Acid Cleaning in Commissioning
Transcript of Acid Cleaning in Commissioning
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3.3 ................................................................................................... 4
3. ......................................................................................................... 43. ............................................................................ 4
- ........................................................................................................................... 5.4 ................................................................................................. 5
.4.4 ................................................................................................... 5.4. ..................................................................................................... 5
.4.3 ....................................................................................................... 5.4. .............................................................................................................. 5
.4. ................................................................................................. 5.4. ................................................................................................... 5
.4.5 ........................................................................................... 5.4.6 ........................................................................................ 5
. .......................................................................... 6..4 ........................................................................................... 7
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.. ...................................................................................... 10. ................................................................................................................ 10
..4 ................................................................................................... 10.. ............................................................................................................ 10
..3 .............................................................................. 10.. ............................................................................................................ 10
.. ...................................................................................... 10 .......................................................................................................... 11 .......................................................................................................... 11
4.Process ............................................................................................................................ 134.1 Pre-flushing of the boiler system ................................................................................ 13
4.1.1 Objectives of the flush ......................................................................................... 134.1.2 Flow rates ........................................................................................................... 134.1.3 Water management ............................................................................................. 134.1.4 Water temperature .............................................................................................. 134.1.5 chemical monitoring ............................................................................................ 134.1.6 Performance of the flush ..................................................................................... 144 1 7 Demin Water consumption 14
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4.4.2 Water temperature .............................................................................................. 204.4.3 Chemical monitoring ........................................................................................... 204.4.4 water consumption .............................................................................................. 20
4.5 Passivation treatment ................................................................................................ 204.5.1 Flow rate ............................................................................................................. 204.5.2 Water temperature .............................................................................................. 214.5.3 Chemical monitoring ........................................................................................... 214.5.4 Water consumption ............................................................................................. 214.5.5 Brief outline of the process .................................................................................. 21
5.Draining and inspection .................................................................................................... 216. Effluent treatment ............................................................................................................ 22Check Lists ......................................................................................................................... 23Reference drawing No. CKW H004 263 c ......................................................................... 23Chemical Cleaning diagram .............................................................................................. 23Check List No.1 ................................................................................................................... 28Initial valves status for filling of system ................................................................................ 28Check List No.2 ................................................................................................................... 34Pre-flushing of the boiler system ......................................................................................... 34
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7 3.3
-(HP): RL42
.- (MP) :RR09
RR06. 3.
.
. 4.4
RR01 RR01
4.
RR02RR03RR04 RR01
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-.4
.4.4 .
.4.100600 m3/h.
.4.3 3 .
.
(80 m3/h) ) ( . 600 m3/h 2 .
. .4.
50 -7 0C (.)
4
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600 t/h .
) 200 t/h
CC06 RR06.
600 t/h . (side-streaming) .
600 t/hRR07 CC07
. .
CC08CC16CC17CC20 .
.
.
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300 t/h .
{ . }
.3 .3.4
60C. 4.
.
60C . 300 t/h.
.3.3.4
.
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HFRL40J1 .
4. % NC90 .
) CC05) CC05 8 barCC05. CC03CC04.
CC31 CC05 1000
ppm HF4. %
. . RR06.
CC068 bar. HF CC32
.
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300 t/h50 - 60C.
. ..4
600 m3/h
..5060C
..3 10 S/cm- 2.4-
pH= 6 - 7
.. 3-:500700 m3..
50 - 60C 1 - 3 .
.
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. J2
. pH
3.
... .
4.
.
.
.52 % .
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temp drain line RR15 from the steam condensate lines RA 10 Z 021, RA 10 Z 023, RB 15
Z 023 and RC 10 Z 021.
Temp. drain line RR16 from the steam condensate line RB 20 Z 0213.3 Acid injection points
- HP-System
The injection point for the acid at the feed water line RL42 shall be at the intersection
f th d i li RL 40 Z 012
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Stage 3:
Feed water lineseconomizerdrumsuper heaterlive steam linetemp. connectingline RR09cold reheat linere heaterhot reheat linefinal discharge line RR 07main
drain collector RR01effluent basin.
3.5 pressure testing of temporarily installed piping
Prior to the commencement of the chemical cleaning process, the boiler system will be filled
at low flow (100 t/h).
As soon as the system is full, and the pressure increases at the pressure gage upstream of
the final discharge valve CC07, regulate the valve in order to maintain a pressure of 28 bars.
Then check all temporarily piping thoroughly.
After checking the chemical cleaning process starts with the initial water flushing.
4.Process
4.1 Pre-flushing of the boiler system
4.1.1 Objectives of the flush
The objective of the cleaning operation is to remove small quantities of loosely adherent
sand dust, Welding flux, wood splinters and construction debris.
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Turbidity less than 0.1 units above the incoming water (measured on absorbiometer 425 nm,
50 mm cuvette).
Conductivity of less than 10 S/cm above the incoming water.
4.1.6 Performance of the flush
Status of valves and flow rates according to Framaborgs check-list
4.1.7 Demin. Water consumption
Approx. 3-4 times filling volume = 7501000 m3.
4.1.8 Brief outline of the process
After completion of pressure the system is full of water. With boiler feed pump in operation at
a flow rate of 100 t/h, the entirely system shall be re vented. When venting being performed
and the system pressure increased, regulate valve CC07 at the end of the system to
maintain a pressure of 8 bars.
Then divert flow via drain line RR02 to stage 1.1 outlet with valve CC05.
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When turbidity and conductivity are stable at low level, flush re heater elements at max.
available of 600 t/h. via outlet drain line RR07 and valve CC07.
Flush through re heater spray water lines successively.
When water quality is satisfied flush through all auxiliaries, i.e. CC08, CC16, CC17, and
CC20, then flush all permanent drains shortly.
Then shut down boiler feed pumps and refill water storage facilities.
Then drain evaporator, economizer and drain lines outside of the turbine house.
4.2 degreasing of boiler system and re-flushing
Note:
The HP-Heaters and the feed-water pipe work up to the isolating valve RL 49 S 002 shall be
degreased separately.
Th t ill b i l t d b f th t il i t ll d id d i d
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After completion of the soak, the detergent will be displaced with max flow rates of the feed
water pumps. (600 t/h).
Then the evaporator will be drained.
4.2.1 Flowrates
- The HP heaters will be circulated with a flow of approx. 30 t/h
- The flow during open circuit treatment will be 300 t/h.
4.2.3 Detergent injection point
For the completely filling of the boiler system only the injection point J1 at the feed water line
RL40 will be used.
4.2.4 Chemical monitoring
The degreasing will be considered to have been successfully completed when the effluent
water on the completion of detergent displacement meets the following criteria:
Turbidity less than 0.1 units above the incoming water
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During the soaking period the HP feed heaters and the feed water lines will be degreased.
Before starting the circulating pumps the flow direction will be set up as follows:
Close valve RL 40 S 002, CC01, open valves CC21/22 in the acid injection line RR21, and
valve CC26 in temporary line RR24 from feed water line RL20 to the mixing tank.
Feed water lines and HP Heaters receive a reverse flow.
The degreasing agentstrisodium phosphate and detergentwill be dosed and circulated
for a duration of approx. 3 hours. Then the system will be shut down and the degreasing
agents allowed to soak for 6 hours.
After completion of the soak degreasing solutions will be displaced from feed water and
boiler system by means of the feed water pumps with a flow of 300 t/h.after removal a
high velocity flushing takes place until the turbidity & conductivity is stable at lowest level.
Then drain evaporator completely.
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This process should also provide an ideal surface in service generation of a passive
magnetite film.
4.3.2 Flow rate
For the cleaning of the boiler (Eco, evaporator and super-heater) a flow of 100/300 t/h if
required, for the re-heater a flow of 350 t/h is necessary.
4.3.3 Temperature
The temperature of the demin. water will be between 50 and 60C.
4.3.4 Chemical monitoring
During the acid cleaning, the following chemical monitoring takes place:
Measurement of the acid concentration by conductivity, iron content by a photometer.
HF concentration and dissolved Iron will be measured in a two minute interval.
4.3.4 Water consumption
Approx. 3 x volume = 750 m3 demin. water (incl. displacement)
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Monitoring of acid concentration and dissolved iron will be dissolved iron will be carried out
at the sampling point CC31 upstream of the valve CC05, and continue until iron
concentration drops down to approx. 1000 ppm and HF concentration reaches approx. 1%.
Then the flow will be diverted through the second and after that through the third water wall.
Monitoring will be in the same way as for the first water wall.
After completion, the flow will be directed through super heater and dumped via intermediate
discharge line RR06.
A backpressure of 8 bars will be required and maintained with valve CC06.
Iron and HF will be monitored at the sampling point CC32, and continued until the above
mentioned criteria will be reached.
When the effluent meets the criteria, shut down boiler system and allow acid to soak for 1
2 hours.
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Then the HP & LP relief station and the spray water line RL20 to the HP station, will be
opened and filled up with fresh acid.
After completion the feed pump and acid injection pump will be shut down for a soak of
approx. 2 hours.
After completion of the soak the bulk of acid will be displaced at a flow of 300 t/h at 50 -
60C temperature.
4.4 Conductivity flush
4.4.1 Flow rate
600 m3/h
4.4.2 Water temperature
50 - 60C
4.4.3 Chemical monitoring
Conductivity less than 10S/cm above incoming water.
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4.5.2 Water temperature
Approx. 40C
4.5.3 Chemical monitoring
pH monitoring at the inlet and at the final discharge line
redox potential measurement at the inlet and at the final discharge line
Required values:
pH 10.2
redox potential: +20 100 mV.
4.5.4 Water consumption
Approx. 1.25 x volume: 300 m3
4.5.5 Brief outline of the process
At a flow rate of 350 m3/h ammonia solution and hydrogen peroxide will be dosed via the
injection point J1 at the feed water line RL40.
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Tube samples will cut from the boiler and the residual of oxides will be measured together
with the client.
6. Effluent treatmentAll effluent shall be collected in the effluent basin.
The acid will be neutralized with lime. About 70% of the necessary amount of lime will be
dosed in to the basin prior to the acid clean. To avoid a settling of lime compressed air shall
be injected via the air injection equipment.
The rest of the lime shall be dosed during the acid displacement.
For proper mixing of the lime and acid, the lime will be directly dosed in to the discharge line
prior to entry to the effluent basin. The pH of neutralized effluent will be in a range of a pH
from 79 units. The basin will be emptied by neutral evaporation.
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Check Lists
Reference drawing No. CKW H004 263 c
Chemical Cleaning diagram
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Water management table Page 1
DayNo. Action Time(min) Flowm3/h Storagem3 Consumptionm3 Make upm3 Availablem31 Pre-flushing of the boiler system
- Filling and venting of boiler system 180 100 1600 300 90 1390- Flushing of stage 1/1 15 400 1390 100 7 1297
- Flushing of stage 1/2 30 600 1297 300 15 1012
- Flushing of stage 2 15 600 1012 150 7 869
- Flushing of stage 3 30 600 869 300 15 584
- Flushing of all permanent drains 30 100 584 50 15 548
15 hours to refill water storages up to at least 1000 m3and heated to 60 - 70C for the heating approx. 30 tones of steam (16 bar) are required.
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Water management table Page 2
DayNo. Action Time(min) Flowm3/h Storagem3 Consumptionm3 Make upm3 Availablem32 Degreasing of boiler system and re-flushing
- Fill economizer and evaporator with hot wettingagent
75 100 1000 125 37 912
- Detergent injection for super-heater & re-heater 30 300 912 150 15 777
- Soaking phase 480 - 777 - 240 1017
- Displacement of detergent 45 300 1017 225 22 814
- Re-flushing to turbidity 45 600 814 450 22 386
3 & 4 Re-filling and heating of four RFWST
40 hours to refill water storages up to at least 1600 m3 and heated to 60-70C for the heating approx. 130 tones of steam (16 bar) are required.
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Water management table Page 4
DayNo. Action Time(min) Flowm3/h Storagem3 Consumptionm3 Make upm3 Availablem35 Acid phase
- Filling and venting 75 100 1600 125 37 1512- Re-circulating and heating 180 300 1512 - 90 1602
- Drain Econ. & Evap. 120 - 1602 - 60 1662
- Fill Econ. & Evap. with hot acid 75 100 1662 125 37 1574
- Once through treatment of Evap. 30 300 1574 150 15 1439- Once through treatment of super-heater 30 300 1439 150 15 1304
- Soaking period of HP-boiler part 60 - 1304 - 30 1334- Once through treatment of re-heater 30 350 1334 175 15 1174- Soaking period of re-heater 120 - 1174 - 60 1234
- Acid displacement 60 300 1234 300 30 964
- Conductivity flushing 60 600 964 600 30 394
- Passivation 60 300 394 300 30 124
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Water management table Page 5
DayNo. Action Time(min) Flowm3/h Storagem3 Consumptionm3 Make upm3 Availablem36 - Soaking period of 3 hours for the passivation
solution- Draining of the system
7 InspectionCut tube specimen
Day 618 hour
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Check List No.1
Initial valves status for filling of system
AbbreviationsUCR: Unit Control Room (to operate from UCR)
RFST: Reserve Feed Water Storage Tank
FWT: Feed Water Tank, RL 01 B 010
BFP: Boiler Feed Pump
W/W: Boiler Water Wall
BEDT: Boiler Empty Drain Tank, RT 10 B 010
BDT: Boiler Blow Down Tank, NC 20 B 001
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Procedure: Initial valve status for filling of system Page:
Pre-condition Valve No. LocationFLR/Level
Valveposition Purpose
Temporary drain manifold
CC 01 Stage 1.1 drain Ground Close Isolation
CC 30 Close SamplingCC 02 Stage 1.2 Drain Close LHS w/w Head
CC 03 Close Rear w/w Head
CC 04 Close RHS w/w head isolation
CC 05 Close Control
CC 31 Close Sampling
CC 50 Open P.I.
CC 06 Stage 2 Drain Close Control
CC 32 Close Sampling
CC 51 Open P.I.
CC 07 Stage 3 drain Close Control
CC 33 Close Sampling
CC 52 Open P.I.
CC 08 LP By-pass drain Close Control
CC 34 Close Sampling
CC 09Connecting line RR09 from HP-part to re-heater
Open Isolation
CC 38 Close SamplingCC 10 System warming line Close Control
CC 11 Close Isolation
CC 37 Open Leak detection
CC 53 Open P.I.
CC 12 Temp. filling pump discharge Ground Close Isolation
CC 13 Close Isolation
CC 14 Temp. filling pump suction Close Isolation
CC 15 Main drain line to effluent basin Open Isolation
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Procedure: Initial valve status for filling of system Page:
Pre-condition Valve No. LocationFLR/Level
Valveposition Purpose
RL 20 S 026 No.5 HP-Heater inlet Open Quick closing 3-way valve
RL 20 S 240/241 Feed line before No.5 HP-Heater Open Drain (to BEDT)
RL 20 S 332/356 Close P.I. (RL 20 P 006)RL 20 S 339/340 Feed line after No.5 HP-Heater Close P.I. (RL 20 P 008)
RL 20 S 042 Close Safety valve
RL 20 S 230/231 Close Vent (to BEDT)
RL 20 S 027 No.5 HP-Heater outlet Open Quick Closing Check Valve
RL 20 S 043/044 Balance line around RL 20 S 027 Open
RL 20 F 002/3 Feed line after No.5 HP-Heater Open Do not alter Flow meter
RL 20 S 364/365S 366/367
S 368/369
OpenP.I. (RL 20 P 010)
(RL 20 P 013)
(RL 20 P 014)RL 20 S 370 Close dp-measurement
RL 40 S 301 Close
RL 31 S 001 Feed water Reg. Station UCR Close Isol.
RL 31 S 004 UCR Close Low-Load Control valve
RL 31 S 005 Open Isol.
RL 32 S 001 UCR Close Isol.
RL 32 S 002 UCR Close By-pass
RL 32 S 004 UCR Close Full load control valve
RL 32 S 005 Close Isolator
RL 32 S 006 Close By-pass
RL 33 S 001 Close Isol.
RL 33 S 002 Close By-pass
RL 33 S 004 UCR Close Full load control valve
RL 33 S 005 Close Isol.
RL 33 S 006 Close By-pass
RL 20 S 245/246 Close Vent
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Procedure: Initial valve status for filling of system Page:
Pre-condition Valve No. LocationFLR/Level
Valveposition Purpose
NA 20 S 338/339S 340/341
Boiler drum CloseRemote water levelindicator
NA 20 S 342/343S 344/345
Close
NA 20 S 346/347S 348/349
Close
NA 20 S 350/351S 352/353
Close
NA 20 S 301/302 Close P.I.(NA 20 P 001)
NA 20 S 303/304 Close P.I. (NA 20 P 002)
*)
NA 20 S 305/306
S 307/308 Blow down line to B.F.V. Close F.I.*)NA 20 S 003 Close NA 20 S 004 Open
NA 20 S 007 Open
NA 20 S 363 Close
NA 20 S 001 Drum over flow to B.D.T. Close
NA 20 S 002 UCR Open
NC 10 S 001/002 L.H.S. w/w Headers CloseDrain (to drainheader evap. part)
NC 17 S 001/002 Close NC 16 S 001/002 Close
NC 15 S 001/002 R.H.S. w/w Headers Close Drain
NC 18 S 001/002 Close
NC 19 S 001/002 Close
NC 11 S 001/002 Rear w/w headers Close
NC 12 S 001/002 Close
NC 13 S 001/002 Close
NC 14 S 001/002 Close
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Procedure: Initial valve status for filling of system Page:
Pre-condition Valve No. LocationFLR/Level
Valveposition Purpose
NA 90 S 305/306 S/H 3 Outlet header Close P.I. (NA 90 P 002)
NA 90 S 308/309 Live steam line RA2 Close Sampling (permanent)
RA 04 S 001 Open Boiler stop valveRA 04 S 002 Open Bypass
RA 10 S 310/314 Close F.I.
RA 10 S 312/316 Close
RA 10 S 311/317 Close
RA 10 S 313/315 Close
RA 20 S 010 UCR Close Hp-Bypass station
RA 10 S 221S 222
UCR
CloseOpen
Drain
RA 10 S 223S 224
UCR
CloseOpen
Drain
RA 10 S 302/305 Live steam line Close P.I. (RA 10 P 001)
RA 10 S 301/304 Close P.I. (RA 10 P 002)
RA 15 S 332/334 Close P.I. (RA 10 P 003)
RA 15 S 001 Warm up line Close
RA 15 S 002 UCR Open
RL 27 S 201/202 S/H attemperator spray water supply Close Drain
RL 27 S 002 UCR Open Isol.
RL 28 S 301/302S 303/304
Spray water to attempt. 1 Close F.I.
RL 28 S 305 Open Isol.
RL 28 S 001 UCR Open Control
RL 28 S 306 Close Isol.
RL 28 S 307 Bypass Open Isol.
RL 28 S 002 UCR Open Control
RL 28 S 308 Close Isol
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Procedure: Initial valve status for filling of system Page:
Pre-condition Valve No. LocationFLR/Level
Valveposition Purpose
NC 73 S 301/302 R/H 2 outlet headerClose/Open
Vent
NC 75 S 001S 002
R/H 1 outlet headerUCR
CloseOpen
Drain
NC 76 S 001S 002
R/H 2 inlet headerUCR
CloseClose
Drain
NE 10 S 301/302 R/H 1 inlet header Close P.I. (NE 10 P 001)
NE 40 S 301/302 R/H 2 outlet Close P.I. (NE 40 P 001)
NE 40 S 001 Close Safety valve (gagged)
NE 40 S 002 Close
RB 10 S 331/332 Hot reheat line Close P.I. (RB 10 P 001)
RB 15 S 223S 224
UCR
CloseOpen
Drain
RB 20 S 220S 221
UCR
CloseOpen
Drain
RL 24 S 201/202 R/H Spray water Close Drain
RL 24 S 002 UCR Open Isol.
RL 25 S 301/302S 303/304
Spray water to L.H.S. R/Hattemperator
Close F.I. (RL 25 F 001)
RL 25 S 305 Open Isol.
RL 25 S 002 UCR Open Control
RL 25 S 306 Close Isol.
RL 25 S 307 Bypass Open Isol.
RL 25 S 003 UCR Open Control
RL 25 S 308 Close Isol.
RL 26 S 301/302S 303/304
Spray water to R.H.S. R/Hattemperator
Close F.I. (RL 26 F 001)
RL 26 S 305 Open Isol.
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Check List No.2
Pre-flushing of the boiler systemNotes on pre-flushing of the boiler
Aim:
The aim of the pre-flushing is to remove loose debris from the system.
This is achieved by flushing the system with water at velocities in the range of 0.3 to 1.4 m/s,
which will require a flow rate of 600t/h (167Kg/sec).
The loose debris being removed, increases the turbidity of the water being discharged. To
arrive an endpoint, chemist stationed at the outlet, monitors continuously the turbidity of the
water being discharge which decrease as the system is being flushed clean.
Turbidity is measured in the form of absorbance using a absorbiometer.
Absorbance can be related back to the suspended debris in the discharge water with the
following assumption: 0.1 absorbance in a 5 cell is equivalent to 1.4 ppm suspended solids.
Our theoretical aim is to achieve an analytical endpoint of 0.1 absorbance above the
incoming water in a 5 cm cell. Our practical end point is to flush till absorbance reading level
out at a low level.
Brief outline of the procedure
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
Flushing ofstage 1/1 & 1/2
1. System has beenpressure tested to28 bar
2. Pressure tripswitch set at 23 bars3. Water storagefacilities full.4. Valves set as perchecklist.5. B.F.Ps temp.filling pump anddemin. watertransfer pumpsready.6. All personnel
ready and incommunication.7. Boiler system isfull.
1. Confirm valve CC15 isstill open.
Valve CC15 must remain openduring all operations!
Notify staff on valve CC07on starting B.F.P. on leakoff.
CC07 CC07 Crack CC07 open.
Increase flow steady to
100t/h
.
Regulate CC07 to maintain
pressure of 8 bars.
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
NC 86S 001
NC 86S 001
NC 82S 001
NC 82S 001
NC 83S 001
NC 83S 001
NC 84S 001
NC 84S 001
NC 85S 001
NC 85S 001
When air is expelled
NC 81NC 82
NC 83NC 84NC 85S 001
NC 81NC 82
NC 83NC 84NC 85S 001
Vent re-heater elements NC 71S 301
NC 71S 301
NC 72S 301
NC 72S 301
NC 73S 301
NC 73S 301
NC 74S 301
NC 74S 301
When air is expelled NC 71NC 72NC 73NC 74S 301
NC 71NC 72NC 73NC 74S 301
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
When venting is completedstart temp. filling pump andfill up feed water tank to
max. available level.
CC12 CC12
Divert flow via stage 1/1drain
CC01CC05
CC01CC05 Crack CC05 open.
CC07 CC07 Regulate CC05 to maintain apressure of 8 bars.
RL 40S 002
RL 40S 002
Increase flow steady to400t/h
Regulate CC05 to maintain 8 bars.
Monitor F.W.T.level Note: during flushing with flow rates
up to 600t/h the temp. filling pumpmust run with max. avail flow rate.When F.W.T. is empty notify staffon the stages drains and run B.F.P.in leak off operation till FWT is filledagain then continue flushing again.
Chemist to be monitoringwater quality at stage 1/1outlet sampling point CC31.
When water quality issatisfactory, flush via HPheaters bypass line
RL 20S 008RL 20
S 026
RL 20S 008RL 20
S 026After 2 mins. flushing viabypass lines
RL 20S 008RL 20S 026
RL 20S 008RL 20S 026
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
When water quality issatisfactory, divert flow viaeconomizer and water walls
to stage 1/2 drain.
CC02
CC03CC04
CC02
CC03CC04
CC01 CC01
Increase flow steady to600t/h
Regulate CC05 to maintainpressure of 8 bars.
When pressure is stableflush through water wallsseparately
CC03CC04
CC03CC04
Chemist to be monitoringwater quality at outletsampling CC31
When water quality issatisfactory, flush via 2ndwater wall
CC03CC02
CC03CC02
Divert flow through 3rdwater wall
CC04CC03
CC04CC03
When water quality issatisfactory, decrease flowrate to 150t/h
CC05 CC05 Close CC05 in
Flushing of
stage 2
Divert flow via super-heater
elements and stage 2 drain CC06 CC06 Crack CC06 openCC05CC04
CC05CC04 Regulate CC06 to maintain
pressure at 8 bars.
When pressure is stable,flush through super-heaterspray-water lines
RL 28S 306RL 28S 308
RL 28S 306RL 28S 308
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
After 5 mins. RL 29S 306RL 29
S 308
RL 29S 306RL 29
S 308RL 28S 306RL 28S 308
RL 28S 306RL 28S 308
After 3 mins. RL 29S 306RL 29S 308
RL 29S 306RL 29S 308
When flushing of super-heater spray-water lines iscompleted, increase flowsteady to 600t/h
Regulate CC06 to maintainpressure of 8 bars.
Monitor FWT level
Chemist to be monitoringwater quality at stage 2outlet sampling point CC32
When water quality at outletand/or water storage
facilities are depleted, notifystaff at CC06 valve ofintention to decrease flowsteady to 150 t/h
CC06 CC06 Close CC06 in
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
Flushing ofStage 3
When 150 t/h is achieved CC07 CC07
CC06 CC06 Regulate CC07 to maintainbackpressure of 8 bars.
When backpressure isstable, increase flow steadyto 400 t/h
Regulate CC07 to maintainpressure of 8 bars.
Flush re-heater spray-waterlines RL 25
S 306RL 25S 308
RL 25S 306RL 25S 308
After 5 mins. RL 26
S 306RL 26S 308
RL 26
S 306RL 26S 308
RL 25S 306RL 25S 308
RL 25S 306RL 25S 308
After 3 mins. RL 26S 306RL 26S 308
RL 26S 306RL 26S 308
When flushing of re-heaterspray-water lines iscompleted, increase flowsteady to 600 t/h.
Regulate CC07 to maintainpressure of 8 bars.
Monitor FWT level
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
Chemist to be monitoringwater quality at the stage 3outlet sampling point CC33.
When water quality isapproaching our endpoint,flush through HP-Bypassstation and back-flush HP-bypass station spray-waterlines
RA 20S 010
RL 20S 302
RL 20
S 304
CC20
RA 20S 010
RL 20S 302
RL 20
S 304
CC20
Check water quality atsampling point CC36
When quality is satisfactoryCC 20
RL 20S 302
RL 20S 304
RA 20A 010
CC 20
RL 20S 302
RL 20S 304
RA 20A 010
Flush through LP-bypassstation CC08 CC08 Regulate CC07 to maintain
pressure of 8 bars.
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
When water quality atsampling point CC34upstream of CC08 is
satisfactory CC08 CC08When water quality at stage3 sampling point CC33 issatisfactory, decrease flowto 100 t/h CC07 CC07 Close CC07 in
Temp. emptying pump onboiler blow down tankready for use.
Confirm temp. water walldrain valves CC02, CC03,CC04, closed CC05
CC25CC05CC25
Emptying pump discharge
Monitor water level at blowdown tank, and startemptying tank if necessary.
During flushing of system drains,listen for steady flow then close.
Drains in the feed line RL 20S 222/S 223
RL 20S 222/S 223
RL 20S 240/S 241
RL 20S 240/S 241
RL 24S 201/S 202
RL 24S 201/S 202
In re-heater spray-water supply
RL 27S 201/S 202
RL 27S 201/S 202
In super-heater spray-water supply
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
Economizer NC 09S 001/S002
NC 09S 001/S 002
Drain header for evaporation part
Lower water wall headers,permanent drains NC 15
NC 18NC !9S 001/S 002
NC 15NC 18NC !9S 001/S 002
RHS w/w headers
NC 11NC 12NC 13NC 14S 001/
S 002
NC 11NC 12NC 13NC 14S 001/
S 002
Rear w/w headers
NC 10NC 16NC 17S 001/S 002
NC 10NC 16NC 17S 001/S 002
LHS w/w headers
Super-heater NC 61NC 62NC 63NC 64NC 65
S 001/S 002
NC 61NC 62NC 63NC 64NC 65
S 001/S 002
Super-heater drains on drainheader HP part
Re-heater NC 75NC 76S 001/S 002
NC 75NC 76S 001/S 002
Drain header for re-heater part
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
Live steam, cold & hot re-heat lines CC16 CC16 Temp. drain manifold
RA 10
S 221
RA 10
S 221
RA 10S 223
RA 10S 223
RC 10S 229
RC 10S 229
RB 15S 223
RB 15S 223
CC16 CC16
Hot re-heat line drain CC17 CC17 Temp. drain manifold
RB 20S 220 RB 20S 220
When steady flow RB 20S 220
RB 20S 220
CC17 CC17
Notify staff on CC07 ofintention to shut down,decrease flow steady CC07 Close CC07 in
Shut down B.F.P. andtemp. filling pump CC07 CC07
Empty blow down tankcompletely.
Refill water storagefacilities.
Heat one feed waterreserve storage tank up60C
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
Open drum venting valve,then drain economizer andevaporator completely.
NC 81S 001/002
CC02CC03CC04CC05NC 09-88?S001-002
NC 81S 001/002
CC02CC03CC04CC05NC09-88?S 001-002
CC15 CC15 Drain external lines.
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Check list No. 3
Degreasing and re-flushing of the boiler systemNotes on degreasing and re-flushing of boiler system
Aim:
Degreasing by means of 0.050.1% nonionic detergent at 60 - 70C for the boiler system, with
subsequent period of approx. 8 hours.
Degreasing by means of 2 -3 % trisodium phosphate and 0.05% ionic detergent for HP-feed water
lines and HP-heaters 4 & 5 tube-nest, at a temperature of 60 - 70C.
Brief outline of procedure
Prior to the commencement of detergent injection economizer and evaporator will be drained.
At a flow of 100 t/h the boiler will be filled subsequently with hot detergent solution. Overflowing the
boiler drum , the super-heater and re-heater elements will be flushed with an increased flow rate of 300
t/h till the boiler system is full of detergent solution. Then the feed water pumps will be shut down for a
soaking period.
During the soaking period of boiler system feed water lines and HP-heaters tube-nests shall be
degreased.
On completion of the soaking period the degreasing solution will be displaced from feed water line via
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
Degreasing andre-flushing ofthe boilersystem
1.Initial waterflushing completed
- confirm CC09, CC15,CC05, CC02, CC03, CC04is open.
2. water storagefacilities full i.e. allRFSTs full at 60-70C
-confirm CC01 is closed
-confirm pressure tripswitch is still activated.
3. FWT full at 60C
4.BFP, S-F-injectionpumps and temp.filling pump ready.
Notify staff at drain valveCC05 on starting BFP onleak off.
5. Detergent ready
Increase flow steady to 100t/h6. All personnelready and incommunication Commence detergent
injection7. Economizer andevaporator empty,super-heaters andre-heaters full ofclean demin. water
Chemist to be monitoringdetergent at stage 1 outletsampling point.
When detergent is detectedat sampling CC31 CC 05 CC05
Vent boiler NC 81S 001
NC 81S 001
Drum vent
NC 86S 001
NC 86S 001
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
When economizer andevaporator is full i.e. openstage 1 drain CC05 CC05 Regulate CC05 to maintain
pressure of 8 bars.
When detergent is detectedat the boiler vents NC 81
S 001NC 81S 001
Increase flow steady to300t/h
Keep pressure with CC05
Divert flow through 1stwater wall
CC 03CC 04
CC 03CC 04
When the bulk of debris isdisplaced, divert flow via2ndwater wall. CC 03
CC02CC03
CC02When the bulk of debris isdisplaced, divert flow via 3rdwater wall.
CC 04CC 03
CC 04CC 03
When the bulk of debris isdisplaced, divert flow viasuper-heaters and re-heaters to stage 3 drain. CC 07
CC 05CC04
CC 07CC 05CC 04
Regulate CC07 to maintainpressure of 8 bars.
Vent super-heaters and re-heaters
NC 82NC 83NC 84NC 85S 001
NC 82NC 83NC 84NC 85S 001
Close vent when detergent isdetected.
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
5 mins after flow has beendiverted to super-heaters,open stage 2 drain line. CC 06
CC07CC 06
CC 07Regulate CC 06 to maintainpressure of 8 bars.
Chemist to be monitoringdetergent at stage 2 outletsampling CC 32.
When the bulk of debris isdisplaced, divert flow to re-heater elements. CC 07
CC 06CC 07
CC 06Regulate CC 07 to maintainpressure of 8 bars.
Chemist to be monitoringdetergent at stage 3 outletsampling point CC 32.
5 mins after the flow has
been diverted to re-heaterelements, flush throughHP-Bypass station andback-flush HP-Bypassstation on spray water lines
RA 20S 010
RA 20A 010
RL 20S 302
RL 20S 302
RL 20S 304
RL 20S 304
CC 20 CC 20When detergent is detectedat sampling point CC 33upstream of the valveCC20
CC 20 CC 20
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
RL 20S302
RL 20S302
RL 20
S 304
RL 20
S 304RA 20S 010
RA 20S 010
When detergent is detectedat stage 3 outlet samplingpoint CC 33, flush line toLP-Bypass station CC 08 CC 08
When detergent is detectedat sampling point CC 34,upstream of the drain valveCC 08 CC 08 CC08
When the bulk of debris isremoved from re-heaterelements, notify staff onCC07 of intention to shutdown.
Shut down BFP CC 07 CC 07
Shut down detergentinjection pump CC 21
CC 22CC 15
CC 21CC 22CC 15
Allow detergent solution tosoak for at least 8 hours orovernight.
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
Degreasing ofHP-Heaterstube-nests andfeed-water line.
Prior to thecommence of thedegreasing, thefeed-water line up to
valve RL 40 S 002and HP-Heatertube-nests must bedrained.
The following valvestatus is required: RL 40
S 002RL 40S 002
(draining is onlynecessary, if thetemperature in thefeed-water piping is
less 60C !)
RL 31S 001
RL 31
S 004
RL 31S 001
RL 31
S 004RL 31S 005
RL 31S 005
RL 32S 001
RL 32S 001
RL 32S 004
RL 32S 004
RL 32S 005
RL 32S 005
RL 33S 001 RL 33S 001
RL 33S 004
RL 33S 004
RL 33S 005
RL 33S 005
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
Check status of BFPsdischarge valves
RL 11S 009
RL 12
S 009RL 13S 009
Confirm setting of HP-Heaters in- and outletvalves
RL 20S 008
RL 20S 025
RL 20S 026
RL 20
S 027Spray-water line to super-heater RL 27
S 001RL 27S 001
Spray-water line to re-heater RL 24
S 001RL 24S 001
Open vents RL 20S 214/S 215
RL 20S 214/S 215
RL 20S 212/S 213
RL 20S 212/S 213
RL 20S 230/S 231
RL 20S 230/S 231
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
RL 20S 245/S 246
RL 20S 245/S 246
Start draining feed-watersystem
RL 20S 222/S 223
RL 20S 222/S 223
RL 20S 240/S 241
RL 20S 240/S 241
CC 21CC 22CC 40CC 41
CC 21CC 22CC 40CC 41
When system is drainedcompletely RL 20S 222/S 223
RL 20S 222/S 223
RL 20S 240/S 241
RL 20S 240/S 241
CC 40CC 41
CC 40CC 41
Fill system with hot water(60 - 70C) from FWT bygravity.
RL 11S 009
RL 11S 009
When air is expelled andhot water detected at vents
RL 20S 241/S 215
RL 20S 241/S 215
RL 20S 212/S 213
RL 20S 212/S 213
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
RL 20S 230/S 231
RL 20S 230/S 231
RL 20S 245/S 246
RL 20S 245/S 246
When system is full RL 11S 009
RL 11S 009
Start S-F-pumps andcommence circulation CC 26
CC26ACC 26CC26A
Regulate CC26 and CC26A tomaintain a backpressure of 2 bars.
When backpressure isstable, dose trisodiumphosphate and detergent.
Chemist to be monitoringP2O5- content in thedegreasing solution.
When P2O5is stable, stoppump circulation and allowdetergent to soak forapprox. 6 hours.On completion of the soak. CC 21
CC 22CC 21CC 22
Drain feed water linepartially by means of thecirculating pump. Thenprepare system (disconnectsuction piping from feedwater line) for re-flushingwith the boiler feed-waterpumps.
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
Re-flushing ofthe boilersystem
1. Water storagefacilities full.
Prior to re-flushing confirmCC 09 is still open. CC 09
2. BFPs and temp
filling pump ready
Furthermore open CC 15
and CC 01
CC 15
CC 01
CC 15
CC 01Confirm pressure tripswitch is still activated.
Notify personnel on CC 05on starting BFP on leak off.
CC 05 CC 05 Crack CC05 open
Monitor FWT level
Chemist to be monitoringpH and turbidity at stage 1sampling point CC 31
Increase flow steady to100t/h
Regulate CC05 to maintainpressure of 8 bars.
Vent feed water system RL 20S 214/S 215
RL 20S 214/S 215
RL 20S 212/S 213
RL 20S 212/S 213
RL 20S 230/S 231
RL 20S 230/S 231
When air has beenexpelled, divert flow via
HP-heaters bypass forapprox. 3 mins.
RL 20
S 008
RL 20S 025
RL 20
S 008
RL 20S 025
RL 20S 026
RL 20S 026
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
RL 20S 027
RL 20S 027
Divert flow via HP-heatertube-nests RL 20
S 008
RL 20
S 008
RL 20S 025
RL 20S 025
RL 20S 026
RL 20S 026
RL 20S 027
RL 20S 027
When the bulk ofdegreasing solution isdisplaced, increase flow to300t/h
When the pH value atsampling point CC31 isapproaching 6, divert flowto economizer and waterwalls to stage 1/2 drain.
CC 02CC 03CC 04
CC 02CC 03CC 04
RL 40S 002
RL 40S 002
CC 01 CC 01 Regulate CC05 to maintainpressure of 8 bars.
Vent evaporator NC 81S 001
NC 81S 001
NC 86S 001
NC 86S 001
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
When air is expelled NC 81S 001
NC 81S 001
NC 86S 001
NC 86S 001
Increase flow steady to600t/h
Regulate CC05 to maintainpressure of 8 bars.
When the bulk of detergentis displaced fromevaporator water walls,divert flow through eachwater wall separately.
CC 03CC 04
CC 03CC04
When turbidity issatisfactory, divert flow to
2nd
, water wall.CC 03
CC 02CC 03
CC 02When turbidity issatisfactory, divert flow to3rdwater wall.
CC 04CC 03
CC 04CC03
When turbidity issatisfactory, open waterwalls together.
CC 02
CC 03
CC 02
CC 03
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
Decrease flow steady to100t/hDivert flow via super-heaterand re-heater to stage 3
outlet drainCC 07
CC 05CC 07
CC 05Regulate CC07 to maintainpressure of 8 bars.
Vent super-heater and re-heater elements
NC 82NC 83NC 84NC 85S 001
NC 82NC 83NC 84NC 85S 001
Close vents when air is
expelled
NC 71
NC 72NC 73
NC 71
NC 72NC 73
Increase flow steady to300t/h
NC 74S 001
NC 74S 001 Regulate CC07 to maintain
pressure of 8 bars.Chemist to be monitoringturbidity at stage 3sampling point CC33
When the bulk of detergentis displaced from super-heater and re-heaterelements, flush super-heater and re-heater spray-water lines.
RL 28S 306
RL 28S 306
RL 28S 306
RL 28S 306
?
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
After 3 mins. RL 29S 306
RL 29S 306
RL 29S 308
RL 29S 308
RL 28S 306
RL 28S 306
RL 28S 308
RL 28S 308
After 2 mins. RL 29S 306
RL 29S 306
RL 29S 308
RL 29S 308
RL 25S 306
RL 25S 306
RL 25S 308
RL 25S 308
After 3 min. RL 26S 306
RL 26S 306
RL 26S 308
RL 26S 308
RL 25S 306
RL 25S 306
RL 25S 308
RL 25S 308
After 2 mins. RL 26
S 306
RL 26
S 306RL 26S 308
RL 26S 308
When flushing of re-heaterspray-water lines iscompleted, increase flowsteady to 600t/h
Regulate CC07 to maintainpressure of 8 bars.
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
When turbidity at stage 3outlet is nearing ourendpoint flush HP-Bypassstation and back-flush HP-
Bypass station spray-waterlines.
RA 20S 010
RA 20S 010
RL 20S 302
RL 20S 302
RL 20S 304
RL 20S 304
CC 20 CC 20When water quality atsampling point CC36 is
satisfactoryCC 20 CC 20
RL 20S 302
RL 20S 302
RL 20S 304
RL 20S 304
RA 20S 010
RA 20S 010
Flush LP-Bypass station CC 08 CC 08
When water quality atsampling point CC34 is
satisfactory CC 08 CC 08Flush stage 2 drain line CC 06 CC 06 Crack CC06 open
Regulate CC07 to maintainpressure at 8 bars.
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
When water at stage 3outlet drain meets theircriteria, decrease flowsteady shut system down.
CC 07CC 15CC 02CC 03CC 04
CC 07CC 15CC 02CC 03CC 04
Drain evaporator !
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Check list No.4
Heating up boiler systemNotes: on heating up boiler system
Aim:
Heating of the iron masses of the boiler system by means of circulating hot water across the system till
a metal temperature of approx. 60C is achieved.
Brief outline of the procedure
With the feed water tank full of hot water, the system will be circulated by means of a boiler feed pump
at a flow rate of 300t/h. the flow will be directed as follows:
BPF - feed water lineeconomizer or evaporator water wallsdrumsuper-heaterlive steam line
temp. piping RR09cold re-heat linere-heaterhot re-heat linetemp. piping RR07 and RR10
main condensate piping RM 20feed water tank.
During circulation, auxiliary steam from unit 1/2 or from auxiliary boiler will be injected into feed water
tank continuously.
As soon as the desired temperature is achieved, the steam injection will be stopped and the pump shut
down.
Prior to the subsequent acid treatment the economizer and evaporator shall be drained completely.
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
Circulation andheating of boilersystem 1. Boiler is filled with
clean water- Confirm CC 09 is stillopen.
2.FWT is full at60C
- Confirm pressure tripswitch is still activated
3. RFST are full at60C
Prior of staring the BFP setvalves as follows: CC 15 CC 15
4. Auxiliary steamready
5. BFPs ready
6. All personnelready and in
communicationNotify staff on valve CC07of intention to start BFP onleak off CC 07 CC 07 Crack CC07 open
Increase flow steady to100t/h
Regulate CC07 to maintain apressure of 8 bars.
Vent boiler system NC 81NC 86S 001
NC 81NC 86S 001
NC 82NC 83NC 84NC 85S 001
NC 82NC 83NC 84NC 85S 001
Super-heater vents
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
NC 71NC 72NC 73NC 74
S 001
NC 71NC 72NC 73NC 74
S 001
Re-heater vents
When air is expelled closethe vents.
Change flow from oncethrough to re-circulationmethod CC 11
CC 10CC 11CC 10 Crack CC01 open
CC 07 CC 07 Regulate CC10 to maintain apressure of 8 bars.
When system pressure is
stable, increase flow steadyto 300t/h
After 1 hour of circulatingvia economizer, drum,super-heaters and re-heater divert flow via lowerevaporator water wallheaders
CC 01RL 42S 002
CC 01RL 42S 002
Check wall temperature offeed water line, live steamline, cold & hot re-heat line.
When wall temperatureapproaching 60C, divertflow via economizer again
RL 40S 002
CC 01
RL 40S 002
CC 01
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
When wall temperature ofapprox. 60C, is achieved,shut down circulation.
CC 37
CC10CC 11
CC 37
CC10CC 11 Leak detection between CC10 and
CC 11
Drain economizer andevaporator.Open boiler vent NC 81
NC 86S 001
NC 81NC 86S 001
CC 01CC 05
CC 01CC 05 Crack CC05 open
When draining hasstopped, open allpermanent evaporator w/wdrains.
NC 10NC 11
NC 10NC 11
Monitor water level on blowdown tank and start drainpump if necessary
NC 12NC 13NC 14NC 15NC 16NC 17NC 18NC 19S 001/
S 002
NC 12NC 13NC 14NC 15NC 16NC 17NC 18NC 19S 001/
S 002
NA 20S 003
NA 20S 003
Boiler drum blow down lineisolation.
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
When evaporator is drainedcompletely
NC 10NC 19
S 001
NC 10NC 19
S 001
NA 20S 003
NA 20S 003
CC 05CC 01
CC 05CC 01
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Check No.5
Acid cleaning phase
Notes on HF acid phase
Aim:
To provide chemically cleaned surfaces free of any loose or adherent mill scale or material.
Briefly outline of the procedure
Economizer and evaporator empty, super-heater, re-heater and steam lines full of clean demin. water.
At a flow rate of 100t/h at 60C, inhibited acid will be dosed via injection point J1 in the feed water line
RL 40 till the economizer and evaporator is filled with acid at a strength of approx. 1%.
After filling, the flow shall be increased to 300t/h and directed via each water wall to the stage 1 outlet
drain.
When iron levels being monitored at the outlet have past their peak and fresh acid being detected, the
acid will be diverted via boiler drum and saturated steam off takes to the super-heaters and dumpedvia stage 2 outlet drain.
When iron and acid meets their above mentioned criteria shut down carefully.
Allow acid to soak for approx. 1 hour to dissolve suspended matters.
On completion of the soak, start B.F.P. and increase flow steady to 350t/h. The flow is directed in such
way that the fresh acid from economizer and evaporator will be pushed through re-heater elements
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
Acid cleaningphase
1. RFST full at 60C - Confirm CC09 is still open CC092. FWT full at 60C - Confirm pressure trip
switch is still activated MSV
3. acid ready
4. BFPs ready
- prior to thecommencement of acidphase, confirm thefollowing valve attitudes:
5. All personnelready and incommunication
CC 01CC 02CC 03CC 04
CC01 economizer "
6. Lime dosingstation ready
CC 05CC 06CC 07
Drain stage 1.2Drain stage 2 3
7. Economizer and
evaporatorcompletely drained.
CC 08
CC 10CC 11
HP-bypass drain
8. Super-heater, re-heaters and steamlines full of cleandemin. water
CC 16CC 17CC 21
CC 37CC 15
CC10CC11 Soak away pit
pumpRFWT
CC 22CC22A
J1 CC 23
CC 24CC 20
CC 40CC 41
J2 J2
RR14 CC36
NC 81NC 86S 001
"
A t l l
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
Notify staff at valve CC05of intention to start BFP inleak off CC 05
CC 05 Crack CC05
Increase flow steady to100t/hCommence injection of1.4t/h inhibited hydrofluoricacid.
CC 21
CC21
Chemist to be monitoringHF-inlet strength atsampling point NC 09
Eco-inlet drain on boiler basement.When acid strength isregulated to 1%, monitor
acid at stage 1 outletsampling point CC31When strong acid isdetected
CC 05 CC 05When pressure increase atstage 1 outlet CC 05 CC 05 Regulate CC05 to maintain a
pressure of 8 bars.Close drum vents when airis expelled NC 81
NC 86
S 001
NC 81NC 86
S 001Commence line dosing toeffluent pit.
Commence re-filling ofFWT with temp. fillingpump.Increase flow steady to Regulate CC05 to maintain
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
300t/h pressure of 8 bars.
When backpressure isstable, divert acid to 1stwater wall.
CC 03CC 04
CC 03CC 04
Chemist to be monitoringacid and iron at stage 1outlet sampling valve CC31When iron levels havepassed their peaks, divertacid via 2ndwater wall. CC 03
CC 02CC 03
CC 02When iron levels havepassed their peaks, divertacid via 3rdwater wall. CC 04
CC 03CC 04
CC 03
When iron levels havepassed their peaks, divertacid to super-heaterelements and stage 2 outlet CC 06
CC 05CC 04
CC 06CC 05CC 04
Regulate CC06 to maintainpressure of 8 bars.
Vent super-heaterelements
NC 82NC 83NC 84NC 85S 301
NC 82NC 83NC 84NC 85S 301
When air is expelled NC 82NC 83NC 84NC 85S 301
NC 82NC 83NC 84NC 85S 301
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
Chemist to be monitoringiron and acid at stage 2outlet sampling point CC 32
When iron levels have
passed their peak,decrease flow carefully toleak off operation CC 06 CC 06 Close CC 06 in
Shut down BFPShut down acid injectionpumpShut down lime dosing
Allow acid to soak for atleast 1 hour
CC 15CC 21CC 22CC22A
CC 15CC 21CC 22CC22A
To avoid penetration ofacid into feed water system RL40S 002
RL40S 002
During soaking timefor the HP-Boilerpart confirm:1- Fill FWT withwater at 60C2- Before startingthe re-heater acidphase=1000 m3water at 60C must
be available3- acid ready
RL 31/32/ 33S 005
RL 31/32/ 33S 005
Isolation downstream feed watercontrol valves.
Actual valve
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
Prior to the commencementof re-heater acid clean setvalves as follows:
CC 02CC 03CC 04
CC 24CC 15RL 33S 005
CC 02CC 03CC 04
CC 24CC 15RL 33S 005
Confirm CC 09 is still open
Confirm pressure switchtrip is still activated.
Notify staff at valve CC 07of intention to start BFP onleak off
RL 40S 002CC 07
RL 40S 002CC 07
Crack CC 07 open.
Increase flow steady to350t/h
Commence lime dosing toeffluent basinVent re-heater elements NC 71
NC 72NC 73NC 74S 301
NC 71NC 72NC 73NC 74S 301
When air is expelled NC 71NC 72NC 73
NC 74S 301
NC 71NC 72NC 73
NC 74S 301
After 3 mins. Of steady flowof 350t/h CC 01
RL 40S 002
CC 01RL 40S 002
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
Chemist to be monitoringacid strength at samplingpoint CC 38 before cold re-heat line
When acid strength dropdown, start acid injectionpump and dose via J2 CC 23 CC 23
Chemist to be monitoringacid and iron at stage 3outlet sampling point CC33When acid is detected treatHP-Bypass line and HP-Bypass spray-water linewith acid.
RA 20S 010
RL 20S 002
RL 20S 004
CC 20
RA 20S 010
RL 20S 002
RL 20S 004
CC 20When acid is detected assampling point CC 36upstream of the valveCC20
CC 20
RL 20S 002
RL 20
S 004
RA 20S 010
CC 20
RL 20S 002
RL 20
S 004
RA 20S 010
Actual valve
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
When iron levels have pasttheir peak at stage 3sampling point, treat LP-Bypass line CC 08 CC 08
When acid is detected atsampling point CC34upstream of the valveCC08 CC 08 CC 08
Notify staff at CC 07 ofintention to shut down.
Decrease flow steady toleak off operation CC 07 CC 07
Shut down BFP
Shut down acid injectionpump
CC 23CC 24
CC 23CC 24
Shut down lime dosingAllow acid to soak for atleast 2 hours in the re-heater elements CC 15 CC 15
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Check list No.6
Displacement of acid and flushing to conductivityNotes on displacement of acid and flushing to conductivity
Aim:
To displace acid from boiler system completely and to achieve a final conductivity of less than 10
S/cm above the incoming water.
Brief outline of the procedure
The HP-boiler part is full of slightly acidic water: the re-heater is full of acid at a strength of 1%.
After starting the BFPs the acid will be displaced at a flow of 300t/h. during displacement all system
vents, drain, dead legs etc. must be rinsed thoroughly, then conductivity flushing with up to max. load
of two feed pumps takes place.
Actual valve
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
Displacementof acid andflushing toconductivity
1. Two RFST arefull at ambienttemperature.
- Confirm CC09 is still open CC09
2. FWT full at amb.
Temperature
- Confirm pressure trip
switch is still activated
MSV 3. BFPs ready Prior to the commencement
of the flush
4. Temp.filling pumpready
Confirm the following valveattitudes:
RL 40S 002
5. Lime dosingstation ready
CC 01CC 02CC 03CC 04
CC 05Notify staff at CC 07 ofintention to start BFP on
leak off. CC 07 CC 07 Crack CC 07 openIncrease flow steady to300t/h
Regulate CC 07 to maintainpressure of 8 bars.
Vent boiler and super-heaters
NC 81NC 86S 001
NC 81NC 86S 001
Check pH at venting through, closevent when pH= 5-6 units.
Chemist to be monitoringiron and acid at stage 3outlet sampling point CC33
NC 82NC 83
NC 84NC 85NC 86S 001
NC 82NC 83
NC 84NC 85NC 86S 001
Commence lime dosing toeffluent basin.Rinse permanent drains
Actual valveA ti
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
Open drains for ca. 1 min.,check steady flow acrossthe valve then close.Monitor water level at blow
down tank.Start tank emptying pump ifnecessary
RL 40S 205/S 206
RL 40S 205/S 206
NC 09S 001/S 002
NC 09S 001/S 002
ECO drain
NC 15NC 18NC 19S 001/S 002
NC 15NC 18NC 19S 001/S 002
NC 11NC 12NC 13NC 14S 001/S 002
NC 11NC 12NC 13NC 14S 001/S 002
NC 10
NC 16NC 17S 001/S 002
NC 10
NC 16NC 17S 001/S 002
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Phase Pre-condition Performances
Actual valveattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
NC 61NC 62NC 63NC 64
NC 65S 001/S 002
NC 61NC 62NC 63NC 64
NC 65S 001/S 002
Flush super-heater spray-water lines RL 28
S 306RL 28S 306
RL 28S 308
RL 28S 308
RL 29S 306
RL 29S 306
RL 29
S 308
RL 29
S 308After 3 mins. RL 28
S 306RL 28S 306
RL 28S 308
RL 28S 308
RL 29S 306
RL 29S 306
RL 29S 308
RL 29S 308
When bulk of acid is
removed from re-heaterelements, flush re-heaterspray-water lines
RL 25S 306
RL 25S 306
RL 25S 308
RL 25S 308
RL 26S 306
RL 26S 306
Actual valveAction
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Phase Pre-condition Performancesattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
RL 26S 308
RL 26S 308
After 3 mins. RL 25S 306
RL 25S 306
RL 25S 308
RL 25S 308
RL 26S 306
RL 26S 306
RL 26S 308
RL 26S 308
Flush re-heater vents NC 71NC 72NC 73NC 74NC 75
S 301
NC 71NC 72NC 73NC 74NC 75
S 301
Check pH at venting trough closevent when pH= 5-6 units
Increase flow steady to 600t/h
Regulate CC 07 to maintainpressure of 8 bars
After 5 mins. of steady flowof 600 t/h decrease flow to300 t/hDivert flow to lower waterwall headers CC 02
CC 03CC 04CC 01
CC 02CC 03CC 04CC 01
RL 40S 002
RL 40S 002
When pressure is stable atCC 07, divert flow via 1st.water wall.
CC 03CC 04
CC 03CC 04
Increase flow steady to 600t/h
Regulate CC 07 to maintainpressure of 8 bars.
Actual valveAction
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Phase Pre-condition Performancesattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
After 3 min. at max. load,divert flow via 2ndwaterwall.
CC 03CC 02
CC 03CC 02
After 3 min. at max. load,
divert flow via 3rd. waterwall.
CC 04CC 03
CC 04CC 03
Decrease flow to 300 t/h Regulate CC 07 to maintainpressure at 8 bars.
When backpressure isstable, divert flow via stage2 outlet CC 06
CC 07CC 06
CC 07Regulate CC 06 to maintainpressure at 8 bars.
Chemist to be monitoringconductivity at stage 2outlet sampling point CC 32
Increase flow steady to 600t/h
Regulate CC 06 to maintainpressure of 8 bars.
When conductivity is lessthan 20 S/cm divert flowvia stage 3 outlet
CC 07CC 06
CC 07CC 06
Chemist to be monitoringconductivity at stage 3outlet sampling point CC 33
When turbidity isapproaching its endpoint,flush via HP-bypass lineand back-flush HP-Bypassspray-water lines
RA 20S 010
RL 20S 302
RA 20S 010
RL 20S 302
RL 20S 304
RL 20S 304
CC 20 CC 20
Actual valveAction
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Phase Pre-condition Performancesattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
After 3 mins. RA 20S 010
RA 20S 010
RL 20S 302
RL 20S 302
RL 20S 304
RL 20S 304
CC 20 CC 20
Open LP-Bypass line CC 08 CC 08
After 3 mins. CC 08 CC 08
When conductivity is lessthan 10S/cm aboveincoming water, decreaseflow steady to 150 t/h
Regulate CC 07 to maintainpressure at 8 bars.
Flush drains in steam lines CC 16 CC 16
Flush drains for app. 1 min.check flow across thevalves
RA 10S 221
RA 10S 221
RA 10S 223
RA 10S 223
RC 10S 229
RC 10S 229
RB 15S 223
RB 15S 223
CC 17 CC 17
RB 20
S 220
RB 20
S 220Notify staff on CC 07 ofintention to shut down
Decrease flow steady shutdown BFPs
CC 07CC 15
CC 07CC 15
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Check list No.7
Passivating treatmentNotes on passivation treatment
Aim:
To passivate the strongly activated metal surfaces and to form by means of Hydrogen Peroxide dosing
an extremely thin coating of iron oxide to prevent post-rusting.
Brief outline of the procedure
With the boiler system full of clean demin. water, Ammonia and Hydrogen Peroxide will be dosed at a
BFP flow rate of 300 t/h. the passivation chemicals shall be dosed via injection point J1 in the feed
water line RL40. The water temperature must not exceed 40C.
The whole boiler system will be filled with passivation solution at a pH of greater than 10.2 and a
positive redox potential reading at a range of +20 +100 mV.
As soon as the reading will be monitored at stage 3 outlet drain, the system will be shut down. A
subsequent soaking period of at least 3 hours is necessary before draining the system. After draining
the system will be prepared for blow-through.
Actual valveAction
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Phase Pre-condition Performancesattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
Passivationtreatment
1. one RFST full at40C.
- Confirm CC09 is still open
2. FWT full at 40Ctemperature
- Confirm pressure tripswitch is still activated
3. Ammonia andperoxide ready
4. BFP ready Confirm the following valveattitudes:
CC 15CC 01CC 02CC 03CC 04
CC 15CC 01CC 02CC 03CC 04
RL 40S 002
RL 40S 002
Notify staff at valve CC 07
of intention to start BFP onleak off CC 07 CC 07 Crack CC07 openIncrease flow steady to 100t/h Regulate CC07 to maintain
pressure of 8 barsVent boiler systemcompletely
NC 81NC 86S 001
NC 81NC 86S 001
NC 82NC 83NC 84NC 85NC 86S 001
NC 82NC 83NC 84NC 85NC 86S 001
Actual valvei d
Action
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Phase Pre-condition Performancesattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
NC 71NC 72NC 73NC 74
NC 75S 301
NC 71NC 72NC 73NC 74
NC 75S 301
When air is expelled. Closevents
Increase flow steady to 300t/h
Regulate CC 07 to maintainpressure at 8 bars.
Commence injection ofammonia and hydrogenperoxide.
Chemist to be monitoringpH and redox potential atinlet sampling point NC09(?)
After 5 mins. of steady flowat 350 t/h, divert flow to thelower evap. water wallheaders, one wall afterother.
CC 01CC 02
CC 01CC 02
After 5 mins. divert flow via2nd. water wall. CC 03
CC 02CC 03
CC 02
After 5 mins. divert flowthrough 3rd. water wall. CC 04CC 03
CC 04CC 03
Chemist to be monitoringpH and redox potential atstage 3 outlet samplingpoint CC33
Actual valvettit d
Action
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Phase Pre-condition Performancesattitude
Action
Floor CommentsValvesclosed
Valvesopen
Openvalve
Closevalve
When ammonia andperoxide is detected at thesampling point, flush viaHP-Bypass station and
back-flush HP-Bypassspray-water lines.
RA 20S 010
RL 20S 302
RA 20S 010
RL 20S 302
RL 20S 304
RL 20S 304
CC 20 CC 20When ammonia andperoxide is detected atsampling point CC 36upstream of the valveCC20
CC 20
RL 20S 302
RL 20S 302
RL 20S 304
RL 20S 304
.