Attachment 3

Auxiliary Boiler Chemical Cleaning and Alkali Boil-out

 Document No. :
ENG/R0/63/15
PT. MAXITHERM BOILERS INDONESIA
Edition : 2016
Revision : 0

CHAPTER – 7
CHEMICAL CLEANING AND ALKALI BOIL-OUT

7.1 CHEMICAL CLEANING

Water – side cleanliness is important for all boilers because water – side impurities can
lead to boiler tube failures. They can also lead to carryover of solids in the steam,
resulting in super heater (If applicable) tube failure or turbine blade damage. The flushing
of all loose debris from the feed water system and boiler, and the use of high quality
water for the hydrostatic test, must be supplemented by proper water – side cleaning
before startup. To remove accumulations of oil, grease and paint, the natural circulation
boil out after the feed water system has been given a phosphate flush. The once –
through boiling and its associated pre- boiling equipment are given a similar flushing.
This boiling out and / or flushing should be accomplished before operation.
After boiling out and flushing are completed, products of corrosion still remain in the feed
water system and boiler in the form of iron oxide and mill scale. It is recommended that
acid cleaning for the removal of this mill and iron oxide be delayed until operation at fairly
high capacities have carried loose scale and oxides from the feed water system to the
boiler. This results in a cleaner boiler for subsequent operation.

7.1.1 Procedure for chemical boiling out

Initial preparation:
a) Boiler hydraulic test is completed.
b) Power supply is available to run the drives.
c) Water and chemicals are available.
d) Boiler filling arrangements are completed.
e) Fuel is available.

In order to prevent fouling of internal parts having small clearances during the internal
boil out and acid cleaning, the drum internals / corrugated plates are not eroded.
However, they are to be thoroughly cleaned with wire brush air or steam blown before
installation.
It is essential to have spare gaskets for upper and lower drum inspection has to be
carried out after alkali boil and after chemical cleaning to ensure effectiveness of the
alkali boil out and chemical cleaning.
 Document No. :
ENG/R0/63/15
PT. MAXITHERM BOILERS INDONESIA
Edition : 2016
Revision : 0

i) Alkali cleaning
This is a most commonly used method of boiler cleaning and case of newly erected
boiler, it is carried out on completion of drying out operation.
Chemicals used must never be introduced in solid form but must first be dissolved in
water and introduced in to the boiler system through either the chemical injection
equipment or through the drum manhole. In the latter case the water level must be
lowered by draining and then restored again afterwards.
All phosphate formula is used for alkali boil out of boiler to minimize the potential for
stress corrosion cracking of stainless steel components in the event that some chemicals
were spilled in to the super heater. If the phosphate solutions enter the super heater (If
applicable)they must be flushed out, but by omitting caustic forming chemicals, the
impact of trace residuals on the super heater (If applicable)is reduced. TRISODIUM
PHOSPHATE and DISODIUM PHOSPHATE are used for alkali boil out. These are to be
mixed with warm / hot water.

a. Atmospheric boiling out

a) Open all air vents and steam drum / water drum manhole. Fill boiler with properly
treated dematerialized water up to first port of drum level glass.
b) Prepare the boil out chemical solution in hot dematerialized water in the chemical
mixing tank. The solution is formulated by dissolving following proportionate QTY of
chemicals depending on the volume of the system to be cleaned.

Mixture Chemicals Lb chemical per 1000 lb water

Caustic Soda (NaOH) 3

1
Soda Ash (Na2CO3) 3
Trisodium Phosphate
2.5
(Na3PO4.12H2O)
2
2.5
Caustic Soda (NaOH)
Trisodium Phosphate
1.5
(Na3PO4.12H2O)
3 1.5
Caustic Soda (NaOH)
1.5
Soda Ash (Na2CO3)

4 Caustic Soda (NaOH) 3

 Document No. :
ENG/R0/63/15
PT. MAXITHERM BOILERS INDONESIA
Edition : 2016
Revision : 0

Boil-out chemicals are highly caustic. Caustic Soda Ash will produce a violent
flash if introduced to water too rapidly. Employees handling the chemicals must
wear protective equipment, I.E. Goggles, gloves, aprons, etc.. and an emergency
shower should be nearby. Use vinegar as an antidote.
The boil-out chemicals shown, in above figure, are intended to serve as only a general
guide. It is strongly recommended that the Client retain a water treatment consultant with
expertise in the field of industrial boiler water chemistry to select the boil out chemicals
and be available to provide consulting direction as required.

c) 0.05 % Na2PO4 – 7H2O. (500 ppm di-sodium phosphate)

d) 0.1 % Na3PO4 – 12 H2O. (1000 ppm tri-sodium phosphate)
e) Mix dissolved chemicals and introduce solution in to drum while at the same time
slowly feeding water to effect a more even distribution along the drum length.
f) Close manhole door and secure tightly.
g) Now raise the temperature within boiler is by following start up procedure as per
section 7.5 to bring water up to atmospheric boiling point.
h) Increase slowly the heat input to boiler to raise the pressure.
i) At a pressure of approximately 30 psig (2.1 Kg/cm2) a good flow of steam from air
release valves will be noticed. Close the air release valves.
j) Continue increase boiler pressure to 15% of normal working pressure.
k) Maintain 15% of normal working pressure to 12 hrs. This will ensure a rapid
circulation of water through boiler.
l) Give blow down at every 2 hrs. Interval from water wall and evaporator drains for 1
min. each.
m) Extinguish fire and blow down boiler manifolds individually by giving blow down for a
period of 2 to 3 min. each.
n) Allow boiler to cool down naturally and when pressure comes to 2.5 kg/cm2 with
manifold blow down closed, blow down steam drum until water level falls below
gauge glass.
o) Following this the entire boiler can be blow down as quickly as possible using all
manifold, drum blow down and drains.
p) When pressure falls to 30 psig (2.1 kg/cm2) open air release valves.
q) With blow down and drain valves keep open, wash through drums. Manifold and
tubes, with high pressure clean water to wash out any remaining sediment.
 Document No. :
ENG/R0/63/15
PT. MAXITHERM BOILERS INDONESIA
Edition : 2016
Revision : 0

r) Close al manholes using new gaskets necessarily. If chemical for pressure boil out
are to be introduced through steam drum manhole, one of this must kept open.
s) Close all blow down and drain valves except super heater (If applicable) drain valve,
which must be left open.
t) The boiler is now ready for the pressure boil out.

b. Pressures boil out

a) Fill boiler with water in the same manner as for atmospheric boil out.
b) Dissolve following chemicals in hot / warm water.
c) Tri-sodium phosphate.
d) Di-sodium phosphate.
e) Concentration shall be maintained 500 ppm during pressure boils out.
f) Introduce solution into drum while at the same time slowly feeding water to effect a
more even distribution along drum length.
g) Close manhole doors and secure tightly.
h) Continue to fill boiler up to 1/3 gauge glass. Do not further raise level initially as water
will swell while heating and any blow down for level control will lead to chemical loss.

Add chemical solution when boiler water alkalinity and phosphate level drops to half the
original values. Do not over-add chemicals. Maintenance of chemical concentration must
be carefully controlled. Excessive caustic can cause embrittlement of the metal.

Never allow temperature of gases entering super heater (If applicable) zone to rise
above normal working steam temperature of super heater (If applicable) until a positive
flow of steam is established through open super heater (If applicable) drain valve.

Water level in gauge will rise to ½ glass as heat is absorbed and water expands. This
level must be maintained.

a) Continue to raise the pressure. At a pressure of approximately 30 psig (2.1 Kg/cm2

g) steam will be seen freely issuing from open air release valve. This may be closed.
 Document No. :
ENG/R0/63/15
PT. MAXITHERM BOILERS INDONESIA
Edition : 2016
Revision : 0

b) Raise gradually pressure to 75 % of the normal working pressure. While raising

pressure give blow down at 15%, 25%, 35%, 50% pressure from blow down valves
for one minute each.
c) Raise pressure to 75% of normal working pressure at hold it for 12 hrs.
d) Blow from water wall header drains every 2 hrs. for one minute each.
e) During this period of gradual pressure raising the plant should be under constant
observation and following inspection is to be made:
• Check all bolted flanges, manhole doors and inspection caps for leaks and
tightness.
• Check amount of movement due to thermal expansion against witness marks.
Restriction to free parts of pressure parts can result in over stressing and
rupture and any such restriction observed must be investigated.
• Check dampers under hot conditions to ensure that they do not bend
throughout their extend of travel and isolation dampers seal efficiency when
closed.
• Check all combustion equipments and auxiliaries for correct functioning. Take
note of any irregularities, which cannot be rectified without shutting down.
f) Boiler water samples are to be obtained from CBD and analyzed for alkalinity,
phosphate content, dissolved silica and oil content. Repeat every 2 hrs. Till oil level in
the sample fall below 5 ppm. Firing is to be stopped after oil level falls below 5 ppm
or 16 hrs. Boil out whichever is adequate.
g) Operate each blow down and drain valve successively for a few seconds to
discharge any accumulated sludge. Repeat several times meanwhile maintaining
drum water level at ½ glasses.
h) Allow boiler to cool down naturally and when pressure come down to 2.5 kg/cm2.
Open all blow down and drain valves (exercising due regard for capacity of blow
down system) to completely blow down the boiler.
When pressure comes down to 30 psig open all air release valves.

ii) Steam line blowing:

Fine mesh strainers are customarily installed in turbine inlet steam lines to protect turbine
inlet steam lines to protect turbine blades or valves against damage from scale or other
solid material that may be carried by the initial flow of steam. In addition, many operators
use high velocity steam to clean the supper heater and steam lines of any loose scale or
foreign material before coupling the steam line to the turbine. The actual procedure used
depends on the design of the unit. Temporary piping for flow by pass to the atmosphere
 Document No. :
ENG/R0/63/15
PT. MAXITHERM BOILERS INDONESIA
Edition : 2016
Revision : 0

is required with all procedures. This piping and any noise reduction silencers must
be securely anchored to resist the high nozzle reaction created during the high
velocity blowing period.
Several methods are used for blowing steam lines, including particularly high
pressure air and steam blowing. The recommended method and the one most used
is steam blowing because experience has shown that temperature shock and high
velocities are the most effective means of removing loose scale. Sufficient shock is
obtained with a series of blows where the steam temperature changes during each
blow. Lower pressure, high velocity steam blowing techniques are also available,
injection to promote thermal shocking of the mill scale and debris. Designed and
managed correctly, these techniques provide safe removal of scale and other solid
particles detrimental to turbine components.
There are two basic methods of supplying steam for steam line blowing with a
natural or forced circulation boiler. The second method is to use high pressure
steam directly from the boiler. The latter method supplies large quantities of steam at
higher pressures. Temporary valve is required to control the flow rates during the
blowing period.
Boiler pressure and temperature can be maintained during the blowing period by
continuous firing. If firing is discontinued during the blowing period, it must be
remembered that any change in boiler pressure changes the saturation temperature
throughout the system. To avoid excessive thermal shock, changes in boiler
pressure should be limited to those corresponding to 75F (42 oC) in saturation
temperature during the relatively short blowing periods.