May, 2002

Technical Bulletin

Chemical Cleaning of a HRSG

Attention: Re: Question: HRSG End Users Understanding Chemical Cleaning of a HRSG When should you Chemically Clean a HRSG?

The purpose of chemical cleaning is to remove contaminants that may impair heat transfer and may eventually lead to failure of the tube. New units undergo some type of chemical cleaning to remove the oils, preservatives and mill scale that are left over from the manufacturing process. An operating unit will need periodic cleaning depending on the type and quality of the feedwater treatment system. When does a unit need to be chemically cleaned? Deposits form on the waterside surfaces of the components of the Heat Recovery Steam Generator (HRSG) even when standard water treatment practices are followed. These deposits are generally classified as hardness type scales or porous type deposits. Corrosion of the feedwater and condensate systems are also major contributors to boiler and steam side deposits. These deposits migrate preferentially to the highest heat flux area of the transfer surfaces. Usually, this is the front of the tube. The most accurate way to determine when a unit needs cleaning is to remove tube samples from the areas of highest heat flux and/or areas where problems have occurred. After the tube sample has been removed, the tube is sectioned and the deposit weight is determined. This is done by hand scraping the deposit from a measured area. This should be done for both the hot side and the cold side of the tube. The procedure for accomplishing this is outlined in ASTM D3483. Alternatively, chemical dissolution of the deposits can be used. This generally results in higher weight values than mechanical scraping. As a guideline for determining when an HRSG should be cleaned, the following recommendations should be applied: Unit Operating Pressure, psig Below 1000 1000 to 2000 Above 2000 Water side Deposit Weight (Grams/ft2)* 20 to 40 12 to 20 10 to 12

*Deposit weight removed from the hot side of the tube using mechanical scraping method

If the tube side deposit weight has reached the level for which cleaning is warranted, the next course of action is to have the deposits analyzed for composition. The chemical composition is valuable information that should be shared with the chemical cleaning contractor and party responsible for the water treatment system of your boiler.

Vogt Power International Inc.

1 of 2

4000 Dupont Circle, Suite 400 Louisville, Kentucky 40207 502/899-4500 Fax: 502/899-4690 Sapulpa Manufacturing Operations: 2110 N. Industrial Drive Sapulpa, Oklahoma 74066 918/227-4202 Fax: 918/227-4207

May, 2002

Technical Bulletin
Why should you chemically clean the boiler? Excessive deposits insulate the underlying area of the tube and raise the operating temperature of the metal. Porous deposits can act as a concentrating mechanism for the boiler water treatment chemicals and can lead to excessive corrosion and caustic gouging. When the deposits become significant, the failures can become random within the tube sections and can cause a high forced outage rate. Removal of the deposits has advantages other than minimization of failures. Cleaning reveals the true boiler metal condition, allowing more complete inspection. Previously unnoticed pits or gouges may become clearly visible. Cracks resulting from fatigue, embrittlement or corrosion may be revealed. A clean unit will operate more efficiently as well. How do I clean my HRSG? Once you have determined that your unit needs to be cleaned, you will need to decide on how to clean your HRSG. It is best to consult with a qualified chemical cleaning company to determine the best type of chemical cleaning system. There are two basic types of cleaning methods. The first is the drain and fill method. This method involves filling the unit with a solution of 5% Hydrochloric acid solution with inhibitors and complexors. The unit is heated to between 180F and 200F and soaked for approximately 4 hours. A portion of the solution is drained and fresh solution is added. This is repeated until testing of the drain solution shows the chemicals have reached equilibrium. This method has been used for many decades to successfully clean boilers. It has the advantage of ensuring the all of the wetted surfaces are cleaned. The disadvantage of this method is the permitting and the disposal expense of the acid solution. The second method is the single drain and fill method. In this procedure, a solution of citric acid, EDTA or similar chemical is externally heated and pumped through the unit. Samples are taken periodically until testing indicates the cleaning process is complete. The spent chemicals are much easier to deal with than hydrochloric acid. The trick to this method is achieving sufficient velocity to ensure adequate cleaning is accomplished throughout the HRSG. In an HRSG, this is particularly difficult since the downcomers and evaporator tubes are in parallel. Flow restrictions must be placed in the downcomers to insure adequate flow through the evaporator tubes. The best chemical choice depends on the constituents identified in the deposits. The preferred method depends on the location and availability of disposal facilities. The chemical cleaning contractor can recommend an optimum solution when supplied with data relating to deposit composition and quantity. In this case, it pays to get a 2nd opinion. As always, if you have questions, contact us as we would be glad to assist. Bob Allen Senior Engineer

For further information, contact: Jeff Daiber Director of Aftermarket Email: Aftermarket@vogtpower.com

Vogt Power International Inc.

2 of 2

4000 Dupont Circle, Suite 400 Louisville, Kentucky 40207 502/899-4500 Fax: 502/899-4690 Sapulpa Manufacturing Operations: 2110 N. Industrial Drive Sapulpa, Oklahoma 74066 918/227-4202 Fax: 918/227-4207