TRICHY

PROCEDURE FOR ALKALI BOILOUT (DRUM DESIGN PRESSURE 80 KG/CM)

Project : M/s.Mahi Cement Page 1 of 3 Boiler No.: MBJ080
1. Prepare the boiler in all aspects for steaming to the design capacity and steam parameters. The steam drum internals including screen boxes shall be in bolted condition so that during acid cleaning, the same shall be dismantled. Close all sampling points and instrument tapings, right at the source. Temporary sampling line for alkali boilout is recommended to avoid choking due to loose mill scale, debris, etc. 2. Ensure slow firing of boiler is completed before alkali boilout. 3. Keep ready the following chemicals :1. Trisodium phosphate (Na3PO4) 1000 ppm.(1 Kg per ton of water). The quantity shall be estimated 1 x water volume of boiler (QM^3 x 1 Kg) 2. Disodium hydrazine phosphate (Na2HPO4) 500 ppm. (0.5 Kg per ton of water) The quantity shall be estimated 0.5 x water volume of boiler (QM^3 x 0.5 Kg) 4. Fill the boiler with DM water (100 mm below manhole door level). Dissolve chemicals in DM water (use plastic containers) and pour into the drum through manhole door. (Do not put solids in drum).

5.

Light-up the boiler and raise the pressure to 40 kg/cm2. The pressure is to be raised slowly. After reaching 40kg/cm, reduce the fire rate and box-up the boiler. Hold the pressure for 2 hrs. Blow down through continuous blow down drain for 2 minutes for every 2 hrs. Blow down is to be given till the pressure reaches to 30 kg/cm.

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PROCEDURE FOR ALKALI BOILOUT (DRUM DESIGN PRESSURE 80 KG/CM)
Project
6.

: M/s.Mahi Cement

Page 2 of 3

Boiler No.: MBJ080

Re-start the boiler and raise the pressure. Maintain the boiler pressure for 24 hrs. and give the blow down as mentioned in the sl.no.4. Analyse boiler water sample at an interval of 4 hrs. for P.alkalinity, M.alkalinity, pH and Oil. 7. Continue the alkali boil out process for the above stipulated Period. 7.1 Samples should be filtered properly to separate fine mill scale prior to analysis. 7.2 Separate sample should be collected for determination of oil.

7.3 Collect samples from blow down line. 5-10 ppm oil content can be considered for termination of process. 8. Depressurize the boiler by crack opening of start up vent valve for 4-6 hours. While reaching 2 kg/cm drum pressure open all the vents and drain the boiler through grid panel bottom headers and combustor bottom headers drain valves. Before opening the headers drain valve, ensure the bed temperature is below 100C. Do not open the bottom headers drain valve when bed temperature is more than 100C. 9. Fill the boiler with cold water and rinse to remove Chemicals. Analyse second or third rinse sample for pH and conductivity to terminate process. pH and conductivity of DM water should match that of rinsed sample. 10. Analyse the sample for the following constituents and record. 1. pH 2. Total alkalinity 3. Oil

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PROCEDURE FOR ALKALI BOILOUT (DRUM DESIGN PRESSURE 80 KG/CM)
Project : M/s.Mahi Cement Page 3 of 3 Boiler No.: MBJ080
11. INSPECTION:Open the boiler drum and header handhole pipes for inspection. Remove loose deposits and flush the headers & drums with Feed water. The headers to be cleaned with water jet. 12. Ensure slow firing of boiler is completed before alkali boilout.

PREPARED BY

APPROVED BY

(R.PALANIKUMAR) MANAGER/CONSTRUCTION

(T.L.FRANCIS) AGM/CONSTRUCTION

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PROCEDURE FOR STEAM BLOWING (CFBC BOILERS)
Project : M/s.Mahi Cement Page 1 of 4 Boiler No.: MBJ080

STEAM BLOWING
STEAM BLOWING IS AN ESTABLISHED PRACTICE FOR THE PURPOSE OF PHYSICALLY REMOVING ANY SUBSTANCE WHICH REMAIN DEPOSITED IN THE SUPER HEATER AND ASSOCIATED PIPE LINES. THESE SUBSTANCES ARE MAINLY SCALES AND LOOSE MINERALS THAT MIGHT HAVE BEEN ENTRAPPED DURING MANUFACTURE, STORAGE AND ERECTION AT SITE. STEAM BLOWING IS TO BE CARRIED OUT ONLY FOR BOILERS WITH SUPER HEATER.

PRINCIPLE
THE PRINCIPLE OF STEAM BLOWING IS TO GIVE THERMAL SHOCK AND DISLODGE THE SCALES. THESE SCALES WILL BE SUBSEQUENTLY DRIVEN OUT BY THE DYNAMIC VELOCITY OF THE EXPANDING STEAM.

PROCEDURE: THE METHOD OF STEAM BLOWING IS AS BELOW:

1. OPERATE THE 40 +KG/CM^2. 2. AT 40 KG/CM STEAM PRESSURE (LINE), SLOWLY OPEN THE MAIN STEAM STOP VALVE BY MAINTAINING THE DRUM LEVEL BETWEEN 55% AND 60%, BLOW THE STEAM TO ATMOSPHERE TILL THE STEAM PRESSURE DROPS DOWN TO 25 KG/CM. BOILER AND RAISE THE BOILER PRESSURE ABOVE

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PROCEDURE FOR STEAM BLOWING (CFBC BOILERS)
Project : M/s.Mahi Cement Page 2 of 4 Boiler No.: MBJ080

CAUTION : DO NOT ALLOW THE WATER TO CARRY OVER (ie. THE STOP VALVE SHOULD BE OPENED IN A SUCH A WAY) WHEN THE TARGET PLATE IS FIXED SINCE THE WATER PARTICLES WILL GIVE CONFUSIVE RESULTS OF THE PLATE CONDITION. 3. SLOWLY REDUCE THE FIRING RATE AND SLUMP THE BOILER. THE MAIN STEAM STOP VALVE SHALL BE CLOSED WHEN THE BOILER PRESSURE REACHES 25 KG/CM^2. 4. AFTER ONE HOUR, THE BOILER SHALL BE RESTARTED WITH ONE COMPARTMENT AND THE BED TEMPERATURE SHALL BE MAINTAINED AT 800C. THE STEAM BLOWING TO THE SHALL BE ONCE AGAIN STARTED DUE TO WHEN THE

PRESSURE REACHES 40 KG/CM^2. BY THE ABOVE PROCEDURE, THE SCALE ADHERING CONTOURS GET CRACKED TEMPERATURE DIFFERENCE AND GET REMOVED TO SUBSEQUENT BLOWS. TEMPORARY DISCHARGE PIPING WHICH LEAD THE STEAM TO THE

ATMOSPHERE SHALL BE WELDED. DOWN-STREAM OF MAIN STEAM LINE MUST BE PROPERLY SUPPORTED AND ANCHORED.

OPERATIONAL PRECAUTIONS:
1) DURING STEAM BLOWING OPERATION, THE UNIT MUST BE

BROUGHTUP MUCH SLOWER WHILE ALL EQUIPMENTS ARE CHECKED AND EXPANSION MOVEMENTS ARE MONITORED CLOSELY. 2) DURING BLOWING, WATER LEVEL IN DRUM GAUGE GLASS MAY

FLUCTUATE VERY WIDELY. FEED REGULATING STATION MUST BE CHECKED FOR PROPER REMOTE OPERATION. SUFFICIENT QUANTITY OF D.M WATER AVAILABILITY MUST BE ENSURED.

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PROCEDURE FOR STEAM BLOWING (CFBC BOILERS)
Project : M/s.Mahi Cement Page 3 of 4 Boiler No.: MBJ080

3)

TEMPORARY DISCHARGE PIPING WHICH SHOULD BE ATLEAST EQUAL TO THE DIAMETER OF PIPING TO WHICH IT IS CONNECTED MUST BE WELL SUPPORTED TO WITHSTAND REACTION FORCES DURING STEAM BLOWING.

4)

DISCHARGE PIPING SHOULD BE SO DIVERTED THAT PERSONNEL AND EQUIPMENTS ARE NOT ENDANGERED. THE AREA SHOULD BE CORDONED OFF.

5)

FOR WELDED TYPE OF NRV, THE INTERNALS SHALL BE REMOVED TO AVOID DAMAGE DURING BLOWING. SIMILARLY THE ORIFICE PLATE OR FLOW NOZZLE AND THERMOWELL SHALL BE REMOVED TO AVOID DAMAGE DURING BLOWING.

DETERMINATION OF STEAM CLEANLINESS:

1) TO DETERMINE THE STEAM CLEANLINESS MS OR STAINLESS STEEL TARGET PLATE CAN BE FIXED AT THE EXIT OF THE BLOW PIPE LINE. 2) THE CLEANLINESS SHALL BE DETERMINED BY LOCATING THE AREA OF HIGHEST CONCENTRATION IMPRESSIONS OF THE 0.2 MM PLATE. DEPTH COUNT IN 1 THE CM^2 RECOGNISABLE LOCATED AREA. 3) THE PIPING CAN BE TERMED CLEANED IF LESS THAN TWO ie.

PARTICLES IMPRESSIONS OF THE CONSIDERED 1 CM^2 AREA SHOWN AND IF THE REMAINING AREA DOES NOT SHOW ANY INDIVIDUAL ROUGH IMPRESSION.

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PROCEDURE FOR STEAM BLOWING (CFBC BOILERS)
Project : M/s.Mahi Cement Page 4 of 4 Boiler No.: MBJ080

CAUTION:
1) FOR THE FIRST BLOWING PROCESS IT IS NOT RECOMMENDED TO USE TARGET PLATE WHERE AS FOR FURTHER CYCLES ALWAYS THE CLEAN SIDE OF THE TARGET PLATE SHOULD BE USED. 2) THE PIPE LINES WHICH ARE NOT PRE-CLEANED ARE EXPECTED TO TAKE BLOWING CYCLES TWICE THAN THE PRE-CLEANED PIPE LINES. DRAWING FOR STEAM BLOWING TEMPORARY PIPING ARRANGEMENT AND

TARGET PLATE FIXING DETAIL

PREPARED BY (R.PALANIKUMAR) MANAGER/CONSTRUCTION

APPROVED BY (T.L.FRANCIS) AGM/CONSTRUCTION

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BED MATERIAL SUPPLIER'S ADDRESS (NORTHERN REGION)
Project : M/s.Mahi Cement Page 1 of 1 Boiler No.: MBJ080

1.

M/s. Baskar Stoneware Pipes (P) Limited, Amar Nagar, Faridabad.

2.

M/s. Triveni Refractories (P) Limited, C/14, S.S.Road, Industrial Area, Ghaziabad.

3.

Refractory International 377-Sector 19, Faridabad 121 002 (Haryana) Fax no.:0129-2227759 Mobile no.:98-101-20140 E.mail : refractoryint@gmail.com Contact person : Mr.Rajendra Gupta