⚡Presentation _CHEMICAL CLEANING OF PRE-BOILER SYSTEM. OBJECTIVES To remove dirt,oil,grease etc., from Condensate,Feed water, Drip and Extraction steam lines of HP and

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Presentation on theme: "CHEMICAL CLEANING OF PRE-BOILER SYSTEM.

OBJECTIVES To remove dirt,oil,grease etc., from Condensate,Feed water, Drip and

Extraction steam lines of HP and." — Presentation transcript:

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CHEMICAL CLEANING OF PRE-BOILER SYSTEM

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CHEMICAL CLEANING OF PRE-BOILER SYSTEM. OBJECTIVES To removedirt,oil,grease etc., from Condensate,Feed water, Drip and Extraction steam lines of HP and.Publish Mckenna Darnley, Modified 6 years ago

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Slide 2

OBJECTIVES To remove dirt,oil,grease etc., from Condensate,Feed water, Drip and Extraction

steam lines of HP and LP heaters prior to putting these systems in regular service. This is to

ensure flow of clean condensate and feed water to the boiler.

Slide 3

STATE OF THE PLANT Hydro-test 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

provided for all the pipelines before flushing. Plugs to be provided in the safety valves of LPHs,water seal inlets in flash

tanks and LPH 1 and in C&I tapping. Screens to be provided on booster pump suction line and acid cleaning pump

suction line

Slide 4

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

chemical cleaning pumps(2 nos.) and connected piping along with required instrumentation is complete. During post

mounting cleaning it is proposed to use chemically clean water from condensate storage tank.

Slide 5

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

emergency make up pumps, condensate normal make up pumps, motor operated valves and lighting.

Slide 6

EQUIPMENTS AND RESOURCES FOR WATER WASHING Condensate storage tanks. Condenser of volume 1000m 3 as a

reservoir for storing the dematerialized water. Turbine condensate pumps (3 nos.). Chemical cleaning pumps(q=300t/h,h=80mwg,n=1500rpm)- 2nos. Compressor plant and pipeline Dn100 to supply air into the washing circuit

with the parameters not less than q=20m 3 /min,p=0.6MPa Pipelines and valves Dn 20-300,Pn 1.6MPa

Slide 7

EQUIPMENT AND RESOURCES FOR CHEMICAL CLEANING AND PASSIVATION Deaerator and Feed Water Storage

Tank. Chemical cleaning pumps (q=300t/h,h=80mwg,n=1500rpm)- 2nos. Pipelines and valves Dn 20-300,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 (flowelements, pressure gauges, level gauges, temperature elements)

Slide 8


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The pre-boiler system consists of Condensate system Drip system Feed water system Extraction steam lines to

Regenerative Heaters

Slide 9

→ Condensate system comprises of 3 nos. of Condensate Extraction Pumps,Low Pressure Heaters, Gland Steam

Cooler,Deaerator,connecting pipelines including excess condensate line upto Condensate storage tank.

Slide 10

→Feed water system comprises 2 nos. of motor driven boiler feed pumps,2 nos. of Turbine driven boiler feed

pumps,their booster pumps and recirculation lines, high pressure heaters, their connecting pipelines upto econimiser

inlet.Reheater and Superheater spray line are also included for the purpose of flushing.

Slide 11

→ Drip system comprises of the shell side of all LP and HP heaters and their normal and emergency drip lines.

Slide 12

→Extraction steam system consists of bled steam lines from different stages of Turbines (HPT,IPT and LPT) to LP and

HP heaters,Deaerator and TDBFPs.

Slide 13

CLEANING METHOD Pre- mounting cleaning. Extraction steam lines to regenerative heaters Post-mounting cleaning.

Feed water line,Condendate line and heater drip lines. Steam blowing. MS line,CRH line, HRH line,steam line to

TDBFPs etc.

Slide 14

METHODS AND SCOPE OF CLEANING Post Mounting Cleaning Main Turbine and BFP Drive Turbine Condenser

Cleaning. Hydro-pneumatic Washing with Demineralized Water of Unit Circulating System. Chemical Cleaning of Water–

Steam path of Heater and Pipeline with hydrofluoric Acid solution. Chemical Passivation of Water-Steam path of Heater

and Pipeline with Hydrogen Peroxide solution added with Ammonia.

Slide 15

Pre-Mounting Cleaning Chemical Cleaning of Pipelines in a bath of Hydrofluoric Acid solution. Spent solution

displacement. Chemical Passivation of Pipelines with Hydrogen Peroxide solution added with ammonia. Air Blowing of

Passivated pipelines for drying.

Slide 16

Main Turbine and BFP Drive Turbine Condenser Cleaning or Condenser Degreasing. STEP- I The demineralized water is

heated upto 70 0 c in the De-aerator FST. The Chemical solution prepared in reagent preparation plant is mixed with

the hot water in the De-aerator FST.


4/12



Slide 17

The hot solution is transferred to Condenser with the help of temporary chemical cleaning pump 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

isolated after closing one temporary gate valve provided in the circuit (refer to scheme.)

Slide 18

FST DEAERATOR AUX.STEAM CHEMICAL BP ACID CLEANING PUMPS CONDENSERS CEPS

Slide 19

STEP –II CEPs are charged from water side by opening suction valve and through proper venting, keeping discharge

valve in closed condition and suction strainer in position. Flushing started by alternately starting and stopping CEPs andcompleting the circulation from CEP discharge to CEP suction line through recirculation line and condenser.

Slide 20

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

Water washing of Condenser started and continued for 4 hrs. using the two circuits already described..

Slide 21

DEAERATOR FST AUX.STEAM CHEMICAL BP ACID CLEANING PUMPS CONDENSERS CEPS

Slide 22

Hydro-pneumatic Washing of Unit Circulating System with Demineralized Water and air. → Hydro-pneumatic washing

of unit circulating system is carried out step by step with simultaneous water and air supply. →Demineralized water for

washing is stored in the De-aerator FST and Condenser. →Hydropneumatic washing is declared completed if

suspended matter content of the washing water reaches no more than 100mg/kg. →Hydro-pneumatic washing of unit

circulating system is done using following four circuits.

Slide 23

CIRCUIT 1: Circuit 1A De-aerator FST – TDBFP A 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 discharge gate valves of four feed pumps – Feed lines to HPH – Bypass line of all HPH – HPH

bypass lines – Water path of HPH 6,7,8 – Feed water line upto boiler feed control unit – Temporary discharge line to

the circulating water line - De-aerator FST.

Slide 24

Circuit 1B De-aerator FST – TDBFP B booster pump suction line – BP strainers – Temporary header connecting the BP


5/12



suction lines downstream of the strainers – Acid cleaning pumps – Temporary discharge header – Temporary lines to

the discharge gate valves of four feed pumps – Feed lines to HPH – Bypass line of all HPH – HPH bypass lines – Water

path of HPH 6,7,8 – Feed water line upto boiler feed control unit – Temporary discharge line to the circulating water

line - De-aerator FST.

Slide 25

Circuit 1C De-aerator FST – MDBFP 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 discharge gate valves of four feed pumps – Feed lines to HPH – Bypass line of all HPH – HPH bypass lines – Water

path of HPH 6,7,8 – Feed water line upto boiler feed control unit – Temporary discharge line to the circulating water

line - De-aerator FST.

Slide 26

Circuit 1D De-aerator 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

discharge gate valves of TDBFP A – Feed lines to HPH – Bypass line of all HPH – HPH bypass lines – Water path of HPH

6,7,8 – Feed water line upto boiler feed control unit – Temporary discharge line to the circulating water line - De-

aerator FST.

Slide 27

Circuit 1E De-aerator FST – Booster pump suction line – BP strainers – Temporary header connecting the BP suction


discharge gate valves of TDBFP B – Feed lines to HPH – Bypass line of all HPH – HPH bypass lines – Water path of HPH

6,7,8 – Feed water line upto boiler feed control unit – Temporary discharge line to the circulating water line - De-

aerator FST.

Slide 28

Circuit 1F De-aerator FST – Booster pump suction line – BP strainers – Temporary header connecting the BP suction


discharge gate valves of MDBFP A – Feed lines to HPH – Bypass line of all HPH – HPH bypass lines – Water path of

HPH 6,7,8 – Feed water line upto boiler feed control unit – Temporary discharge line to the circulating water line - De-

aerator FST.

Slide 29

Circuit 1G De-aerator FST – Booster pump suction line – BP strainers – Temporary header connecting the BP suction


discharge gate valves of MDBFP B – Feed lines to HPH – Bypass line of all HPH – HPH bypass lines – Water path of

HPH 6,7,8 – Feed water line upto boiler feed control unit – Temporary discharge line to the circulating water line - De-

aerator FST.

Slide 30


6/12



Circuit 1H De-aerator FST – Booster pump suction line – BP strainers – Temporary header connecting the BP suction


discharge gate valves of four feed pumps – Feed lines to HPH – 50 % bypass line of all HPH– Feed water line upto

boiler feed control unit – Temporary discharge line to the circulating water line - De-aerator FST.

Slide 31

Circuit 1I De-aerator FST –Booster pump suction line – BP strainers – Temporary header connecting the BP suction


discharge gate valves of four feed pumps – Feed lines to HPH – 100 % bypass line of all HPH – Feed water line upto

boiler feed control unit – Temporary discharge line to the circulating water line - De-aerator FST.

Slide 32

Circuit 1J De-aerator FST –Booster pump suction line – BP strainers – Temporary header connecting the BP suction


discharge gate valves of four feed pumps – Feed lines to HPH bypass line for 6A,7A,8A – Feed water line upto boiler

feed control unit – Temporary discharge line to the circulating water line – De-aerator FST.

Slide 33

Circuit 1K De-aerator FST –Booster pump suction line – BP strainers – Temporary header connecting the BP suction


discharge gate valves of four feed pumps – Feed lines to HPH bypass line for 6B,7B,8B – Feed water line upto boiler

feed control unit – Temporary discharge line to the circulating water line – De-aerator FST.

Slide 34

Circuit 1E De-aerator FST –Booster pump suction line – BP strainers – Temporary header connecting the BP suction


discharge gate valves of four feed pumps – Feed lines to HPH – Water path of HPH 6A,7A,8A – Feed water line upto

boiler feed control unit – Temporary discharge line to the circulating water line – De-aerator FST.

Slide 35

Circuit 1L De-aerator FST –Booster pump suction line – BP strainers – Temporary header connecting the BP suction


discharge gate valves of four feed pumps – Feed lines to HPH – Water path of HPH 6B,7B,8B – Feed water line upto

boiler feed control unit – Temporary discharge line to the circulating water line – De-aerator FST.

Slide 36

CIRCUIT 2: Circuit 2A Condenser – CEP suction lines – Acid cleaning pumps – CEP discharge header – Condensate line

bypassing LPHs – line down stream of LPHs – Temporary discharge line to the circulating water system – De- aerator

FST Circuit 2B Condenser – CEP suction lines – Acid cleaning pumps – CEP discharge header – Water side of LPHs –

Line down stream of LPHs – Temporary discharge line to the circulating water system – De-aerator FST


7/12



Slide 37


bypassing LPHs – Temporary header for water supply to the HPH steam space – Steam side of HPH 6A – HPH

discharge line – Temporary discharge line to the circulating water system – De-aerator FST

Slide 38

Circuit 3B Condenser – CEP suction lines – Acid cleaning pumps – CEP discharge header – Condensate line bypassing

LPHs – Temporary header for water supply to the HPH steam space – Steam side of HPH 6B – HPH discharge line –

Temporary discharge line to the circulating water system – De-aerator FST

Slide 39

Circuit 3C Condenser – CEP suction lines – Acid cleaning pumps – CEP discharge header – Condensate line bypassing

LPHs – Temporary header for water supply to the HPH steam space – Steam side of HPH 7A – HPH discharge line –


Slide 40

Circuit 3D Condenser – CEP suction lines – Acid cleaning pumps – CEP discharge header – Condensate line bypassing



Slide 41

Circuit 3E Condenser – CEP suction lines – Acid cleaning pumps – CEP discharge header – Condensate line bypassing

LPHs – Temporary header for water supply to the HPH steam space – Steam side of HPH 8A – HPH discharge line –


Slide 42

Circuit 3F Condenser – CEP suction lines – Acid cleaning pumps – CEP discharge header – Condensate line bypassing



Slide 43


bypassing LPHs – Temporary header for water supply to the LPH steam space – Steam side of LPH 1A – LPH discharge

line – Temporary discharge line to the circulating water system – De-aerator FST

Slide 44

Circuit 4B Condenser – CEP suction lines – Acid cleaning pumps – CEP discharge header – Condensate line bypassing

LPHs – Temporary header for water supply to the LPH steam space – Steam side of LPH 1B – LPH discharge line –



8/12



Slide 45

Circuit 4C Condenser – CEP suction lines – Acid cleaning pumps – CEP discharge header – Condensate line bypassing

LPHs – Temporary header for water supply to the LPH steam space – Steam side of LPH 2 – LPH discharge line –


Slide 46

Circuit 4D Condenser – CEP suction lines – Acid cleaning pumps – CEP discharge header – Condensate line bypassing



Slide 47

Circuit 4E Condenser – CEP suction lines – Acid cleaning pumps – CEP discharge header – Condensate line bypassing



Slide 48

M M M M M M M M M M M M M M M M M M LPH-1A LPH-1B LPH-2 LPH-3 LPH-4 M M M DRIP /P-A DRIP /P-B M M M M

BP M MMM M MM M M M M M MAIN CONDENSER - 1 MAIN CONDENSER - 2 M M M M M M GSC CPU M CEP-3CEP-

2CEP-1 M HPH-6A HPH-7A HPH-8A M M M M M M M M M HPH-6B HPH-7B HPH-8B M M M M M M M M M M M M M M M

M M TO ECO I/L

Slide 49

BP M MMM M MM M M M M M MAIN CONDENSER - 1 MAIN CONDENSER - 2 M M M M M M GSC CPU M CEP-3CEP-

2CEP-1 M HPH-6A HPH-7A HPH-8A M M M M M M M M M HPH-6B HPH-7B HPH-8B M M M M M M M M M M M TO ECO

I/L

Slide 50

M M M M M M M M M M M M M M M LPH-1A LPH-1B LPH-2 LPH-3 LPH-4 M M BP M M M MM M M M M M MAIN

CONDENSER - 1 MAIN CONDENSER - 2 M M M M M M CPU M CEP-3CEP-2CEP-1 M M M M M M M M M M M GSC M M M

Slide 51

M M M M BP M MMM M MM M M M M M MAIN CONDENSER - 1 MAIN CONDENSER - 2 M M M M M M GSC CPU M CEP-

3CEP-2CEP-1 M HPH-6A HPH-7A HPH-8A M M M M M M HPH-6B HPH-7B HPH-8B M M M M M M M M M M M M M M M

TO ECO I/L

Slide 52

M M M M M M LPH-1A LPH-1B LPH-2 LPH-3 LPH-4 M M M DRIP /P-A DRIP /P-B M M BP M MMM M MM M M M M M

MAIN CONDENSER - 1 MAIN CONDENSER - 2 M M M M M M GSC CPU M CEP-3CEP-2CEP-1 M M M M M M M M M


9/12



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⚡Presentation _CHEMICAL CLEANING OF PRE-BOILER SYSTEM. OBJECTIVES To remove dirt,oil,grease etc., from Condensate,Feed water, Drip and Extraction steam lines of HP and