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ABO Procedure - Marwar Rev. 0
ABO Procedure - Marwar Rev. 0
For
End User
CONTENTS
SR. NO. DESCRIPTION
SECTIONS
1.
ABSTRACT
2. OBJECTIVES
3. PRE-REQUISTIES
4. CHECK LIST
5. REQUIRED CHEMICALS
6. SAFETY PRECAUTIONS
9. PROCEDURE
2. OBJECTIVE
The purpose of alkali boil out is to remove the deposits like oil, grease and mill scale etc., resulting out of
manufacturing, fabrication and erection procedures from boiler internals. Such deposits in the boiler tube
walls restrict the heat flow across the tube bundles resulting failure due to overheating.
3. PRE-REQUISITES
Ensure all the pre-commissioning checks are completed including trial runs and ensure proper
1
operation of all the accessories.
Completion of boiler hydro test and duct refractory dry out (Refractory dry out is applicable only for
2
CC HP Boiler).
Ensure availability of Utilities like cooling water for BFP, Blow down tank, Instrument air for Control
3
valves, plant/service air (if applicable), etc.
Ensure availability of drain and vent system from various parts of Boiler and their routing to trench /
4
safe location.
Clean the steam drum thoroughly and carryout joint inspection. Firmly box-up the steam drum
5
manhole (one side) with new gaskets.
6 Box up all the manholes in the flue gas path after joint internal inspection with all agencies involved.
Insulation of Boiler casing, steam drum, and necessary ducting should be completed. Provide
7 personal protection guards for hot areas where insulation is not feasible.
Ensure installation of expansion pointers for measurement of Boiler thermal expansion. Mark the
8
pointer location in cold condition.
Ensure that transportation locks for spring supports is removed and mark location of cold load
9
setting.
During Alkali boil out one drum level transmitter, pressure transmitter to be taken into service Ensure
and confirm whether all the necessary safety interlocks are implemented and tested for reliable
10
operation. Both the level gauges should be kept on line and level transmitter readings to be cross
checked with direct level gauge reading.
The following equipment’s should be made operational from DCS.
· Feed water control valves.
11
· Deaerator level control valve.
· Isolation valves in the Feed water line in the feed water control station on the BFW pump discharge.
23 All hoppers level switches are commissioned and indication available in DCS.
24 All scrap materials are removed from boiler platforms and walkways.
Insulation- Boiler Drum, All headers, Evaporator down comers, water and steam circuit drains,
25
casing.
Signature
Sr.No. Description Status
& Date
All temporary supports must be removed and boiler is free for thermal expansion.
1
8 Pressure gauges on drum and main steam line are installed and taken in line.
Keep all the isolation valves in attemperator spray water piping in open condition
14
and control valves in close condition
15 All the logic and interlocks of boiler and its accessories were checked.
Total quantity of chemical required: - (Water holding capacity (m3) × required ppm)/1000
Quantity of chemicals is decided to maintain initial phosphate concentration For HP section 5000 ppm &
for LP section 3000 ppm in boiler along with the chemical total 15 kg normal good quality detergent/
Washing powder to be added in boiler drum for foaming purpose only.
6. SAFETY PRECAUTION
Before commencement of Alkali boil out please ensure below mentioned safety pre-cautions are available.
Good quality rubber hand gloves for handling Tri-sodium phosphate.
Emergency eye wash station at drum elevation and near drainage station.
Firefighting system is ready and adequate quantity of fire extinguisher is available.
Adequate illumination is available.
Neutralizing pit is ready and adequate quantity of lime (HCL) is available for neutralizing.
Ensure while giving blow down bottom header area a properly cordoned off with barricade.
9. PROCEDURE:
After ensuring the above said checklist, alkali boil out can be started and according to start up procedure
mentioned below.
9.1 Boiler Filling
Start boiler initial filling pump and charge boiler initial filling line.
9.1.1 Boiler initial filling to be done from initial filling provided at Boiler Feed water line (applicable for both
HP and LP section).
9.1.2 As the water comes through economizer & evaporator vents, close the valves completely after
removing air in the system.
9.1.3 Before initial filling the boiler ensure below mentioned valves are in closed condition
Sr.No. Description
EBD and CBD line valves Tag no’s
Tag no’s:
CC HP Boiler
EBD Valves: (CCHP-12-GB-001, CCHP-12-GB-002, CCHP-12-GT-001, CCHP-12-GT-002)
CBD Valves: (CCHP-11-GB-002, CCHP-11-GB-003, CCHP-11-GT-001, CCHP-11-MOV-001)
1 PH – HP Section
EBD Valves: (PHHP-12-GB-001, PHHP-12-GB-002, PHHP-12-GT-001, PHHP-12-GT-002)
CBD Valves: (PHHP-11-GB-002, PHHP-11-GB-003, PHHP-11-GT-001, PHHP-11-MOV-001)
PH –LP Section
EBD Valves: (PHLP-12-GB-001, PHLP-12-GB-002, PHLP-12-GT-001, PHLP-12-GT-002)
CBD Valves: (PHLP-11-GB-002, PHLP-11-GB-003, PHLP-11-GT-001, PHLP-11-MOV-001)
9.1.4 LEVEL-water to be filled below 150mm below the center line of drum. Level to be visually ensured
from other side which is open. Ensure drum vents are in open condition.
PH boiler
After ensuring required drum level in boiler the startup sequence to be followed as first open Boiler inlet
damper and after inlet damper is fully opened open boiler outlet damper (Before opening boiler inlet and
outlet damper please ensure bypass damper is in full open condition). After opening both inlet and outlet
damper start closing bypass damper to establish gas flow through PH boiler. Gas flow rate to be maintained
to warm up the drum water temperature to 60-70 deg.C.
By controlling the bypass damper for PH and AQC boiler gas flow through both the boilers to be increased
and accordingly boiler pressure will start increasing. Required pressure to be maintained during ABO is
tabulated below.
Sr.no Boiler Pressure raising during ABO
Keep the system stable for 4 hours, then start opening the drain valves one by one for few seconds.
Check the quality of the blow down water. After every 2 hours blow down shall be given from all water side
header drains. No. of blow down will depend on blow down water quality which needs to be checked during
every blow down. When the oil & grease content comes below 5 ppm.
Keep it replenished with DM water and keeps draining the system and samples to be taken and checked.
Continue with the hot rinsing and draining process. After rinsing when the blow down water quality is as
same as the feed water quality.
Phosphate concentration
Alkalinity (Both M-alkalinity and P-alkalinity)
Oil & Grease
Turbidity
PH & Conductivity
NOTE: When the boiler pressure is around 8 kg/cm2(g) note down the boiler expansion readings. Measure
and mark the boiler locations in hot condition. Also observe and mark the location of hot condition for spring
supports.
OBJECTIVE
It is essential to carry out hot rinsing process after alkali boil out to remove residue phosphate, oil and
grease from boiler and also to ensure boiler blow down water quality matches with feed DM water.
SAFETY PRECAUTION
Before commencement of hot rinsing process please ensure blow down sump is properly barricaded
with proper caution tag.
While collecting samples all required PPE’s must be worn
PRE-REQUISITES
CHECK LIST
After ensuring the above said checklist, hot rinsing process can be started
Start boiler initial filling pump and charge boiler initial filling line up to boiler drain header inlet.
Start boiler filling from boiler feed water line.
Fill DM water up to drum center line.
After filling water up to drum center line stop DM transfer pump/initial fill pump
While filling boiler take DM water sample and test at lab for
a. PH
b. Oil and grease
c. Turbidity
d. Phosphate
e. M-alkalinity and P-alkalinity
During blow down collect water sample and test below mentioned parameters at laboratory.
a. PH
b. Turbidity
c. Phosphate
d. M-alkalinity and P-alkalinity
Hot rinsing procedure will continue till boiler blow down water quality matches with feed DM water
quality.
After completion of Hot Rinsing Process Header Cleaning and Flushing to be carried out. For Header
Cleaning and Flushing Evaporator Header stub needs to be cut (List of headers to be provided at site)
and Flushing with Normal temperature DM water (Preferably from DM transfer pump) to be carried
out.
1. Drain water from boiler. Open steam drum manholes. Open all the manholes in boiler inlet
duct/casing.
2. Carry out joint inspection of steam drum inside and the boiler inlet duct refractory lining. Also
check the condition of SH and Evaporator supporting arrangement.
The alkali analysis is done from the blow down samples and the report is given in Table.1 and the
rinsing water analysis report is given in Table.2.
TABLE NO -01
Blow PO4 M ALK
Oil &
Date Time PH P ALK Grease
down no (ppm) (ppm) (ppm)
(ppm)
2
3
4
5
6
7
8
9
10
11
TABLE NO-02
Date Parameter Time DM Water Blow down water
pH
Conductivity
Oil and grease
phosphate
Once this procedure is completed, it is to be signed by the Commissioning in-charge and End User
Representative.
Remarks: -
Date Date
Required Chemicals:
A. Petroleum Ether.
B. Concentrated sulphuric acid.
C. What man no.40 filter paper.
Required apparatus:
A. Separating funnel of 1 litre capacity.
B. Porcelain dish.
C. Desiccators.
D. Balance Weight (Upto three decimal).
E. Oven
Testing Procedure:
1 Place one liter of the sample in a suitable Separating funnel.
2 Add 2-3 ml of concentrated Sulphuric acid & shake well.
3 Add 15 ml. of Petroleum ether (40- 60 Degc C) & shake well for 5 minute.
4 After adding petroleum ether while shaking Open the stopper intermittently and let
the air out from the funnel.
5 Add further 25 ml petroleum ether to the funnel and shake vigorously for 5 minutes.
6 Drain the water.
7 Transfer the ether layer through a what man no.40 filter paper in to a clean dried
Previously weighed porcelain dish.
8 Two to three washings with petroleum ether about 10 ml is sufficient.
9 Keep the porcelain dish in oven maintained the temperature 60 degc c, ensure the
Complete evaporation of petroleum ether.
10 Cool in a desiccators and weigh.
11 Calculation:
Oil and Grease (In ppm) = Residue in the porcelain dish (mg) x 1000
Required apparatus/Instruments:
B. Calibrated pH meter
C. Beaker
Testing Procedure
General procedure for p H measurement using any standard pH Meter is as follows.
3. Ensure that the p H Meter is calibrated using buffer solutions prior to the p H Measurement.
4. Pour approximately 50 ml. of sample into the beaker and insert cells and move the cell and down
for several times to wash off any solids present on the cell.
5. Discard the water from the beaker. Repeat the same and note down the p H reading on display in
numbers.
6. Remove the cell rinse in distilled water and leave standing in distilled water.
Required Chemicals/Reagents:
A. Standard solutions
Required apparatus/Instruments:
B. Calibrated Conductivity meter
C. Beaker
Testing Procedure
1. Switch on the instrument wait for 10-15 minutes to stabilize.
2. Set the temperature compensation knob to the temperature of the sample.
3. Ensure that the Conductivity Meter is calibrated using standard solutions prior to the conductivity
measurement
4. Pour approximately 50 ml. of sample in to the beaker .Immerse cell and move up and down for
several times to ensure equilibrium.
Procedure for testing of Turbidity in Alkali Boil out samples
Required apparatus/Instruments:
A. Calibrated Turbidity meter
B. Test tube
Testing Procedure
1. Switch on the instrument and allow 10-15 minutes warm up.
2. Calibrate the instrument prior testing the sample..
Required Chemicals/Reagents:
A. Phenolphthalein indicator
B. Burette for titration
Required apparatus/Instruments:
C. Conical flask
D. Test tube
Testing Procedure
1. Take 100 ml of sample in a conical flask.
2. Add 3 to 4 drops of Phenolphthalein indicator,
3. Mix well and titrate against 0.02 N Sulphuric acid.
Required Chemicals/Reagents:
A. Mixed indicator
B. Burette for titration
Required apparatus/Instruments:
C. Conical flask
D. Test tube
Testing Procedure
1. Take 100 ml of sample in a conical flask.
2. Add 3 to 4 drops of Mixed indicator,
3. Mix well and titrate against 0.02 N Sulphuric acid.
Required Chemicals/Reagents:
A. Spectrophotometer
Reagents required for spectrophotometer for testing of phosphate as mentioned in the OEM
manual to be followed.
Material Safety Data Sheet
Material Name: Trisodium Phosphate, 12 Hydrate Crystalline (Technical Grade) ID: C1-150
* * * Section 1 - Chemical Product and Company Identification * * *
Chemical Name: Trisodium Phosphate, 12 Hydrate Crystalline (Technical Grade)
Product Use: For Commercial Use
Synonyms: Sodium phosphate tribasic, Tribasic sodium phosphate, Trisodium orthophosphate, Orthophosphate trisodique, TSP
Supplier Information
Chem One Ltd. Phone: (713) 896-9966
14140 Westfair East Drive Fax: (713) 896-7540
Houston, Texas 77041-1104 Emergency # 1-800-424-9300
General Comments
NOTE: Emergency telephone numbers are to be used only in the event of chemical emergencies involving a spill, leak, fire,
exposure, or accident involving chemicals. All non-emergency questions should be directed to customer service.
* * * Section 2 - Composition / Information on Ingredients * * *
____________________________________________________________
Issue Date: 09/09/98 10:35:26 CLW --------- Page 2 of 7 Revision Date: 12/27/2010 4:00 PM SEP
Material Safety Data Sheet
Material Name: Trisodium Phosphate, 12 Hydrate Crystalline (Technical Grade) ID: C1-150
____________________________________________________________
Issue Date: 09/09/98 10:35:26 CLW --------- Page 3 of 7 Revision Date: 12/27/2010 4:00 PM SEP
Material Safety Data Sheet
Material Name: Trisodium Phosphate, 12 Hydrate Crystalline (Technical Grade) ID: C1-150
____________________________________________________________
Issue Date: 09/09/98 10:35:26 CLW --------- Page 5 of 7 Revision Date: 12/27/2010 4:00 PM SEP
Material Safety Data Sheet
Material Name: Trisodium Phosphate, 12 Hydrate Crystalline (Technical Grade) ID: C1-150
Limited Quantity Shipments: Shipments for air must be marked with the Proper Shipping Name Environmentally Hazardous
Substance, solid, n.o.s. (Trisodium Phosphate) and shall be marked with the UN Number (3077) preceded by the letters "UN", placed
within a diamond. The width of the line forming the diamond shall be at least 2 mm; the number shall be at least 6 mm high. The
total weight of each outer packaging cannot exceed 30 kg.
Excepted Quantities: The maximum quantity of this material per inner receptacle is limited to 30 g per receptacle and the aggregate
quantity of this material per completed package does not exceed 1kg. The inner receptacles must be securely packed in an
intermediate packaging with cushioning material to prevent movement in the inner receptacles and packed in a strong outer box with a
gross mass not to exceed 29kg. The completed package must meet a drop test. The requirements are found in 2.7.6.1. The package
must not be opened or otherwise altered until it is no longer in commerce. For air transportation no shipping paper is required. The
package must be legibly marked with the following marking:
NOTE: The “*” must be replaced by the primary hazard class, or when assigned, the division of each of the hazardous materials contained in the package. The “**” must be
replaced by the name of the shipper or consignee if not shown elsewhere on the package. The symbol shall be not less than 100 mm x 100 mm and must be durable and
clearly visible.
International Maritime Organization (I.M.O.) Classification
I.M.O. Classification: Sodium Phosphate, Tribasic is not regulated under the I.M.D.G./I.M.O. regulations.
____________________________________________________________
Issue Date: 09/09/98 10:35:26 CLW --------- Page 6 of 7 Revision Date: 12/27/2010 4:00 PM SEP
Material Safety Data Sheet
Material Name: Trisodium Phosphate, 12 Hydrate Crystalline (Technical Grade) ID: C1-150
to discharges of this substance.
B: Component Analysis - Inventory
Component CAS # TSCA DSL EINECS
Trisodium Phosphate Dodecahydrate 10101-89-0 No No Unlisted
____________________________________________________________
Issue Date: 09/09/98 10:35:26 CLW --------- Page 7 of 7 Revision Date: 12/27/2010 4:00 PM SEP
RELEASED FOR CONSTRUCTION