RIHAND SUPER THERMAL POWER PROJECT

STAGE-II COMMISSIONING DEPARTMENT

UNIT 3 ACID CLEANING PROCEDURES
A) ACID/CHEMICAL REQUIREMENTS: SL
NO
1.
2.
3.
4.
5.

ACID
Hydrochloric
acid
(HCL)
Rodine
Ammonium Bifloride
Ammoniated
Citric
Acid
Di/Trisodium
phosphate

6.

Hydrazine/ammonia
solution

7.

Caustic Soda Lye

8.

Bleaching powder

Blr
water
Quantity
Concentration
required
in %
5%+1%

70 tons

0.20 %
0.25 %

800 lts
1000 kg

Used for Process

Acid pickling
soaking

&

Ammoniated citric
acid rinse
0.1 % & 0.2 % 800
& Neutralization
in the boiler
1500 kgs process
250
ppm
1000
& Passivation
hydrazine/pH
1000 Lts
process
10
PH
5.5For neutralization
9.0/Floride < 2 70 tons
of acid
ppm
For neutralization
5 tons
of
hydrazine
/ammonia
0.2 %

800 kg

B) Other requirements check list:

1. Drum internals (primary separators) are removed & inspected after ABO
cleaning & boxed up.
2. Bottom ring header manholes are opened for inspection /cleaned /
checked for tightness of all baffle plates & boxed up.
3. Sample piece is tested for inhibiter effectiveness.
4. Sample piece is made ready to put inside the drum during acid cleaning
5. Temporary pipelines are laid as per the scheme attached.
6. Drum gauge glass to be replaced with a rubber/plastic U-tube
manometer arrangement.
7. Nitrogen cylinder arrangement at 0 mtr for capping after acid cleaning.
(During draining process) completed along with 500 no of cylinders 6.2
m3 each.
8. Valves to be provided in filling line to BCW suction manifold,
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STAGE-II COMMISSIONING DEPARTMENT

economizer, ring header (B85& B86).

9. Readiness of temporary system such as
o Boiler filling to be completed with in 1 hr
o LP purge water at 8-10 ksc near the BCW pump on continuous
basis.
10.
Readiness of 2 Acid tank & 1 Mixing tank for ammonium
Bifloride
11.
Emergency power to boiler fill pump, acid injection
Pump, temporary DM Water filling pumps.
12.
Drum metal temperature & minimum 4 thermocouples at ring
hdr With monitoring at control room.
13.
Internals of NRV before Eco feed valve E2 removed
14.
Telephone at acid tank/pump area .
15.
Service water available at tank area( spillage of acid /diluting
etc..)
16.
Minimum four safety shower
17.
O & M instructions along with emergency operation instructions
Available along with persons involved in activity.
18.
First aid facility available at
Location. (Eye lotion,rogen,tincture,iodine,cotton,burnout)
19.
All temporary piping carrying steam/hot water insulated.
20.
Permanent boiler instruments to be isolated except providing a
Temporary gauge 0-2.5 ksc in the drum for monitoring N2
Pressure in the drum during N2 capping.
N2 cylinder pressure to be checked for healtiness for ensuring
availability .
21.
All effluent disposal lines are supported at different locations
22.
Fire extinguisher available near chemical mixing tank area
23.
Fire house from hydrant tapping ready
24.
All temporary erected lines to boiler radiography done
25.
Lighting near chemical mixing tank ,low point drain area,N2 filling
Area Available.
26.
Area barricading done in chemical tank area , low point drain
Area, N2 filling area
27.
Danger sign around Acid mixing tank area.
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28.
29.

STAGE-II COMMISSIONING DEPARTMENT

Gauge for air pressure for Acid Unloading.
All acid tank and lines to be flushed with DM water after
completion of activity and declared safe before dismantling.

MOCK TRIAL:
Mock trial is to be conducted one day in advance
so as to check
the healthiness of various pumps, valves and other connected system.
Boiler filling in 1 hr (approx) and draining in 1 hr(approx) are to be
achieved.

C) Readiness / Preparation of Chemical solutions : Preparation of 30-32 % HCL with Rodine is completed in 2 acid tanks .
Preparation of ammonium bifloride with DM water is completed in
chemical mixing tank .
Shifting of above bi-floride solution to the 2 acid tanks is done.
Mixing of inhibited acid with bi-floride solution by running the
chemical injection pump on recirculation fro 1 hr before injection to
boiler.
Preparation of ammoniated citric acid with citric acid monohydrate &
liquor ammonia.
Preparation of neutralizing solution in mixing tank.(Di-sodium
phosphate do deca hydrate / Tri-sodium phosphate do deca
hydrate)( 0.1 % & 0.2 % in the boiler)
Preparation of blended solution of hydrazine/ammonia solution for
passivation of boiler.
D) ACID CLEANING PROCEDURE STEP BY STEP: D-1 ) Boiler filling with DM water & lighting up the boiler to raise the
temp. to 80 0c before going for acid injection

Fill the boiler through the bottom ring header drain (B85,86)
/economizer / up to the bottom gauge glass . Then stop filling .
Start back filling & flushing of the SH with hydrazine 200 ppm & pH
>10 till it over flows to the drum . Stop filling when drum level comes
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STAGE-II COMMISSIONING DEPARTMENT

to normal level.
Light up the boiler as per procedure with BCW in-service.
EBD/CBD should be full closed & vent valves to be full open.
Stop the boiler once drum metal temp & BCW pump suction manifold
temp reaches around 80 0C. Shut down the boiler. Stop BCW pump.
Box up the boiler by stopping natural air path & gas path. (SAPH3A
gas O/L damper & air inlet, FD outlet gate closed)
Drain the boiler water circuit. (BCW pump valves keep open)

D-2) Filling of Boiler along with Acid injection (Picking/Soaking )

Fill the boiler with 60-70 0C water from the 250 mm temporary
header through water walls (B85,86) / Eco filling line/ BCW pump
suction manifold drain ( 2 lines of 120 mm)

Start injection of chemicals at the discharge of the temporary DM

water filling pump through the acid injection pump & regulation
valve at the acid pump discharge .
The sample of the mixed water is to be monitored after injection
point i.e sample point A as per drawing at regular interval of 5
min .
The sample result of acid shall be 5% + 1% other wise regulate
the acid as desired in the water been filled to the boiler.
The temp. of the water & acid mixture dosed is to be regulated with
in 60-70 0C.(should not exceed above 700C )
Once the boiler drum level is at the bottom port stop filling through
BCW suction manifold . Continue filling through other sources.
Fill the boiler up to the drum level is 100 mm above center line.
Start Boiler Water Circulating (BCW) pump B ,center pump.
Collect sample from BCW pump discharge header & record them as
per the annexed log sheet after every 5 minutes & analyze for acid
strength & iron concentration.
After 30 min stop the BCW pump & allow the acid for soaking.
After 30 min again start the BCW pump & run for 5 min & then
stop
Take sample at every 10 min interval.
Continue this process till the iron content is in equilibrium for 3
consecutive sample .
The total time allowed for this exercise is 6 hrs including filling &
draining (time taken for filling & draining to be recorded during

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STAGE-II COMMISSIONING DEPARTMENT

mock trial and depending upon that time retention time to be
decided so the total acid contact time will be not allowed to exceed 6
hours,1 hr for filling & 1 hr for draining approx)
Stop BCW pump B .
Then keep the N2 capping system ready .
Prior to draining operate the same BCW-B for 5 minutes.
Start draining the boiler under N2 capping to the neutralization Pit.
Maintain the N2 capping pressure at 0.5 ksc to 1.0 ksc

D-3) DM water rinse after Acid pickling/Soaking is completed :

Refill the boiler with DM water at 60-70 0C.

While filling the drum vent valve are to be operated carefully to
maintain the pressure at 0.5 ksc of N 2 . Fill up to 50 % of the gauge
glass .
Then start back flushing of the SH through the LTSH drain till the
water level is raised in the drum up to 8-9 ports .
Run BCW-B
Take sample from BCW discharge till uniform concentration of acid &
iron are attained in the system as indicated from sample from BCW
discharge. Analyse the sample for pH.
Drain the boiler under N2 capping as practiced earlier.
Continue this operation till the sample result pH is upto 4.0 .The pH
of DM water rinse should not be allowed to go above 4.0

D-4) Ammoniated Citric Acid rinse after DM water rinse:

Fill the boiler with 60-65 0C water from the 250 mm temporary
header through
Water walls (B85, 86) / Eco filling line/ BCW pump suction manifold
drain ( 2 lines of 120 mm)
Start injection of citric acid solution prepared at temporary DM
filling pump discharge through the acid injection pump & regulation
valve at the acid pump discharge .
The sample of the mixed water is to be monitored at pump discharge
i.e sample point A as per drawing at regular interval of 5 min .
( 0.2 % concentration at the boiler inlet)
Adjust the pH at the filling point around 3.5-4.0 through sample
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STAGE-II COMMISSIONING DEPARTMENT

point A
Once the boiler drum level is at the bottom port stop filling through
suction manifold .
Fill the boiler up to the drum level middle in the gauge glass .
Start Boiler Water Circulating (BCW) pump B for 5 minutes.
Collect sample from BCW pump discharge header after stopping the
pump & analyze for acid strength & iron concentration.
Again After 30 min run the pump for 5 min collect the sample after
stoppage of the pump .
Continue this operation till 3 consecutive samples read the acid %
& iron content are steady .
This operation shall be minimum 4 hrs & maximum 5 hrs duration
Then drain the boiler under positive nitrogen pressure of 0.5 to 1.0
ksc .
D-5) Demineralised water rinse:
Fill the boiler with 60-70 0C water from the 250 mm temporary
header through
WW drain / Eco drain/ BCW pump suction manifold connection ( 2
lines of 120 mm)
Raise the water level up to +100 mm mark
Operate the BCW pump for 5 min .
Stop the pump & drain the boiler under nitrogen capping .
Continue the boiler filling & draining operation till the sample at
point B is having IRON < 25 ppm .
Maintain the N2 capping pressure at 0.5-1.0 ksc .
D-6) Neutralisation of the boiler system:
U Tube manometer to be replaced with normal gauge glass & all
instrumentation made available
Preparation of neutralizing solution & feeding to the boiler along with
DM water filling parallel through Water walls (B85, 86) / Eco filling
line / BCW pump suction manifold connection ( 2 lines of 120 mm)
. Nitrogen capping is to be maintained around 0.5 to 1 ksc.
Once boiler filling is complete open the drum vents .
Start the BCW pump-B .
Light up the boiler & raise the pressure to 10 ksc .
Hold the pressure for about 6 hrs .
Blow off all instruments for release of any acid particle. (All
instruments needing isoltion list to be prepared before isolation)
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STAGE-II COMMISSIONING DEPARTMENT

After 6 hrs kill the fire .
Allow the boiler to cool naturally .
Drain the boiler after metal temperature of < 90 0C is achieved
Boiler is drained with drum vents open to atmosphere & no N 2
capping is used .

D-7 ) Passivation of Boiler :

Fill the boiler with DM water & inject the prepared blended solution
so that the final water having 200 ppm of N 2H4 & pH of 10 is feed to
the boiler .
Fill through the Water walls (B85, 86) / Eco filling line / BCW pump
suction manifold connection 2 lines .
Fill up to the normal drum level .
Start the boiler circulation pump-B
Lightup the boiler at slow rate .
Raise the drum pressure to 40 ksc & hold it for 24 hrs .
Feed make water to be fed to boiler through MDBFP should have
residual N2H4 25 ppm & pH 10. For this Ammonia & hydrazine to be
dosed in the FST to maintain above values.
After 24 hrs shut down the boiler & allow it to cool down slowly .
At 95 0C stop the BCW pump & drain the boiler under atmospheric
pressure & aerate the system.
After cool down, open the upper & lower drum for inspection and take
out inspection pieces.
Manually clean them , refit the drum internals etc .
Restore all temporary connections make the boiler available for steam
blowing ,safety valve floating
E) Neutralisation of boiler effluents:
As soon as the acid is drained to the neutralizing pit caustic soda is
added to neutralize .
As soon as the citric acid is drained to the neutralizing pit caustic
soda is added to neutralize .

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