Specification For Chemical Cleaning

ARUCHEM
TECHNICAL SPECIFICATION FOR 4 x 600 MW

600 MW UNIT CHEMICAL CLEANING STERLITE ENERGYLTD,
JHARSUGUDA-Orissa
PRE-COMMISSIONING CHEMICAL CLEANING OF PRE-BOILER & MAIN BOILER SYSTEM
STERLITE ENERGY LTD

SEPCO-III & LARSEN & TOUBRO LTD
THIS DOCUMENT IS THE PROPERTY OF ARUCHEM

AND HIS ONLY ALLOWED TO BE USED BY EXPRESS
PERMISSION FROM ARUCHEM-CHENNAI.
TECHNICAL SPECIFICATION FOR CHEMICAL

CLEANING OF PRE-BOILER & MAIN BOILER System
DOCUMENT NO: AEPL/CC:027/09
Service Provider
No-79 Valmiki Street,

Thiruvanmiyur-Chennai-600041
Phone-044-2443 0705 /2490 1623 Fax 044-2442 4755
Email: arudra@eth.net
VEDANTA SEPCO-III L&T ARUCHEM
DOCUMENT NO: AEPL/CC:027/09 Page 38 of 42

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CONTENTS
1. Purpose for chemical cleaning

2. Reference
3. Scope of Chemical cleaning and water holding capacity
4. Preparation before chemical cleaning
5. Chemical cleaning circuit and Cleaning Process
6. Disposal of chemical cleaning Waste Solution
7. Quality Specifications
8. State of the Plant
9. Safety Procedure
10. Safety Precautions
Appendix I: Chemical Process & Testing Parameters

Appendix II: Quantity of chemicals (One unit)
Appendix III: List of Chemical Cleaning Equipments
Appendix IV: Budget of equipment and material
Appendix V: Utility Requirements during chemical cleaning
Appendix VI: Analytical Testing Method
Appendix VII: Format of Log Sheet
Appendix VIII: Schematic Drawing for chemical cleaning

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1.0. Purpose for chemical cleaning;
The sub-critical controlling drum type boiler is supplied by SEPCO-III, China.

According to the requirement of Guidelines for Boiler Chemical Cleaning
of the Thermal Power Plant, before start the boiler, it is necessary to
carryout chemical cleaning for those whose steam pressure is higher than
9.8 MPa. The purpose for chemical cleaning is to remove the high
temperature oxides formed during the process of rolling and machining of
the boiler and the corrosion production, greasy dirt, welding slag, and
other sundries created during storing, transporting and erection.
A protecting passivation film is formed during the process of chemical

cleaning to keep the surfaces cleanness of thermal equipment, improve
the quality of water and steam in thermal system, prevent accident
caused by the deposition and corrosion, and ensure that the unit could
start smoothly and operate safety.
2.0. Reference
• Guide lines for high pressure boiler chemical cleaning IS-10391-1992
3.0. Scope of Chemical Cleaning and Water holding capacity;
3.1. Alkali cleaning of Pre Boiler System (Boiler Front system)
Pre- boiler system includes HP& LP condensers, Feed storage tank,

condensate pipes, and HP/LP heaters, Booster pump suction line and by
pass lines.
Condensate Extraction pump shall be used for alkali cleaning.
3.2. Inhibited Hydrochloric acid cleaning of Main Boiler:
The main boiler system includes portion of feed water pipes, Economizer, Steam
drum (Half level) lower Ring header, water walls, down comer and connecting
pipes of boiler side.
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Boiler circulating water pump shall be used for recirculation during
chemical cleaning.
3.3 Cleaning water capacity (Approx)
Description Water capacity
(M3) Approx
1. ALKALI FLUSHING FRONT SYSTEM
HP/LP Condenser Hot well Low level 600
Deaerator (Feed Storage tank) 200
HP heaters 30
LP heaters 50
Pipes of condensate & feed water 90
Total Alkali cleaning Volume 970 M3
2. ACID CLEANING OF BOILER
Economizer , Header and piping 200
Water wall tubes, Header , down 120
comers and risers
Steam Drum ½ level 35
Temporary pipes and cleaning tanks 20
Total Alkali cleaning Volume 375 M3
4.0. Preparation before chemical cleaning;

4.1: Alkali Flushing of Pre-Boiler System:
• Condensate Extraction pump keep ready for operation.
• Necessary temporary pipe connections shall make as per
scheme.
• Blank/remove flow nozzle/instrument prior to alkali cleaning.
• HP spray desuperheating pipes should be separated, and install
after chemical cleaning.
• Necessary cooling arrangement for CEP.
• Reinforcement bar inside the condenser tanks should be carefully
checked.
• Use φ219×6 pipes to connect before Economizer inlet to FST.
Provide sampling points on temporary pipes.
• Make condenser temporary liquor level indicator by transparent

hose pipes. Its height should be 100 cm higher than the highest
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stainless pipe of condenser, and be graved with scales in order to

monitor.
Connect drain pipes to neutralization pit/ plant drain channel.
Inlet of condensate pump should meet the requirement of
commissioning. Set suction strainers at pump inlet.
Temperature measuring points of fee water and condensate system
could put into operation.
Complete the commissioning of waste water system. The system
has to meet the requirement of receiving and treating waste water.
Complete the commissioning of auxiliary steam system, and meet
the requirement of operation.
All motor operated valves in feed water and condensate system
should be completely commissioned and meet the requirement of
normal operation.
The nozzles inside deaerator could not be installed for the moment.
Auxiliary steam heating, liquor level signals and temperature
measuring points could be put into operation.
DM water system could be put into operation and the DM water

tank shall be kept full.
4.2. Acid Cleaning of Boiler;
• The temporary pipes for acid cleaning inlet, outlet and drain pipes
should adopt mild steel tubes of φ219×6mm.
• The Inlet pipes of economizer should adopt φ219× 6 mm mild steel

pipes and it shall be connected before feed water check valves of
feed water operating plot form.
• The outlet pipes connect from the bottom lower ring header stubs
(100 mm). (Each one tapping from each corner side). All the
tapping connects to the common header φ219×6 mm mild steel
tubes.
• The boiler circulating water pump (CC Pump) will be used during
acid cleaning for intermediate circulation.

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• Set a 20 M3 cleaning tank with Steam header inside. The inside

should be cleaned. The cleaning tank could not be set near cable
channel or important equipments.
• The (2)two acid cleaning pumps (with one stand by) out side
cleaning tank are set parallel, make a recirculation loop with φ
219× 6 mm pipes.
• The tank drain pipe of φ108 is installed at the bottom of the tank.
• The auxiliary steam supply temporary pipes φ108×4 mm pipes and
connect to the mixing tank. The insulation should be done . Set 2-3
draining points. The parameter of steam should meet the following
requirements: Pressure is 0.8 – 1.0 MPa, temperature is 250 – 300 oC
and flow is 15 – 20 t/h.
• Acid transfer pump shall be used for transferring acid from tanker in
to mixing tank. Pump gland packing shall be PTFE materials.
• Ensure the temporary pipe should not have any debris before
erection.
• Thermometer and Pressure gauges in temporary system shall be

installed.
• Ensure that the communication between steam drum position and

acid cleaning operation area is established.
• Don’t install cyclone separator. Sample tubes/coupon (2 Nos) shall

be kept both the end before closing of steam drum.
• Don't install water lever gauge in drum. Use PVC transparent hose
pipe at back nozzle of water level gauge valves as temporary level
gauge.
• Connect air vent pipe from steam drum φ50 pipe for nitrogen filling
and hydrogen exhausting.

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• DM water source is connected from main DM supply pipes or

Deaerator water pipes to cleaning tank with φ159 steel pipe.
• Provide necessary sampling points at Inlet & Out let.
• Complete the installation of waste water discharge system. Ensure

the system could be put into operation.
• Ensure uninterrupted Power Supply chemical cleaning pump.
• Temporary piping systems ensure no leaks.
• Ensure all the chemicals shall have available at site.
• Analytic instrument, testing chemical, recording tables and labor

safety protective articles should be all ready and transported to the
field before acid cleaning.
• All the valves of temporary system shall have number and Tag
nameplates. Check that all the valves are easy to operate and
reliable. The valves contacted with acid liquor should be wrapped
with plastic membrane.
• Ensure availability of illumination at boiler, fire tender and
ambulance during chemical cleaning.
• The access doors, fire observing opening, air dampers, air ducts,
and flues of boiler shall be closed.
5.0 Cleaning circuit and Cleaning Process;
5.1. Alkali Flushing of Pre- Boiler System:

5.1.1. Basic Technique;
• Alkali cleaning process adopted with Non Ionic wetting agent with
Trisodium Phosphate. These combinations of the chemicals have a
strong ability of releasing oil & dirty without corrosion of parent
metal.
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• The Alkali cleaning process includes Mass flushing, hot alkali

cleaning and DM water flushing.
• The complete process use hot well of condenser as water tank,

condensate pump as drive.
• Adopt the method of flushing by sections and multiple releasing so

as to release all the sundries inside the system.
• Auxiliary steam as heat source and raise the temperature through

Deaerator feed water tank.
5.1.2 Flushing steps
Assisted with test running of condensate pump, carry out water

flushing to condenser
• Flow Path: Condenser→ Condensate Extraction pump → (CPU) by
pass → shaft heater bypass → Condensate Re- circulation line →
condenser.
• Fill DM water to condenser up to top portion. (Check water
capacity while filling).
Start up condensate pump to carry out flushing. The circulating
time should be 30min.
• Once flushing is completed, open blow down valve to drain until
water level of condenser empty. Then stop condensate pump to
completely drain the residuary liquid in condenser.
• Evaluate the water quality by visually, if the water quality is clear,
carry out water flushing of pre boiler system.
5.1.2.2 Circuit Sequence of Pre boiler system;
Flow Path: 1: Condensate System

• Condenser Hot well→ CEP→ CPU bypass → shaft heater and bypass
→ LP Heater and bypass circuit→ deaerator→ Feed water pipes→
Booster pump Suction(Inlet)→ Temporary line →Condenser

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Flow Path: 2: Feed Water System

• Condenser Hot well →CEP → Temporary line →HP feed water pipes
Discharge→ HP heater and bypass → Inlet of Economizer→
temporary pipes→ Feed Storage Tank →Temporary line→
Condenser.
Flow Path: 3: HP Drip System
• Condenser Hot well → CEP → Temporary line to HP Heater -1 Shell

side→ HP Heater 2 & 3 Shell side → temporary pipes→ HP
condenser.
Flow Path: 4: LP Drip System

• Condenser Hot well → CEP → Temporary line to LP Heater-5 Shell
side→ LP Heaters 6 & 7 A& 7B → LP condenser.
5.1.2.3. DM water Flushing:

• Integrate with test running of Condensate Extraction pump to
carryout water flushing of pre boiler system.
• Fill DM water to hot well of condenser until reach the highest level.
Start condensate pump.
• Carry out open-circuit flushing till achieving water clarity visually

clear and turbidity less than 5 NTU.
• Continue closed cycle flushing circuit wise for boiler feed

&condensate system and shell side of HP/LP heaters.
• Ensure flushing flow rate should be ≥ 600t/h until the water become
clean.
• While carryout water flushing, initially flush by pass circuit of HP
heaters and LP heaters, after water is clean; flush main parts of HP
heater and LP heater.
• Clear the strainer after completing water flushing.

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5.1.3 Alkali cleaning of Pre-Boiler System.
The chemical using for alkali cleaning is 0.05 ~ 0.1 % Non Ionic Detergent
and 0.2~ 0.3 % of Tri-Sodium phosphate. The temperature should be
maintained at 55 ~ 60 o C.
• Establish circulation circuit wise. Raise the temperature of to 55~

60oC by using auxiliary steam.
• Add alkali cleaning liquor into condenser steam side from
temporary dosing equipment.
• Carryout alkali cleaning of main circuit and by pass circuit one by

one.
• The water level of condenser should be 50~100 mm higher than
heat exchanging tubes and strictly control water level.
• Check alkalinity and phosphate every 30 minitus.
Completion Criteria: Drain the solution after achieving steady value of

alkalinity (or) after circulating 8~10 hours.
5.1.4 Water flushing
Once alkali cleaning is completed, open the drain valves to complete

alkali solution in the neutralization pit. Fill the condenser with DM water,
Start CEP to flush the entire system. The flow of water should not be lower
than ≥600t/h during flushing.
Completion criteria: Ensure the out let drain water pH ≥ 7.5 and the water
should be clear without any sundries.

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5.2. Acid Cleaning of Main Boiler:
5.2.1. Basic Technique;

• The Scope of Chemical Cleaning covers during pre-commissioning
of the unit entire evaporative system of the boiler and the
Economizer. The following will constitute brief technical
specifications in connection with chemical cleaning of boiler.
• The aim of Chemical Cleaning is to remove mill scale, oil, paint,

preservatives, rust, welding slag’s that would have entered during
the assembly of new tubes. After carrying out the process, the
internal surfaces of the tubes are passivated by means of
protective layer to prevent further rusting and corrosion.
• The cleaning circuit consists of the following equipments of the

boiler.
• Economizer,
• Steam Drum NWL
• Water wall tubes,
• Down Comer & Riser tubes.
• Super heater is not to be chemically cleaned. Instead, it is flushed
and filled up with Ammoniated Hydrazine (pH 9 ~9.5 and 250 ppm
Hydrazine).
• The Chemical Cleaning process includes Mass flushing, hot alkali
Cleaning, Acid cleaning, citric acid rinse, neutralization &
Passivation.
• Boiler Alkali flushing followed by inhibited acid cleaning process

adopted with Non Ionic wetting agent with Tri sodium Phosphate
and Di-Sodium phosphate. These chemicals were strong ability of
releasing oil dirty without corrosion of parent metal. The acid
cleaning process adopted with 4~5 % of inhibited hydrochloric acid
with Ammonium Bi fluoride.
• For boiler filling, heating and chemical dosing shall be used
chemical cleaning pump. However, boiler circulating pump shall
be used for intermediate circulation.

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5.2.1: Sequence of Cleaning Process:
Cleaning Process of main boiler system as follows;
• DM Water flushing
• Alkali cleaning
• Water flushing after alkali cleaning
• Hydrochloric acid cleaning
• Water flushing after acid cleaning
• Citric acid rinsing
• Neutralization
• Passivation
5.2.2. Boiler proper cleaning circuit
According to the characteristic of boiler configuration, it could be divided

into two circuits.
1. First circuit: Heating & Chemical Dosing with temporary Pump.
• Cleaning tank→ Acid cleaning pump→ Temporary line to

Economizer Inlet → Steam Drum → Water wall→ Bottom Ring
Header→ Temporary lines→ cleaning tank.
After chemical dosing, start Boiler circulating pump for intermediate

circulation.
2. Second circuit: Intermediate Circulation with CC Pump.
Steam drum→ down comer → boiler circulating water pump→ Discharge

line of CC Pump lower ┐Ring header→ water wall tubes→ Steam Drum
│ ↑
→ ECO Re-Circulation lines→Economiser

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5.2.3: Super Heater Filling & DM Water Flushing (Cold & Hot)
Fill the super heater and flush till drain water is clear, Prepare protecting
liquor of 250 PPM of hydrazine hydrate and ammonia pH 9.5~ 10. Fill the
solution to super heater. After achieving pH and hydrazine at overflow
lines through saturation steam tubes connected to steam drum (Water
sample to be collected inside the steam drum) stop filling the system.
Keep tube samples inside the steam drum; close both side steam drum
manholes.
Fill boiler with DM water to flush boiler till water is clear, check the water
quality and ensure the accepted level. Raise the temperature 70~75 Deg
C by using auxiliary steam. Circulate the hot water 4~6 hrs. Check the
water quality.
5.2.4 Alkali cleaning

This process to remove the oil & dirt on the surface of system to provide
well situation for hydrochloric acid cleaning. Fill the boiler with DM water
and raise the temperature 70~75 Deg C. add the following chemicals one
by one.
• Trisodium Phosphate -Na3PO4 - 0.3~0.4%
• Di- sodium Phosphate -Na2HPO4- 0.1~ 0.2 %
• Wetting Agent – 100 ppm %
• Temperature of alkali cleaning 70 ±5
• Hours for alkali cleaning: 8~10hrs.
After completion of chemical dosing, start one Boiler circulating pump for
10~15 minutes for intermediate circulation. The same process continued
every one hour (Circulation & Choking technique). Check periodically
alkalinity, Phosphate at every 30 mints.
Completion Criteria: After achieving steady values of Alkalinity and

phosphate then start drain the complete system. The Spent Alkali Solution
shall be neutralized with hydrochloric acid.

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5.2.5 Water flushing after alkali cleaning
After complete draining of alkali solution, fill the boiler with DM water and
flush until the draining water pH ≤7.5.
5.2.6 Hydrochloric acid cleaning
Fill the boiler with DM water and raise the temperature 55~60 Deg C. add
the following chemicals one by one.
Chemical Dosage & Parameters conditions:
• Inhibitor Coronil- 213 Special - 0.2~0.3%

• Hydrochloric acid -- 4~5 %
• Ammonium Bi Fluoride – 0.2 ~0.25 %
• Temperature: 60 ± 5 oC
• Hours: 5~6hrs,
Maintain the water levels at steam drum below the NWL. Periodically start
boiler water circulating pump for intermediate circulation. It should
operate for 10 mints. Check % of acid and total Iron. Once the Iron and
acid values were stabilized then drain the complete spent acid solution
under nitrogen capping.
5.2.7 Drain out Spent acid by Nitrogen purging;

Close air vent pipes of drum and fill nitrogen into drum through air vent.
The acid solution would slowly drain out. Regulate the speeds of filling
nitrogen and draining acid solution and keep the pressure of drum at the
range of 0.4 ~ 0.5 bar. When the spent acid is complete drained, stop
filling nitrogen.
5.2.8. DM Water Rinse:
Drain the Mixing tank and fill with DM water. Open the air vent pipes of
drum and startup cleaning pump to fill water into boiler, carry out rinsing
the system till getting normal water pH 4.0 and total Fe ≤ 50 Mg/l. The
system draining is carried out under nitrogen capping in every step
starting from acid pickling up to DM rinsing.
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5.2.9 Citric Acid Rinsing:
The advantage of this Citric Acid Rinse is to remove effectively the

dissolved Iron from the system. Fill the boiler with DM water and raise the
temperature 60~65 Deg.C.
Citric acid - 0.2 %

Ammonia Liquor pH 3.5~4.0,
Temperature: 60±5 oC
Hours: around 3-4 hrs,
Citric Acid is charged into the system to obtain the concentration of 0.2 %
and the pH maintained between 3.5~4.0, by the addition of Ammonia.
The temperature shall be maintained during this process at 55~600 C.
Boiler water circulating pump should operate for 10 mints one by one.
Circulation is to be maintained for 3~4 hours. Check the inlet and outlet
sample pH and total Iron at regular intervals. Once achieved the constant
value of Iron at out let, start drain the complete system under nitrogen
capping.
5.2.10. DM Water Rinse: I;
Fill the Boiler system with DM water and establish circulation for ½ an hour.
Measure the iron in the inlet and return line. Drain the system under
nitrogen capping.
5.2.11. DM Water Rinse: II;
Again fill the Boiler system with DM water and establish circulation for 1~2
hour. Measure the iron in the inlet and out let line. The DM Rinse Operation
continued till the Iron values drop down 25 PPM. Drain the system under
nitrogen capping.

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5.2.12. Neutralisation
DM Water is filled in the boiler system and the raise the temperature
80~850 C and then 0.5~1.0 % of Sodium Carbonate is inject into the boiler
through chemical circulation pump. Establish circulation through boiler
water circulating pump should operate for 30 mints one by one. All
Instrumentation tapping are flushed and venting of the system carried out
several times to get rid of Hydrogen. Keep circulation for 4 Hrs. Check the
pH values periodically; finally the entire system is drained under
atmospheric pressure.
5.2.13. Passivation:
The aim of Passivation is to prevent corrosion since cleaned surfaces are

more susceptible to corrosion that can take place at a faster rate.
Hydrazine Hydrate -300 ~ 350 ppm

Ammonia Liquor pH 9.5~10.0,
Temperature: 85±5 oC
Hours: around 20 hrs,
Fill the boiler system with DM water and establish circulation. Raise the
temperature of solution up to 80-90ºC by addition of steam, add
hydrazine hydrate to get the concentration of 300~350 ppm and add
ammonia solution to raise the pH up to 9.5~10.0. Boiler water circulating
pump should be started for 30min one by one, circulation continued for
20 hours. Measure the Hydrazine concentration and pH periodically.
During passivation, the water level should be a little higher than the level
of rinsing. After complete passivation, quickly drain the passivation
solution under atmospheric pressure. The Spent solution shall be oxidised
by using Bleaching Powder.
After completion of draing, the steam drum manhole shall be opened for
natural cooling. If found any loose debris, it shall be removed manually
with cotton cloth.

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6.0. Disposal of Cleaning Waste Solution:

The water after system water flushing could be discharged into drain
channel directly. Other cleaning waste liquor should be carried out
unharmfull treatment before discharged. The waste liquor should be
treated until reach the allowable discharging standard with local
pollution control board norms..
6.1 Disposal of alkali cleaning waste liquor;

The main component of alkali cleaning waste liquor is phosphate, which
is unharmful substance. So the alkali cleaning waste liquor could be
stored in disposal pool of waste liquor at first. Then use acid cleaning
waste liquor to neutralize.
6.2 Disposal of hydrochloric acid waste liquor
Discharge hydrochloric acid waste liquor into treating pool of waste liquor
and neutralize with alkali cleaning waste liquor. Then use proper NaOH
liquor and lime powder to neutralize. The pH of wasting liquor should be at
the range of 6.0~9.0, then discharge after static.
6.3 Disposal of passivating waste liquor
The citric acid in passivating waste liquor could be oxidized with sodium
hypochlorite. Because phosphate is unharmful substance, so add a little
acid to neutralize ammonia to make the pH at the range of 6 ~ 9.
6.4 Discharge quality of the waste Water:
Secondary standard of maximum consitstency of second kind of pollutant
pH 6~9
COD 150 mg/l
Harmful Substance Maximum allowable discharge consistency
pH 6~9
suspend substance 150 mg/l
COD 150 mg/l

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7.0. Quality specification;
After cleaning work completed, open the access of condenser,

deaerator and Steam drum to clean deposits inside if found. Evaluate the
result of chemical cleaning according to the guide for Boiler chemical
cleaning of Thermal Power Plant DL/T794-2001china High Pressure boiler
chemical cleaning IS-10391India.
7.1 Check alkali cleaning effect with eye observation, there shall not be
oil dirty on the Inside walls of equipment.
7.2 Surface of equipment shall be clean, without rudimental oxide and

welding slags after chemical cleaning. There should be no evident
over washed phenomenon caused by separated metal coarse
crystal and copperized phenomenon.
7.3 Average corrosion speed of metal indicated by corrosion indicating

plate should be less than 8g/ (M2/h), the total corrosion quantity
should be less than 80g/M2.
7.4 The surface after chemical cleaning should be formed with

passivation protecting film without secondary rusting corrosion and
point corrosion.
7.5 Valves and meters in fixed equipment should not be damaged.
7.6 Cut pipes to judge cleaning effect. If cleaning result is ensured to be

well (observe the monitoring pipes), it is not necessary to check by
cutting pipes. The pipe cutting part of new unit shall choosing part of
pipes with low velocity of flow in system. It is forbidden to gas cutting
to cut pipes. The length of sample pipes should not be less than
150mm when being cut manually. The length of sample pipes cut by
grinding wheel should not be less than 400mm.

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8.0 STATE OF THE PLANT:

Ensure the commissioning of the following; -
• Ensure free expansion of the furnace and ducts and provision of
expansion markers.
• Blow-down system of boiler.
• Readiness of N2 capping system.
• Availability of auxiliary steam system.
• Emergency lighting in boiler area.
• Fire water system in boiler area.
• All the safety measures discussed and implemented in advance
with suitable instruction & caution tags provided at strategic
places & equipment.
•
• Boiler Chemical cleaning circuit consisting of with Chemical
dosing pump, Circulation tank, circulating pumps, valves & piping
is fabricated as per the drawing. Circuit tested for leakage, if any,
attended.
• The entire system is flushed thoroughly including the temporary
pipelines.
• During the acid cleaning process, all the permanent instruments

are isolated except providing a temporary pressure gauge
/temporary gauge on temporary scheme.
• For chemical cleaning process, the internals of the non-return

valve if provided it may be removed in order to facilitate fast filling
and draining of the system.
• SH Air vent lines, Nitrogen capping lines are properly tagged and
taken in to suitable location for easy operation
• Proper neutralizing arrangement is available at site to Neutralize
and dispose off the effluent in line with local pollution control
board norms.
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8.1. The following systems to be under operation condition;

• Potable/service water supply system,
• DM water Supply and tank facilities,
• Auxiliary Steam Supply,
• Waste water pumps,
• Power Supply of Acid cleaning Pumps,
• Storm Sewage system,
• Fire water system for emergency use,
• Leak test of temporary chemical line
• Flushing of temporary line and chemical mixing tanks

• Connection of temporary equipment to main lines
• Connect temp.line to Economizer.
• Connection of temp.line to bottom header.
• Connect temporary piping to header drain.
• Connect temp line to Vent Station.
• Connect temp line to S/H drain line.
• Check the Aux Steam condition.
• Check waster neutralization treatment facilities condition.
• Waster water ponds are empty to receive and ready to treat
wastewater.
• Treating equipment-Pumps, Screens, Blowers are available and
ready to operate.
• Treating chemicals as recommendation are readily available.
8.3. Permanent Valve Operation and Maintenance
 Permanent valves must be operated by commissioning team.
 Red Tag must be posted after closing inlet/outlet valves of boiler
Re- circulation Pump
 Protect all the permanent instruments of main line in cleaning
region by means of blocking isolating /plugging, etc.

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9.0 SAFETY PRECAUTIONS:
9.1. Safety Equipments:
Ensure the availability of the following Safety equipments to all

operating personal involved in the process of chemical cleaning. Person
working at high level will be provided with safety belts.
1. Gum Boots (Various sizes)

2. Rubber gloves
3. Rubber or Polythene aprons
4. Helmets
5. Safety goggles plain glass
6. Face Mask
9.2. Emergency Provisions.
• Flushing and washing water supplies shall be provided at all

possible points of discharge, spillage or escape of chemicals.
• Adequate provisions shall be made for emergency treatment of

the eyes, comprising eye wash bottles, located conveniently to
places where discharge, spillage or escape of chemicals can
occur.
• Safety shower shall be provided.
• A suitable first aid treatment room with outside telephone facilities

shall be provided within a reasonable distance of the place
where chemicals are being used.
9.3.Emergency Procedure:
• The testing team should be aware of the operating procedures of

fire extinguishers to be used for quenching minor or major fires.
• The testing team should be aware of the procedure to be

followed in case of accident involving personnel injury.
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• An operator posted at the pump area, should be instructed to

stop the pumps and properly isolate the system in the event of
emergency.
• All the test team members should be well conversant with the
emergency operating instructions
9.4 Splashes of the eye;
• Immediately flood the eye with water. To be effective the eyelids

must be opened. The eyelids should be pushed apart using the
thumb and index finger of the left hand. The casualty will probably
not be able to open the eye himself because of painful spasms.
• If an Eye wash bottle is used the jet should not be directed at the
front of the eye. It should be directed in from the side, so that flow
is over the surface of the eye.
• Irrigation should be continued for 5 – 10 minutes after which the

casualty should be taken to the first aid room.
• Irrigation should be continued in the first aid room. Remember

vision is saved by thorough irrigation; no other treatment can
prevent damage if this is omitted.
• After thorough irrigation the eye should be covered with a pad;

the patient should be referred for medical opinion.
9.5. Irritation of the skin
• If signs of skin irritation occur the persons should be removed from

contact and referred for medical opinion.
• In the event of the splashing of the skin with chemicals the

effected area should be washed thoroughly avoiding spreading
contamination to the face and eyes.
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9.6. Safety Identification:
• Test area will be cordoned off and unauthorized persons entry

shall be prohibited. Suitable signboard shall be displayed.
Whenever any inspection in made during the cleaning process,
the location should be adequately ventilated
9.7. Fire Tender/Ambulance
• Ensure that one fire tender with operators and ambulance will be
kept ready in round the clock operation during chemical cleaning
operation in case of any emergency.

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Appendix I: Chemical Process & Testing Parameters;

Sampling requirement during process of chemical cleaning;
Cleaning process Test items Analyze Control Remark

periods(min) range
Super Heater Filling Hydrazine - Super heater
Ammonia 250 ppm protection
pH 9.5~10
Water flushing Deposit 30 Water is Check with

clean eyes
Boiler Front alkali cleaning Temp 60 55~60
Water flushing after alkali Appearance 30 Side

cleaning drainage
PH 30 ≤7.5 water
Alkali cleaning to Main Na3PO4 60 0.3-0.4% Measure
boiler outlet and
Na2HPO4 60 0.1-0.2% inlet sample
at the same
time
Wetting 60 0.1%
agent
Boiler Acid cleaning HCL 30 4-5% Measure
ABF 0.25% outlet and
Inhibitor 0.2% inlet sample
at the same
Fe3+ 30 ≤300mg/L
time
Fe2+ 30 /
Temperature 30 55±5
Water flushing after acid PH 30 ≤4.0 Measure

cleaning drainage
Iron 30 ≤50mg/L sample
water
Citric Acid Rinsing Citric acid 60 0.2 % Measure
Ammonia pH 3.5~4.0 outlet and

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PH 30 3.5-4.0 inlet sample

at the same
Pure iron 60 ≤300mg/L time
Temperature 60 70±5
Neutralization Sodium 60 0.5~1.0

Carbonate
Temp 60 80±5
passivation Hydrazine 85 350 ppm Measure

pH 9.5-10.0 outlet and
Temperature 60 80-90 inlet sample
at the same
time
****************

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Appendix-II: Quantity of Chemicals for One Unit:

Chemical Name Specification Quantity (Kg)
/(MT)
Non Ionic Detergent Non Ionic Detergent 1400 Kg
Na3PO4 .12H2O Industrial, solid, purity≥95% 4000 Kg
Na2HPO4.12H2O Industrial, solid, purity≥95% 2000 Kg
Hydrochloric acid (30%) Liquor, solid, purity≥30% 65 MT
Coronil 213 Spl-Inhibitor Liquor 200Kg/Barel 1200 Kg

Inhibitor efficiency≥99%
Ammonium Bi Fluoride Purity 98.5 % 1000 Kg
Ammonia Liquor Industrial grade≥25% 4000 Kg

Sodium Carbonate solid
3750 Kg
Citric acid solid 800 Kg
Hydrazine hydrate 80 % 400 Kg
Caustic Lye Industrial grade≥48% 30 MT
Lime Powder 70 % ( 25kg/pakage) 10 MT
Bleaching Powder Industrial grade 2000 kg
Nitrogen 6.5 M3 /Cylinder 300 Cylinder

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Appendix-III: List of Chemical Cleaning Equipments:
S.NO DESCRIPTION SPECIFICATION QTY
1. M.S. TANK
1 Circulation Tank 20 M3 01 No
2. CHEMICL CLEANING PUMPS

1. Main Circulation Pumps Motor : 110 Kw / 3 Phase /
415 v / 50 Hz 04 Sets
Pump : 250 M3/ hr / 120
MWC /2900 RPM
2. Chemical Transfer Pumps Motor : 20 HP / 3 Phase / 415
v / 50 Hz
Pump : 30M3 / hr / 40 MWC / 02 Sets
2900 RPM
3. ELECTRICAL ITEM
1. MCC Panel for 4 Motors 160 Kw / 3 Isolation and 01 set
control Panel
2. MCC Panel for 2 Motors 20 HP 01 Set
3. 3.5 Core Electrical Cable Distribution Cable 100 Meters

150 Sq.MM.
4. INSTRUMENTS
1 Pressure Gauge 0-20 Kg / cm2 06 Nos
2 Temperature Gauge 0-120 Deg.C 02 Nos
3 Electrical testing kit - 1 set
4 Chemical testing Kit 1 set
5. GENERAL ITEMS
1 Chemical analytical 1 lot
apparatus and reagents
2 Fasteners as reqd
3 Safety Equipment as reqd
6.M.S ERW Pipes; unit
1. Ø12’’ Inch ERW ‘B’ Class meters 06
2. Ø 10” Inch ERW ‘B’ Class meters 50
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8 Ø 1” Inch ERW ‘B’ Class meters 50
7. Elbows
1. Ø 10” Inch 90 Deg 2 Nos
5. Ø 3”Inch 90 Deg 25 Nos
8.C.S. Gate Valves 300 #
1. Ø 8” Inch 300 # class 08 Nos

6. Ø 1” Inch Butt weld 16 Nos
7. Ø 6 ” Inch NRV 300 # class 3 Nos
9 Nitrogen Manifold 1 sets
10. Acid Transfer Pipes

50 mm Hose As reqd
Injector As reqd
11. Safety Items
1 Safety Helmet As reqd
2 Gumboot As reqd
3 Hand Glows As reqd
4 Respirator As reqd
5 Face Mask As reqd
6 Apron As reqd

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Appendix-IV . ANALYTICAL PROCEDURE
1. INHIBITOR EVALUATION
INHIBITOR:
• An inhibitor is a chemical substance, when added in small

concentration effectively decreased the corrosion rate. Pickling
Inhibitors used for practical applications are usually mixtures of
various chemicals. Most of the pickling inhibitors function by forming
an absorbed layer on the metal surface. Probably, no more than a
mono layer in thickness which essentially blocks discharge of
HYDROGEN ION and dissolution of metal ions. It should be borne in
mind that an addition of an inhibitor to an acid, the corrosion
potential of steel is not altered although the corrosion rate may be
appreciably reduced.
• Inhibitor is chosen for a particular solvent and application to

provide maximum protection and minimize substantially the rate of
corrosion of parent metal. Temperature of the bath and time of
contact of the metal with the solvent are decisive factors in the
function.
• It is therefore essential to test the inhibitor for evaluation prior to its

usage specifically for two functions:
1. Percentage of protection offered

2. Corrosion rate reduction obtained
PROCEDURE:
• Prepare test coupons in duplicate of the material to be chemically

cleaned, for example carbon steel SA 213 T1 etc. The surface area
of each coupon in no case should be less than 25 sq.cm. It should
be polished on all sides. Close to mirror surface quality and free of
sharp edges. There shall be no oxide scale left on the surface.
• The coupon should be degreased with Acetone initially.
• Prepare in a container, 400 ml. of the acid bath mixed with inhibitor.
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• Measure accurately, the surface area of the coupon - A sq.cm.

• Weight the acetone cleaned dry coupon - WI mgms.
• Prepare acid bath in 400 ml. (Hot 65-70 deg.C.). DM water adding
acid solvent selected to attain required concentration of the acid
and 0.3% inhibitor.
• Hang the sample in the bath (nylon rope) well immersed without
touching the container walls. Note the time.
• Keep the container in an oven and strictly maintain the
temperature at 65 – 700 C.
• Remove the coupon exactly after 60 minutes. Do not touch by
hand.
• Wash it in hot DM water several times. Acetones dry perfectly.
• Cool in a dessicator. Desiccant should be only silica gel.
• Weigh the coupon - W2 mgm.
Express corrosion rate mgm/sq.cm./hr.
W1 - W2
----------- mg./sq.cm.
A
• Efficiency of the inhibitor is evaluated as follows:
• Repeat the procedure with two weighed coupons under similar
conditions of acid strength, temperature and time.
• One pre-weighed coupon should be immersed in uninhibited acid
for 60 minutes.
• The other pre-weighed coupon should be immersed in inhibited
acid for 60 minutes.
Work out metal loss in both the cases.

Efficiency of the inhibitor:
X = Loss of Wt.in uninhibited acid
Y = Loss of Wt.in inhibited acid
Efficiency = X-Y
------ x 100%
X
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2. DETERMINATION OF TSP , DSP and Alkalinity;

Reagents required:
1. Hydrochloric Acid Standard (0.05N)
2. Mixed Indicator Solution (0.5g of bromocresol green + 0.75 gm. Of
methyl red/1 ltr.of ethylalcohol.
3. Phenolphthalein Indicator Solution (dissolve 1g. in 100 ml. Of
ethylalcohol).
Procedure:
• Pipette 10 ml. of filtered solution into a 150 ml beaker. Add 4 drops
of phenolphthalein indicator titrate against o.05N of HCL solution
until colorless; Record the volume as (PE). Add few drops of mixed
indicator to the same conical flask; titrate without refilling the
burette to a reddish-grey end point. Record the volume as (ME).
Calculation:
The concentration of Na3Po4 solution as follows;
Na3Po4.12 H20 (TSP) ppm: PE x 1900
Na2Hpo4.7H2o (DSP) ppm: ME-- (2PE) x 1345
Total Alkalinity as CaCo3 (ppm) = ME x 500
3. DETERMINATION OF HYDROCHLORIC ACID

Required reagents:
1. 1N NaOH solution
2. Mixed Indicator (0.075 gm. Methyl Red and 0.05gm. Bromocresol
Green 100ml. Ethanol).
Procedure:
• Take 10ml. of sample in a clean conical flask.
• Add 50 ml. of DM water
• Add 3-5 drops of Indicator
• Titrate it against 1N NaOH solution
• The end point is red to green
Calculation:
% of HCl = T.V. x 1N x 36.5 x 100
----------------------------
10 x 1000
= T.V. x 0.365

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5. DETERMINATION OF IRON
Required reagents:
1. 0.01 M EDTA
2. Chloroacetic acid 10%
3. Sodium Acetate 10%
4. Sulphosalicyclic Acid 20%
5. Potassium Per-sulphate
Procedure:
• Take 10ml. of aliquot in a clean Erlenmeyer flask.
• Add 5 to 10 drops of 10% chloroacetic acid solution.
• Add 5 to 10 drops of 10% sodium acetate solution.
• Add 5 drops of 20% sulphosalicyclic acid.
• Add pinch of potasium persulphate
• Titrate against 0.01M EDTA
• End point is red to pale yellow colour.
Calculation:
Iron as Fe ppm = T.V. x 0.01 x 55.847 x 1000 x 1000

-------------------------------------------
V x 1000
6. DETERMINATION OF CITRIC ACID
Required reagents:
1. 1 N NaOH solution
2. Phenolphthalein Indicator or Thymol Blue Indicator
Procedure:
• Take 10ml. of sample in a clean conical flask
• Add 50 ml. of DM water.
• Add 3-5 drops of indicator
• Titrate it against 1N NaOH solution
• The end point is colourless to pink or blue

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Calculation:
% of Citric Acid = T.V. x 1N x 70 x 100
-------------------------
100 x 1000
= T.V. x 0.70
% of Citric Acid = T.V. x 1N x 64 x 100
Monohydrate ----------------------------
100 x 1000
= T.V. x 0.64
7. DETERMINATION OF HYDRAZINE
Required Reagents:
1. 0.1N Potassium Bromate - Potassium Bromide
2. 1:1 or Con.HCl
3. Methyl orange
Procedure:
• Take 10 ml. of sample in a clean conical flask
• Add 50 ml. of distilled water.
• Add 10 ml. of conc.HCl. Mix well.
• Add 3 drops of Methyl Orange.
• Titrate it against 0.1N KBrO3 solution until yellow colour from
red.
Calculation:
N2H4 ppm = T.V. x 0.1 x 8 x 1000
--------------------------
V
Where TV = Titre volume
V = Volume of aliquot taken

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Appendix-V. LOG SHEET NO
DATE:
PROJECT :
UNIT :
PROCESS : Detergent Flushing/ Hot Water Flushing;
I. ADDITION OF CHEMICALS:
DATE TIME (HRS) NAME OF CHEMICAL QUANTITY

ADDED.
II. ANALYTICAL DATA:
Sl. No. Date Time Total Total pH Temp

(HRS) Alkalinity as Phosphate
CACO3 (PPM)
(PPM)

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LOG SHEET NO. 2
DATE:
PROJECT :
UNIT :
PROCESS :
ACTIVITY: SUPER HEATER FLUSHING & FILLING
ANALYTICAL DATA:
Sl. No. DATE TIME (HRS) pH HYDRAZINE REMARKS.

PPM

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LOG SHEET NO. 3
DATE:
PROJECT :
UNIT :
PROCESS : ACID CLEANING

ADDED.
III. ANALYTICAL DATA:
Sl. No. DATE TIME ACID TOTAL REMARKS

(Hrs) STRENGTH % IRON
(PPM)

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LOG SHEET NO. 4
DATE:
PROJECT :
UNIT :
ACTIVITY : CITRIC ACID RINSE

ADDED.
II. ANALYTICAL DATA:
Sl. No. DATE TIME (HRS) pH CITRIC IRON

ACID % PPM

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LOG SHEET NO. 5
DATE:
PROJECT :
UNIT :
ACTIVITY : PASSIVATION.
DATE TIME (HRS) Name of chemicals quantity added.

ANALYTICAL DATA:
Sl. No. DATE TIME (HRS) pH REMARKS

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APPENDIX-VI: SCHEMATIC DRAWING
• Detergent Flushing of Condenser/ Condensate System

& Feed System.
• Alkali Flushing & Acid Cleaning of Main Boiler System

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SCHEMATIC DRAWING FOR ALKALI FLUSHING OF BOILER FRONT SYSTEM

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SCHEMATIC DRAWING FOR ACID CLEANING OF 600 MW BOILER

Specification For Chemical Cleaning

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ARUCHEM

TECHNICAL SPECIFICATION FOR 4 x 600 MW

PRE-COMMISSIONING CHEMICAL CLEANING OF PRE-BOILER & MAIN BOILER SYSTEM

STERLITE ENERGY LTD

THIS DOCUMENT IS THE PROPERTY OF ARUCHEM

TECHNICAL SPECIFICATION FOR CHEMICAL

DOCUMENT NO: AEPL/CC:027/09

No-79 Valmiki Street,

VEDANTA SEPCO-III L&T ARUCHEM

DOCUMENT NO: AEPL/CC:027/09 Page 38 of 42

PRE-COMMISSIONING CHEMICAL CLEANING OF PRE-BOILER & MAIN BOILER SYSTEM

1. Purpose for chemical cleaning

Appendix I: Chemical Process & Testing Parameters

DOCUMENT NO: AEPL/CC:027/09 Page 38 of 42

PRE-COMMISSIONING CHEMICAL CLEANING OF PRE-BOILER & MAIN BOILER SYSTEM

1.0. Purpose for chemical cleaning;

The sub-critical controlling drum type boiler is supplied by SEPCO-III, China.

A protecting passivation film is formed during the process of chemical

• Guide lines for high pressure boiler chemical cleaning IS-10391-1992

3.0. Scope of Chemical Cleaning and Water holding capacity;

3.1. Alkali cleaning of Pre Boiler System (Boiler Front system)

Pre- boiler system includes HP& LP condensers, Feed storage tank,

Condensate Extraction pump shall be used for alkali cleaning.

3.2. Inhibited Hydrochloric acid cleaning of Main Boiler:

PRE-COMMISSIONING CHEMICAL CLEANING OF PRE-BOILER & MAIN BOILER SYSTEM

4.0. Preparation before chemical cleaning;

• Make condenser temporary liquor level indicator by transparent

PRE-COMMISSIONING CHEMICAL CLEANING OF PRE-BOILER & MAIN BOILER SYSTEM

stainless pipe of condenser, and be graved with scales in order to

DM water system could be put into operation and the DM water

4.2. Acid Cleaning of Boiler;

• The Inlet pipes of economizer should adopt φ219× 6 mm mild steel

DOCUMENT NO: AEPL/CC:027/09 Page 38 of 42

PRE-COMMISSIONING CHEMICAL CLEANING OF PRE-BOILER & MAIN BOILER SYSTEM

• Set a 20 M3 cleaning tank with Steam header inside. The inside

• Thermometer and Pressure gauges in temporary system shall be

• Ensure that the communication between steam drum position and

• Don’t install cyclone separator. Sample tubes/coupon (2 Nos) shall

DOCUMENT NO: AEPL/CC:027/09 Page 38 of 42

PRE-COMMISSIONING CHEMICAL CLEANING OF PRE-BOILER & MAIN BOILER SYSTEM

• DM water source is connected from main DM supply pipes or

• Provide necessary sampling points at Inlet & Out let.

• Complete the installation of waste water discharge system. Ensure

• Ensure uninterrupted Power Supply chemical cleaning pump.

• Temporary piping systems ensure no leaks.

• Ensure all the chemicals shall have available at site.

• Analytic instrument, testing chemical, recording tables and labor

5.0 Cleaning circuit and Cleaning Process;

5.1. Alkali Flushing of Pre- Boiler System:

PRE-COMMISSIONING CHEMICAL CLEANING OF PRE-BOILER & MAIN BOILER SYSTEM

• The Alkali cleaning process includes Mass flushing, hot alkali

• The complete process use hot well of condenser as water tank,

• Adopt the method of flushing by sections and multiple releasing so

• Auxiliary steam as heat source and raise the temperature through

5.1.2 Flushing steps

Assisted with test running of condensate pump, carry out water

Flow Path: 1: Condensate System

DOCUMENT NO: AEPL/CC:027/09 Page 38 of 42

PRE-COMMISSIONING CHEMICAL CLEANING OF PRE-BOILER & MAIN BOILER SYSTEM

Flow Path: 2: Feed Water System

• Condenser Hot well → CEP → Temporary line to HP Heater -1 Shell

Flow Path: 4: LP Drip System