Yermarus Boiler # 2 Chemical Cleaning Report
STEP
Sr. No
Major Activity
Sample description
STEP # 1
1
Super Heater Back
Before starting SH Back filling
filing
STEP # 2
2
Hot water flushing During draining of water
STEP # 3
STEP # 4
STEP # 6
STEP # 7
STEP # 8
Activity Log
PH, Ammonia in PPM
SH backfilling started on 04 March 2016 followed by boiler filling. SH back filling started at 14:30 Hrs &
completed at 16.15 Hrs, Sample Collected from Boiler filling pump vent line on 04 March 2016 at 12 :40 Hrs.
at site BHEL chemical lab PH value found 9.4.
PH, Ammonia in PPM
Boiler lighted up at19:20 Hrs on March 04,2016. By running BCP with AB-1,3 & 4 oil gun in service Boiler,
water temperature increase gradually up to 90 Deg and stop the boiler light up at 20.50 Hrs, and started
Drain at 21.05 Hrs. Sample taken at BCP Discharge line,
On March 05, 2016 at 12.20 Hrs first batch TSP 200Kgs & DSP 100Kgs added in the mixing tank and
transferred into the boiler, at 13.10 Hrs Second batch of TSP 150 Kgs & DSP 75 Kgs added in the mixing
tank and transferred into the boiler, at 13.30 Hrs Third Batch of TSP 50 Kgs & DSP 25 Kgs added in the
mixing tank and transferred into the boiler. At 14:50 Hrs BCP started. At 15:40 Hrs boiler sample water taken
from BCP discharge drain. At site BHEL chemical lab 10.6 PH and 142.5 Phosphate in ppm. at 15.10 Hrs
boiler lighted up and AB # 2 & 4 taken into service.
3
After filling water & adding TSP/DSP. PH, Ammonia in PPM
4
One hour after TSP/DSP adding
PH, (PO43-) Phosphate in PPM
5
Two hour after TSP/DSP adding
PH, (PO43-) Phosphate in PPM
Three hour after TSP/DSP adding
PH, (PO43-) Phosphate in PPM
7
Four hour after TSP/DSP adding
PH, (PO43-) Phosphate in PPM
8
Five hour after TSP/DSP adding
PH, (PO43-) Phosphate in PPM
9
Six hour after TSP/DSP adding
PH, (PO43-) Phosphate in PPM
10
Seven hour after TSP/DSP adding
PH, (PO43-) Phosphate in PPM
11
Eight hour after TSP/DSP adding
PH, (PO43-) Phosphate in PPM
During draining of water after hot
water rinse
PH, (PO43-) Phosphate in PPM
During draining of water after cold
water rinse 1
PH, (PO43-) Phosphate in PPM
During draining of water after cold
water rinse 2
PH, (PO43-) Phosphate in PPM
On March 7, 2016 second cold water flushing started, at 00.10 Hrs. boiler Filling Started, at 01.50 Hrs. BCP
Started , BCP Stopped at 2.30 Hrs., draining started at 2.50 Hrs. during draining sample collected from BCP
Discharge line at 03.20 Hrs. & value tested with result of 9.5 PH & 19 PPM of phosphate.
6
12
Alkali flushing
Hot water rinse
13
STEP # 5
Sample to be check for
14
Cold water rinse
At 16:45 Hrs boiler sample water taken from BCP discharge drain. At site BHEL chemical lab 10.5 PH and 190
Phosphate in ppm.
At 17:40 PM Hrs Boiler water taken from BCP discharge drain. At site BHEL chemical lab 10.7 PH and 237.5
Phosphate in ppm. .
At 18:30 Hrs Boiler water taken from BCP discharge drain. At site BHEL chemical lab 10.8 PH and 237.5
Phosphate in ppm. .
At 19:30 Hrs Boiler water taken from BCP discharge drain. At site BHEL chemical lab 10.8 PH and 237.5
Phosphate in ppm. .
At 20:30 Hrs Boiler water taken from BCP discharge drain. At site BHEL chemical lab 10.8 PH and 261.25
Phosphate in ppm. .
At 21:30 Hrs Boiler water taken from BCP discharge drain. At site BHEL chemical lab 10.8 PH and 285
Phosphate in ppm. .
At 22:30 Hrs Boiler water taken from BCP discharge drain. At site BHEL chemical lab 10.8 PH and 285
Phosphate in ppm. .
At 23:25 Hrs sample taken and found ph. 10.9 & 332 Phosphate in ppm. Boiler shutdown at 23:15 Hrs.and
hot draining started at 23:50 Hrs.
On March 6, 2015 at 05 :30 Hrs boiler filling Started , 08:05 Hrs BCP started, at 09:00 Hrs. Boiler Light up
started by taking AB -1,2 oil gun in service, water temperature increase gradually up to 90 Deg and stop the
boiler light up at 10.15 Hrs, BCP stopped at 10.45 Hrs and Hot water draing started.
Boiler filing started for cold water flushing at 16.15 Hrs. filling started, and at 17.10 Hrs. BCP started, at
18:20 Hrs. BCP stopped, and at 19.00 Hrs. draining started, during draining sample collected from BCP
Discharge line at 19.05 Hrs.& value tested at Site BHEL Chemical Lab and found result as 9.7 PH & 15.2 PPM
of phosphate.
15
During draining of water after cold
water rinse 3
PH, (PO43-) Phosphate in PPM
Third time cold water flushing performed and at 08:10 Hrs. boiler Filling Started, at 08.50 Hrs. BCP Started ,
BCP Stopped at 10.20 Hrs. and draining started at 10.45 Hrs, during draining sample collected from BCP
Discharge line at 11.15 Hrs.& value tested with result of 8.3 PH & 9.5 PPM of phosphate. By considering the
third Cold water flushing water Sample values BHEL declared completion of cold water flushing. Boiler
started Water filling for EDTA Cleaning at 16.40 Hrs. and completed filling at 19.15 Hrs
16
70Minutes after EDTA adding
PH, EDTA (Total) (% by weight), Iron (ppm)
On March 8, at 09:00 Hrs Boiler ID &FD fan started, 10:30 Hrs.BCP started, at 12:20 Hrs. Boiler lighted up.
At 13 : BCP suction temperature reached at 95 Deg C, Boiler Hot box up and BCP drain. At 13:30 two batch
of Boiler water drained. At 16:40 Hrs. 42 T of EDTA added. At 18:00 Hrs. EDTA first sample collected. As per
BHEL site chemical analysis PH-6.3, EDTA - 3.4, Iron 2960 PPM.
17
115 minutes after EDTA adding
PH, EDTA (Total) (% by weight), Iron (ppm)
160 minutes after EDTA adding
PH, EDTA (Total) (% by weight), Iron (ppm)
19
190 minutes after EDTA adding
PH, EDTA (Total) (% by weight), Iron (ppm)
20
210 minutes after EDTA adding
PH, EDTA (Total) (% by weight), Iron (ppm)
21
240 minutes after EDTA adding
PH, EDTA (Total) (% by weight), Iron (ppm)
22
One hour after adding sodium nitrite PH, Sodium nitrite (% by weight)
On March 9,2016 at 21:20 Hrs boiler drained to some qty. and at 22.15 Hrs. started adding Ammonia & 17.5
T of Sodium Nitrate for Passivation process, and on March 9 2016 at 00:45 Hrs. first sample collected. As per
BHEL site chemical analysis PH-8.9.
18
23
EDTA stage
At 18:45 EDTA second sample collected. As per BHEL site chemical analysis PH-6.6, EDTA - 3.8, Iron 2380
PPM.
At 19:30 Hrs. EDTA third sample collected. As per BHEL site chemical analysis PH-6.3, EDTA - 4.38, Iron 3940
PPM.
At 20:00 Hrs. EDTA fourth sample collected. As per BHEL site chemical analysis PH-6.2, EDTA - 4.09, Iron
3960 PPM.
At 20:30 Hrs. EDTA fifth sample collected. As per BHEL site chemical analysis PH-6.3, EDTA -3.65, Iron 3880
PPM. By the considering of the last collected sample BHEL declared completion of EDTA cleaning.
At 21:00 Hrs. EDTA fifth sample collected. As per BHEL site chemical analysis PH-6.4, EDTA - 3.9, Iron 3880
PPM. By considering the last EDTA water Sample values BHEL declared completion of EDTA Chemical
Cleaning
Two hour after adding sodium nitrite PH, Sodium nitrite (% by weight)
At 01:15 Hrs. second sample collected. As per BHEL site chemical analysis PH-9.2.
24
Three hour after adding sodium nitritePH, Sodium nitrite (% by weight)
At 01:50 Hrs. third sample collected. As per BHEL site chemical analysis PH-9.2
25
Four hour after adding sodium nitrite PH, Sodium nitrite (% by weight)
At 03:40 Hrs.fourth sample collected. As per BHEL site chemical analysis PH-9.4. By considering the fourth
water sample, BHEL declared the completion of Passivation process
26
During draining of water after Cold
water rinse 1
PH, Conductivity
On March 9 2016, at 4.40Hrs. boiler drain started, at 11.10 Hrs.boiler filling started for cold water rinsing, at
13:50 Hrs. fisrt cold water rinsing sample taken, As per RPCL site chemical Lab analysis PH-9.1 & conductivity
1483 µs/cm
27
During draining of water after Cold
water rinse 2
PH, Conductivity
At 16.40 Hrs. boiler filling started for Second cold water rinsing , at 17.50 BCP started and at 18.35 Hrs. BCP
stopped, boiler drain started at 18.45 Hrs. At 19:05 Hrs. seocnd cold water rinsing sample taken, As per RPCL
site chemical Lab analysis PH-9.2 & conductivity 833 µs/cm.
During draining of water after Cold
water rinse 3
PH, Conductivity
On March 10,2016 at 04.10 Hrs. boiler filling started for Third cold water rinsing , at 06.50 Hrs BCP started
and at 07.25 Hrs. BCP stopped, boiler drain started at 08:10 Hrs. At 08:35 Hrs.Third cold water rinsing
sample taken, As per RPCL site chemical Lab analysis PH-9.5 & conductivity 83 µs/cm.
During draining of water after Cold
water rinse 4
PH, Conductivity
At 11.15 Hrs. boiler filling started for fourth cold water rinsing , at 13.50 hrs. BCP started and at 14.30 Hrs.
BCP stopped, boiler drain started at 14.45 Hrs. At 15:10 Hrs. fourth cold water rinsing sample taken, As per
RPCL site chemical Lab analysis PH-9.3 & conductivity 47.6 µs/cm. by the considering of this water sample
values BHEL declared the completion of cold water rinsing cleaning process and completion of chemical
cleaning activity for Unit# 2
28
29
Passivation
Cold water rinse