PROCESS CHART AND COMPLETION CRITERIA (Relevant to Annexure- 1 E)
Sl Process Chemicals Concentration Temperature Test Duration and
No parameter limiting criteria
1 SH backfilling Ammonia & N2H4>200ppm Ambient N2H4, pH Till vent sample
hydrazine pH> 10.0 found 200ppm
hydrate of hydrazine
and pH>10
2 Cold water --- --- Ambient Turbidity Circulating
flushing water turbidity
<10NTU
3 Hot water --- --- >70 0C Turbidity Circulating
flushing water turbidity
<10NTU
4 Acid pickling Acid Inhibitor: 0.20% 65-70 0C Acid conc, Three stabilized
inhibitor, HCl: 5% Iron reading of iron
Hydrochloric ABF: 0.25% or total acid
acid, contact time of
Ammonium 6 hrs including
bifluoride the time for
filling,
whichever is
earlier
5 DM water --- pH ~4.0 60-65 0C pH 30 mins hot
rinse water
circulation &
drain
6 Ammoniated Citric acid, Citric acid: 0.2%, 60-65 0C acid conc, Two hrs
citric acid Liquor pH: 3.5-4.0 pH, circulation after
rinse Ammonia Iron complete
addition of
chemicals
7 DM water --- Iron <25 ppm 60-65 0C Iron Rinse water Iron
rinse (1st, < 25ppm
2nd…..)
8 Neutralizatio Sodium Sodium 80-85 0C pH 6hrs circulation
n carbonate carbonate: 0.5% at 80-85 0C
after addition of
chemical
9 1st stage Hydrazine Hydrazine 400- 80-90 0C Hydrazine, 20 hrs
Passivation hydrate, 500 ppm, pH circulation at
Ammonia pH ~10.0 80-90 0C after
addition of
chemicals
10 2nd stage Hydrazine Hydrazine 200 Boiler light Hydrazine, Maintain boiler
passivation hydrate ppm, up pH pressure 40-
pH ~10.0 45ksc for 24hrs
CHECKLIST FOR BOILER CHEMICAL CLEANING
1. Boiler chemical cleaning is to be conducted during the initial phase of boiler overhauling work
followed by corrosion mapping of boiler tubes.
2. The chemical cleaning arrangements viz tanks pipelines, pumps, and pressure gauges,
temperature gauges are completed are per the schematics. Hydraulic tests of all temporary
pipes, valves and acid circulation pump done.
3. Removal of drum internals completed.
4. Fixing of orifices at down comers completed (if required).
5. Nitrogen capping lines, header and pressure gauge erected and tested for leakages.
6. Low range press gauge in N2 filling header for monitoring of capping pres (0.5-1.0ksc).
7. Insulation of chemical mixing tank, steam pipe, pump supply and return line completed.
8. All necessary sampling system (boiler filling line, return line and at discharge of boiler
circulation pump) along with sample coolers is available.
9. Super heaters are plugged and tested for leakages (for 200/210MW units).
10. Positive pressure in super heater vent line to be ensured and it is to be recorded (for
200/210MW units).
11. Overflow lines from drum to solution tank completed and tested (for 200/210MW units).
12. To ensure flushing of each header and system, arrangement to be made for drain line
through-ness checking and flushing (in case of two isolating valves in drain line, line to be cut
between two valves otherwise extra valve to be provided).
13. Inhibitor efficiency test done in laboratory & result found satisfactory.
14. The expiry date of the inhibitor is to be checked before starting use.
15. All chemicals as per the procedure are available at site.
16. Testing of chemicals as per the requirement completed.
17. Neutralization and effluent disposal arrangement are available.
18. Safety arrangement:
i. Safety shower and eye wash system near acid handling area.
ii. Fire water and sufficient fire hoses at chemical handling area and boiler.
iii. Medical facilities/ ambulance and first aid box at site for chemical burns.
iv. Firefighting personnel’s during the cleaning process.
v. Safety appliances for personnel at site.
vi. Sufficient water availability at chemical handling area for flushing, washing etc.
vii. A mock drill to be conducted under the supervision of safety for the preparedness of
above points before the start of acid pickling activity.
19. Proper illumination of chemical handling, n-pit, and boiler area at all elevation.
20. Communications arrangements at chemical handling, boiler drum N2 filling and effluent
disposal areas. Telephones and walkie- talkie at suitable locations.
21. Super heater backfilling filling pumps and tanks are available and tested.
22. Steam and DM water lines for solution preparation cum circulation tank are completed.
23. Flushing water for acid pumps are available at site.
24. Test coupons are available at site.
25. Chemical cleaning activity board and logbooks are available.
26. Availability of MSDS of all the chemicals at use at the locations
27. Adequate DM water available for chemical cleaning activity.
28. Emergency power supply for one circulation pump from DG set.
29. Mock drill for following emergency conditions and action plan:
i. Chemical spillage and leakages.
ii. Undesired chemical reaction during process.
iii. Failure of valves, pumps, and pipelines
iv. Drop in S.H. pressure during process.
v. Failure of N2 capping
30. Chemical mixing tank with steam heating coil, acid storage tanks, separate tank for super
heater back flushing are available with transfer pumps of adequate capacity are available.
31. Acid storage tanks are available and checked for any leakage. Rubber line condition is
satisfactory.
32. Acid unloading arrangement from tankers (use only pumps for unloading).
33. Acid and other dosing pumps are available.
34. Arrangement of temporary laboratory with white light facility near to chemical cleaning
area.
35. Lab testing facilities for parameters like acidity, Fe, hydrazine, pH etc as per the procedures.
36. Isolation of all instruments and sampling lines in economizers, boiler, and super heaters
before start of acid cleaning process and flushing of these lines during 2nd stage passivation.
37. Fixing of boiler tube samples at drum before start of the cleaning process and removal after
1st stage passivation for inspection.
38. Formation of chemical cleaning team consisting of Operation, maintenance, re-
commissioning & Chemistry.
39. Any station specific point can also be incorporated in check list.
