Alkali Boil Out

Steam Boiler alkali boil out
procedure
Boiler Alkali boil out is carried out to remove material
such as lubricants, oil and rust. During manufacturing
seamless steel tubes, mill scales are bound to be formed,
and some of these can remain inside. During fabrication and
erection of the pressure parts, some amount of oil and
lubricants can also. get into the tube surface apart from
tube weld slag and other materials.
Before commencing alkali boil out, the boiler is flushed

with hot and cold water to remove loose debris and sand.
During this process, the drum internals should not be in
position and care should be taken to avoid water into the
super heaters system.
Prerequisites alkali boil out of the boiler
the following prerequisites/inputs have to be ensured.
Mechanical completion of boiler including auxiliaries

and piping.
Completion of hydraulic test activities and refractory
dry out.
Readiness of electrical and instrumentation controls
and adequate illumination in and around boiler house.
(Electrical power for motorized valves and gauge glass
illuminator.)
Availability of DM water through boiler feed water
pumps.
Readiness of sample collection system and availability
of required chemicals for the alkali boil out.
Boiler ready for light up with thermal expansion
provisions.
Availability of lab facilities to test the water. (pH
and oil detection)
Readiness of chemical dosing system.
All the debris is removed from Boiler and all the
access doors in the boiler should be closed.
Good working drum level gauge glass with illuminator
assembly, Boiler drum pressure gauge, safety /relief
valves with gags or hydrostatic plugs are removed,
CBD, IBD and all drain valves in good working
conditions, water level control and associated alarms,
cooling water piping and air piping, furnace pressure
gauge and Temperature indications for flue gas, feed
water and steam line.
During alkali boil out, transmitters connected to
steam drum and steam piping is isolated to avoid any
damages to transmitters due to alkali.
Blow down and drain connections are terminated to safe
location.
Alkali out Chemical quantity per blowing should be available

Tri sodium phosphate, Caustic soda and Detergent.
Procedure for 1st Stage boil-out
Fill the specified quality feed water 50mm below the steam
drum manhole rim. Exact quantity of chemicals is to be
dissolved in DM water externally in a container, and the
concentrated solutions so prepared are to be poured in to
the drum through the manholes. The entire quantity of
chemical has been dissolved and poured in to the drum. Close
the manhole and fill the drum to the normal level. Increase
slowly the heat input to boiler to raise pressure to 30psi
(2.1 kg/cm2 (g). A good flow of steam from air release
valves will be noticed. Up on seeing this, close the air
release valve.Continue increasing the pressure to 10kg/cm2
(g). Maintain pressure at l0kg/ cm2 (g) for a period of 16
hours. This will ensure rapid circulation of water through
boiler. Give blow down at every 2 hours interval from water
wall drains for one minute each. Extinguish the fire and
blow down the water from the boiler manifolds individually
for a period of 2-3 minutes each.Allow boiler to cool down
naturally. When pressure comes to 2.5kg/cm2 (g) with
manifolds closed, blow down steam drum water, until water
level falls below gauge glass. Following this, the entire
boiler water can be blown down as quickly as possible using
all manifold drains and drum blow down drains. This way
evacuate the water before any dirt or oil has time to settle
down. When pressure falls to 30 psi (2.1 kg/ cm2 ) open air
release valves.With blow down and drain valves open wash the
drum, Manifolds, and tubes with high pressure clean water to
wash out any remaining sediment.
Procedure for 2nd Stage boil-out
Follow the above procedure, and increase the pressure up

20kg/ cm2 (g) and carry boil-out operation by maintaining
this pressure for a period of 12 hours. The pressure of
20kg/ cm2 (g) is to be maintained by controlling the fuel
firing and modulation of the start -up vent. During this
process normal water level in drum is to be ensured. Operate
IBD for 10 seconds every one hour. Blow down through low
point drains by opening the valves, one by one but one at a
time for one minute interval each mean while ensure the drum
level.Blow down the water wall drains every two hours for
one minute. Blow down the system at an interval of every 2
hours. After every blow down operation collect drum water
sample and analyze for phosphate and oil content. Replenish
phosphate concentration through HP dosing system as and when
the residual value goes less than half of the concentration
maintained at the start of the process.Samples are taken
from the blow down and analyzed for pH, alkalinity, oil
content and conductivity. The quantity of oil and grease
found in the boiler water determines the duration of the
boil-out.continue the boil-out operation till the oil
content in the sample collected show less than 5ppm.
Completion of Boil-out
When analysis confirms the oil presence in the samples is

equal to or less than 5ppm the boil out operations treated
as completed.For confirmation it is suggested to collect 3
samples within 5 minutes of each other and check the
consistency of the results.
Post Boil-out Operation
Operate each blow down and drain valve successively for a

few seconds to discharge any accumulated sludge. Repeat
several times, meanwhile maintain drum level. Allow the
boiler to cool down naturally. When the drum pressure comes
to 2kg/cm2 (g) open all air release valves. When the drum
pressure drops to atmospheric, drain the boiler by opening
all valves on drain headers. Fill the boiler up to the drum
to the required level and back flush the super heaters into
the drum till the sample collected from super heater off
take tube mouth in the drum shows a low conductivity and
high clarity. After completion of Alkali boil out and boiler
is considerably cooled, flush the boiler with DM water till
the system is free from alkali solution (i.e.) pH value of
effluent should be equal to that the DM water used for
flushing.
Final Inspection
After boiler has cooled down completely, open all manhole

doors and remove all manifold inspection caps to inspect the
internal surfaces. Re-weld the end caps on headers as per
recommended procedures and carry out necessary NDT and
stress reliving as applicable.Accumulated dirt and sludge
should be scrapped out in drum, manifolds and tubes washed
through high pressure clean water. Examine all heating
surfaces and gas passes of boiler for excessive
soot deposits resulting from low firing rates employed in
Boil out. Clean manually the soot deposits. Check all
refractory for any cracks. Check for any ash accumulation in
any area. Check that expansion joints are set correctly and
that expansion clearances are adequate.
NOTE – Boiler water contains chemicals, which are hazardous

for human safety and hence safe disposal is necessary.

Alkali Boil Out

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Steam Boiler alkali boil out

Before commencing alkali boil out, the boiler is flushed

super heaters system.

Prerequisites alkali boil out of the boiler

the following prerequisites/inputs have to be ensured.

Mechanical completion of boiler including auxiliaries

Alkali out Chemical quantity per blowing should be available

Procedure for 1st Stage boil-out

Procedure for 2nd Stage boil-out

Follow the above procedure, and increase the pressure up

When analysis confirms the oil presence in the samples is

Post Boil-out Operation

Operate each blow down and drain valve successively for a

After boiler has cooled down completely, open all manhole

NOTE – Boiler water contains chemicals, which are hazardous

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