na3 PO4 12H2O and maintain
circulation for 6 hours.

iii)

Hot drain the system under atmospheric air by keeping the drum vents
open.

f) Passivation
The objective of passivation is to prevent corrosion since the cleaned
surfaces are more susceptible for corrosion at a very fast rate. The
corrosion is prevented by providing a thin of magnetite (first stage), which
gets strengthened in the subsequent firing of the boiler (second stage).
7

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR WESTERN REGION

i) First Stage Passivation

The system is filled with DM water and adjusted for circulation. The
temperature of water is raised and maintained at 85C by external
steam heating. PH of DM water is raised to 9.5 by adding ammonia
and hydrazine is changed to get a connection of 200 ppm. The solution
is left to circulate for about 20 hours at a temperature of 85 90C.
The hydrazine concentration is maintained at 200 ppm through out the
operation.
After 20 hours, the solution is drained hot from the system and left
aerated by natural draft.
ii)

Inspection of preparatory work for second stage passivation

The drum is inspected thoroughly and all loose debris cleaned
manually. Bottom headers hand hole pipe connections are removed and
the headers are cleaned with water.
The super heater plugs and down comer orifice plates are removed and
drum internals are refitted. SH connections to be normalized .All the
provisional equipments are dismantled and original fittings and
mounting are installed back. The boiler should be prepared for regular
operation, upon completion of hydraulic test at working pressure.

iii)

Second Stage Passivation

The chemicals viz. ammonia liquor, raising the pH to 9.5 and
hydrazine, to get a concentration of 200 ppm are charged in the
operating level in drum and lighted up. The steam pressure in drum is
gradually raised to 40 Kg/cm and maintained at that value. Water
samples are taken from feed line to find out hydrazine concentration
and pH value. The boiler is kept in service for 24 hours maintaining the
hydrazine concentration not less than 20-25 ppm in feed water.
At the end of the process, the boiler is boxed up and allowed for
natural cooling. At 2 Kg/cm drum pressure, all vents are opened and at
about 90C drum temperature, the water in the system is drained and
the system is left aerated.
The second stage passivation marks the end of the chemical cleaning
process. Thereafter boiler is released for steam blowing operations.

FW 006
FW 005

ECO

T o D H -II

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W W O /L H D R

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9
114
114
114
114

DC

BHEL, PSW R HQ - NAG PUR

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR WESTERN REGION

BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR WESTERN REGION

SPECIFICATION OF CHEMICAL AND QUALITY

FOR
ALKALI BOIL OUT AND ACID CLEANING ACTIVITIES
OF
2 X 126 TPH AFBC BOILERS AT JSL, RAIGARH
(FOR ONE BOILER ONLY)
SL. NO.

NAME OF CHEMICAL

QUALITY

1.

Disodium Phosphate Na2HpO47H2O

250 Kg.

2.

Trisodium Phosphate Na3PO412H2O

(IS: 573: 1973)

500 Kg.

3.

Hydrochloric Acid: 30%

(IS: 265: 1976)

20 Tons

4.

Coronil: 213 Special

5.

Citric Acid
(IS: 5464: 1970)

300 Kg.

6.

Ammonia: 25%

120 Liters.

7.

Hydrazine Hydrate: 80%

400 Liters.

8.

Nitrogen Cylinders
(6.2 m3 each, IS: 1747: 1972)

9.

Ammonium Bifluoride

600 Kg

10.

Hydrated Lime

15 Tons

11.

Beaching Powder

3 Tons

150 Liters.

120 Nos.

10