Chemical cleaning check list

SL N O 1. Make the temporary system with root argon welding as per the attached drawing. Two temporary glass water level gauges with filter screen aperture < 3mm or polythene shall be installed at the drum. For that raduation should be marked from !"## to $"## mm of the center line of the drum. %emove &" no.s of cyclone separator assembly and 11" nos of screen drier assembly from drum. 'ncrease the height of emergency water discharge pipe ()*+, in the drum to $"## mm above the drum centerline. -pen the )*+ and .*+ discharge valves / connect to the acid return line. *lock all 1aturated links of 12 (13 4os, with rubber blocks. 'nstall 0# mm dia restriction orifice at " down comer inlet. 42 blanking arrangement to be provide at drum vents (2, / eco vents(2, .lose all valves of boiler sampling tube7 dosing tube / instrument tube. -pen economi8er / drum recirculation valve. Activities Status

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1#. .ut the temporary hand hole end plates (2" nos, of ww header and (" nos, distribution header / then connect the 133 / 21& mm pipe. 11. The rated pressure of the temporary acid cleaning system7 steam and water inlet and outlet is not less than 1.5 Mpa. 2ydro test pressure is 1.# Mpa for temporary pipe. 12. 9lace filtration screen <0mm aperture at the suction of the cleaning pump and pump flow is 3## t:h7 3 no. 13. Fi; the corrosion sampling probe at the front water wall (2,7 cleaning tank (2,7 drum (2,7 and chemical pump discharge (2,. 1". 'nstall acid proof thermometer or infra red thermometer and sampling tube at li<uid entering and li<uid returning main pipeline. 10. -ne or two inspection tube is to be provided for inspection of the fluid and it is to be of around 3## to 30# mm long and blocked by flange / valves at both the ends. 15. 'nsulation of temporary and main system is complete.

)nsure the temporary line connect from temporary pump discharge at neutrali8ing 16. pit to settling basin for =aste disposal from !! neutrali8ation tank to settling basin through 2 e;isting and 1 temporary pump. / make sure neutrali8ing chemicals ready. 13. 1pecified chemical in sufficient <uantity is available at site. 1&. +M water! 26## m3 (appro;, is available. 2#. =ear protective glasses and gas mask while add the chemicals into the cleaning tank. 21. )nsure the .1T level of the .99!1 and both +M1T 1 / 2 levels are full. Water flushing: 1. 1tart the fill pump from +M plant and fill the cleaning tank with +M water. 2. 3. ". >s per the drawing ?open the valve no 37 &7127 13 / 1 in order to fill the boiler. 1tart flushing / simultaneously control the drum level with the help of valve no1# above the centerline at $ 20# mm till drain is clear of debris. For water flushing follows the route?.leaning tank! cleaning pump!main pipe!eco i:l header! eco o:l header!drum!down comer (water wall,! 0. bottom ring header! main pipe!cleaning tank %epeat the process until drain is clean of debris. Then drain the boiler by opening the valves no "7 07 5/ 107 eco drain7 )*+7 .*+ and " down comer drain valves to the neutrali8ation pit. Alkali flushing: 5. Follow the same route as shown above. Fill +M water in the chemical tank/ maintain the +=@ $10# and raise the temperature of water up to 00 deg with the 6. help of steam. >s temperature raise up to 00 deg add chemicals i.e.(Tri 1odium phosphate, #.3#A!#."#A 4a39-" $ #.1#A!#.2#A4a229-" (+isodium hydrogen phosphate, $ #.#0A (rinse agent, then raise the temperature up to 30 oc and circulate the 3. &. chemical for 3!1# hrs >s per the drawing!open the valve no 37 &7 127 13 / 1in order to fill the boiler. +rain the alkali water from the boiler for 1# sec for every 3 hrs

1#. .heck .hemicals concentration7 temperature / 92 value for every 5# min 11. 1top cleaning pump and drain the boiler by opening the valves no "7 07 5/ 10 and eco drain7 )*+7 .*+ and " down comer drain valves to the neutrali8ation pit. Water flushing: 12. =ith +M water allow flushing till the drain is clear with out debris also maintain the 92 value < &.# / +=@$ 20# mm 13. >fter complete inspection of debris and turbidity7 drain the boiler by opening the same valves as mention above. Acid cleaning: 1". Fallow the same route as shown above. Fill +M water / control +=@$ 10# mm / open the steam line valve no16 to increase the temperature up to 00 deg. 10. >dd the chemical (acid, like 2.@ (".#A to ".0A, $ %hodine 213 special$ #.10A sodium fluoride( 4aF, $ #.#0A to #.1A surface activator(12!35&,$ ".#A to ".0A 2.@ mi;ed solution into the tank and circulate for 1!2 hrs at 5# oc 15. >s per the drawing!open the valve no 37 &7 127 13 / 1 in order to fill the boiler / also open the drum vents. 16. For acid cleaning follow the same route as mention above. 13. .heck the 2.@7 Fe 2$7 Fe3$ and temperature every 2# min. 'f fe3$ content reaches #."A drain the boiler partially under 42 capping7 and refill with fresh pickle and continue the process. 1&. 'n order to drain the boiler open the valves no "7 07 5/ 6 and eco drain7 )*+7 .*+ and " down comer drain valves to the cleaning tank. Second route in acid cleaning: 2#. 'f 2.@7 Fe 2$ / Fe 3$ concentration is found good7 then change the routeB .leaning tank!cleaning pump ! main pipe! front bottom water wall lower header $1:2 left water wall lower header $ C right water wall lower header! front water wall $ 1:2 right water wall $ C left water wall ! riser tube!drum! riser tube! rear water wall header$ C left water wall header $ C right water wall header! rear water wall lower header$ C left water wall lower header $ C right header water wall lower header!main pipe! tank 21. For above process open the valve no 37 &7 127 137 3 in order to fill the acid in the boiler. 22. 1tart the cleaning pump maintain the flow around #.13 m:s and clean the system for 1! 2 hrs. Take the sample of Fe ion7 2.@ at every 2# min. 23. Then drain the boiler by opening the valves no "7 5/ 6 and eco drain7 )*+7 .*+ and " down comer drain valves to the cleaning tank.

2". 'f fe3$ content reaches #."A drain the boiler partially under 42 capping7 and refill with fresh pickle and continue the process.

Third route in acid cleaning: 20. 'f 2.@7 Fe 2$7 Fe 3$7 concentration is ok7 then again change the route!!.leaning tank!cleaning pump ! main pipe! rear bottom water wall lower header $1:2 left water wall lower header $ C right water wall lower header! rear bottom water wall $ 1:2 right water wall $ C left water wall ! riser tube!drum! riser tube! front water wall $ C left water wall $ C right water wall! front water wall lower header$ C left water wall lower header $ C right water wall lower header!main pipe! tank. 25. For above process open the valve no 37 &7 127 137 2 in order to fill the acid into the boiler. 26. .lean the system for 1!2 hrs7 take the sample of Fe ion7 2.@ at every 2# min and maintain the flow around #.2 to #.0 m:s 23. 'f fe3$ content reaches #."A drain the boiler partially under 42 capping7 and refill with fresh pickle and continue the process. 2&. >cid cleaning is finish when there is no change in the Fe ions and 2.@ concentration for 3 times. 3#. Then normali8e flushing route as follows!! .leaning tank! cleaning pump! main pipe!eco i:l header! eco o:l header!drum!down comer (water wall,!bottom ring header! main pipe!cleaning tank. 31. +rain the chemical to neutrali8ing pit by opening the valves no "7 07 57 10 and eco drain7 )*+ drain7 .*+ drain to the neutrali8ation pit. 32. Water flushing: 33. %efill with +M water7 circulate for 1 to 1.0 hrs and then drain to the neutrali8ing pit7 continue this process till 92 value comes to " / concentration of Fe ions < 0# mg:l 3". .heck 927 Fe2$7 Fe3$ at every 2# min. Rinsing process: 30. For %inse use chemical like!! Dse #.10A of phosphoric acid (239-", $#.2A of sodium polyphosphate(4a093-1#, as the rinse agent and circulate at 92 of 3.0to ".# by addition of 423 for 1to 2 hrs at a temperature of around "0 deg. 35. 'f iron concentration in the rinse agent is < 3## mg:l stop it and direct enter to the passivation.

36. 'f iron con is E 3## mg:l7 replace the rinsing li<uor with +M water / phosphoric acid till the concentration of iron is <3##mg:l. Maintain the +=@$3## mm through out. 33. Passivation: 3&. >dd 423 to increase 92 &.0 to 1#.# with in 3# min and raise the temperature to 00 deg and also add 1A to 2A sodium nitrite and circulate for " F 5 hrs at 00 deg by maintain +=@ $3## mm "#. .heck the 2.@7 Fe 2$ and Fe3$7 temperature every 3# min. "1. .orrosion sampling plate shows corrosion speed less than 3 g:m2.h and total corrosion less than 3#g:m2 "2. 1top the chemical cleaning pump and drain the boiler by opening the valve no. "7 07 5 and eco drain7 )*+7 .*+ and " down comer drain valves to the neutrali8ation tank. nspection after cleaning: 9hysical checking!! .lean the inside surface of the drum and removes the sediments/ check the surface of the economi8er7 lower header and monitor the 2 3 " 0 5 6 3 & 1# 1 water wall tube. %emove the temporary system and install the permanent system with in 6 days. -pen the drum manhole at both the end in order to have forced ventilation for 2 days. >ll the waste li<uid such as alkali li<uid7 acid li<uid7 passivator etc shall be discharged from the cooling pond. >lkali waste to be retain in settling basin till completion of acid pickling waste neutrali8ation. 9ickling waste li<uid 92 to be modified to 5! & using 4a-2 2ydra8ine to be disposed with sodium hypochlorite until the residual chlorine is < #.0 mg:l .lean the drum internal / install the cyclone separators and screen driers. .lean the sludge in the lower header. 9reserve the boiler by filling with nitrogen Chemicals use at a time of emergenc!: .hemical are sodium carbonate7 sodium bicarbonate solution7 boracic acid solution7 ammonia solution acetic acid solution7 sodium bicarbonate solution7 sodium carbonate solution7 some tablets like pain killer7 throat tablets band!aid

List of chemicals for chemical cleaning

Sl no 1 2 3 " 0 5 6 3 & 1# 11 12

"esignation 2ydrochloric acid Trisodium phosphate +isodium hydrogen phosphate 9hosphoric acid 1odium polyphosphate >mmonia li<uor 1odium fluoride +etergent .orrosion inhibitor 1odium hydro;ide +ry lime 1odium hypochlorite

Chemical formula 2.@ 4a39-" 4a229-" 239-" 4a093-1# 423.224aF

Purit! E3# A E&0 A E&0A E3" A E&0A E22A E&0A *)1T

Amount #kg$ "5### 35## 13## 5## 50# 13### 0"# 3## 1"## 3#### 2### 2###

usage >cid cleaning of boiler >lkali flushing >lkali flushing %inse %inse >ttemper 92 value >cid cleaning of boiler >lkali flushing >cid cleaning of boiler +isposal of waste li<uid )mergency disposal +isposal of waste li<uid

%hodine 213 > 4a-2 .a.-3 4a.l-

*)1T E"#A 'ndustrial product 'ndustrial product