HRSG Chemical Cleaning Procedure

HRSG Chemical Cleaning Procedure

Flushing Step

1.

Flushing all temporary lines.

2.

Flushing Make up water line to integral Deaerator.

3. Flushing integral Deaerator to Deaerator drums to LP drums and

LP de -super heater sprays line.
4. Flushing LP drum to LP evaporator and LP continuous blow-down line.
5. Flushing discharge line of feed water pump to HP economizer to HP
Drum and HP de-super heater spray line.
6. Flushing HP drum to HP evaporator and HP continuous blow-down line.

NOTE:
a. ALL flushing using temporary pumps flow rate 100m3/hr.
b. Block diagram of chemical cleaning is attached.
c. Flushing water will be drained to neutralization pit. The water will be checked if
can be disposed to open drain by temporary pump or else will be carried away
by truck to dispose to licensed water treatment company.

Preparation Work Before Cleaning

1)

Clean manually inside surface of deaerator, LP drum and HP drum by

manpower before start chemical cleaning.

2)

Determine the injection points and circulation lines including proper vents
and drains.

3)

Installation of temporary orifice at down comers in the LP & HP drums and

replace the existing steam drum level gauges with clear vinyl hoses.

4)

Isolate the system to be cleaned by either closing valves, dropping valves,

blind flanges or temporary by-pass lines (refer to valves check list).

5)

Locate the area for circulation tank and pump (refer to equipments setting area
lay-out).

6)

Locate the draining points, water supply, power supply, nitrogen supply and
stream supply.

7)

Hook-up the chemical cleaning equipment with the system to be cleaned.

8)

Test-run the equipment and check leak of the temporary piping.

NOTE: The insulation of the permanent system must be finished at least 90%

HRSG Chemical(Alkaline) Cleaning

1)

After all temporary piping has been installed, leak check and water flushing.

2)

Fill the LP&HP super heater with demineralized water using temporary
back fill super heater pump until overflow through stream drums. Then stop
back fill super heater pump.
Note: All demisters are removing from the super heater outlet nozzles will be
leave in side the stream drums and during cleaning process.

3)

Closed all stream drum manholes. Fill the HRSG system with demineralized
water by temporary chemical cleaning circulation pump until full. Circulate water
in the system by temporary chemical cleaning pump.

4)

Heating up the cleaning system by direct steam from package boiler and
indirect heating by temporary heat exchanger to approx. 905 and maintain
this temperature using temporary heat exchanger.

100MW combined Cycle Power Plant

Section 1 Instruction to Tender

I-1

5)

Add. Alkaline solution 1.5% of NaCO3(Soda Ash)+1.5% of Na3PO4 (Trisodium

phosphate) and 0.1% of KAT-09S(Surfactant) + foam inhibitor (Defoamer) if
required, in the circulation tank and circulate thoroughly in the system.

6)

Adjust the drum level by at half level in HP drum and full of deaerator drum and
LP drum.

7)

Continuous circulate the system and start sampling the solution. Consider
analysis of pH and alkaline every hour and % PO4, TDS and oil every 2 hours.

8)

During circulation, temperature of all the pipes for alkaline cleaning to be

checked to confirm all the pipes are flow with chemical.

9)

After 12 hours, adding 300 ppm of ELIMINOX for passivation.

10)

When analysis show equilibrium result of alkaline (not less then 24 hrs) stop
heating.

11)

Stop circulation pumps and drain the system to circulation tank for neutralizing
and truck out for disposal at licensed waste treatment plant.

12)

After complete draining; the system shall be filled with approx. 70.
demineralized water, heated by steam from package boiler in the temporary
heat exchanger and direct steam. (The system shall be filled the level at higher
level of the alkaline solution level in the HP drum).

13)

Circulate the system approximate 1 hour.

14)

Drain the first rinse to tanker and truck out for disposal at licensed waste
treatment plant.

15)

Second rinse; repeat step 11 or 13 again until the fluid is clear and drain to
neutralizing pit. Check the water if suitable to be disposed to open drain. If cant,
it will be carried away by truck to the approved licensed water treatment plant.

16)

Open drum manholes for inspection by visual inspection. Once accepted,

remove all orifices, plugs and restore the drum internal parts. Then closed all
steam drum manholes.

17)

Backwash the super heater line.

100MW combined Cycle Power Plant

Section 1 Instruction to Tender

I-2

Preservation
1)

Mix. Preservation solution 400 ppm of ELIMINOX and ammonia water to adjust
the pH
9, with demin water in the circulation tank circulate
thoroughly(treated demin water).

2)

Fill the treated demin water in to the system by circulation pump until full
(venting of LP drum, HP drum, deaerator drum, LP super heater lines and HP
super heater lines).

3)

Pressurize the system under nitrogen pressure to 0.5-1.0 bar. Closed all vent
and drain valves and tagging of closed condition.

Safety Plan
1)

Working area shall be barricaded with proper device and warning signs.

2)

All personnels handling the chemical cleaning shall be equipped with

protective overall, boot, gloves, goggles and mask.

NOTE: Job Safety Analysis (JSA) is attached.

Safety Plan
Chemical Cleaning waste solution and first rinse are carrying out for dispose at
licensed waste treatment company. Second rinse and after shall be neutralize to pH
5.5-9.0 at circulation tank before draining through plant drainage system.

100MW combined Cycle Power Plant

Section 1 Instruction to Tender

I-3