O.P.

JINDAL SUPER THERMAL POWER

PLANT
(4X600 MW)

PROCEDURE FOR CHEMICAL CLEANING

OF BOILER USING EDTA (ETHYLENE DIAMINE
TETRA ACETIC ACID)
 LIST OF
CONTENTS
Plant Details

Objectives

Proposal

Service Required

State of plant

Sampling During Process

Method

Completion Criteria
PLANT DETAILS
The steam generator is a controlled circulation, Radiant,
Reheat Boiler. The furnace consists of water cooled tubes
complete with down comers, water and steam headers,
bottom hoppers, drains, vents, sampling line connections
etc.
Boiler Design Data:

SH Outlet Pressure : 178 kg/cm2

SH Outlet Temperature : 540 0C
Feed water Temp.(at Eco inlet) : 254 o C
Maximum Continuous
Rating : 1950 t/h
Water Holding Capacity:

Water wall+Drum(full)
(160+75)=235 m3
Economizer : 150 m3
Superheater : 20o m3
Reheater : 160 m3
OBJECTIVE
The objective of this procedure is to chemically
clean and passivate the internal surfaces of the
steam generating portion(water touched
surfaces) and pre heating surfaces
(Economiser) using specified chemicals
employing a single step process. This will
render the above mentioned surfaces free of mill
scale and other deposits and form uniform &
smooth protective layer of magnetite to resist
corrosion.
PROPOSAL
The objectives are achieved by carrying out the following
proposals:

By carrying out one Alkali Flushing, one Hot water flushing

followed by cold DM water rinsing. Generally loose rust,
debris,oil,grease deposits and other materials left in the
Boiler are removed.

Then, it is subjected to ammoniated EDTA cleaning for the

removal of patchy mill scale and adherent rust. The acid
pickled surface is passivated for the formation of uniform
and adherent magnetite layer. Both chemical cleaning and
passivation process are completed in a single step in
the EDTA cleaning process.
SERVICES REQUIRED

Prior to the commencement of chemical

cleaning all the DM water storage tanks should
be kept full and the DM water generating units kept
in regenerated condition. Approximately 2400 m3 of
DM water will be consumed during the entire
process. At any time of acid cleaning a minimum of
two Boiler volumes (approximately 2X745 m3) of
DM water should be available in ready stock to
facilitate rapid flushing of the system in the event of
Chemistry upset.
 All the required quantities of chemicals as given
below should be made available prior to the
commencement of the process:
Name of Chemicals
Quantity
1 Tri Sodium Phosphate
(Na3PO412H2O ) 550
kgs

2. Disodium Hydrogen Phosphate

(Na2HPO4 12H2O) 300
kgs

3. Ammoniated EDTA
ammoniated solution (pH = 9.0 to 9.8)
(EDTA : Ethylene diamine tetra acetic acid) 55 tons

4. Ammonia solution (20% Min as NH3) 5000

liters
 State of the plant
Readiness of the following is to be ensured:

During the acid cleaning process all the permanent

Boiler instruments are isolated except providing a
temporary pressure gauge of 0 to 5 kg/ cm2 in the drum for
monitoring pressure in the drum during acid cleaning.

Provisions should be made at the following locations for

the measurement of temperature:

A) Two locations in the drum (left & right) for the

measurement of Boiler water temperature. Long
thermocouples of around 400 mm length shall be installed
directly in the spare / unused stubs in the drum.
Alternatively; metal temperature measuring thermo couple
with suitable adapter can be used.
B) Water wall metal temperature measurements as given
below:
At AB elevation 4 number thermocouples shall be installed on
corner water wall tubes (outside the furnace) and at GH
elevation 2 numbers thermocouples shall be installed in the
front and rear water wall (outside the furnace) at accessible
locations.

C) Two more thermocouples with pads one each at left and right
side of ECO coil shall be welded at suitable locations inside the
boiler (or penthouse) to measure the metal temperature in the
gas side.

(Total 6 nos. thermocouples will be used for measurement of

water wall tube metal temperature and 2 nos. for economizer
tube temperature
 SAMPLING DURING PROCESS

 To get representative samples of the process solution, sampling

points with sample coolers are to be provided at the following
locations: 25mm dia pipe shall be used for sampling line.
(A)Drum water sample to be drawn from CBD sample and from spare
tapping point in water side through the permanent saturated steam
coolers.

(B) One number of sampling line to be drawn from the middle CC

pump casing. (which is to be run during acid cleaning).

(C) Two numbers of sampling point is to be provided from bottom

ring header through hand hole cover. The sampling line from cooler
outlet shall be extended to zero meter with an isolation valve.

 For alkali flushing, rinsing, chemical cleaning and passivation

processes, essential control and instruments viz. protections,
interlock, alarms, measurement, annunciation etc. required for
safe light-up of boiler are made available as per mutually agreed
list between JPL and BHEL at site.
One set of boiler auxiliaries are made ready and available
for boiler light up. This includes Chemical Dozing pump,
tank fan oil pump etc. A checklist, containing minimum
requirements to be made ready prior to commencement
of Chemical cleaning.

In the steam drum, primary separators, screen driers

are to be installed and secondary separators are not to be
installed in the upper drum. In the bottom drum, the screen
plates shall be retained and orifices are not to be installed.

The economizer recirculation valve shall be kept open

throughout the chemical cleaning process.
 Boiler water wall test tube coupons are placed at two ends
inside the drum and bottom ring header to see the effectiveness
of the cleaning.

 Chemical cleaning system / equipment should be complete as

per the approved scheme.
 METHOD
ALKALI FLUSHING
Requisite quantities of Tri-sodium Phosphate
(Na3PO4) & Di Sodium Hydrogen Phosphate(Na2HPO4)
are added to the mixing tank along with DM Water and
the solution is thoroughly mixed by recirculation so
that final solution in the Boiler contains 0.1 % TSP
and 0.05 % DSP. The solution will be injected into
the Boiler through the bottom ring header drain and
economizer drain operating the chemical filling pump.
Further DM water will be taken in the Boiler up to
normal level.
Light up the boiler as per O&M instructions and
gradually raise the boiler water temp. up to 130-140 deg C.
Trip the boiler and keep the fans running for cooling. Keep
one CC pump running.

Note: All the three CC pumps shall be put into operation on

rotation
periodically.
After 30 minutes, stop the CC pump. When the boiler water
temperature comes down to 90 OC, drain the boiler in the hot
condition to the plant’s water disposal system, by keeping open
the drain valves fully.

HOT WATER RINSE

Once the draining is complete Boiler is refilled with DM water.
Boiler is lit up and the Boiler water temperature is gradually
raised to 130-140 0C. Then the Boiler is tripped and Fans are
kept running for cooling.
The running CC pump is stopped after 30 minutes and Boiler is
drained in hot condition to the plant’s water disposal system
by keeping open the drain valves fully. The pH and PO4 will
be measured in the drain water The pH and PO4 ate to be
reduced to a level below 7.5 and 10 ppm respectively.

COLD WATER RINSE

Cold water rinsing is done using fill and dump method.

Draining will be done to the plant’s water disposal system. pH
will be monitored during draining. The rinsing operation will be
continued until pH of the drain water is almost equal to pH of
inlet water used for rinsing. All CC pumps are run one
by one for proper rinsing.

 All sampling and blow down lines are flushed. All

temperature / pressure measurements relevant to the process
ACID CLEANING & PASSIVATION

Required quantity of ammoniated EDTA (40% wt/wt)

solution will be kept ready in the EDTA storage tank.

The inhibitors “BHELMAX” & “BHELSOL”, Hydrazine

hydrate and ammonia for addition in the Chemical
dissolving tank will also made available near the mixing
tank.

All the Boiler Blow down valves are kept shut and drum
vent valves & start up vent are kept open during Boiler
filling.
40 Cu.m of DM water will be drawn in the mixing tank. The
temporary chemical fill pump is started and system put
into recirculation. Required quantity of Ammoniated
EDTA (40% wt/wt ) solution is transferred from the EDTA
storage tank to the mixing tank. The EDTA concentration in
the mixing tank is checked. Transferring of the EDTA
solution is stopped when the EDTA concentration
reaches 3 +/- 1% by weight. Required quantity of
Hydrazine hydrate and inhibitors (BHELMAX &
BHELSOL) are also added. Recirculation is done till all
the chemicals are uniformly mixed up. With this one batch
of EDTA Chemical solution is ready for filling into the Boiler.
The approximate quantities of various chemicals
that are to be mixed per batch of 40 m3 is :

1. EDTA ammoniated (40 % ) concentrate : 3 to 4 m3

2. BHELMAX : 60 kgs
3. BHELSOL : 60
litres
4. N2H4.H2O (80%) : 60 litres
Ammonia is added if required to adjust the pH between 9.0
and 9.8. DM water is used to make up to 40 m3.

This solution is filled into the Boiler through Low Point drain
header with the temporary chemical fill pump. Fill the boiler up
to +200 mm from the normal working level in the drum. Start
the CC pump for thorough mix up of the chemical solution for
30 minutes. Check the boiler water sample.

Preparation of Chemical solution and batch filling is

repeated as explained in above till the solution level in the
Drum reaches the center line of the gauge glass.

The composition of the filling solution is:

EDTA content : 3 +/- 1% W/v
Hydrazine : 1000 ppm (min)
pH : 9.0 to 9 .8

The Boiler is lighted up as per normal operating

The Drum and super heater vents are closed when steaming
starts, say at 1 kg / sq. cm. pressure in the Drum. SH start up
vents are kept crack open.

The time at which the temperature of Boiler water reaches 110

0
C is noted.

Once the temperature of Boiler water reaches 140 0C, the

firing rate is controlled in such a way that the Boiler water
temperature is maintained at 140 - 145 0C, for a minimum
period of 4 hours. Then the Boiler is tripped but running of
CC pump is continued.

The ID & FD Fans are allowed to run to bring down the

Boiler water temperature. In case it appears that the results
of iron concentration may not level out when temperature is
expected to be 110 0C, ID/FD fans are stopped suitably during
Samples are taken at every 30 minutes interval from
the sampling points. when the temperature in the system
had reached 1100 C and analysed for pH, EDTA
concentration and Iron content.

After attaining the completion criteria of pickling process,

system is allowed to cool with the ID & FD Fans in
operation (ID & FD Fans are to be restarted, in case they
have been stopped to meet the completion criteria, to
bring down the Boiler water temperature). Open the Drum
air vents when the pressure reaches 1 kg/sq.cm
When the temperature comes down to 950C the running CC
pump is stopped and the system is drained completely in hot
condition to the effluent pit by opening all the drain valves.

TREATED DM WATER RINSE

Prepare a blended solution of ammonia & Hydrazine

with calculated quantities in the dissolving tank in order to
achieve a solution pH 9.0 to 9.5 and hydrazine content 50 ppm
in the DM water being filled in the boiler.

Fill the boiler with the above treated DM water through

low point drains and economizer up to just above the centre
gauge glass.
Start the middle CC pump and light up the boiler as per O&M
Instruction.
Drum level will drop after starting the CC pump. Again fill the
boiler with
treated DM water solution to make up the level up to 100 mm
above NWL.

Raise boiler water temperature up to 110 deg .C and then shut

down the
boiler. Allow the boiler to cool down naturally. When the
boiler water
temperature comes down to 95 deg C. drain the boiler in hot
condition to
plant drain and allow the system for natural aeration.

Boiler Drum manhole is opened for removal of Coupons. Manually

clean the
drums if required.

Lower drums manholes are opened for inspection and cleaned

manually, if
INSPECTION
The test coupons placed at identified locations are taken
out. All coupons should have uniform coating of the
protective layer.

The Drum internal surface is visually inspected for uniform

smooth coating of protective layer.

The ring headers will be inspected and loose debris if any, will
be removed.
 COMPLETION CRITERIA

COLD RINSE AFTER ALKALI FLUSHING

The rinsing operation is continued until pH of the

effluent is almost equal to pH of inlet water used for
rinsing.

EDTA CLEANING

Cleaning process is to be continued till iron

concentration in three consecutive samples show
equilibrium status. When the iron concentration in
the cleaning solution is constant it indicates that all
the oxides have been dissolved. However, a minimum
EDTA contact period of 6 hours from the time of
attaining the required temperature (110 0C) shall be
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