Titolo Identificativo Rev. Pag.

Di
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BOILER PRESERVATION 0 1 12
6556-EPCC4-52-1B-SP-M-3013
PRESCRIPTIONS
Volume N. Prodotto/Struttura
Volume no. product/structure

Tipo doc. Emittente Edizione in lingua Derivato da Rev.

doc. type issued by language derived from rev.

AC ENGLISH
Job no Progetto Cliente
client
Project IOCL
PANIPAT NAPHTHA
3034 CRACKER L&T

Rev. Descrizione
rev. kind of revision

0 FIRST ISSUE

0 P I A. COLOMBO R. ORSARIA R.SARDANO 02.03.2007

Rev St. Sc. Preparato Controllato Verificato Verificato Verificato Approvato Data
Rev. st. sc. Prepared checked checked checked checked approved date

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
Confidential informations, property of Ansaldo Caldaie S.p.A., not to be used for any purpose other than that for which they are supplied.
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TABLE OF CONTENTS

1 INTRODUCTION ...............................................................................................................4

2 CHEMICALS .....................................................................................................................4

2.1 LONG PERIOD (more then 10 days) ....................................................................................................... 4

2.2 SHORT PERIOD (less then 10 days) ....................................................................................................... 4

2.3 CAPPING METHOD LONG PERIOD (more then 10 days) ..................................................................... 5

2.4 CAPPING METHOD SHORT PERIOD (less then 10 days)..................................................................... 5

3 PREOPERATIONAL STORAGE ......................................................................................5

3.1 WET STORAGE AFTER HYDRAULIC TEST ........................................................................................... 5

3.2 WET STORAGE AFTER BOILER CHEMICAL CLEANING ..................................................................... 7

4 BOILER STORAGE AFTER OPERATION .......................................................................7

4.1 SHORT TIME STORAGE........................................................................................................................... 7

4.2 LONG TIME STORAGE ............................................................................................................................. 7

5 WET STORAGE................................................................................................................8

5.1 BOILERG FILLING .................................................................................................................................... 8

5.2 CHECK DURING THE STORAGE............................................................................................................. 9

6 DRY STORAGE ................................................................................................................9

6.1 NITROGEN SYSTEM ALIGNMENT .......................................................................................................... 9

6.2 SH SECTION .............................................................................................................................................. 9

6.3 ECONOMIZER SECTION .......................................................................................................................... 9

6.4 EVAPORATOR SECTION ....................................................................................................................... 10

7 CAPPING METHOD........................................................................................................11

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
Confidential informations, property of Ansaldo Caldaie S.p.A., not to be used for any purpose other than that for which they are supplied.
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7.1 OPERATING SEQUENCES..................................................................................................................... 11

8 OPERATIONS RESTORE ..............................................................................................12

8.1 AFTER LONG PERIOD STORAGE......................................................................................................... 12

8.2 AFTER SHORT PERIOD STORAGE ...................................................................................................... 12

8.3 AFTER DRY STORAGE .......................................................................................................................... 12

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
Confidential informations, property of Ansaldo Caldaie S.p.A., not to be used for any purpose other than that for which they are supplied.
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1 INTRODUCTION

A boiler that will be out of service for periods of time should be carefully prepared for the
idle periods and closely watched during the outage to guard against corrosion.

Rusting of tube surfaces, as indicated by the formation of red hematite (Fe2O3) not only
causes a roughened tube surface but also results in attack of parent metal.

This can be illustrated by the following reaction:

4Fe2O3 + Fe ⇒ 3 Fe3O4
Hematite Parent metal Magnetite

This reaction will occur at the expense of the boiler metal, regardless of whether the
ferric oxide is formed as a result of atmospheric rusting or by the introduction of ferric
oxide into the boiler from auxiliary equipment.

The following prescriptions for boiler lay up are generic and can be applied to all boilers
in three ways:

- the wet storage method

- the dry storage method
- the capping method

moreover include the suggested recommendations regarding the storage during the
precommissioning phase.

2 CHEMICALS

2.1 LONG PERIOD (more then 10 days)

In the long period wet storage will be used the following chemicals or equivalent
products:

HYDRAZINE (N2H4) AMMONIA (NH3)

200 ppm 10 ppm

2.2 SHORT PERIOD (less then 10 days)

In the short period wet storage will be used the following chemicals or equivalent
products:

HYDRAZINE (N2H4) AMMONIA (NH3)

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
Confidential informations, property of Ansaldo Caldaie S.p.A., not to be used for any purpose other than that for which they are supplied.
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25 ppm 10 ppm

2.3 CAPPING METHOD LONG PERIOD (more then 10 days)

In case of capping method, will be used (except superheater ), the chemicals or

equivalent products required for long period and are:

In the long period capping method will be used the following chemicals or equivalent
products:

HYDRAZINE (N2H4) AMMONIA (NH3)

200 ppm 10 ppm

2.4 CAPPING METHOD SHORT PERIOD (less then 10 days)

In the short period whit capping method will be used the following chemicals or
equivalent products:

HYDRAZINE (N2H4) AMMONIA (NH3)

25 ppm 10 ppm

3 PREOPERATIONAL STORAGE

3.1 WET STORAGE AFTER HYDRAULIC TEST

In order to decrease the water consumption and the consequently water wastage, the
following method can be applied also after the hydraulic test and before the chemical
cleaning as per preoperational storage.

To avoid to drain and to waste the chemicals if leakages are detected in the BOILER
section it is better to inject the chemicals after positive result of the hydraulic test.

In this case the water used for the hydraulic test will be drained and the BOILER will be
filled again with chemical in order to reach the concentrations described as soon as for
the wet storage.

Fill BOILER by normal filling line or by the points used for the hydraulic test with
temporary pump.

Use demineralized water or water with suitable chemical characteristic as per hardness,
sulphite and chloride concentration.

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
Confidential informations, property of Ansaldo Caldaie S.p.A., not to be used for any purpose other than that for which they are supplied.
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The best operation is to fill the boiler up to the drum bottom entering to the down comer
end economizer by dedicate filling line.

During the economizer and evaporator filling operation maintain open the drum vent,
stop filling when drum level reach 50%.

After this operation backfill the superheater entering through the outlet header drain by
temporary line from discharge filling pump.

Check the vents to be sure that any air pocket as been vented out.

Start Secondary SH filling until the water comes out of the Primary SH vents.
Close Secondary SH vents when water comes out of until drum level observed
increasing.

Pressurise the boiler up to 0.5 barg by nitrogen system, or provisory piping connected to
the BOILER sections, in order to avoid air infiltration as described at Point 5 “DRY
STORAGE”.

If nitrogen system is not available, continue boiler filling in normal way up to the
complete drum filling until water came out of the vents.

Reduce filling flow and close by care drum vents in order to increase at 5÷6 bar the
boiler pressure, stop filling pump and close dram vents.

Check daily the pressure value and restore it in case decrease near 0.

Be careful in the last filling phase in order to not exceed the design values of the
sections.

During the preservation period, the following chemical parameters will be weekly
checked:

pH
N2H4
NH3
Total Fe
Total and acid conductivity

When the N2H4, NH3 concentrations decrease of 30 %, shall be necessary restore the
initial value.

If during the preservation period the total iron value increase up of 2 ppm, the
completely change of boiler water is necessary.

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
Confidential informations, property of Ansaldo Caldaie S.p.A., not to be used for any purpose other than that for which they are supplied.
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When the time preservation will be more than one or two months the water in the boiler
section shall be necessary replace completely whit new demineralizate water
additivated as described at point 2.

For a very long period a suggestion is to realise a temporary circuit in order to do a

periodic circulation in the boiler.

To have an effective protection of all the boiler surfaces it is very important to keep the
chemical concentration uniform in all the boiler circuit.
For this reason the way for dosing chemicals in the filling water is a critical operation
that must be strictly controlled.
Knowing the total volume of the boiler, the filling water flow (from pump operating
curves or by metering device) and consequently filling time, it is possible to dose in the
filling water the exact amount of ammonia and hydrazine requested.

3.2 WET STORAGE AFTER BOILER CHEMICAL CLEANING

(Before first start up phase)

In case a long period of inactivity, before first start up and operation, it is recommended
to preserve the BOILER according to this procedure.

If condensate system it is not available the temporary chemical cleaning piping can be
used for BOILER filling.

The prescriptions are the same above mentioned for wet storage after hydraulic test
(see point 2 and 3), but it is mandatory to use demineralized water.

4 BOILER STORAGE AFTER OPERATION

4.1 SHORT TIME STORAGE

If the BOILER remains out of service after the operation period for a short time (about
10 days) it is possible to operate using the capping method as below described:
Increase the drum level to the top; increase the hydrazine water concentration up to 10
ppm in the economiser and evaporator by the dosing system.

When no pressure is present at the drum, put in service the nitrogen system as
described at the Point 7 “CAPPING METHOD” to preserve the superheater.

4.2 LONG TIME STORAGE

For time exceeding 10 days, according to the circumstances, is possible to use one of
the following methods:

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
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- wet storage method (see ch. 5.0)

- dry storage method (see ch. 6.0)

- capping method (see ch. 7.0)

5 WET STORAGE

For a long period, in order to fill the BOILER with the approximate values described at
Point 2; operate jointly the chemical pumps and the feed water pump.

Using N2H4 refer to the total preservation volume.

Operate the condensate pump to fill the deaerator system, then start the feed water
pump by operating on recirculating line with the hydrazine and ammonia dosing pumps
at 60 l/h to mix the chemical solution in the deaerator system.
When the right chemical concentration in the deaerator is achieved start to fill the
BOILER system.

The ammonia will be added in the N2H4 dosing tanks.

5.1 BOILERG FILLING

Check that feedwater characteristics in the deaerator are within the settled limits.

with feed water pump in service, open the fed water control valve and proceed with the
filling of the system

- maintain in service the chemical injection pumps at the maximum flow

- when drum water level reaches approximate 50 %, reduce to minimum flow the feed
pump and increase the level up to water comes out of drum vents.

- close drum vents and proceed to fill superheater carefully.

- when water comes out of the superheater start up vent, stop the filling pump flow.
- Close the feed water manual inlet valve.
- When all the section is filled is possible proceed to pressurise the BOILER by the
nitrogen system.
- Maintain the drum level at the max value indicate open the isolating nitrogen bottles
valve and pressurise BOILER up to 0,5 bar.
- maintain the BOILER pressurised for all the preservation time to avoid air infiltration.

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
Confidential informations, property of Ansaldo Caldaie S.p.A., not to be used for any purpose other than that for which they are supplied.
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5.2 CHECK DURING THE STORAGE

- The BOILER should be checked in order to maintain the pressure in the BOILER
more than 0,5 bar.

Periodically is recommended to check the chemical characteristics of the BOILER

water solution and if required restoring the scavenger dosage by the chemical
injection at the drum.

- In case of long outage it is recommended to change boiler water every 2 months (in
any case it is in function of the analytical results of iron content).

6 DRY STORAGE

To be sure that there are no oxygen residuals, it is necessary to push out all the air by
water, so fill completely the BOILER as described at Point 5 using demineralised water
to reach the level in the nitrogen line at atmospheric pressure and then drain under
nitrogen pressure as described below.

If the BOILER will be stored immediately after operation period, is possible to drain the
boiler under residual pressure, when the pressure value reach 1 bar, and introduce the
nitrogen jointly at the drain operation.

6.1 NITROGEN SYSTEM ALIGNMENT

open the BOILER supply valve

open the isolating nitrogen bottles valve

by the PV valve, pressurise BOILER up to 0,5 bar.

Start the BOILER drain

6.2 SH SECTION

Start the drain at the superheater section under nitrogen pressure

uring the drain phase maintain the nitrogen tank at set pressure by PV control
pressure valve.

when the nitrogen comes out from the SH drain close the respective drain valves

6.3 ECONOMIZER SECTION

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
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Starts drain at economiser section by opening economiser manual drain valves and
drain the economiser under nitrogen pressure.

When the nitrogen comes out from the economiser drain, close the drain valves

6.4 EVAPORATOR SECTION

open the EVA drain manual valves and drain the evaporator under nitrogen pressure.

When the nitrogen comes out from the evaporator drains, close the drain valves

Maintain the BOILER pressurised for all the conservation time to avoid air infiltration.

If the pressure in the nitrogen decreases, proceed to restore it.

NOTE

BOILER can be effectively stored for long periods by filling the pressure parts with
nitrogen.

- Maintain all the BOILER sections pressurised with nitrogen at 0.3÷0,5 barg, (higher
pressure will increase eventually nitrogen leakage).
- Keep bottled the BOILER section and monitored the pressure.
- If there are pressure drops, check the circuit and stop the leakage, then operate with
nitrogen system to restore the pressure.

CAUTION

Before any personnel enter the drum or waterside of the unit during storage,
insure that all nitrogen has been purged from the BOILER.

WARNING: nitrogen is an odourless, colourless gas and although it is not toxic it can
displace atmospheric oxygen and cause suffocation of personnel.
Boiler under nitrogen storage must be roped off and the danger clearly marked.

Any personnel working adjacent to the boiler must have safety clearance, which
includes a test of the oxygen level in the atmosphere in the actual work area.

Personal oxygen meters are to be obtained for, and worn by, the individual involved.
Similar, but more extensive tests must be carried out before allowing access to within
casing or deadspaces. particular care must be taken when opening up the pressure
parts during storage.

For drum inspections, an oxygen mask must be worn.

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
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Operators must be instructed in the use of pressurised gases, and warned of the
dangers of frostbite when handling them.

Once the boiler is filled with nitrogen, a slight positive pressure should be maintained;
200 mm water gauge is the minimum pressure to be used.

A higher pressure can be used if there are no leaks.

The nitrogen supply valve is then closed and any leaks which develop are quickly
detected by the failing pressure.

However, it is often very difficult to maintain a completely tight boiler, especially when
valves have been in operation a long time.

If it is found that excessive nitrogen is being lost through leaks then the minimum
positive pressure obviously becomes more economic.

Effort should be made to identify and rectify leaks.

For monitoring the quality of the storage gas , samples can be taken at suitable open-
ended drains.

If the oxygen content rises much above 1% by volume, further nitrogen purging should
be carried out.

7 CAPPING METHOD

This method is a combination of wet (ECO / EVA) and dry method (SH).

As the BOILER is taken off-load no action is taken until the pressure approaches 1 bar.

The supply nitrogen of cylinders is connected to the nitrogen system and at the BOILER
section connections, so that when opened, nitrogen rather than air is admitted.

The method ensures low oxygen levels so avoiding corrosion, and as the water quality
is normal the BOILER can rapidly be returned to service.

7.1 OPERATING SEQUENCES

- Maintain the drum level at the operating water level

- when the BOILER system pressure reach 1 bar open the respective inlet drum
nitrogen

- open drain at the superheater section

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
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- when the nitrogen comes out from the SH drain close the drain valves

8 OPERATIONS RESTORE

8.1 AFTER LONG PERIOD STORAGE

For restore the BOILER operating conditions is necessary to change the total storage
water.

- Close the NITROGEN SYSTEM isolating valves \

- Open the superheaters and drum vents at the BOILER sections

Drain the BOILER

- Fill the BOILER with demi water at the request chemical condition for normal
operation.

- The filling sequence is described in the start up and shut down procedure

8.2 AFTER SHORT PERIOD STORAGE

Before BOILER restart, check the water chemical characteristic; if the pH and the
hydrazine are within the operating value characteristic is possible start up the unit
without change the water in the BOILER.

During the first start up phase maintain open the blow down valves and check the
chemical characteristic in the BOILER.

If the water characteristic values are out of the prescription proceed to change the water
in the BOILER.

8.3 AFTER DRY STORAGE

The operating conditions after dry storage will be reached isolating the nitrogen system.

Open the superheater and drum vents and proceed to fill the BOILER.

Informazioni strettamente riservate, di proprietà Ansaldo Caldaie S.p.A., da non utilizzare per scopi diversi da quelli per cui sono state fornite.
Confidential informations, property of Ansaldo Caldaie S.p.A., not to be used for any purpose other than that for which they are supplied.