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[TECHNICAL
PROPOSAL]

1.1ScopeofWork
TheScopeofWorkforthechemicalcleaningofHRSGisasfollows.
Sr.No.

01

02

03

Description

Detaildrawings,Water,andAccommodationforsupervising
team,Storeandofficefacility.Thedetailofotherfacilitiesisas
follows.
Filteredwater,RawWater
Gatepassesforourstaff,equipment&tools
Isolation/removalofpressuregauges,temperaturegauges
&othersensitiveinstrumentwhichcanbedamagedduring
chemicalcleaning
UninterruptedElectricitySupply(3Phase,440V)
RemovalofSteamdruminternals
Provision & Installation of temporary piping & fittings
coming from the boiler, water tank, filtered water, steam,
air, nitrogen lines to circulating facilities to Contractors
temporarycirculatingarrangement.
Gas/OilfuelforTemporaryBoiler/ElectricalHeating
Crane/Troller/Forklifter for offloading and loading of
Contractorequipment,tanksetc.onsite
Supply and transportation of all material, tank, equipment,
temporary fittings (up to first isolation valve of inlet of
circulatingpump),sitelaboratoryetc.tosite
Chemical Cleaning of HRSGs, inspection and analysis report
submission.Thedetailsareasfollows.
WaterFlushing
AlkalineBoilout/Degreasing
AcidPickling/RemovalofIronOxide
Neutralization
WasteWaterTreatment&Disposal
Passivation
Laboratoryfortesting
Weight Measurement of test pieces before and after
chemicalcleaning
Allthechemicalsrequiredforthework
Equipments for acid circulation (Tanks, Pumps, Electrical
panel&Piping)

WorkScopeBy

CNCEC

GulfEngineering
Services

GulfEngineering
Services

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[TECHNICAL
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1.2SystemCleaningScope
FollowingisthevolumeofHeatRecoverySteamGenerator(HRSG).
a.CleaningVolume

Description

Volume

Unit

HPTubes,Headers

50.9

M3approx.

HPRemoteDrum

39.5

M3approx.

HPTotal

LPTubes,Headers
LPRemoteDrum

90.4

M3approx.

6.85
16.7

M3approx.
M3approx.

LPTotal

23.6

M3approx.

TOTAL

114.0

M3approx.

Interconnectionpipingandcirculationvolumeapproximately

16.0M3approx

TotalCleaningVolume

130.0M3approx

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[TECHNICAL
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1.3MethodStatement
a. AlkalineBoilOut/Degreasing
Thepurposeofboiloutistoeliminateoil,greaseandrestofpaintsfrominnersurfaceofboiler
tubes,whichcanformabarriertoheattransferwhichmayresultindamagetotubesdueto
localoverheating,especiallywithboilerfunctioningwithnaturalcirculation.
Residueofoilmayleadtofoaming,whichinturncauseswatertomixwithsteam,resultingin
unreliablewaterlevelreadingsandtheformationofdepositsinthesuperheater.
AnalkalineboiloutprocedurepriortoacidpicklingofHRSG/boilerispreferred.

b. PreferredAcidcleaningTechnologyforpreoperationalcleaningofHRSG

WehavepreferredCitricacidforpreoperationalcleaningofHRSGduetofollowingreasons.

CitricacidisusedasacleaningagentforremovalofmillscalefromnewHRSG/boilers.

Inhibited Citric Acid (2 3%) solution at elevated temperatures (80 85 C0) is used as a cleaning
agenttoremoveironrust/ironoxides.

CitricAcidhasanadvantageofnotreadilyprecipitatingironhydroxides.However,itsprecipitation
can further be prevented when acid is used as monoammonium citrate by neutralizing with
Ammoniaorusedtogetherwithotherorganicacids.

Beingweekaciditislesshazardousduringcleaningprocess.

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[TECHNICAL
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LessreactivethereforelessdangeroustoHRSGduringpreoperationalcleaningthanmineralacids
likeHCl/HF.

Citricacidiscomparativelymoreenvironmentallyfriendly.

Nospecialsafetymeasureshavetobeadoptedwhileusingcitricacid.

Dischargeofwasteiseasyandneutralizationrequireslessquantityofacidscomparatively.

c. Neutralization/Passivation
Neutralization&Pasivationiscarriedoutforstabilizingthesurfaceofactivatedmetals
(mainly carbon steel) caused by acid pickling/cleaning. Paasivation/neutralization is
carriedoutbycirculatingthesolutionwithpassivatingagentfortwelvetosixteenhours.
Hydrazine Hydrate is used as a Passivating agent preferably with neutralizing agent
(AmmoniumHydroxide).

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1.4Chemicals

Followingisthedescriptionofthechemicalstobeusedinthechemicalcleaningprocess.
a. Degreasing/AlkalineBoilOut
ChemicalDescription

Purity

DosingRate

Quantity Unit

SodiumCarbonate(Na2CO3)

100%

4KG/1000KG

525

KG

TriSodiumPhosphate(Na3PO4)Powder

43%asP2O5

4KG/1000KG

525

KG

NonIonicWettingAgent(alowfoaming
detergent/surfactant)

100%

0.050.1%

65

KG

ChemicalDescription

Purity

DosingRate

Quantity Unit

CitricAcid

100%

2.03.0%

2600

KG

AcidInhibitor(CorrosionInhibitor)

100%

0.050.1%

130

KG

AmmoniaGas(CompressedGas
Cylinders)

100%

TomaintainpH 500

KG

b. RemovalofIronOxide/AcidPickling

c. Passivation
ChemicalDescription

Purity

DosingRate

Quantity Unit

HydrazineHydrate

54%asN2H4

200ppm

30

KG

AmmoniaGas(CompressedGas
Cylinders)

100%

TomaintainpH

100

KG

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[TECHNICAL
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d. Neutralization/WasteWaterEffluentTreatment
ChemicalDescription

Purity

DosingRate

Quantity Unit

HydrochloricAcidLiquid

31%

10

MT

HydratedLimeCa(OH)2

24%

01

MT

TomaintainpH
OfAlkalineEffluent
TomaintainpHof
AcidicEffluent

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[TECHNICAL
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2.0ChemicalCleaningProcedure
2.1INTRODUCTION

Theobjectiveofthisprocedureistoremoveoilandgrease,sludge,rustscaleandprocessingdebrisfrom
internalsurfaceoftheequipments/pipingduringmanufacturinganderectionworks.
Aftercarryingoutcleaningprocess,theinternalsurfacesoftubesarepassivatedbymeansofprotective
magnetiteirontopreventfurtherrustingandcorrosion.

Themethodofcleaningonthisprojectinvolvesthefollowingsteps,thedetailofwhichisgiveninthe
followingpages:

Stage1
Stage2
Stage3
Stage4
Stage5
Stage6
Stage7
Stage8
Stage9
Stage10

PreliminaryChecks
Flushing
AlkalineBoilOut/Degreasing
Rinsing
AcidPickling(CitricAcidcirculation)
Flushing
Neutralizingandpassivation
Inspection
NeutralizationofWasteEffluent
PreservationofHRSG

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[TECHNICAL
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2.2OUTLINEOFCHEMICALCLEANINGPROCEDURE

Item OPERATION
No.
1

Stage1PreliminaryChecks

1.1

Checkallchemicalsandothermaterialsarepresentinsufficientquantityandqualitytoperform
thecleaning.

1.2

SampleCouponstobeinstalledintothecleaningcircuitatagreedlocation.

1.3

CompleteerectionoftemporarycleaningpumpsandPipework.Testrunpumps.

1.4

Connectupotherutilities(steam,demineralisedwater,compressedair&nitrogen).

1.5

Fill temporary pipework only with demineralised water. Apply hydraulic pressure test to the
temporary lines to 1 times the system static head (ca 9 bar). Repair leaks as necessary. Test
steam,water,airandnitrogenlinesforintegrity,andrepairleaksasrequired.

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[TECHNICAL
PROPOSAL]

Stage2Flushing

2.1

Prior to chemical cleaning initial flushing, with raw water at high flow, through the cleaning
circuitwillbecarriedoutinorderremovethecoarsematerialintheentirecircuit.Theflushing
will be stopped when through all draining points clean water without sludge and debris is
dischargedfromalldrainingpoints.

Stage3AlkalineBoilOut/Degreasing

3.1

The task of this step is to remove loose iron oxide coatings, oil, grease and silica containing
deposits.

3.2

Boiler will be partially filled (1/2) using LP and HP feed water pumps. Then discharge of feed
waterpumpsintotheboilerwillbeclosedandalkalinecleaningsolutionwillbepumpedintothe
inlet of LP and HP economizers using temporary dosing pumps. Then boiler will be filled with
feedwaterpumpsatminimalspeeduptolevelslightlyabovethelowestcontrollevel.

3.3

CleaningSolutionwillbeheatedupto70oC.Thisprocedure(heatingandcooling)shallbetwo
timesrepeatedandintheendcleaningsolutionshallbedischargedout.

Stage4Rinsing

4.1

AlkalinesolutionwillbedrainedunderpositivepressureofNitrogen(57bar)

4.2

4.3

Aftercompletionofcirculation,systemwillbefilledwithDMwater.
Waterwillbecirculated2to3cycleandthendrainedunderplantair.

Stage5AcidPickling

5.1

System filled up with DM water and circulation will be started. Vent on all high points will be
openedtoensurethatsystemiscompletelyfullofwater.

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[TECHNICAL
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5.2

Waterwillbeheatedtotemp70+/5Cduringcirculation.

5.3

CalculatedamountofAcidInhibitorwillbetransferredtothecirculatingwater.

5.4

Citricacidwillbeintroducedinthecirculatingwaterslowlytomaintain3%concentrationof
citricacid.

5.5

Temperatureofcirculatingcleaningsolutionwillbemaintainedat70+/5c.

5.6
Circulationofacidcleaningsolutionwillbecontinuedforminimum4hoursuntildissolvediron
remainedconstantforatleast1.0to1.5hours.
5.7

Measurementoffollowingparameterwillbecarriedevery30minutesduringcleaning
pH
Acidconcentration
TotaldissolvedIroninppm
Temperature

Stage6Flushing

6.1

CitricAcidSolutionwillbedrainedunderpositivepressureofNitrogen(57bar)

6.2

6.3

Aftercompletionofcirculation,systemwillbefilledwithDMwater.
Waterwillbecirculated2to3cycleandthendrainedunderplantair.

Stage7Neutralization&Passivation

7.1ThesystemwillberefilledwithDMwater.

7.2
Circulationwillberestartedandtemperaturewillberaisedto70+/5c.

7.3
Ventlinesonallhighpointswillbeopenedtoensuretheremovalofairinthesystem.
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7.4

[TECHNICAL
PROPOSAL]

7.5

7.6

7.7

7.8

7.9

7.10

7.11

Circulateforreactivationofbasemetalmeasuringfollowingatregularintervals:

pH
Temperature.
Continuecirculationfor2to4cycles.
AmmoniasolutionandhydrazinehydratewillbeaddedslowlytothecirculationmixtureuntilpH
reaches9.5to10.5andhydrazineabout200ppm.
pHandtemperaturewillbemeasuredatregularintervals.
Circulationwillbecontinuedfor24cyclestocompletethepassivation.
Solutionwillbedrainedquicklyafterpassivation.
Duringdrainingalllowpointwillbeopened.
Nitrogengasshouldbeblownthroughthesystemtoaccelerateremovalofallremaining
passivationsolution.

Stage8Inspection

8.1

Temporaryconnectionsfromboilerpressurepartswillbedisconnected.

8.2

Steamdrummanholeswillbeopenedtoallowinternalpartstoventilateandreleasethe
residualheatinmetaldrum.

8.3

Thesteamdrumandsamplecouponwillbeinspectedtodeterminetheperformanceof
cleaning.

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[TECHNICAL
PROPOSAL]

Stage9NeutralizationofWasteEffluent

9.1

WasteEffluent(Acidic/Alkaline)willbeneutralizedinneutralizationtanktopHbetween6to9
beforedisposal.

10

Stage10Preservation

10.1

PreservationwillbedonebyClienteitherwet/dry.

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[TECHNICAL
PROPOSAL]

3.0ChemicalCleaningEquipments
3.1MechanicalEquipments

ItemNo.

EquipmentDescription

QTY

01

CirculationChemicalPumps

03

02

CirculationSolutionTank(Cap.60M3)

02

03

NeutralizationSolutionTank(Cap.60M3)

01

04

WasteDisposalTankFiber(Cap.25M3)

01

05

AcidDecantingPumps

02

06

WasteWaterPumps

02

07

ReverseFlowManifold

01

08

SteamInjectionManifold

01

09

Containerwithtools/spares/accessories

01

10

Containerwithlaboratoryequipmentand
accessories

01

11

Setofsitesafetyequipment

01

12

AmmoniaGasexitAssembly

02

13

HosePipesfordisposal

10

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3.2LaboratoryInstruments

Followinglaboratoryinstrumentswillbecarriedoutfortestingandmeasuring.

A.LaboratoryInstruments

Sr.# ITEM
1

PhotospectrometerDR2700

ElectronicBalance

pHMeter

ConductivityMeter

B.LaboratoryReagents/TestingChemicals

Sr.#

ITEM

IodineCrystals

PotassiumIodide

SodiumBicarbonate

SodiumHydroxide

Phenolphthalein

IsopropylAlcohol

PotassiumFluoride

MethylRed

BromocresolGreen

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[TECHNICAL
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C.Glassware
Sr.# ITEM
1

Thermometer

Pipette(Graduated)

Pipette

ConicalFlask

ReagentBottle

Cylinder(Glass)

MeasuringFlask

pHPaper

3.3Preparationofchemicalcleaning

Priortochemicalcleaning,itisnecessarytoisolateorremoveallcontrolvalves,gaugesandinstrument,
thetemporaryequipmentsandpipingwillbeconnectedtothespecifiedlinesasperfinalizedprocedure
anddrawings:
Connectionbetweentemporaryequipmentsandmainequipments:
1. It is good practice, though not a requirement to remove all (HP & LP) drum internals before
chemicalcleaning,removalofinternalwillbedonebyclient.
2. TemporarypipingwillbeconnectedtothespecifiedvalvesorlinesinordertofillHPSH&LPSH
withdemineralizedwater.
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Temporarypipingshallbeconnectedtothespecifiedvalvesand/orlineforthecirculationof
HP/CPH&LPsection.
Temporary piping shall be connected to the chemical connection of HP/LP bottom headers in
ordertocirculateflushingwater.
AllHRSGinstrumentationleadsincontactwiththesolutionwillbeisolatedduringthecleaning
processbyClient.
ProvisionshallbemadebyClienttoprovideDMwater.
ProvisionshallbemadefordrainlinesofadequatesizetoemptyofHRSGasquicklyaspossible.
Provisionshallbemadefornecessaryventsandventsshouldbeconnectedtothesafelocation
byusingvenylhose.
Demineralized water (DM Water) shall be transferred to circulation tank through temporary
pipingthatisconnectedtothestartupfillwaterline.
Drainingpipingincludingneutralizationtank/pumpsshallbecompleted.
Electricalwiring/cablingworksshallbecompletedforrunningthepumps
Sample coupon will be installed in to the cleaning circuit at agreed location.

[TECHNICAL
PROPOSAL]

3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

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[TECHNICAL
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3.4SafetyMeasures
FollowingarethedetailsofthesafetymeasurestobefollowedatEngrosite.

Personalawarenessofchemicaloperationsisthekeytoasafeworksite.

AllClientpersonnelaretobemadeawareofthecleaningschedule,andnotifiedthatpersonnel
considered nonessential to the cleaning operations are to respect the barricade tape placed
aroundthearea,andwouldnotenterthezoneunlessabsolutelynecessary.

Theimmediateareasurroundingtheboiler,andGESpumpingequipmentwillbebarricadedoff
withcautiontapeofarecognizeddesignandtypeassociatedwithnoaccessareas.

EyewashstationwillbeprovidedbyGESandplacedatthefrontoftheBoiler.Personnelwillbe
madeawareoftheirexactlocation.

Alltheweldsandconnectionsonthetemporarypipesusedforchemicalcleaningwillbemade
inhighquality.

Alltherelatedvalvesnumberedandtagshavetobeputonthem.

Water,steam,electricityandlighteningwillbeprovidedinthechemicalcleaningarea.

Acustomerliaisonwillbeprovidedduringthecleaningintheeventifasafetysituationarises
thatrequiresaction.

PPE:Allthepersonnelparticipatinginthecleaningprocesswillhavetowearprotectivesafety
equipments,i.e.helmets,goggles,masks,protectiveclothes,safetylongshoes,andacidproof
rubbergloves.

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[TECHNICAL
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Necessarywarningsignswillbeinstalled.

During the chemical cleaning operation, clean running water will be available to wash away
splashofhazardouschemicals.

MSDSofchemicalswillbeplacedatcleaningsite.

Firstaidequipmentswillbemadeavailableatsite.

AmbulancehastobeprovidedatProjectsitebyClient.

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