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COMMISSIONING PROCEDURE
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BOILER CHEMICAL CLEANING
PLG-100-COM-PR-001 PROCEDURE Page 3 of 13
TABLE OF CONTENT
1.0 TITLE 4
2.0 SCOPE 4
3.0 REFERENCE 4
1.0 TITLE
Procedure for boiler chemical cleaning
2.0 SCOPE
This procedure covers the general requirements for boiler acid cleaning based on
chemical to be implemented. The purpose of boiler chemical cleaning is to remove
oil/grease, rust/scaling, which is formed during boiler pressure parts fabrication. Final
step of boiler chemical cleaning is to perform magnetite film layer formation on boiler
tube as an indication boiler is ready to operate.
3.0 REFERENCE
3.1 JINAN BOILER OPERATION MANUAL
3.2 CHEMICAL SUPPLIER DOCUMENT
9.1.1 Fill water to boiler through feedwater line until level in the steam drum
is below manhole .While filling the water to steam drum, open air vent
on the steam drum, and closed after there is no air comes out from the air
vent. Stop the circulation pump, and drain the water necessary through
bottom header until the water is clean
9.1.2 Fill the water again until level in the steam drum is below manhole.
During water filling to boiler, charging the steam from low pressure
boiler for heating the water in chemical tank (50°C – 60°C)
9.1.3 Continue for circulating the water, open three (3) valve at bottom header,
and maintain drum level below normal level. During this circulation
maintain chemical tank level at 75%.
9.1.4 Stop circulation pump and add hydrazine (75 kg), start again circulation
pump, and continue filling water until main steam line (hydrazine
blanket). Crack open drain valve 2” on main steam line check valve
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BOILER CHEMICAL CLEANING
PLG-100-COM-PR-001 PROCEDURE Page 8 of 13
blank, if water already comes out, stop circulation pump, and close main
steam line air vent.
9.3.1 After circulating the chemicals solution for four (4) hours, stop
circulation pump.
9.3.2 Drain the boiler until empty.
9.3.3 Fill water to boiler until normal level water, stop the pump and drain the
boiler directly (boiler flushing process).
9.4.1 After boiler flushing is finish, fill demin water to chemical tank.
9.4.2 After the level is sufficient start circulation pump, and continue filling
water to boiler until level in the steam drum is below manhole.
9.4.3 Stop the pump and heating the water by using steam from temporary low
pressure boiler until water temperature reaching 50°C. Stop steam supply
from the boiler if temperature already reach 50°C.
9.4.4 Add chemicals to tank alternatively:
- HCl 30% 4500 kg (4 kemps)
- Armohib 28 (2 pail)
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BOILER CHEMICAL CLEANING
PLG-100-COM-PR-001 PROCEDURE Page 9 of 13
9.5.1 After draining boiler is finish and chemical tank is empty, fill demin
water to chemical tank. After the level is sufficient, start circulation
pump and continue filling water to boiler until level in the steam drum is
at normal level water.
9.5.2 Circulate the water for two (2) hours, and drain the boiler (1st flushing)
9.5.3 Repeat the process until conductivity of the water is below 20µS/m.
9.6.1 After flushing to low conductivity is complete, fill the boiler again until
level in the steam drum is below manhole.
9.6.2 While continue circulating, heating the water by using steam from
temporary low pressure boiler until water temperature reaching 50°C.
Stop steam supply from the boiler if temperature already reach 60°C.
9.6.3 Add chemicals to tank alternatively for neutralization phase, and
circulate for four (4) hours :
- Citric acid 50% 500 kg (20 sacks)
- Ammonia 1000 kg (7 drum)
9.6.4 Ensure chemical solution pH is 9.6
9.6.5 Add chemicals to tank for passivation phase, and circulate for two (2)
hours :
- Sodium nitrite 388 kg (15 sacks)
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BOILER CHEMICAL CLEANING
PLG-100-COM-PR-001 PROCEDURE Page 10 of 13
9.6.6 After chemical circulation is complete, stop the pump and drain the
boiler.
9.7.1 After draining the boiler is complete, fill the water again until level in
the steam drum is below manhole, and stop the circulation pump.
9.7.2 Add ammonia (260 kg or 2 drum) to chemical tank and circulate for four
(4) hours. Ensure chemical solution pH is 10.2
9.7.3 After the circulation is complete, drain the boiler
9.8 Inspection
9.8.1 Inspect steam drum, compare the result by picture (by comparing the
result before and after acid cleaning)
9.8.2 Install the dismounted drum internal parts.
9.8.3 Cut three (3) bottom header cap, and compare the result before and after
acid cleaning (others three bottom header cap already cut off for
temporary pipe connection)
finished, the boiler is to be operated under low load. min 2,7 MPa for
about 10 – 24 hour with a dosage in the feed water. During treatment the
boiler is being blown off powerfully. After this time when the boiler
water will be show satisfactory values of chemical analysis, the boiler is
to be set in operation. the purpose of this so called “Protecting Film
Operation” are :
a) Build up a protecting film of magnetite on almost uniform
thickness.
b) Blowing off of finely powdered slug residual
During this magnetite formation the following analysis to be carried out by the
laboratory personnel under GPOS SUPERVISION:
Day no. 5
30 °C Demin Water
Final Flushing
Day no. 6 Final flushing 30 °C Demin water
Day no. 7 Filling for
3°C 0 Demin water
Hydrostatic pressure test.
Day no. 8 – 10
30 °C Demin water
Magnetite formation
Total ± 1750