3/15/2016 Presentation"CHEMICALCLEANINGOFPREBOILERSYSTEM.OBJECTIVESToremovedirt,oil,greaseetc.

,fromCondensate,Feedwater,D
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CHEMICALCLEANINGOFPREBOILERSYSTEM.OBJECTIVESToremove
dirt,oil,greaseetc.,fromCondensate,Feedwater,DripandExtractionsteamlinesof
HPand.
PublishMckennaDarnley,Modified6yearsago

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Presentationontheme:"CHEMICALCLEANINGOFPREBOILERSYSTEM.
OBJECTIVESToremovedirt,oil,greaseetc.,fromCondensate,Feedwater,Dripand
ExtractionsteamlinesofHPand."Presentationtranscript:
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Slide1
CHEMICALCLEANINGOFPREBOILERSYSTEM

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3/15/2016 Presentation"CHEMICALCLEANINGOFPREBOILERSYSTEM.OBJECTIVESToremovedirt,oil,greaseetc.,fromCondensate,Feedwater,D

Slide2
OBJECTIVESToremovedirt,oil,greaseetc.,fromCondensate,Feedwater,DripandExtraction
steamlinesofHPandLPheaterspriortoputtingthesesystemsinregularservice.Thisisto
ensureflowofcleancondensateandfeedwatertotheboiler.

Slide3
STATE OF THE PLANT Hydrotest of the entire system to be flushed declared completed. All the regenerative
equipments are installed in position and temporary pipeline connection as per scheme is complete. The bore of the
temporary pipelines should preferably be the same as that used in permanent system. All permanent support are
providedforallthepipelinesbeforeflushing.PlugstobeprovidedinthesafetyvalvesofLPHs,watersealinletsinflash
tanks and LPH 1 and in C&I tapping. Screens to be provided on booster pump suction line and acid cleaning pump
suctionline

Slide4
Availability of auxiliary steam. Reagent preparation plant. Sampling points for each circuit. Level gauge on tank,
pressure gauges and temperature indicators wherever required. All the cutting and welding work on instrument
tapping points are complete upto isolating root valves. All the orifices,flow nozzles, control valves and NRV internals
are removed and a checklist is prepared. Spool pieces are provided wherever required. Installation of temporary
chemicalcleaningpumps(2nos.)andconnectedpipingalongwithrequiredinstrumentationiscomplete.Duringpost
mountingcleaningitisproposedtousechemicallycleanwaterfromcondensatestoragetank.

Slide5
Readiness of process water supply system,condenser circulating water system with pump house. Availability of
compressed air. Proximate analysis laboratory facility. Power supply to acid cleaning pumps,CEPs,condensate
emergencymakeuppumps,condensatenormalmakeuppumps,motoroperatedvalvesandlighting.

Slide6
EQUIPMENTSANDRESOURCESFORWATERWASHINGCondensatestoragetanks.Condenserofvolume1000m3asa
reservoir for storing the dematerialized water. Turbine condensate pumps (3 nos.). Chemical cleaning pumps
(q=300t/h,h=80mwg,n=1500rpm)2nos.CompressorplantandpipelineDn100tosupplyairintothewashingcircuit
withtheparametersnotlessthanq=20m3/min,p=0.6MPaPipelinesandvalvesDn20300,Pn1.6MPa

Slide7
EQUIPMENT AND RESOURCES FOR CHEMICAL CLEANING AND PASSIVATION Deaerator and Feed Water Storage
Tank.Chemicalcleaning pumps(q=300t/h,h=80mwg,n=1500rpm) 2nos. Pipelinesand valves Dn20300,Pn 1.6MPa
SG Package neutralizing basin for collecting the spent solutions. Reagent Preparation Plant designed for storage,
preparation and supply of chemical reagents. Chemical reagents. Washing process controlling instruments (flow
elements,pressuregauges,levelgauges,temperatureelements)

Slide8
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3/15/2016 Presentation"CHEMICALCLEANINGOFPREBOILERSYSTEM.OBJECTIVESToremovedirt,oil,greaseetc.,fromCondensate,Feedwater,D

The preboiler system consists of Condensate system Drip system Feed water system Extraction steam lines to
RegenerativeHeaters

Slide9
Condensate system comprises of 3 nos. of Condensate Extraction Pumps,Low Pressure Heaters, Gland Steam
Cooler,Deaerator,connectingpipelinesincludingexcesscondensatelineuptoCondensatestoragetank.

Slide10
Feed water system comprises 2 nos. of motor driven boiler feed pumps,2 nos. of Turbine driven boiler feed
pumps,their booster pumps andrecirculation lines, highpressure heaters,theirconnecting pipelinesuptoeconimiser
inlet.ReheaterandSuperheaterspraylinearealsoincludedforthepurposeofflushing.

Slide11
DripsystemcomprisesoftheshellsideofallLPandHPheatersandtheirnormalandemergencydriplines.

Slide12
ExtractionsteamsystemconsistsofbledsteamlinesfromdifferentstagesofTurbines(HPT,IPTandLPT)toLPand
HPheaters,DeaeratorandTDBFPs.

Slide13
CLEANINGMETHODPremountingcleaning.

ExtractionsteamlinestoregenerativeheatersPostmountingcleaning.

Feedwaterline,Condendatelineandheaterdriplines.Steamblowing.

MSline,CRHline,HRHline,steamlineto

TDBFPsetc.

Slide14
METHODS AND SCOPE OF CLEANING Post Mounting Cleaning Main Turbine and BFP Drive Turbine Condenser
Cleaning.HydropneumaticWashingwithDemineralizedWaterofUnitCirculatingSystem.ChemicalCleaningofWater
SteampathofHeaterandPipelinewithhydrofluoricAcidsolution.ChemicalPassivationofWaterSteampathofHeater
andPipelinewithHydrogenPeroxidesolutionaddedwithAmmonia.

Slide15
PreMounting Cleaning Chemical Cleaning of Pipelines in a bath of Hydrofluoric Acid solution. Spent solution
displacement.ChemicalPassivationofPipelineswithHydrogenPeroxidesolutionaddedwithammonia.AirBlowingof
Passivatedpipelinesfordrying.

Slide16
MainTurbineandBFPDriveTurbineCondenserCleaningorCondenserDegreasing.STEPIThedemineralizedwateris
heatedupto700cintheDeaeratorFST.TheChemicalsolutionpreparedinreagentpreparationplantismixedwith
thehotwaterintheDeaeratorFST.
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Slide17
The hot solution is transferredto Condenserwiththe help of temporary chemicalcleaningpump through temporary
pipelines connecting pump discharge header to the CEP discharge header and the cooling device sprayers of
Condenser. Circulation is completed by bringing this solution from condenser to Chemical Cleaning pump suction
header through CEP suction header and temporary pipeline connection. Circulation is continued for 4 hrs. System is
isolatedafterclosingonetemporarygatevalveprovidedinthecircuit(refertoscheme.)

Slide18
FSTDEAERATORAUX.STEAMCHEMICALBPACIDCLEANINGPUMPSCONDENSERSCEPS

Slide19
STEPIICEPsarechargedfromwatersidebyopeningsuctionvalveandthroughproperventing,keepingdischarge
valveinclosedconditionandsuctionstrainerinposition.FlushingstartedbyalternatelystartingandstoppingCEPsand
completingthecirculationfromCEPdischargetoCEPsuctionlinethroughrecirculationlineandcondenser.

Slide20
Circulation is continued for 4 hrs. After cleaning the spent solution is pumped from condenser to neutralizing basin.
WaterwashingofCondenserstartedandcontinuedfor4hrs.usingthetwocircuitsalreadydescribed..

Slide21
DEAERATORFSTAUX.STEAMCHEMICALBPACIDCLEANINGPUMPSCONDENSERSCEPS

Slide22
HydropneumaticWashingofUnitCirculatingSystemwithDemineralizedWaterandair.Hydropneumaticwashing
ofunitcirculatingsystemiscarriedoutstepbystepwithsimultaneouswaterandairsupply.Demineralizedwaterfor
washing is stored in the Deaerator FST and Condenser. Hydropneumatic washing is declared completed if
suspendedmattercontentofthewashingwaterreachesnomorethan100mg/kg.Hydropneumaticwashingofunit
circulatingsystemisdoneusingfollowingfourcircuits.

Slide23
CIRCUIT 1: Circuit 1A Deaerator FST TDBFP A booster pump suction line BP strainers Temporary header
connectingtheBPsuctionlinesdownstreamofthestrainersAcidcleaningpumpsTemporarydischargeheader
TemporarylinestothedischargegatevalvesoffourfeedpumpsFeedlinestoHPHBypasslineofallHPHHPH
bypasslinesWaterpathofHPH6,7,8FeedwaterlineuptoboilerfeedcontrolunitTemporarydischargelineto
thecirculatingwaterlineDeaeratorFST.

Slide24
Circuit1BDeaeratorFSTTDBFPBboosterpumpsuctionlineBPstrainersTemporaryheaderconnectingtheBP
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3/15/2016 Presentation"CHEMICALCLEANINGOFPREBOILERSYSTEM.OBJECTIVESToremovedirt,oil,greaseetc.,fromCondensate,Feedwater,D

suctionlinesdownstreamofthestrainersAcidcleaningpumpsTemporarydischargeheaderTemporarylinesto
thedischargegatevalvesoffourfeedpumpsFeedlinestoHPHBypasslineofallHPHHPHbypasslinesWater
pathofHPH6,7,8FeedwaterlineuptoboilerfeedcontrolunitTemporarydischargelinetothecirculatingwater
lineDeaeratorFST.

Slide25
Circuit1CDeaeratorFSTMDBFPboosterpumpsuctionlineBPstrainersTemporaryheaderconnectingtheBP
suctionlinesdownstreamofthestrainersAcidcleaningpumpsTemporarydischargeheaderTemporarylinesto
thedischargegatevalvesoffourfeedpumpsFeedlinestoHPHBypasslineofallHPHHPHbypasslinesWater
pathofHPH6,7,8FeedwaterlineuptoboilerfeedcontrolunitTemporarydischargelinetothecirculatingwater
lineDeaeratorFST.

Slide26
Circuit1DDeaeratorFSTBoosterpumpsuctionlineBPstrainersTemporaryheaderconnectingtheBPsuction
lines downstream of the strainers Acid cleaning pumps Temporary discharge header Temporary lines to the
dischargegatevalvesofTDBFPAFeedlinestoHPHBypasslineofallHPHHPHbypasslinesWaterpathofHPH
6,7,8 Feed water line upto boiler feed control unit Temporary discharge line to the circulating water line De
aeratorFST.

Slide27
Circuit1EDeaeratorFSTBoosterpumpsuctionlineBPstrainersTemporaryheaderconnectingtheBPsuction
lines downstream of the strainers Acid cleaning pumps Temporary discharge header Temporary lines to the
dischargegatevalvesofTDBFPBFeedlinestoHPHBypasslineofallHPHHPHbypasslinesWaterpathofHPH
6,7,8 Feed water line upto boiler feed control unit Temporary discharge line to the circulating water line De
aeratorFST.

Slide28
Circuit1FDeaeratorFSTBoosterpumpsuctionlineBPstrainersTemporaryheaderconnectingtheBPsuction
lines downstream of the strainers Acid cleaning pumps Temporary discharge header Temporary lines to the
dischargegatevalvesofMDBFPAFeedlinestoHPHBypasslineofallHPHHPHbypasslinesWaterpathof
HPH6,7,8FeedwaterlineuptoboilerfeedcontrolunitTemporarydischargelinetothecirculatingwaterlineDe
aeratorFST.

Slide29
Circuit1GDeaeratorFSTBoosterpumpsuctionlineBPstrainersTemporaryheaderconnectingtheBPsuction
lines downstream of the strainers Acid cleaning pumps Temporary discharge header Temporary lines to the
dischargegatevalvesofMDBFPBFeedlinestoHPHBypasslineofallHPHHPHbypasslinesWaterpathof
HPH6,7,8FeedwaterlineuptoboilerfeedcontrolunitTemporarydischargelinetothecirculatingwaterlineDe
aeratorFST.

Slide30
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Circuit1HDeaeratorFSTBoosterpumpsuctionlineBPstrainersTemporaryheaderconnectingtheBPsuction
lines downstream of the strainers Acid cleaning pumps Temporary discharge header Temporary lines to the
dischargegatevalvesoffourfeedpumpsFeedlinestoHPH50%bypasslineofallHPHFeedwaterlineupto
boilerfeedcontrolunitTemporarydischargelinetothecirculatingwaterlineDeaeratorFST.

Slide31
Circuit 1I Deaerator FST Booster pump suction line BP strainers Temporary header connecting the BP suction
lines downstream of the strainers Acid cleaning pumps Temporary discharge header Temporary lines to the
dischargegatevalvesoffourfeedpumpsFeedlinestoHPH100%bypasslineofallHPHFeedwaterlineupto
boilerfeedcontrolunitTemporarydischargelinetothecirculatingwaterlineDeaeratorFST.

Slide32
Circuit 1J Deaerator FST Booster pump suction line BP strainers Temporary header connecting the BP suction
lines downstream of the strainers Acid cleaning pumps Temporary discharge header Temporary lines to the
dischargegatevalvesoffourfeedpumpsFeedlinestoHPHbypasslinefor6A,7A,8AFeedwaterlineuptoboiler
feedcontrolunitTemporarydischargelinetothecirculatingwaterlineDeaeratorFST.

Slide33
Circuit 1K Deaerator FST Booster pump suction line BP strainers Temporary header connecting the BP suction
lines downstream of the strainers Acid cleaning pumps Temporary discharge header Temporary lines to the
dischargegatevalvesoffourfeedpumpsFeedlinestoHPHbypasslinefor6B,7B,8BFeedwaterlineuptoboiler
feedcontrolunitTemporarydischargelinetothecirculatingwaterlineDeaeratorFST.

Slide34
Circuit 1E Deaerator FST Booster pump suction line BP strainers Temporary header connecting the BP suction
lines downstream of the strainers Acid cleaning pumps Temporary discharge header Temporary lines to the
dischargegatevalvesoffourfeedpumpsFeedlinestoHPHWaterpathofHPH6A,7A,8AFeedwaterlineupto
boilerfeedcontrolunitTemporarydischargelinetothecirculatingwaterlineDeaeratorFST.

Slide35
Circuit 1L Deaerator FST Booster pump suction line BP strainers Temporary header connecting the BP suction
lines downstream of the strainers Acid cleaning pumps Temporary discharge header Temporary lines to the
dischargegatevalvesoffourfeedpumpsFeedlinestoHPHWaterpathofHPH6B,7B,8BFeedwaterlineupto
boilerfeedcontrolunitTemporarydischargelinetothecirculatingwaterlineDeaeratorFST.

Slide36
CIRCUIT2:Circuit2ACondenserCEPsuctionlinesAcidcleaningpumpsCEPdischargeheaderCondensateline
bypassingLPHslinedownstreamofLPHsTemporarydischargelinetothecirculatingwatersystemDeaerator
FSTCircuit2BCondenserCEPsuctionlinesAcidcleaningpumpsCEPdischargeheaderWatersideofLPHs
LinedownstreamofLPHsTemporarydischargelinetothecirculatingwatersystemDeaeratorFST

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Slide37
CIRCUIT3:Circuit3ACondenserCEPsuctionlinesAcidcleaningpumpsCEPdischargeheaderCondensateline
bypassing LPHs Temporary header for water supply to the HPH steam space Steam side of HPH 6A HPH
dischargelineTemporarydischargelinetothecirculatingwatersystemDeaeratorFST

Slide38
Circuit3BCondenserCEPsuctionlinesAcidcleaningpumpsCEPdischargeheaderCondensatelinebypassing
LPHsTemporaryheaderforwatersupplytotheHPHsteamspaceSteamsideofHPH6BHPHdischargeline
TemporarydischargelinetothecirculatingwatersystemDeaeratorFST

Slide39
Circuit3CCondenserCEPsuctionlinesAcidcleaningpumpsCEPdischargeheaderCondensatelinebypassing
LPHsTemporaryheaderforwatersupplytotheHPHsteamspaceSteamsideofHPH7AHPHdischargeline
TemporarydischargelinetothecirculatingwatersystemDeaeratorFST

Slide40
Circuit3DCondenserCEPsuctionlinesAcidcleaningpumpsCEPdischargeheaderCondensatelinebypassing
LPHsTemporaryheaderforwatersupplytotheHPHsteamspaceSteamsideofHPH7BHPHdischargeline
TemporarydischargelinetothecirculatingwatersystemDeaeratorFST

Slide41
Circuit3ECondenserCEPsuctionlinesAcidcleaningpumpsCEPdischargeheaderCondensatelinebypassing
LPHsTemporaryheaderforwatersupplytotheHPHsteamspaceSteamsideofHPH8AHPHdischargeline
TemporarydischargelinetothecirculatingwatersystemDeaeratorFST

Slide42
Circuit3FCondenserCEPsuctionlinesAcidcleaningpumpsCEPdischargeheaderCondensatelinebypassing
LPHsTemporaryheaderforwatersupplytotheHPHsteamspaceSteamsideofHPH8BHPHdischargeline
TemporarydischargelinetothecirculatingwatersystemDeaeratorFST

Slide43
CIRCUIT4:Circuit4ACondenserCEPsuctionlinesAcidcleaningpumpsCEPdischargeheaderCondensateline
bypassingLPHsTemporaryheaderforwatersupplytotheLPHsteamspaceSteamsideofLPH1ALPHdischarge
lineTemporarydischargelinetothecirculatingwatersystemDeaeratorFST

Slide44
Circuit4BCondenserCEPsuctionlinesAcidcleaningpumpsCEPdischargeheaderCondensatelinebypassing
LPHs Temporary header for water supply to the LPH steam space Steam side of LPH 1B LPH discharge line
TemporarydischargelinetothecirculatingwatersystemDeaeratorFST
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Slide45
Circuit4CCondenserCEPsuctionlinesAcidcleaningpumpsCEPdischargeheaderCondensatelinebypassing
LPHs Temporary header for water supply to the LPH steam space Steam side of LPH 2 LPH discharge line
TemporarydischargelinetothecirculatingwatersystemDeaeratorFST

Slide46
Circuit4DCondenserCEPsuctionlinesAcidcleaningpumpsCEPdischargeheaderCondensatelinebypassing
LPHs Temporary header for water supply to the LPH steam space Steam side of LPH 3 LPH discharge line
TemporarydischargelinetothecirculatingwatersystemDeaeratorFST

Slide47
Circuit4ECondenserCEPsuctionlinesAcidcleaningpumpsCEPdischargeheaderCondensatelinebypassing
LPHs Temporary header for water supply to the LPH steam space Steam side of LPH 4 LPH discharge line
TemporarydischargelinetothecirculatingwatersystemDeaeratorFST

Slide48
MMMMMMMMMMMMMMMMMMLPH1ALPH1BLPH2LPH3LPH4MMMDRIP/PADRIP/PBMMMM
BPMMMMMMMMMMMMMAINCONDENSER1MAINCONDENSER2MMMMMMGSCCPUMCEP3CEP
2CEP1MHPH6AHPH7AHPH8AMMMMMMMMMHPH6BHPH7BHPH8BMMMMMMMMMMMMMMM
MMTOECOI/L

Slide49
BPMMMMMMMMMMMMMAINCONDENSER1MAINCONDENSER2MMMMMMGSCCPUMCEP3CEP
2CEP1MHPH6AHPH7AHPH8AMMMMMMMMMHPH6BHPH7BHPH8BMMMMMMMMMMMTOECO
I/L

Slide50
M M M M M M M M M M M M M M M LPH1A LPH1B LPH2 LPH3 LPH4 M M BP M M M MM M M M M M MAIN
CONDENSER1MAINCONDENSER2MMMMMMCPUMCEP3CEP2CEP1MMMMMMMMMMMGSCMMM

Slide51
MMMMBPMMMMMMMMMMMMMAINCONDENSER1MAINCONDENSER2MMMMMMGSCCPUMCEP
3CEP2CEP1MHPH6AHPH7AHPH8AMMMMMMHPH6BHPH7BHPH8BMMMMMMMMMMMMMMM
TOECOI/L

Slide52
MMMMMMLPH1ALPH1BLPH2LPH3LPH4MMMDRIP/PADRIP/PBMMBPMMMMMMMMMMMM
MAINCONDENSER1MAINCONDENSER2MMMMMMGSCCPUMCEP3CEP2CEP1MMMMMMMMM
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Slide53
ACID CLEANING: Acid cleaning is made using the same four circuits on which water washing is made. To make
closed circuit the deaerator is included into the scheme, in which cleaning solution can be heated if required.
Reagentsinliquidform,eachbyseparatepipeline,aresuppliedfromreagentpreparationplantintosuctionpipeline
ofacidcleaningpump.MinimumHydrofluoricacidsolutiontemperatureis200Candoptimumtemperatureis400
C Acid cleaning phase duration is 48 hours at temperature up to 40 0 C Hydrofluoric acid cleaning solution
concentrationisselecteddependingonferricoxidequantityinthecircuittobewashed.

Slide54
CLEANINGSOLUTIONDISPLACEMENT:Primarydisplacementofspentcleaningsolutioniscarriedoutbycompressed
airfromthecompressorhousethisallowssavingofwaterforwashing.Thefinalremovalofsolutioniscarriedout
with standard speed in drainable section not less than 1m/s and in non drainable section not less than 2m/s.
Solution is removed from the circuits by hydraulic pneumatic method with water supply from condensers by acid
cleaningpumps.Acidcleaningisdeclaredfinishedifdischargewaterconductivityreaches20s/cm.

Slide55
PASSIVATION: Passivation of acid cleaned surface is carried out with Hydrogen Peroxide solution added with
ammonia. Before passivation the acid cleaned surface is neutralized with the circulation of ammonia solution.
Passivationiscarriedoutwithdemineralizedwaterunderthefollowingconditions:HydrogenPeroxideconcentration
is 0.02%. Ammonia Concentration is upto 0.8%. Solution temperature is 40 0 C. Duration 46 hours. Solution flow
velocityis0.3to0.5m/s

Slide56
Metalsurfacetreatmentwithoxidantsolutionpermitstoformthinprotectiveferricoxidefilm.
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