SHREE POWER

PROCEDURE FOR ALKALI BOILOUT

1.0 OBJECTIVE
The purpose of alkali boil out is to remove from boiler internals the
deposits like oil, grease, mill scales etc. Resulting out of manufacturing,
fabrication and erection procedures. Such deposits in the boiler tube walls
severely restrict heat flow across the tube walls resulting failure due to
overheating.

2.0 PREREQUISITES
In order to commence alkali boil out of the boiler, following
prerequisites / inputs have to be made available :

2.1 Mechanical completion of boiler including auxiliaries and piping.

2.2 Completion of boiler hydro test and other commissioning activities
including refractory dry out.
2.3 Readiness of electrical, controls and instrumentation.
2.4 Adequate illumination in and around the boiler house.
2.5 Electrical power for motorized valves, gauge glass illuminator, etc.
2.6 De mineralized water through boiler feed water pumps.
2.7 Readiness of sample collection system.
2.8 Chemicals required for the process.
2.9 Full readiness of the boiler for lighting up and its thermal expansion.
2.10 Water testing facilities including pH and oil detection.
2.11 Readiness of chemical dosing system.
2.12 Inspection and mechanical cleaning.
2.13 Make visual check of the entire boiler unit and remove all debris.
2.14 Remove drum internals (if required) from steam drum as specified by TBW
engineer.
2.15 After visual checks , close all access to the boiler unit internals.
2.16 Controls, interlocks and other requirements.

Following minimum controls and requirements are necessary for boiler operation.
2.17 Good working drum level gauge glass with illuminator assembly.
2.18 Boiler drum pressure gauge.
2.19 Safety / relief valves with gags or hydrostatic plugs removed.
2.20 CBD and all drain valve is good working condition.
2.19 Water level control and associated alarms.
2.20 Cooling water / air piping.
2.21 Furnace pressure gauge.
2.22 Temp. indications for bed, flue gas, feed water and steam line.
2.23 Safety interlocks.

During alkali boil out, transmitters connected to steam piping and steam
drum will be kept isolated to avoid any damages to transmitters due to
alkali.
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Quantity of Chemicals for one Alkali Boil out

Chemicals (per boiler, per boil out) Quantity

1. Hydrous Trisodium phosphate 300 kgs

( Na3PO4. 12H2O )

2. Anhydrous di Sodium phosphate 60 kgs

( Na2 HPO4 )

3. Wetting Agent 15.0 kgs

( Surfactant / Detergent )

3.0 PROCEDURES

3.1 Ensure that blow down and drain connections are terminated to safe
location.
3.2 Ensure that all dampers are in good working condition and OPEN
:CLOSE positions are marked correctly.
3.3 Ensure that the feed pumps operate satisfactorily.
3.4 Fill specified quality feed water to NWL by keeping all vents open. Drain
the water completely through bottom drain, keeping the header outlet valve
fully open. With this the boiler gets rinsed.
3.5 Fill the unit such that the water is visible in second port from bottom of
direct gauge glass. ( Fill the drum through normal feed water connections )
Water should be used for boil out operation. Add some hydrazine in
deaerator storage tank to have ppm of hydrazine traces in boiler water.
3.6 Exact quantity of chemicals is to be carried in dry form up to the drum level
platform. The chemicals are to be dissolved in DM water externally in a
container near the drum manhole in batches. The concentrated solution so
prepared are to be poured in to the drum through the manholes. When the
entire quantity of chemical has been so dissolved and poured into the
drum, close the manhole.
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3.7 BOILER LIGHT UP

1 After ensuring the above, light up the unit and raise boiler pressure very
slowly to closely monitor the thermal expansion of the pressure parts and no
case pressure raising should not exceed cold start up pressure raising curve.
2 Ensure that the normal water level is maintained in the drum through out the
boil out operation.

3.8 DURATION

Raise boiler pressure to 50% of working pressure (Drum) or 40kg /cm2

whichever is lover. Carry out the boil out operation by maintaining this pressure
for a period of 12 hours. The pressure is to be maintained by controlling the fuel
firing and modulation of the start up vent. During this process normal drum level
to be ensured.

3.9 BLOWDOWN

On attaining approx. 5kg/cm2(g) drum pressure, quickly operate the

intermittent blow down for 10 sec. restore drum water level to N.W.L. Allow drum
pressure rise up to a value which is 50% of operating pressure or 40 kg/cm2(g)
whichever is lower. Ensure that water level in the drum is replenished each time.
Leave the CBD valve slightly open to prevent chocking of sample line and
sample cooler. Operate the IBD for 10 seconds once every hour.

With due care considering the firing conditions in side the combustor Each
bottom header drains to be operated once in every hour for 30 sec to remove the
sediments from the bottom headers. It is advised to stop the firing to very
minimum to avoid any hot spots in the pressure parts which may done in
consultation with TBW commissioning engineer.

At the end of 12 hours of boil out operation, a sample of boiler water is tested for
oil traces, to determine the end point of the process.

If the level are not coming down even after adequate draining, if required
chemicals may be added to drum through HP dosing system.

After stopping the firing, operate all the bottom header drains for 30-45 second
to remove the sediments from the headers.

4.0 COMPLETION OF BOILOUT

4.1 Boiler water sample is analyzed for presence of oil. When analysis confirms
that oil present in the sample, is within limits (=< 5 ppm ) the boil out
operations treated as complete.

Rising to be done to match the boiler pH very close to feed water pH

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For confirmation it is advised to collect 3 samples within 5 minutes of each
other and check for consistency of results.

5.0 POST BOIL OUT OPERATION

5.1 Box up the boiler and allow the unit to cool by natural cooling. When
the drum pressure drops to 2 kg/cm2 open the drum air vent & start
up vent.
5.2 When the drum pressure drops to atmospheric, drain the boiler by
opening all valves on drain headers.
5.3 After draining the boiler, cut the inspection caps in all bottom
headers to inspect for any sediment and for cleaning and flushing.
In case of in bed evaporator coils both in bed coils bottom
and top header end caps and inspection caps to be cut and inspected. It is to be
ensured that all the drain holes in the baffle plates to be clean and free from any
blockage / foreign materials like weld slag / welding consumables.

5.4 Open the steam and water drum manholes and remove the
sediments (if any).
5.5 Back flushing of super heaters and flushing of the drum down
comer, supply pipes convection tubes thoroughly.
5.6 Re weld the end caps on headers as per the recommended
procedures.
5.7 After welding radiography (if req.) post weld heat treatment (if req.)
hydro test of boiler to be completed to the maximum working
pressure.
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PROCEDURE FOR STEAM BLOWING

1.0 OBJECTIVE
Steam blowing is carried out for removing foreign particles like
rust, dirt scale and welding burr from the boiler system to prevent
any impact damage to steam drive equipment at consumer end.

2.0 PRE REQUISITES

2.1 After completing the post chemical boil-out activities and before
proceeding with steam blowing the following activities need to be
completed.
2.2 Completion of temporary exhaust piping including reaction
supports.
2.3 Removal of internals of NRV & FLOW NOZZLE on main steam line.
2.4 Operability of boiler stop valve.
2.5 Readiness of boiler for operation.
2.6 Readiness of start up vent valve for operation.
2.7 Readiness of instrumentation namely drum level transmitter,
pressure indicators, pressure transmitters, direct level gauge and
necessary instrumentation for safe boiler operation.
2.8 Readiness of feed water system and feed water pump.
2.9 Availability of qualified boiler operators and operation staff.
2.10 Adequate safety equipments and first aid kit for operating personnel
for protection against high noise level and hot surfaces.
2.11 Equipments start up in sequence along with all the safety
protections for all the equipments.
2.12 All the boiler safety interlocks like drum level very low, furnace
pressure high, steam temperature high, equipments trip interlocks.
2.13 Control valves readiness for boiler level, deaerator level etc.
2.14 Motorized valves.
2.15 Blow down tank level control system.
2.16 Temperature gauges and transmitters.
2.17 Draft gauges and transmitters.
2.18 Controllers and other panel instruments.
2.19 Enunciators.
3.0 PREPARATION

3.1 Cut the main steam line at a suitable location (if required) to
facilitate welding of a temporary division piece. Attach a temporary
rigid pipe with suitable bend to exhaust the blow off steam in a safe
direction from the main steam line. The location of this temporary
exhaust pipe shall be such that it is after the manual isolation valve
on line and adequate structural components like beams etc. are
available for locking against reaction forces.
3.2 To check the extent of removal of foreign particles, targets are
installed near the exit of temporary exhaust pipe. Target plates are
rectangular plates of soft material like aluminum of brass etc. which
would get impingement by articles blowing off steam. The target
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plates are mirror finish on one face and fitted on a rigid M.S.
mounting with the machined face, facing the blowing steam.
3.3 When the impingement noticed on the target plates are within the
limits, steam blowing is declared as complete.
4.0 PROCEDURE
4.1 Fill boiler with specified quality feed water to NWL.
4.2 Light up the boiler as per, cold start up procedure, ensuring that the
boiler stop valve is fully closed. Also ensure drain valve before stop
valve is kept open to remove condensate from main steam line.
4.3 Raise the boiler pressure gradually to slightly lower than the
working pressure(50% of working pressure) or 40 Kg/cm2
whichever is lower by controlling fuel firing / modulating the start up
vent as required.
4.4 Crack open boiler stop valve bypass valve on main steam line so
that a little steam begins to flow out of the exhaust pipe.
4.5 Maintain pressure as specified in 4.3
4.6 After ensuring that entire main steam piping is hot and no
condensate is left over the pipe, prepare for blowing steam.
4.7 Prior to blow off, clean the blowing area off working personnel.
4.8 Just before starting the steam blow, reduce drum level to 120 mm
from NWL and stop firing burner.
4.9 Throttle the start up vent and quickly open boiler stop valve on line
to release steam from main line in to atmosphere.
4.10 When boiler pressure drops to about 20 Kg/cm2, close boiler stop
valve. So that by the time the valve is fully closed, the boiler
pressure settles down.
4.11 Follow step 4.1 through 4.9 until clear target plates are obtained as
per turbine manufacturer requirement.
Note-
1. Target plates are fitting towards the end of steam blowing cycle.
Plates are fitting before starting each blow with blow sequence
number clearly punched on them for comparison and record.
2. Steam blowing pressure to be decided at site considering the
parameter if for a retrofit job.
3. It is suggested to do steam blowing (Around 8-10 blows, pressure
rise to be done as per pressure rising curve) in the day time and
night time to be left for cooling the steam line to dislodge the scale /
deposits from the piping. Steam piping needs to be isolated for
cooling.

PRECAUTIONS

1. The superheated spray water attemperators should not be placed

into service so as to cause thermal shocking to loosen deposits or
scale.
2. The steam separating design capabilities of the drum internals
should not be exceeded so as to cause excessive carry over when
operating at reduced pressure to achieve higher steam velocities.
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PROCEDURE FOR REFRACTORY DRYOUT

1.0 OBJECTIVE

1.1 The objective of this procedure is to ensure proper drying,

curing of refractory applied in the combustor and other
components.
1.2 The castables usually undergo considerable chemical changes,
during initial heating. Controlled heating, through these reaction
ensure maximum strength. While heating there must be free
airflow over the system to ensure removal of moisture.

2.0 PREREQUISITES

2.1 Ensure the following pre-commissioning checks, for the

completion of refractory drying out is over.
2.2 Ensure the availability of adequate feed water, bed material, fire
wood, oil & oil firing system, draft system and instrument
required for boiler firing.
2.3 Fill the entire combustor with bed material 300 mm above the
bubble cap to avoid any damage to the air nozzles.
2.4 Fill the drum with the specified quality feed water below 50 mm
level from the normal water level. Ensure that above bed super
heaters are filled with water.
2.5 Ensure the availability of adequate qualified boiler operating
staff/ operators.

3.0 PROCEDURE

3.1 Refractory backing / dry out cycle requires very slow and
controlled heating of refractory as recommended by the
refractory manufactures.
3.2 Ensure the readiness of boiler for firing as per the procedures
of cold start up and fill the bed material covering all bed coils.
3.3 Raise temperature of flue gas boiler outlet at approximately 25
deg C /hr. reaching 100 deg C and hold temperature for 4- 6 hr.
at 100 deg C for soaking refractory cast able. If the temperature
falls, increase the firing rate and maintain the required
temperature.
3.4 Raise temperature of flue gas boiler outlet again @ of 25
deg/hr. to 125 deg C and hold temperature for 4 to 6 hr. for
soaking of refractory castables.
3.5 Once the above heating schedule is over, the boiler may be
taken to MCR/service condition or refractory may be cooled
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down with natural cooling with FD, & ID fans off. Fan auxiliary
dampers should be in fully closed position.

NOTE :

1) Keep open all the vent lines on the boiler drum, top super
heater headers 100% through out the refractory dry out period.
2) Maintain normal water level through out the period.
3) Temperature mentioned are indicative as the rate of raise is
depends upon the firing rate, and maintained close to these
values with less variation and may be around 5 deg C.
3.6 After dry out, before draining the bed material, FD fan to be
started to kill the fire in the furnace.

4.0 REMARKS

Adequate care should be taken to ensure the drum level at

NWL or as specified by TBW through out the process.
During the process vent valves on the drum, above bed
super heater header vents to be kept open.