PREPARATION BEFORE ACID CLEANING

1. Initial boiler filling with hot water through BFP at 90-100 C for tightness
checks.

2. Super heater will be kept filled up to avoid acid contamination. Test closure
installed at SH output (LHS & RHS) and hangers jacked. HP Bypass emergency
opening Manos tat will be kept disconnected to check for any passing of test
closures.

3. Dosing of chemicals (Acid) by acid recirculation pump -- Eco.Recirculation line

–Economiser – Drum.

4. The following values are to be a kept closed prior to acid injection.

a. Economiser inlet value RL50G201.
b. Feed water control value RL50G401, RL51G401, RL52G201.
c. Feed water system should be kept filled up and then bypassed.
d. HPH 5 & 6 tubes should be kept filled up and then bypassed.
e. All BFPs discharge values & their bypass values.
Note: Periodic samples to be taken in feed water line (upstream of RL50G201) to
ensure no acid contamination – by contractor.
f. CBD root value NC10G1.
g. Drum overflow root value NC11G1.
h. Drum chemical dozing line UH30 G61/62.
i. Boiler initial filling valves RL54 G5 & G6 and their bypass value RL 54 G3
& G4.
j. Boiler & RAP soot blower steam isolating values NV07G1 7 NV28G1.

5. The following instrument isolating values to be kept closed prior to acid cleaning.
i. Drum level 3H switch - NA20 L3 and L12
ii. Drum level 2H switch - NA20 L004
iii. Drum level H switch - NA20 L005
iv. Drum level 3L switch - NA20 L008 & L013
v. Drum level 2L switch - NA20 L007
vi. Drum level L switch - NA20 L006
vii. Drum level transmitter - NA20 L2 & L011
viii. Drum level local gauges - NA20 L9 & L010
ix. Drum level remote level indicator - NA20 L014
 NOTE: Drum level transmitter NA20 L001 – impulse lines are cut and re-routed
for temporary local level indicator for acid cleaning.
x. Drum pressure H - NA20 P005 (PSH)
xi. Drum pressure 3H - NA20 P003 (PA -3H)
xii. Drum pressure gauge (local) - NA20P4
xiii. Drum pressure control recorder - NA20 P001 (PCR)
xiv. Drum pressure process - NA20 P002 (PIP)
xv. Drum pressure process - NA20 P002 (PIP)
xvi. Drum pressure HH - NA20 P006 (PS-HH)
xvii. Pressure gauge root value (after RL50G201)
6. Drum vents (2” new drum vent provided from saturated stream lines NC35 3” ø
header and 1” ø manual vent) should remain always open throughout the acid
cleaning period unless asked to be closed by the contractor.

7. Test specimen is placed inside drum.

8. Drum level will be maintained with reference to a local (temporary) level

measurement such that the riser tubes are below the level of water for effective
circulation (with N2 gas injection).

9. Acid cleaning effluents after proper neutralization will be discharged to siphon

shaft through U#7/8 circulation water outlet piping (via BBD Pit-3 pump
discharge line). Hence Pit-3 pump should be kept isolated electrically with its
discharge valve closed during boiler-5 acid cleaning.

10. For Acid recirculation pump, 415V power supply is arranged from 56CB2 bus.

11. DP return condensate (from common header) will be lined up to U#5 for

a. Filling/mixing in acid solution tank & maintaining boiler water temperature.

b. To fill FWT if boiler is to be filled with hot water using BFPs.

12. TENTATIVE SEQ UENCE OF OPERATIONS:

A). Filling boiler up to NWL with BFP at 90 – 100 C.
B). System tightness check by operating acid recirculation pump.
C). To decide boiler draining is necessary or not. (Depending on water quality &
Temperature of water)
D). Refill boiler to NWL with BFP (temperature 60 C)
E). Fill super heater completely ensuring back flow to the drum.
F). Line up boiler for acid cleaning after necessary isolations.
G). Dosing chemical for de-coppering phase.
 H). De-coppering phase (6 – 7hrs)
I). Draining – Filling – Draining – filling.
J). Acid phase (6 – 8 hrs)
K). Draining under N2 blanketing -- Filling – Draining – Filling. (With BFPs &
with back flushing through super heater)
-- Flushing isolated lines & re-isolate.
L). Cold passivation with sodium nitrate + final de-coppering phase. (10 – 12 hrs.)
M). Draining the boiler
N). Normalizing the isolations, test closure removal, etc.
- Opening drum manhole and removal & inspection of test specimen.
- Sample cutting & tube welding.
O). Boiler filling and light up for t\hot passivation.

START UP AND FINAL (HOT) PASSIVATION

1. Confirm that the boiler has been restored and drum doors are closed.

2. Fill boiler with de-mineralized water (pH>9) and drain.

3. Check for any leak.

4. Drain boiler and replace tube (this operation must be done as fast as possible).

5. Fill again to operational level by hot water containing hydrazine (50ppm and
pH>9) back-flush super heater.

6. Drain boiler and super heater.

7. Fill boiler with adequate chemicals to maintain>pH9 and drain completely.

8. Refill boiler (not super heater) to operation level using a solution containing
50ppm of N2H4 and ammonia 50 ppm and maintain same concentration in FWT
also.

9. Prepare the boiler for firing.

10. Fire the boiler as per standard boiler manufacturer procedure.

11. After reaching 2 bars start purging from the bottom headers: open the continuous
blow down as per request of chemist.

12. Continue purging each 30’ opening each valve for about 1’ – as decided by
chemist.

13. After reaching 5 bars try to remain at this pressure for about 2 hrs. using HP
bypass & start up vent.

14. In case it is difficult to maintain the pressure constant allow the minimum
possible increase.

15. Try to avoid extinguishing fire. This is to avoid any fluctuation of the pressure.

16. Continue purging according to the above scheme or as decided by chemist.

17. At the end of the step at 5 bars it is suggested to have hydrazine content > 80
ppm.

18. Increase the pressure to reach 10 bars (increase the temperature by about 30 – 40
C per hour)

19. Continue same program of purging as recommended by chemist.

20. Check water turbidity and in case it gets close to normal operation values reduce
time (45’ – 30’ – 15’) of draining as well as percentage of opening of continuous
blow down.
21. Maintain the pressure at 10 bars for about 2 hrs.

22. In case it is difficult to maintain the pressure constant allow the minimum
possible increase.

23. Try to avoid extinguishing fire. This is to avoid any fluctuation of the pressure.

24. Continue same program of purging unless differently advised by chemical lab
(see point 19)

25. At the end of the step of 10 bars it is suggested to have hydrazine content > 60
ppm.
26. Increase the pressure to reach 30 bars (increase the temperature by about 30 – 40
C per hour)
 27. Continue same program of purging unless differently advised by chemical
laboratory.

28. Maintain the pressure to 30 bars for about 4 hours.

29. In case it is difficult to maintain the pressure constant allow the minimum
possible increase.

30. Try to avoid extinguishing fire. This is to avoid any fluctuation of the pressure.

31. Continue same program of purging unless differently advised (see point 19)

32. At the end of the step of 30 bars it is suggested to have hydrazine content > 50
ppm.

33. Increase the pressure to reach 50 bars (increase the temperature by about 30 – 40
C per hour)

34. Continue same program of purging unless differently advised (see point 19)

35. Maintain the pressure at 50 bars for about 6 hours.

36. In case it is difficult to maintain the pressure constant allow the minimum
possible increase.

37. Try to avoid extinguishing fire. This is to avoid any fluctuation of the pressure.

38. Continue same program of purging unless differently advised by chemical lab.

39. At the end of the step at 50 bars it is suggested to have hydrazine content 2 – 5
ppm.

40. Slowly increase pressure to operating level stay in this condition for few hours
and control all parameters before admitting to turbine.

NOTE: The hydrazine values shown above are just a reference that permits to avoid a
continuous monitoring of the chemical parameters. During operation you must
guarantee always the presence of an excess (few ppm) of hydrazine to permit
the formation of magnetite. Even if you find lower values (respect to those
listed above), you do not have to worry as a matter of fact it is sufficient to have
hydrazine present in slight excess.