Document Number:

AE&E CZ s.r.o. PX-PPKZ-0935331

Prepared: Approved: Document status: Customer’s Number:

Jan Gänsdorfer Jan Gänsdorfer

Date: Date: Platný Revision: Page:
30.10.2009 30.10.2009
0 1/11

Ambarli
Reg. No.: 28.5010
Order No.: -
Project Stage:

Alkaline Boil-out, chemical cleaning Procedure

Preliminary

Content

1 Purpose of chemical cleaning ................................................................................. 2

1.1 Boiler Basic data:.............................................................................................. 2
1.2 Boiler internal volumes ..................................................................................... 2
2 Alkaline cleaning procedure.................................................................................... 3
2.1 Basic conditions to be fulfilled prior to alkaline cleaning .................................. 3
2.2 The scope of cleaning ...................................................................................... 3
2.3 Cleaning procedure .......................................................................................... 4
2.4 Criteria for evaluation of alkaline cleaning........................................................ 6
2.5 Boiler post- chemical cleaning operation.......................................................... 6
3 Acid chemical cleaning ............................................................................................ 7
3.1 Basic conditions to be fulfilled prior to acidic cleaning ..................................... 7
3.2 The scope of cleaning ...................................................................................... 7
3.3 Performance of the cleaning............................................................................. 7
3.4 Criteria for evaluation of acidic cleaning......................................................... 11
3.5 Boiler post- cleaning operation ....................................................................... 11

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 Document Number:
Ambarli PX-PPKZ-0935331
Customer’s Number:
Alkaline Boil-out, chemical cleaning Procedure
Revision: Page:
Registration number: 28.5010
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1 Purpose of chemical cleaning

Chemical cleaning ensures special proces for removing grease and other
mechanical impurities from internal surfaces of HRSG pressure systems.
Chemical cleaning is proposed in 2 options – alkaline cleaning and acid
chemical cleaning. The correct option shall be chosen based on inspection of
internal pressure parts of the boilers during boiler erection. In compliance with
VGB R 513 acid chemical cleaning should be performed if the amount of
deposits exceeds 100 g/m2 . Nevertheless because of the boiler construction
(horizontal evaporator tubes with natural circulation) and its higher sensitivity of
the boiler internal surfaces purity there is strongly recommended to apply an
acid chemical cleaning procedure.
During designing, preparation and execution of boiler chemical cleaning
recommendation of the VGB R 513 guideline shall be followed.
1.1 Boiler Basic data:
HP Part
Outlet steam mass flow 78,1 kg/s
Outlet steam temperature 540°C
Outlet steam pressure 115 bar(g)
IP Part
Outlet steam mass flow 13,2 kg/s
Outlet steam temperature 326 °C
Outlet steam pressure 31 bar(g)
LP Part
Outlet steam mass flow 8 kg/s
Outlet steam temperature 195 °C
Outlet steam pressure 4 bar(g)
RH Steam
Outlet steam mass flow 90,13 kg/s
Outlet steam temperature 540 °C
Outlet steam pressure 31 bar(g)

1.2 Boiler internal volumes

Boiler pressure part Item Volume (m3)

Superheater inc.steam pipe 20.67
Evaporator inc.downcomer and riesers 45.10
HP Economiser inc.feed water pipe 43.06
Drum – steam part 19.26

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Alkaline Boil-out, chemical cleaning Procedure
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Drum – water part 21.77

HP part - TOTAL 149.86
RH Superheater inc.steam pipes 50.16
Superheater inc.steam pipes 8.25
IP Evaporator inc.downcomer and riesers 32.21
Economiser inc.feed water pipe 4.63
Drum – steam part 7.99
Drum – water part 9.45
IP part - TOTAL 62.53
Superheater inc.steam pipes 27.83
Evaporator inc.downcomer and riesers 55.20
LP Economiser (CPH) inc.feed water pipe 55.49
Feed water tank – steam part 20.00
Feed water tank – water part 78.30
LP part - TOTAL 236.82
Boiler Total 489.37

2 Alkaline cleaning procedure

Alkaline cleaning of evaporator and ECO systems shall be performed in
compliance with VGB R 513, art.4.5.1. „strong alkaline boil out“. Alkaline
cleaning stall be done during plant hot test after GT start up when flue gas heat
can be utilized for heating of alkaline cleaning solution.
2.1 Basic conditions to be fulfilled prior to alkaline cleaning

• Pressure test of the boiler has been done

• Boiler drum has been manually cleaned
• Condensators has been already flushed and is at disposal
• Condensate pumps are in disposal
• Make Up water is at disposal
• Sampling of LP, IP and HP saturated steam and LP IP and HP boiler
water is in operation
• Temporaries are installed and respective chemicals are ready to use
• GT is prepared for idle run test
2.2 The scope of cleaning
The following pressure parts of boiler will be cleaned:
HP system:

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Alkaline Boil-out, chemical cleaning Procedure
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Economizer
Evaporator
Drums till the operational levels
Internal volumes per 1 boiler: 110 m3
IP system:
Economizer
Evaporator
Drums till the operational levels
Internal volumes per 1 boiler: 47,5 m3
LP system:
Condensate heater
Evaporator
FW tank till the normal levet
Internal volumes per 1 boiler: 47,5 m3

2.3 Cleaning procedure

Alkaline cleaning will be done in the following steps:

2.3.1 Flushing of the boiler

The task is to remove mechanical impurities from. Feed(Make Up) water will be
used for this purpose. During test of Condensate pumps it will be flushed the
condensate piping into the condensate heater, condensate heater up to the LP
boiler drum. All drains from the evaporator stall be opened. Feed water pumps
stall be operated at max. permissible flow ( it is necessary to check pump
pressure-flow diagram ). Main feeding valve shall be fully opened until max.
level in the boiler drums is reached. Then feed water flow will be controlled
through coupling speed (or feed water outlet valve, if necessary).After short
flushing, when the amount of impurities in the discharged water is visually
checked, condensate pump is put out of operation, boiler is fully discharged and
flushed once again by the same procedure. In case that discharged water still
contains large visible impurities this procedure has to be repeated.
With the same manner will be flushed the IP and HP boiler systems.
Waste water from flushing: Removing of waste water from flushing does not
represent any problem. Waste water normally contains 50 -100 mg/l of solids,
that can be settled in the cooling or neutralization pit and water can be pumped
into sewerage. Neverthless this procedure has to be consulted with chemical
service of the client.

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Alkaline Boil-out, chemical cleaning Procedure
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2.3.2 Application of the alkaline chemical solution

Boiler will be filled with the make up water and then cleaning solution will be
pumped into the condensate heater, IP and HP economizers.
GT will be started and pressure in the boiler drums will be increased acc. to
start up curves up to approx 20 bar(g) in the HP drum, 8 bar(g) in the IP drum
and 3 bar in the FW tank. During the boiler heating by pass line shall be slightly
opened. The flue gas temperature upstream of the first superheater should not
be higher than 500 oC. Boiler shall be operated at this pressure for 2 hrs and it
is necessary to prevent carry over into the superheater - conductivity of the
saturated steam is checked.
After 2 hrs pressure in the boiler shall be decreased with max. allowable speed
up to 2-4 bar(g).
This procedure (heating and cooling) shall be 2x repeated and in the end
clearing solution stall be discharged at max. allowable speed into the
neautralization pit.
Boiler will be then flushed incl all vents and drains from the top of the boiler up
to the lowest point of the boiler.
The whole clearing with alkaline solution stall be repeated once again.

2.3.3 Wastes from alkaline cleaning

It is supposed to collect cleaning solution in the neutralization pit of the boiler.
The solutions will be neutralized using hydrochloric acid until pH about 7 is
reached. Then discharge solution shall be diluted and cooled down using raw
water until permissible values from the point of temperature and composition for
discharge into sewerage are reached. Neutralized solutions stall be discharged
in co-operation with chemical service of the client to comply with local
prescriptions.

2.3.4 Chemicals for alkaline cleaning

The following chemicals are fed per m3
NaOH 100% 1 kg
Na3PO4x12H2O 0,5 kg
Non foaming wetting agent 0,01 l
HCl 32 for passivation of the cleaning solution

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2.3.5 Engineering aspects

2.3.5.1 Temporary Equipments

The main parts are temporary dosing pumps , dissolving tank, effluent
neutralizing tank, connecting pipings made from carbon steel or rubber hoses,
valves.

2.3.5.2 Dosing of chemicals

Cleaning solution will be prepared in the temporary dissolving tank having
approx.1 m3 volume and pumped using temporary dosing pump into the boiler
in front of condensate heater, IP and HP economizers. Cleaning solution shall
be pumped into the boiler filled with feed water up to minimal boiler level pumps
are out of operation ).
When handling with chemicals safety prescriptions has to be strictly kept mainly
when working with sodium hydroxide.

2.3.5.3 Feeding of the boiler

Boiler feeding has to be controlled in such a way that level in the boiler drums is
maintained sligtly above the lowest permissible level.

2.4 Criteria for evaluation of alkaline cleaning

Chemical cleaning can be declared as satisfactory and completed when:
• Chemical cleaning procedure has been done as prescribed
• Sufficient amount of chemicals has been dosed into boiler ( pH of the
cleaning solution has to be approx. 12,5)
• Neutralization of waste water has been done as mutually agreed prior
chemical cleaning commencement
• Inspection of both drums has been performed and final mechanical
cleaning has been done in case that it was necessary
• Inspection sockets on headers has been cutted and the surface of
headers has been found generally clean, large impurities,if any, has to
be removed manually.
2.5 Boiler post- chemical cleaning operation
Steam blowing is preferred to be done consecutively in few days after chemical
cleaning
In case that that boiler hot test cannot follow i tis necessary to carry out proper
boiler lay up procedure.
Intermittent blowdown should be often done ( at every boiler shutdown ) and
continuous blowndown has to be largely open during first weeks of operation.

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3 Acid chemical cleaning

Acid chemical clearing will be used when deposits on pressure part sof the boiler
are higher than 100 g/m2. Acid cleaning usually allows to prepare better quality of
boiler internal surfaces comparing to alkaline cleaning. It is advisable to carry out
acidic cleaning by specialized company having practical knowledge of this activity
and securing thus that all safety measures are kept. This company has to
possess respective approval of authorities.
It can be used variety of different acids for cleaning but preferable is the usage of
hydrofluoric acid that has the best cleaning ability for removing of iron oxides.
Acidic cleaning has to be done during cold commissioning phase max. 2 weeks
prior start of the hot testing of the boiler. Selection of the best cleaning process
depends on local conditions –e.g. if there is not low pressure steam for heating of
cleaning solutions then the only procedure that can be applied is acid cleaning
using hydrofluoric acid. In case that there is source for heating of cleaning
solutions then other acids can be used e.g. citric acid.

3.1 Basic conditions to be fulfilled prior to acidic cleaning

• Pressure test of the boiler has been done

• Boiler drums has been manually cleaned
• Condensate tank has been already flushed and is at disposal
• Make up water is at disposal
• Sampling of LP, IP and HP boiler water are in operation
• Temporary equipments are installed and respective chemicals are ready
to use
• Safety precautions are fulfilled
3.2 The scope of cleaning
Option 1 – Static method
The following pressure parts of LP and HP will be cleaned:
Economizer, Evaporator
Option 2 – Forced circulation method
The following pressure parts of LP and HP will be cleaned:
Economizer, Evaporator, Drum, Superheater, main steam piping
3.3 Performance of the cleaning

3.3.1 Option 1

3.3.1.1 Initial flushing

The whole pressure part of the boiler will be flushed with water to remove loose
dirt, sand, dust etc.

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Two flushings are supposed to be done in dependance to cleanliness of

discharged water.
During the first flushing tightness of the whole system will be checked.
Flushing phase will be completed when discharged water is clean and free from
rough impurities.
Then only evaporator and ECO will be drained, superheater will kept full of
water to prevent ingress of the cleaning solution into the superheater
3.3.1.2 Degreasing
Removing of eventual oily or greasy substances from internal surfaces of
evaporator and economizer will be done by means of non –foaming degreasing
agent Alkon Special, which is effective also at lower temperatures.
Solution of 0,5 kg/m3 will be prepared in the dissolving tank, then twice pumped
into the system and drained back to the dissolving tank. This phase will approx.
4 hrs.
Degreasing solution will be then discharged from the boiler into the effluent
neutralizing storage tank.
3.3.1.3 Pickling
Oxides layer will be removed by the following mixture of chemicals:
1,5 %hydrofluoric acid + 0,2% corrosion inhibitor Rhodine A
The mixture will be prepared in the dissolving tank and pumped into the system.
Cleaning solution will be exchanged several times between dissolving tank and
the cleaned system to ensure homogenous mixture and precise laboratory
analysis.
Temperature: circa 20 deg C.
Duration: until steady iron and acid concentration in the cleaning solution is
achieved . It is supposed that pickling phase will be completed in 4-6 hrs.
Then the pickling solution will be discharged into effluent neutralizing tank.
3.3.1.4 Final rinse
Boiler will be then filled with water and flushed several times. This phase will be
finished when iron concentration in the discharged water is less than 50 mg
Fe/l. Discharged water from flushings will be neutralized similarly to a/m step.
3.3.1.5 Neutralization, temporary passivation
This stage will be performed as follows: Mixture of 0,3% citric acid and 0,1% of
inhibitor Rhodine A will be prepared in the dissolving tank and pumped into the
boiler. After 1 hour the solution will be discharged back to the dissolving tank.
Ammonia will be then added to increase pH to 8,5 –9 and then sodium nitrite in
concentration 0,5 g/l will be added.
Boiler will be filled with this mixture and after 2 hours the solution will be drained
into the effluent neutralizing tank .
Then the boiler drums will be opened and remaining not-dissolved impurities, if
any, will be cleaned mechanically.

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3.3.1.6 Wastes from acidic cleaning

All waste solutions will be collected in the effluent neutralizing tank for
neutralization and treatment. Mixing of the waste solutions and its neutralization
will be secured by pressure air.
Waste solutions from flushings- there is no need for special treatment.
Discharged water will be collected in the neutralization tank and set back water
pumped into local sewage system
Waste solution from degreasing- active carbon will be added to the discharged
water in order to adsorb organic matters present in the solution and then
drained into local sewage system.
Waste solution from pickling and flushing after pickling- discharged water will be
neutralized using lime to precipitate calcium fluoride,iron oxides and adjust pH
of the solution. Active carbon will be also added to decrease content of organic
matters. After laboratory control set back water can be discharged into the
sewerage ( Dilution of this set back water using raw water will be done, if
necessary ). Solid waste will be transported in authorized storege area or on
other agreed place
Waste solution from passivation- discharged water will be oxidized using
chlorinated lime with addition of active carbon.

3.3.2 Option 2

3.3.2.1 Flushing
The aim of this cleaning phase is the same as specified in option 1. Both LP
and HD system will be filled with water and tightness test of the whole system
using temporary pumps will be done. Water in both systems will be circulated
for circa 15 min. and then, during continuous drain and refill, the whole system
will be flushed. In case that there is not enough of demineralized water the
system can be drained and flushing can continue when enough water is at
disposal.
Flushing phase will be completed when discharged water is clean and free from
rough mechanical impurities.
3.3.2.2 Degreasing
The aim of the process is the same as specified in option 1.
Degreasing of both systems will be done using 0,5 % solution of proper
detergent e.g. Dubaryl DCX at 70 °C.
Both systems will be filled with water and ,during circulation and system
heating-up, detergent will be added. Cleaning solution will be circulated for 8
hours. When decreasing phase is complete cleaning solution will be discharged
into the effluent neutralizing storage tank..
3.3.2.3 Pickling
The system will be filled up with water and then inhibitor (RODINE 31 A) will be
dosed into the system through dissolving tank to reach concentration of 0,2 %in
the cleaning system. The solution will be consequently homogenized by means
of 1 hr circulation through both systems.
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Similarly hydrofluoric acid will be consequently dosed through dissolving tank

to reach concentration 1% in the cleaning system. Pickling solution will be
circulated and cleaning procudure will proceed at 50 - 60 °C for approx. 2-3 hrs.
Samples will be taken and analysed in 1hour intervals. The acid and iron
concentrations will be determined. The pickling phase is finished when steady
iron and acid concentrations in the cleaning solution are achieved .
Used pickling solution will be then drained into the neutralisation tank .
3.3.2.4 Final rinse
Boiler will be then filled with water and flushed several times. This phase will be
finished when iron concentration in the discharged water is less than 50 mg
Fe/l.
3.3.2.5 Neutralisation, temporary passivation
This stage will be performed as follows: The system will be filled up with water
and then the inhibitor (RODINE 31 A) will be dosed into the system through
dissolving tank to reach concentration of 0,1 %in the cleaning system. The
solution will be homogenized by means of 1 hr circulation through both systems.
Citric-acid will be then dosed through dissolving tank to reach concentration
0,3% in the cleaning system.
Concentration of dissolved iron will be checked in 0,5 hr intervals and cleaning
proper will proceed till the value uf dissolved iron is stabilized. Ammonia will be
then added to increase pH to 8,5 –9. Consequently passivation phase will
commence by adding of hydrogen peroxide. Passivating solution will be
circulated for 4 hrs at temperature circa 50°C.
At the end of passivation phase solution will be drained into the effluent
neutralizing tank.
Boiler drums will be then opened and remaining not-dissolved impurities, if any,
will be removed mechanically.
3.3.2.6 Wastes from acidic cleaning
All waste solutions will be collected in the effluent neutralizing tank for
neutralization and treatment. Mixing of the waste solutions and its neutralization
will be secured by pressure air.
Waste solutions from flushings- there is no need for special treatment.
Discharged water will be collected in the neutralization tank and set back water
pumped into local sewage system
Waste solution from degreasing- active carbon will be added to the discharged
water in order to adsorb organic matters present in the solution and then
drained into local sewage system.
Waste solution from pickling and flushing after pickling- discharged water will be
neutralized using lime to precipitate calcium fluoride, iron oxides and adjust pH
of the solution. Active carbon will be also added to decrease content of organic
matters. After laboratory control set back water can be discharged into the
sewerage ( Dilution of this set back water using raw water will be done, if
necessary ). Solid waste will be transported in authorized storage area or on
other agreed place

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 Document Number:
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Customer’s Number:
Alkaline Boil-out, chemical cleaning Procedure
Revision: Page:
Registration number: 28.5010
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Waste solution from passivation- discharged water will be oxidized using

chlorinated lime with addition of active carbon.
3.3.3 Engineering aspects

3.3.3.1 Temporary Equipments

The main parts are temporary process pumps, dissolving tank, effluent
neutralizing tank , injector for dosing of liquid chemicals or the suitable dosing
pump, connecting pipings made from carbon steel or rubber hoses, valves.
In the option No. 2 (circulating method) shall be the temporary piping connected
so that circulation from both sides (form side of ECO and form the main steam
line) will be possible. Therefore an suitable temporary bypass of the drum shall
be installed.
Demineralized water supply line will be fire hose, as well as effluents discharge
from neutralizing tank.
3.3.3.2 Preparation of cleaning solutions
All cleaning solutions will be prepared in the dissolving/neutralizing tank, liquid
chemicals will be dosed by means of injector.

3.4 Criteria for evaluation of acidic cleaning

Chemical cleaning can be declared as satisfactory and completed when:
• Chemical cleaning procedure has been done as prescribed
• Neutralization of waste water has been done as mutually agreed prior
chemical cleaning commencement
• Inspection of both drums has been performed and final mechanical
cleaning has been done in case that it was necessary
• Inspection sockets on headers has been cutted and the surface of
headers has been found generally clean, large impurities, if any, has to
be removed manually.
•
Testing tube samples do not exhibit remaining oxide layer higher than 20
g/m2
3.5 Boiler post- cleaning operation
Passivation of the pressure parts of the boiler is only temporary one and
ensures boiler protection for approx. 2 weeks. Natural protective magnetite
layer will be formed during “hot” operation and therefore it is recommended to
start boiler immediately after removing of temporaries. If this is not possible
proper lay up of already clean boiler has to be applied.

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