Acid Cleaning

A
OBJECTIVE : To remove the grease & protective coating from the boiler tube surface by filling the
boiler with alkaline solution & then lighting up the boiler , raising the pressure to 40 ksc , holding at 40
ksc & giving blow down as per the steps described below . The process is known as the alkali boil out
of new boilers .
COMPLETION CRITERIA :-
RESPONSIBILITY :BHEL/NTPC Commissioning/erection /operation/chemistry group .
Minimum 8 Nos of blow down or the oil level in blow down sample is < 5 ppm .
Rinsing with water , boiler water circuit PO4 < 2ppm.
SH back flushing with N2H4 & NH3 so that PO4 < 2ppm .
CHEMICALS REQUIRED :DISODIUM PHOSPHATE
= 200 KG
TRISODIUM PHOSPHATE = 400 KG

N2H4 & NH3 for back flushing of SH =
SERVICES REQUIRED FOR ALKALI BOIL OUT :-
Sufficient quantity of DM water .

Manpower for manning at various locations boiler , chemical dosing area , Boiler fill pump house.
Fire fighting team shall be available as long as the boiler is in lighted up condition
Shift chemist & staff round the clock .
One Boiler fill pump in service & stand by pump available .
Telephone at boiler drum level / chemical mixing area /lighting at various location s of boiler
/Walky-talkies for control room & other locations .

LDO oil in sufficient quantity .
REQUIREMENTS FOR BOILER ALKALI BOIL OUT :Boiler is ready for light up as per 1 st light up requirement given in annexure - 1 .
Furnace expansion constraints are checked & removed by joint walk down check from boiler top
to Bottom ring header .
Other preparedness checks as per check list in annexure - 2 .

Readiness & availability of operating parameters in CRT as listed in annexure - 3
Readiness of the valves from remote operation as per list annexure - 4
O&M manuals /Operating instructions for various auxiliaries , BCW pumps .
Emergency operating procedures .
Emergency operating procedures in case total power failure .
Page 1 of 7
H-1
PROCEDURES :The total alkali boil out procedure is divided into the following sub procedures as outlined below .
Chemical preparation & boiler filling procedure .
Boiler light up & pressurisation to 40 ksc procedure .
Blow down & sampling procedure .
After completion of blow down boxing up procedure .
Cooling down of boiler & monitoring .
Boiler draining .
Boiler refilling , SH back filling & boiler draining .
Inspection of boiler drum / bottom ring header & cleaning .

Prerequisites :Boiler/economiser are in drained condition .
Bottom drain hdr main drain valve to IBD is closed .
Except the Bottom Ring hdr rear side drain all other drain to bottom drain hdr are closed .
Boiler fill line is also isolated .
Page 2 of 7
H-2
Page 3 of 7
Boiler pressure 10 ksc .

Take one set of expansion readings .
Monitor all the boiler parameters every hr as per the log sheet .
Keep line up the FW LLCV for taking makeup either through IBV or main valve as per requirement .
Monitor D/A level .
Monitor D/A level .
Monitor D/A level .
Boiler pressure reached 40 ksc . & maintain for 4 hrs at this pressure .
Check for any abnormality in MS/CRH/HRH hdrs at drum level & below (For hammering etc)
Here reduce the oil pressure to bare minimum i.e 3.5 ksc . Dont allow the pressure to go up .
Monitor the drum metal temp/drum level.
H-3
1 st Blow Down & Sampling procedure .
Once 4 hrs passed at 40 ksc the boiler is ready for its 1 st blow down .
Try to maintain 8-9 ports water level in the drum & make up fully lined up to take level as early as
possible after /during blow down .

People should be ready at boiler 0 mtr along with chemistry group .
Charge the sample cooler .
The bottom drain hdr main isolation valve to IBD tank is fully open .
Open the sample line drain .
Inform control room to Hand trip the boiler .( close the start up vents one valve in each line i.e
S81/S82)
Open the bottom ring header drain valve B-92 electrically from local .(30 sec to full open)
At the expire of one minute close the electrically operated valve B 92 full .
Then collect the sample from sample cooler discharge with care so that it should not fall on hand .
The sample is to be analyzed for alkalinity , Phosphate , silica , oil content .
Once the main valve B - 92 is closed give clearance to start the boiler (light up). Open the start
up vents .
Then close the manual isolation valves in drain line & main drain to IBD . Isolate the sample
Now open the manual valve B 89 up to the 20 % opening mark very fast .
Once it opens 20 % , count 1 minute .
cooler .
Boiler Light up & Raising the Boiler pressure to 40 ksc . & maintain for 2 hrs at this
pressure .
Keep all 4 oil guns in service . Raise the Boiler pressure to 40 Ksc , then reduce oil pressure to
minimum 3.5 ksc to maintain the pressure . Keep it at 40 ksc for 4 Hrs .
H- 4
H-5
2 nd Blow down & Sampling procedure .

Follow the same procedure till the completion criteria achieved .

Stop the ID/FD fan after reducing the flow .
Create the natural draft flow path by opening the FD fan discharge damper , blade pitch , ID fan
Page 4 of 7
H-6
inlet gate, guide vane , discharge gate all full open . SADC shall be full open .
Close the SH start up vents .
Stop the LDO pump at FOPH .
Isolate the oil valves at all corners & at oil station in firing floor as well .
MDBFP-C shall be in service till boiler pressure drops down as HP purge is in service . This can
only be stopped after switching over to LP purge from boiler fill pump .
Take makeup as per requirement
Fill up the boiler cooling down monitoring log sheet .

At boiler pressure of 5 ksc open the start up vents & SH drains .
Open the drains before MS stop valves LHS/RHS
At drum metal temp of 90 0 C open the drum vents . At this point only one BCW pump can be kept
H-8
Cooling down of boiler & monitoring .
in service .
At BCW pump suction manifold temp of 90 0 C or less stop the BCW pump .
Now the boiler is ready for draining .
Boiler draining .
Before draining the boiler the C row drain & main drain shall be clear .
Dilution water should be arranged by fire hydrant water or # 3,4 side settling bin water can be
continuously overflown to C row .

Chemistry group shall be informed about draining , so that the diluted water pH can be measured
To drain the boiler open the bottom ring header (Rear) drain to drain header full both manula &
MOV B92 .
Open the economiser inlet header drain both manual & MOV E 18 full .
Now slowly open the main drain valve to IBD tank initially 25 % . After measuring the pH & the
drain line margin further opening can be done .

Once the main boiler draining is completed , the drain pipe looping can be drained by opening the
bottom most drain that is the sampling point .
H-9
H-10
Boiler refilling , SH back flushing to drum & boiler draining .
The mixing tank is to be flushed properly .

Tank is to be filled , steam to be charged .
Once temp picked up 80 0 C boiler is to be filled till one port is visible in the drum via both bottom
ring header & economiser .

SH is to be filled with hydrazine & ammonia solution to have a pH of 10 & hydrazine 200 ppm .
Once the drum level starts increasing stop SH filling .
Drain the boiler .
Monitor the drain water for residual PO4 in both boiler & SH water

After complete draining of the boiler /economiser PTW shall be issued to ME for opening the boiler
drum & Bottom Ring Header manholes for inspection & cleaning & temporary pipe lines for acid
cleaning .
Thoroughly clean the boiler drum & bottom ring header .
Boiler drum primary separators are to be removed for Making ready for Acid cleaning .
Page 5 of 7
BOILER ALKALI BOIL OUT PROCEDURE .

1.
2.
3.
4.
The boiler shall be filled with an alkaline solution of

500 ppm
1000 ppm Trisodium Phosphate
Disodium phosphate
Filling shall be done simultaneously with both the Bottom ring header & Economiser .
Boiler will be lighted up & pressurized to 40 ksc
Holding at 40 ksc for 4 hrs
Sample to be taken from CBD sampling point .
5.
6.
Measurement for
Alkalinity
Phosphate
Dissolved Silica
Oil Content
If the phosphate content drops to < 50 % of initial value then dose phosphate again .
Fire out the boiler
Blow down through the bottom drain hdr drain to IBD . Keep open the valve for 1 minute
.
7.
8.
Record the pressure drop , make up the level immediately .

Again light-up & pressurize the boiler to 40 ksc . Hold it f 2 hrs .
Repeat the blow down for 8 times (minimum) or till the oil content reaches < 5 ppm
9.
10.
11.
12.
13.
when it is declared completed .

Box up the boiler & allow natural cooling .
At 2 ksc pressure at least one CC pump shall be in service .
At drum temp. 90 0 C Open the drum vents .(all 4 valves )
Stop the CC pump .
Drain the boiler once the CC pump suction manifold temp < 90 0 C . by opening the
14.
15.
bottom drain hdr valve full to the C: row drain .

Inspect the drum /bottom ring header & clean them .
Page 6 of 7
ANNEXURE - 3
OTHER REQUIREMENTS CHECK LIST.
AA
1.
Boiler roof hdr all hangers are released & all tie rods are in position . Necessary inspection & clearance
2.
3.
4.
5.
w.r.t this by ME/BHEL .

Boiler drum only primary separators are erected ( secondary separators I,e he scrubbers are not erected)
Boiler bottom drum i.e the bottom ring headers the baffle plates are in position , but the orifices are not put .
Boiler drum end points are insulated .
Boiler drum level measurement through gauge glass available with requisite lighting arrangement .
6.
Communication to UCB with lamp arrangement is completed .

All boiler expansion indicators are fixed at drum level L/R / 73 mtr / 45/48 mtr /23 mtr /Bottom ring hdr &
7.
measurement protocol formats are available .

All temporary pipe lines are connected i.e
MAIN BOILER .
From the Mixing tank area pump discharge to the Bottom drain hdr stub provided for alkali boil out .
Drain line from EBD tank to the nearest plant drain where the blowdown as well boiler draining is to
be done after alkali boil out is completed .
8.
9.
10.
Sampling point is provided from the bottom drain hdr . Temporary Sample cooler is erected , cooling
water provided from boiler fill line . Cooler discharge is provided to the nearest plant drain .
LP purge from boiler fill pump is available .
HP purge from BFP discharge is flushed for all 3 BCW pumps & sample result is with in limit .
Boiler is completely drained including economiser , SH/RH etc .All drain valves are in open position &
respective main valves are also open
BB
1.
Mixing tank is filled , leakage checked , if any attended , tank flushed & drained . Tank level monitoring
2.
transparent PVC hose is fixed .

Boiler fill line through to mixing tank , pressure gauge is available in boiler fill line near mixing tank before
3.
4.
5.
6.
7.
8.
9.
the valve to monitor the fill line pressure .

Auxiliary steam is available to the Mixing tank from APRDS .
Power supply from the respective unit to the chemical cleaning area is available
Emergency power supply also available from EMCC .
Availability of recirculation pumps in chemical cleaning area at least 2 pumps out of 5 pumps erected .
Proper lighting/approach in mixing tank area
Clearing of C row drain where the IBD drain is connected .
Clearing of the bottom drain header area .
MIXING TANK AREA :-
Page 7 of 7
Annexure I
Status of equipments for BLU of Unit #5

Sl.
NO
I
1.0
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
ACTIVITY
Status
BOILER
ID FAN 4A
Lube oil flushing
VFD room A/C plant commissioning.
Cooling water pipe flushing & charging.
VFD panels commissioning.
Charging of VFD transformers.
ID Fan motor trial.
Inlet guide vane calibration and remote operation.
Ducts checking and clearance including air leak test.
ID Fan interlock & protection checking.
ID Fan trial.
2.0
i)
ii)
iii)
iv)
v)
FD FAN 4B
Lube oil flushing.
Motor trail run.
Flushing of cooling water lines and charging.
Interlock & protection checking.
Fan trail run.
3.0
i)
ii)
iii)
iv)
v)
vi)
vii)
CC Pumps
Purge line flushing & Cavity filling
Booster pump motor trail
Booster pump trail
O/H tank with pneumatic control valves auto operation.
Pump trail 4C
Pump trail 4B
4.0
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
SAPH 4B
Lube oil flushing.
Cooling water readiness for lube oil pumps.
Motor trail run.
SAPH trail with air motor
SAPH trail with electric motor
Soot blower commissioning.
Fire fighting system flushing and readiness.
Water washing system flushing and readiness.
Rotor stoppage alarm
Commg of hot spot detection system. (fire sensor)
5.0
i)
ii)
iii)
FURNACE & AIR /FLUE GAS DUCTS

Furnace gas tightness test.
Completion of furnace & duct insulation.
Completion of wall blower internal inspection for nozzle clearance
checking.
Page 8 of 7
iv)
v)
Boiler expansion indicators with initial position punching.

SADC internal inspection after C&I clearance.
6.0
BOTTOM ASH HOPPER

Completion of refractory & dry out.
Fixing and closure of B. A hopper gates.
Sealing and hopper cooling water arrangement and over flow line
connection to drain.
7.0
i)
ii)
iii)
iv)
v)
SCANNER AIR FAN

Discharge dampers operation checking.
Interlocks & protection checking.
Scanner guide pipes fixed at all corners and clearance.
Trial run of AC scanner air fan.
Trial run of DC scanner air fan.
8.0
i)
ii)
iii)
iv)
v)
LIGHT OIL SYSTEM

Air blowing of pipe lines.
Oil flushing.
Motorised / pneumatic valves commissioning from remote.
Commissioning of corner oil /air nozzles valves.
FSSS interlocks readiness, with oil system.
9.0
i)
ii)
FIRE FIGHTING SYSTEM

Charging of boiler fire hydrant system.
Boiler corner stations spray nozzles availability.
10.0
i)
ii)
iii)
iv)
v)
vi)
ALKALI BOIL OUT

Chemicals availability.
DM water availability.
Readiness of DM water pumps and chemical feeding pumps with
mixing tank.
Piping from tank / pumps to boiler.
Removal of separators and internal inspection of drum & ring
headers.
Readiness of blow down tank at boiler 0 meter and its drain
extension.
11.0
i)
ii)
iii)
iv)
C&I SYSTEM
FSSS system readiness.
SADC
DDCMIS
Availability of measurements and alarm pertaining to Secondary
air, Flue gas, Feed water, Steam, Boiler metal temp. points, Drum
level indication and drum pressure indicator at UCB.
12.0
i)
ii)
iii)
iv)
PA SYSTEM
PA system at ID Fan area.
PA system at LHS & RHS at drum level
PA system at FD Fan area.
PA system at operating floors.
Page 9 of 7
13.0
FUEL OIL HANDLING SYSTEM

LDO HANDLING SYSTEM
HFO HANDLING SYSTEM
II
i)
ii)
iii)
iv)
ESP (Pass A)
Mechanical readiness of ESP internals.
Charging of ACP
Commissioning of rapping system.
Completion of insulation.
III
1.0
TG
TG ECW PUMPS
Motor trail
ECW tank readiness.
Coupled trial run of TG ECW pumps
2.0
SG ECW PUMPS
Motor trail
Coupled trial run of TG ECW pumps
3.0
MDBFP 4C
Lube oil flushing
Motor trial run
Interlock/ protection check of motor & voith coupling
HC scoop commissioning.
Motor + voith coupling trial run
Hydraulic test of feed line.
Deareator readiness with all instrumentation
Interlock/ protection check of pump.
Coupled trial run of MDBFP - 4C
4.0
ACW PUMPS
Motor trail
Coupled trial run of ACW pumps
5.0
CW PUMPS
CWP 4A Motor trail
Coupled trial run of CW pump 4A
6.0
APRDS
Auxiliary steam
IV
DM PLANT, PT PLANT, RAW WATER SYSTEM.
ELECTRICAL SYSTEM
Page 10 of 7
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
11 KV SWITCHGEAR
3.3 KV SWITCHGEAR
415 V SWITCHGEAR
220 V BATTERY & CHARGERS
UPS BATTERY & CHARGERS
24 V BATTERY & CHARGERS
LIGHTING
DG SET
VI
1.0
2.0
3.0
AIR-CONDITIONING
A/C OF CER
A/C OF VFD
A/C OF ESP
VII
1.0
2.0
COOLING TOWERS
CW channel
Cooling tower 4B
VIII
1.0
2.0
COMPRESSED AIR SYSTEM

INSTRUMENT AIR SYSTEM
SERVICE AIR SYSTEM
Page 11 of 7
TURBINE SIDE VALVES FOR BLU

Sl No.
Valve No Valve description
Mechanical
readiness
AS 6
Aux. steam to D/A initial heating
Ready
AS10
Aux. steam to D/A pegging.
Ready
AS114
Ready
CHD 7
CHD 13
FD 6
Aux. steam to D/A pegging line drain

regulating valve.
Hydrazine dosing at MDBFP C
suction
Ammonia dosing at MDBFP C
suction.
MDBFP C discharge valve
FD 11
100% HPH Bypass line.
Ready
FD 12
50% HPH Bypass line.
Ready
FD 13
Feed control station.
Ready
10
FD 16
Feed control station by pass.
Ready
11
12
PGB 391 Motorised valve to MDBFP C motor

AA- 201 cooler / working oil cooler.
ECW - 7 TG - ECW PP # A discharge valve.
Ready
Ready
Ready
Ready
Ready
13
ECW 8
TG - ECW PP # B discharge valve.
Ready
14
ECW 9
TG - ECW PP # C discharge valve.
Ready
15
ECW 83 Boiler ECW PP # A discharge

valve.
ECW - 84 Boiler ECW PP # B discharge
valve.
ECW
ACW PP # A discharge valve.
16
17
Local commg
Ready
Ready
Ready
18
ECW
ACW PP # B discharge valve.
Ready
19
ECW
ACW PP # C discharge valve.
Ready
20
ECW- 64
Emergency make up from DM make

up.
Ready
Page 12 of 7
Remote
commg
Boiler side valves for BLU

Sl
Valve No
Description
No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
E18
E19
B92
B 86
B 88
E2
E2A
B 21
B 85
B 87
B 81
B 68
B 83
B 82
B 69
B 84
B 72
B 73
B 76
B 77
B 74
B 75
B 78
B 79
S 74
Eco I/l header drain

Eco feed line drain
Bottom Ring header drain
Bottom Ring header steam Blow off
Bottom Ring header steam Blow off
Economiser I/L valve
IBV of E2
Eco Recirculation valve
Emergency drain from Drum.
Emergency drain from Drum.
CBD drain
CBD drain
CBD drain
CBD drain
CBD drain
CBD drain
Vent valve left Drum
Vent valve right Drum
SH DIV panel drain to SH drain
26.
S 75
header (left)
SH DIV panel drain to SH drain
S23
S25
S21
S22
S19
S24
S26
S77
S76
S 11
S12
S 13
S14
header (right)
BP lower rear header Left
BP lower rear header Left
BP lower front header drain
BP lower front header drain
SH roof I/L header drain
BP lower rear header drain right
BP lower rear header drain right
SH platen I/L header drain
Platen SH in let header drain.
SH roof O/C header vent left
SH roof O/C header vent left
SH roof O/C header vent Right
SH roof O/C header vent Right
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Mechanical
Local commg
Page 13 of 7
Remote commg
Sl
No
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
Valve No
Description
S68
S69
S70
Div panel header vent

Div panel header vent
Div panel to SH platen I/L header
S71
vent
Div panel to SH platen I/L header
S79
S81
S82
S83
S84
MS - 1
MS 3
MS 5
MS 2
MS 4
MS 6
S 85
S 87
S 86
S 88
vent
SH O/L header vent
SH start up vent
SH start up vent
SH start up vent
SH start up vent
MS stop valves (Boiler left)
IBV of MS 1
IBV of MS 1
MS stop valve (Boiler right)
IBV of MS 2
IBV of MS 2
Electromotive relive valve MS left.
IBV to ERV - S 85
Electromotive relive valve MS right.
IBV to ERV - S 86
Mechanical
Local commg
Ready
Ready
Page 14 of 7
Remote commg
Boiler side dampers and gates for BLU

Sl
No
Valve/gate No
1.
Desc
ription
HID fan - B inlet gate.
NC 02AA 201
2.
HID fan - B inlet gate.
3.
HID fan - B discharge gate.
LA 20 AA201
LA 20 AA 202
7.
LA 20 AA 203
8.
HFD fan # B SCAPH Bypass

damper.
HFD fan # B SCAPH I / L
damper.
HFD fan # B SCAPH O / L
damper.
HFD fan B blade pitch control.
Over
R
eady
NA 44AA 202
R
eady
HESP C pass outlet damper

NA 43AA 203
R
eady
HESP C pass outlet damper

NA 43AA 204
R
eady
HESP D pass outlet damper

NA 44AA 203
R
eady
HESP D pass outlet damper

NA 44AA 204
R
eady
HScanner air fan- A discharge

damper.
HScanner air fan- B discharge
HS 12AA 201
damper.
HNA 22 AA 201 SAPH # B flue I/L damper.
HS 11AA 201
20.
Over
HESP D pass inlet damper.
17.
eady
NA 44AA 201
16.
Over
HESP D pass inlet damper.
15.
eady
NA 43AA 202
14.
Over
eady
HESP C pass inlet damper.
13.
R
eady
eady
NA 43AA 201
12.
Over
eady
HESP C pass inlet damper.
11.
eady
LBO 2AA 201
19.
HFD fan B discharge damper.
10.
Over
eady
LBO 2AA 101

9.
R
R
HID fan - B discharge gate.
6.
Over
eady
NC 02AA 204
5.
Over
Over
eady
eady
R
eady
21.
HSAPH # B flue O/L damper.

NA 22 AA101
22.
R
eady
HPAPH # B flue gas I/L damper.

NA 21 AA 201
23.
NA 40 A201,202
R
emote
commg
eady
NC 02AA 203
4.
L
ocal commg
eady
NC 02AA 202
18.
M
echanical
Over
eady
HCommon damper flue gas to
ESP
C& D pass.
R
eady
Page 15 of 7
Over
24.
HSAPH # A flue gas I/L damper.

NA 12 AA 201
25.
HPAPH # A flue gas I/L damper.

NA 11 AA 201
26.
27.
R
eady
R
eady
HSAPH # B air I/L damper.

LA 20 AA204
HLA 20
AA
SAPH # B air I/L damper.

HSAPH # B air O/L damper.
LA 20 AA206
29.
HSAPH # A air O/L damper.
HPAPH #A air I/L damper
R
eady
HPAPH #B air O/L damper

FE40 AA205
R
eady
HPAPH #B air I/L damper

FE40 AA20 4
Over
eady
FE30 AA204
33.
R
R
HPAPH #A air O/L damper
32.
Over
eady
FE30 AA205
31.
eady
LA 10 AA206
30.
Over
eady
205
28.
R
eady
R
eady
Page 16 of 7
NATIONAL THERMAL POWER CORPORATION

TALCHER SUPER THERMAL POWER PROJECT
COMMISIONING DEPARTMENT
Stage II , 4 X 500 MW units
UNIT 5 ACID CLEANING PROCEDURES
A
OBJECTIVE : To remove the patchy mill scale & rust from boiler heat exchanging surface i.e
water wall , boiler drum , down comer pipes ,economiser and excluding the SH /RH circuit by acid
cleaning process after successful alkali boil out is completed .
RESPONSIBILITY :-
COMPLETION CRITERIA :-
BHEL/NTPC Commissioning/erection /operation/chemistry group .
ACID/CHEMICAL REQUIREMENTS :-
SL
NO
1.
2.
3.
4.
5.
6.
ACID
Hydrochloric acid (HCL)
Rodine
Ammonium Bifloride
Blr water
Quantity required
Concentration in %
5 % +/- 1 %
0.20 %
0.25 %
in tons
Ammoniated Citric Acid

Di/Trisodium phosphate
solution
7.
Caustic Soda Lye
8.
Bleaching powder
Acid pickling &

soaking
Ammoniated citric
0.2 %
acid rinse
Neutralization
0.1 % & 0.2 % in the

boiler
250 P pm
Hydrazine/ammonia
Used for Process
process
Passivation process
hydrazine/pH 10
PH 5.5-9.0
For neutralization of
/Floride < 2 ppm
acid
For neutralization of
hydrazine /ammonia
SERVICES REQUIRED FOR ACID CLEANING
:-
Sufficient quantity of DM water .

Boiler fill pump in service & stand by pump available .
Auxiliary steam from APRDS .
Electric power supply to chemical cleaning area from SSS SWGR/ EMCC .
Manpower for manning at various locations
Fire fighting team shall be available as long as the boiler is in lighted up condition
Shift chemist & staff round the clock .
Telephone /lighting/Walky-talkies
LDO oil in sufficient quantity
F
REQUIREMENTS FOR ACID CLEANING
:-
Boiler is ready for light up as per 1 st light up requirement given in annexure - 1 .

Furnace expansion constraints are checked & removed by joint walk down check from boiler top to
Bottom ring header .
Other preparedness checks as per check list in annexure- 2 .
Readiness & availability of operating parameters in CRT as listed in annxure- 3
Readiness of the valves from remote operation as per list annxure- 3
G
PROCEDURES :-
Page 17 of 7
Chemical preparation & boiler filling procedure
H-1
BB
Boiler light up & pressurisation to 40 ksc procedure

Blow down & sampling procedure .
Cooling down of boiler & monitoring
Boiler draining .
OTHER REQUIREMENTS :Drum internals are removed & inspected after alkali boil out & boxed up.
Bottom ring header manholes are opened for inspection /cleaned / checked for tightness of all
perforated panels & boxed up.
Sample piece is joint tested for inhibiter effectiveness ( RODINE)
Sample piece is made ready to put inside the drum during acid cleaning
Temporary pipe lines are laid as per the scheme attached .
Drum gauge glass to be replaced with a rubber/plastic tube arrangement
Nitrogen cylinder arrangement at 0 mtr for capping after acid cleaning . (during draining process)
Valves to be provided in filling line to suction manifold, economizer, ring header etc
Readiness of temporary system such as
o Boiler filling to be completed with in 1 hr
o LP purge water at 8-10 ksc near the BCW pump on continuous basis .
o Draining of the boiler with in 1 hr
o Telephone connections to the Boiler fill pump area / Acid cleaning area / Drum level
o
CC
DD
D-1.0
/Fuel oil pump house etc .

Readiness of PA system
Readiness of 2 Acid tank / Mixing tank for ammonium bifloride
READINESS / PREPARATION OF CHEMICAL SOLUTIONS :-
Preparation of 30-32 % HCL with Rodine is completed in 2 tanks .

Preparation of ammonium bifloride with DM water is completed in another tank .
Shifting of above bi-floride solution to the 2 acid tanks .
Mixing of inhibited acid with bi-floride solution by running the pups on recirculation
Preparation of ammoniated citric acid with citric acid monohydrate & liquor ammonia .
Preparation of neutralizing solution in mixing tank.(Di-sodium phosphate do deca hydrate / Tri-
sodium phosphate do deca hydrate)( 0.1 % & 0.2 % in the boiler)

Preparation of blended solution of hydrazine/ammonia solution for passivation of boiler .
ACID CLEANING PROCEDURE STEP BY STEP :BOILER FILLING WITH DM WATER & LIGHTING UP THE BOILER TO RAISE THE
TEMP. TO 80 0C BEFORE GOING FOR ACID INJECTION :-
Fill the boiler through the bottom ring header /economizer / up to the bottom gauge glass . Then stop
filling .
Start back filling of the SH at hydrazine 200 pip & pH >10 till it over flows to the drum . stop filling
Light up the boiler as per procedure
EBD/CBD should be full closed & vent valves to be full open .
Stop the boiler once drum metal temp. & BCW pup suction manifold temp. >/ 80 0C . Box up the
boiler by stopping natural air path .

Drain the boiler water circuit . ( CC pump valves keep open )
Page 18 of 7
D-2.0
valve at the acid pump discharge

The sample of the mixed water is to be monitored at pump discharge i.e sample point A as per
drawing at regular interval of 5 min .

The sample result for acid shall be < 5% +/- 1% other wise regulate the acid as desired .
D-3.0
Fill the boiler with 60-70 0C water from the 250 mm temporary header through
WW drain / Eco drain/ BCW pump suction manifold drain ( 2 lines of 120 mm)
Start injection of chemicals at the suction of the filling pump through the acid pump & regulation
D-2.0
FILLING OF BOILER ALONG WITH ACID INJECTION :-
The temp. of the water & acid mixture dosed is to be regulated with in 60-70 0C.
Once the boiler drum level is at the bottom port stop filling through suction manifold .
Fill the boiler up to the drum level is 100 mm above center line .
Start Boiler Water Circulating (BCW) pump B (center pump)
FILLING OF BOILER ALONG WITH ACID INJECTION :Collect sample from BCW pump discharge header & record them as per the annexed log sheet .
After 30 min stop the pump & allow the acid for soaking.
After 30 min again start the BCW pump & run for 5 min & stop .
Take sample at 10 min interval .
Continue this process till the iron content is in equilibrium n for 3 consecutive sample .
The total time allowed for this exercise is 6 hrs including (the filling 1 hr &draining 1 Hr)
Stop BCW pump B .
Then keep the N2 capping system ready .
Start draining the boiler under N2 capping to the neutralization Pit near # 6 .
Maintain the N2 capping pressure at 0.5 ksc to 1.0 ksc
DM WATER RINSE AFTER ACID PICKLING/SOAKING IS COMPLETED ( 6 HRS

ACTIVITY) :-
D-4.0
Refill the boiler with DM water at 60-70 0C.

While filling the drum vent valve are to be operated to maintain the pressure at 0.5 ksc . Fill up to 50
% of the gauge glass .

Then start back flushing of the SH through the LTSH drain till the water level is raised in the drum up
to 8-9 ports .
Run BCW-B for 5 min .
Take sample from BCW discharge & point A
Drain the boiler
Continue this operation till the sample result pH is 4-5 .
AMMONIATED CITRIC ACID RINSE AFTER DM WATER RINSE :Fill the boiler with 60-70 0C water from the 250 mm temporary header through
Start injection of citric acid solution prepared at the suction of the filling pump through the acid
pump & regulation valve at the acid pump discharge

The sample of the mixed water is to be monitored at pump discharge i.e sample point A as per
drawing at regular interval of 5 min . ( 0.2 % concentration at the boiler inlet)

Adjust the pH at the filling point around 3.5-4.0 through sample point -A
Once the boiler drum level is at the bottom port stop filling through suction manifold .
Fill the boiler up to the drum level middle in the gauge glass .
Start Boiler Water Circulating (BCW) pump B (center pump) for 5 min at an interval of 30 min &
stop .
Collect sample from BCW pump discharge header after stopping the pump & record them as per
the annexed log sheet .

Again After 30 min run the pump for 5 min collect the sample after stoppage of the pump .
Continue this operation till 3 consecutive samples read the acid % & iron content are steady .
Page 19 of 7
D-5.0
D-6.0
Fill the boiler with 60-70 0C water from the 250 mm temporary header through
Raise the water level up to +100 mm mark
Operate the BCW pump for 5 min .
Stop the pump & drain the boiler under nitrogen capping .
Continue the boiler filling & draining operation till the sample at pointB is having IRON < 25 ppm .
Maintain the N2 capping pressure at 0.5-1.0 ksc .
NEUTRALISATION OF THE BOILER SYSTEM :U Tube manometer to be replaced with normal gauge glass
Preparation of neutralizing solution & feeding to the boiler along with DM water like acid filling
parallely through Eco /WW/Suc. Manifod drain . Nitrogen capping is to be maintained .

Once boiler filling is complete open the drum vents .
Start the BCW pump-B .
Light up the boiler & raise the pressure to 10 ksc .
Hold the pressure for about 6 hrs .
Blow off all instruments for release of any acid particle .
After 6 hrs kill the fire .
Natural cooling of the boiler .
Drain the boiler after metal temp. < 90 0C

While draining back flushing of SH with DM water conditioned with hydrazine & ammonia .
Boiler is drained with drum vents open to atmosphere & no N2 capping is used .
PASSIVATION OF BOILER :-
Fill the boiler with DM water & inject the prepared blended solution so that the final water having
250 ppm of N2H4 & pH of 10 to the boiler .

Fill through the WW/Eco/Suction manifold drain
Fill up to the normal drum level .
Start the boiler circulation pump-B
Lightup the boiler at slow rate .
Raise the drum pressure to 40 ksc & hold it for 24 hrs .
Feed water to be fed to boiler should have residual N2 H4 25 pip & pH 10
Ammonia & hydrazine to be dosed in the FST to maintain above values .
After 24 hrs shut down the boiler & allow it to cool down slowly .
EE
DEMINERALISED WATER RINSE :-
D-7.0
This operation shall be minimum 4 hrs & maximum 5 hrs duration .

Then drain the boiler under positive nitrogen pressure of 0.5 to 1.0 ksc .
At 95 0C stop the BCW pump & drain the boiler under atmospheric pressure & aerate the system
After cool down open the upper & lower drum for inspection
Manually clean them , refit the drum internals etc .
Restore all temporary connections make the boiler available for steam blowing .
NEUTRALISATION OF BOILER EFFLUENTS
:-
As soon as the acid is drained to the neutralizing pit caustic soda is added to neutralize .
As soon as the citric acid is drained to the neutralizing pit caustic soda is added to neutralize .
Neutralization of Hydrazine & ammonia by bleaching powder .
Page 20 of 7
NATIONAL THERMAL POWER CORPORATION

TALCHER SUPER THERMAL POWER PROJECT
COMMISIONING DEPARTMENT
Stage II , 4 X 500 MW units
UNIT 5 ACID CLEANING LOG SHEETS
PROCESS : BOILER FILLING & ATTAINING 80 0 C BOILER TEMP.

DATE
Sl
no
1.
2.
3.
4.
5.
6.
7.
Activity
Start Time
Complete Time
Boiler Filling through Eco/WW

Super Heater Filling
Starting of BCW pumps
Boiler Light Up
Attaining 80 0 C
Killing of Fire
Boiler Draining
Remarks
( It Should Take 1 Hr)
PROCESS : BOILER FILLING & ACID INJECTION WITH ACID PICKLING &
SOAKING
Sl
Activity
no
1.
Boiler Filling through

Eco/WW/BCW suction manifold
2.
3.
along with acid injection

Suction manifold closed
Boiler drum level > 100 mm above
4.
5.
centerline ( 7 ports)
1 st Starting of BCW pump - B
Boiler Draining
Start Time
Complete Time
Remarks
Water temp.60-70 0 C
Acid concentration 5 % +/- 1%
( run for 30 min)

Page 21 of 7
PROCESS : Chemical sampling during acid injection Sampling interval 5 minutes

Sampling point A ( discharge of fill pump)
Time
Sample no
Sample Result
Remarks
( 5 %+/-1% )
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Page 22 of 7
PROCESS : Chemical sampling during acid pickling & soaking

Sampling interval 5-10 minutes
Sampling point B ( discharge of BCW pump)
Time
Sample
no
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Note :
Iron Content
Remarks
Starting Of BCW pump for 30 min
Stopping of BCW pump for 30 min
Sampling at 10 min interval
Total time allowed for acid inside the boiler including filling & draining
should not be more than 6 hrs .
Page 23 of 7

Sl
no
1.
PROCESS : BOILER RINSING BY FILLING DM WATER AT 60-70 0 C
Activity
Start Time
Complete
Remarks
Time
Eco/WW/BCW suction
manifold up to 50 % in the
Drum pressure to be maintained at 0.5 ksc by
gauge glass
regulating the valve
2.
3.
SH back flushing
1 st Starting of BCW
( run for 5 min)
4.
pump B for 5 min

Collect sample from BCW
Sample to be checked for pH it should be > 4-5
5.
6.
discharge hdr.
1 st Boiler Draining

Eco/WW/BCW suction
gauge glass
7.
2nd Starting of BCW

( run for 5 min)
8.
pump B for 5 min

9.
discharge hdr.
2nd t Boiler Draining
( It Should Take 1 Hr) maintain drum pressure 0.5
10.
ksc
Eco/WW/BCW suction
gauge glass
11.
3rd Starting of BCW pump

( run for 5 min)
12.
B for 5 min
13.
discharge hdr.
3rd Boiler Draining
( It Should Take 1 Hr) maintain drum pressure 0.5

ksc
Time
Sample no
Sample Result
Time
Sample no
PH 4 - 5
1.
3.
5.
Sample Result
PH 4 - 5
2.
4.
6.
Page 24 of 7

Sl
no
1.
PROCESS : BOILER FILLING & AMMONIATED CITRIC ACID INJECTION

Activity
Start Time
Complete
Time
Remarks
Eco/WW/BCW suction manifold
along with CITRIC acid injection

Suction manifold v/v closed
Boiler drum level up to middle of
Acid concentration 0.2 % & pH 3-4
2.
3.
4.
5.
the gauge glass

1 st Starting of BCW pump - B
Sample collection after stopping
6.
BCW pump
Boiler Draining
( run for 5 min) & stop for 30 min
PROCESS : Chemical sampling during citric acid injection ,Sampling interval 5

minutes ,Sampling point A ( discharge of fill pump)
Time
Sample no
Sample Result
( 0.2 % )
Remarks
1.
2.
3.
4.
5.
PROCESS : Chemical sampling during citric acid pickling & soaking Sampling
interval 5-10 minutes ,Sampling point B ( discharge of BCW pump)
Time
Note :
Sample
no
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Acid %
Iron Content
Remarks
1 st Starting Of BCW pump for 5 min
2 nd Starting Of BCW pump for 5 min
Sampling at 10 min interval
3 rd Starting Of BCW pump for 5 min
4 th Starting Of BCW pump for 5 min
Total time allowed for this process is min 4 hrs & max 5 hrs .
Page 25 of 7
PROCESS : BOILER RINSING BY FILLING DM WATER AT 60-70 0 C AFTER CITRIC ACID

SOAKING
Sl
no
1.
Activity
Start
Complete
Time
Time
Remarks
Boiler Filling through Eco/WW/BCW
suction manifold up to 100 mm above
the center line.
Drum pressure to be maintained at

0.5 ksc by regulating the valve
( run for 5 min)
2.
1 st Starting of BCW pump B for 5
3.
min
Collect sample from BCW discharge
4.
hdr.
1 st Boiler Draining
5.
Under N2 capping 0.5 ksc

the center line.
Sample to be checked for pH it should be

> 4-5

( run for 5 min)
6.
2nd Starting of BCW pump B for 5
7.
min
8.
hdr.
2nd t Boiler Draining
9.
maintain drum pressure 0.5 ksc

the center line.
> 4-5
10.
3rd Starting of BCW pump B for 5
11.
min
12.
hdr.
3rd Boiler Draining
Time
Sample no

( run for 5 min)
> 4-5
( It Should Take 1 Hr) maintain drum
Sample Result
Time
Sample no
Iron < 25 ppm

1.
3.
5.
pressure 0.5 ksc

Sample Result
Iron < 25 ppm
2.
4.
6.
Page 26 of 7
PROCESS : NEUTRALISATION OF THE BOILER SYSTEM.
Sl
Activity
no
1.
Boiler Filling through Eco/WW/Suc
manifold with neutralizing solution
N2 capping to be maintained at
2.
injection .
After Boiler filled open the drum
3.
4.
5.
6.
7.
8.
vents .
Starting of BCW pump - B
Boiler Light Up
Raising the pressure to 10 ksc
Hold the pressure for 6 hrs .
Blowing off all instruments
Kill the fire after 6 hrs is
9.
10.
complete .
Allow natural cooling of the boiler .
Stop BCW-B after drum metal
11.
temp. is 90 0C .
While draining the boiler back
Start Time
Complete Time
Remarks
0.5 ksc .
flushing of the SH with DM water

injected with Hydrazine &
12.
ammonia .
Draining of the boiler with drum
vents open & no N2 capping is
required.
Page 27 of 7
PROCESS : NEUTRALISATION OF THE BOILER SYSTEM.

Sl
Activity
no
1.
manifold with neutralizing solution
N2 capping to be maintained at
2.
injection .
After Boiler filled open the drum
3.
4.
5.
6.
7.
8.
vents .
Boiler Light Up
Blowing off all instruments
Kill the fire after 6 hrs is
9.
10.
complete .
11.
temp. is 90 0C .
While draining the boiler back
Start Time
Complete Time
Remarks
0.5 ksc .
flushing of the SH with DM water

injected with Hydrazine &
12.
ammonia .
Draining of the boiler with drum
vents open & no N2 capping is
required.
Page 28 of 7
PROCESS : PASSIVATION OF THE BOILER SYSTEM.

Sl
Activity
Start Time
Complete Time
Remarks
no
1.
manifold with blended solution of
Maintain N2H4 250 p p m
N2H4 & NH3 injection with drum

vent open.
2.
3.
4.
5.
6.

Boiler Light Up at slow rate
Feed water to boiler should have
7.
N2H4 250 p p m & pH 10

Kill the fire after 24 hrs is complete
8.
9.
& allow slow cooling of the boiler .

10.
temp. is 90-95 0C .
Drain the boiler under atmospheric
& pH 10 in the fill water .
Fill up to normal level .
Chemicals to be added to FST

directly through manhole .
No N2 capping is required.
condition .
Page 29 of 7
PROCESS : NEUTRALISATION OF CHEMICALS DRAINED .
Sl
no
CHEMICAL
Draining of chemical
Start
Complete
Time
Time
Neutralisation details
Start
Complete
Time
Time
Neutralisng
Effluent
chemical
result
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Page 30 of 7
DETAILS OF ACID CLEANING ACTIVITIES

Unit 5 / TSTPP/NTPC /STAGE II /4X500 MW UNITS
Sl
DESCRIPTION
no
Chemical used
Quantity
used
Filling criteria
Boiler light
up required
Pressure
Waiting
/Temp raise
time/approx.
to
time
Completion
criteria.
Drum metal
1.
temp &
Boiler filling with DM water &

lighting up the boiler to raise the
NIL
NIL
temp. To 80 0 C before acid
Only DM
water in 1 hr.
BCW pump
YES
80 C
suction
manifold
injection .
temp. is >
80 0 C
2.
3.
Draining the boiler

Filling of boiler along with acid
injection .
NIL
HCL
NIL
NIL
ACID
NIL
concentratio
n shall be <
DM water rinse after acid

4.
5.
6.
7.
8.
pickling/soaking is completed ( 6
hrs activity) :
Ammoniated citric acid rinse after
DM water rinse :
Demineralised water rinse :
Neutralisation of the boiler
system :
Passivation of boiler :
Page 31 of 7
DETAILS OF ACID CLEANING ACTIVITIES

Unit 4 / TSTPP/NTPC /STAGE II /4X500 MW UNITS
Sl
DESCRIPTION
no
9.
Normal process time
Time of
Time of
Total time
required
start
completion
required
Boiler filling with DM water &

lighting up the boiler to raise the
temp. To 80 0 C before acid
10.
11.
12.
13.
14.
15.
16.
injection .
Draining the boiler
Filling of boiler along with acid
injection .
DM water rinse after acid
pickling/soaking is completed ( 6
hrs activity) :
Ammoniated citric acid rinse after
DM water rinse :
Demineralised water rinse :
Neutralisation of the boiler
system :
Passivation of boiler :
Page 32 of 7

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A

RESPONSIBILITY :BHEL/NTPC Commissioning/erection /operation/chemistry group .

Rinsing with water , boiler water circuit PO4 < 2ppm.

CHEMICALS REQUIRED :DISODIUM PHOSPHATE

TRISODIUM PHOSPHATE = 400 KG

SERVICES REQUIRED FOR ALKALI BOIL OUT :-

Sufficient quantity of DM water .

/Walky-talkies for control room & other locations .

Other preparedness checks as per check list in annexure - 2 .

Chemical preparation & boiler filling procedure .

Boiler pressure 10 ksc .

1 st Blow Down & Sampling procedure .

possible after /during blow down .

2 nd Blow down & Sampling procedure .

After completion of blow down boxing up procedure .

Fill up the boiler cooling down monitoring log sheet .

Cooling down of boiler & monitoring .

continuously overflown to C row .

drain line margin further opening can be done .

Boiler refilling , SH back flushing to drum & boiler draining .

The mixing tank is to be flushed properly .

ring header & economiser .

Inspection of boiler drum / bottom ring header & cleaning .

BOILER ALKALI BOIL OUT PROCEDURE .

The boiler shall be filled with an alkaline solution of

1000 ppm Trisodium Phosphate

Record the pressure drop , make up the level immediately .

when it is declared completed .

bottom drain hdr valve full to the C: row drain .

w.r.t this by ME/BHEL .

Communication to UCB with lamp arrangement is completed .

measurement protocol formats are available .

transparent PVC hose is fixed .

the valve to monitor the fill line pressure .

MIXING TANK AREA :-

Status of equipments for BLU of Unit #5

FURNACE & AIR /FLUE GAS DUCTS

Boiler expansion indicators with initial position punching.

BOTTOM ASH HOPPER

SCANNER AIR FAN

LIGHT OIL SYSTEM

FIRE FIGHTING SYSTEM

ALKALI BOIL OUT

FUEL OIL HANDLING SYSTEM

DM PLANT, PT PLANT, RAW WATER SYSTEM.

COMPRESSED AIR SYSTEM

TURBINE SIDE VALVES FOR BLU

Valve No Valve description

Aux. steam to D/A initial heating

Aux. steam to D/A pegging.

Aux. steam to D/A pegging line drain

100% HPH Bypass line.

50% HPH Bypass line.

Feed control station.

Feed control station by pass.

PGB 391 Motorised valve to MDBFP C motor

TG - ECW PP # B discharge valve.

TG - ECW PP # C discharge valve.

ECW 83 Boiler ECW PP # A discharge