CPP Steam & BFW System Position : SFE (SG & D)

Commissioning Methods

Captive Power Plant

RELIANCE, JAMNAGAR

TO STUDY THE METHODS & PROCEDURES FOR

SAFE PRECOMMISSIONING & COMMISSIONING
OF
STEAM & BFW SYSTEM

CHECKED BY: PAGE : 1 OF 19

JLB RELIANCE, JAMNAGAR REV : 00
CAPTIVE POWER PLANT ISSUE : 01
APPROVED BY: DATE : 15.02.2007
NKM AUTHOR : JKP
 CPP Steam & BFW System Position : SFE (SG & D)
Commissioning Methods

CONTENT

SL Topic Page No

1 SILENT STEAM BLOWING

2 NON CONVENTIONAL CLEANING METHODS

3 CHEMICAL CLEANING OF PIPE LINES

CHECKED BY: PAGE : 2 OF 19

JLB RELIANCE, JAMNAGAR REV : 00
CAPTIVE POWER PLANT ISSUE : 01
APPROVED BY: DATE : 15.02.2007
NKM AUTHOR : JKP
 CPP Steam & BFW System Position : SFE (SG & D)
Commissioning Methods

SILENT STEAM BLOWING

INTRODUCTION

This is a well established method that has been used extensively for cleaning of all types of steam raising
plant, including large diameter steam lines. The basis of the method is to use steam at the lowest
possible pressure consistent with achieving the required steam flows. This steam has a high specific
volume and therefore the steam velocities are high during steam blowing, making it relatively easy to
achieve the required CFR (Cleaning Force Ratio) with steam mass flows that are much less than the
normal flow rates. Typically, for a high pressure system, the steam flow needed to achieve the CFR is
about 40% of normal flow. This procedure differs from conventional, pressure cycle, steam blowing in that
the steam used for blowing is produced continuously and the exit steam velocity is controlled to below
sonic velocity at the exit of the steam piping which greatly reduces the noise produced during steam
blowing.

Rather than exhausting to atmosphere directly, the exhaust steam exits into temporary pipe work fitted
with a series of quench attemperators. Each attemperator comprises a stepwise expansion in line size
with a facility to spray water into the flowing steam. Quench water is injected into the steam at each
attemperator. After the final attemperator the steam exits to atmosphere via a Muzzler.

The effect of the expansion and attemperation is to reduce the velocity and energy of the steam in the
temporary pipe work thereby minimizing the noise on discharge. For each of the steam systems being
cleaned, the temporary exit piping before the first attemperator is flanged to accept a remotely operated
target plate inserter. This allows target plates to be safely inserted and removed whilst blowing is in
progress. In this way, a series of target plates can be run to monitor the progress of the steam blow.

This method offers several significant advantages.

Increased disturbance factor by reducing exit pressure.

Large reduction in noise by eliminating the sonic velocity exit steam.
Low pressure exit piping required.
No pipe restraints required.
Continuous blowing minimizes the time required.
Eliminates the need for temporary blow-out steam valves.

The steam blowing is designed to produce a disturbance factor (cleaning force ratio) of 1.0, or higher, at
the inlets of the lines being blown.
The main advantage of continuous steam blowing is the very short programme time needed to achieve
acceptable target plates. Typically each system being steam blown will take 12 to 30 blowing hours for
acceptance targets depending on target criteria. The other advantage is that the low pressures used
mean that the exit piping is fabricated from thin wall steel pipe and no special pipe supports are needed.
This greatly reduces the cost for the exit piping.

CHECKED BY: PAGE : 3 OF 19

JLB RELIANCE, JAMNAGAR REV : 00
CAPTIVE POWER PLANT ISSUE : 01
APPROVED BY: DATE : 15.02.2007
NKM AUTHOR : JKP
 CPP Steam & BFW System Position : SFE (SG & D)
Commissioning Methods

PROCESS
The silent steam blowing procedure consists basically of four major steps:
Warming up the line
Blowing the line
Thermal cycling the line
Re blowing the line
Target insertion & certification
WARMING UP THE LINE:
The line to be blown is first warmed up by crack opening the valve. The primary purpose of this is to
warm up the line and drain the condensate if any in the header. The secondary purpose is the detection
of leaks in the silent steam blowing assembly. If there are any leaks in the temporary piping, they can
be detected during this phase and can be rectified accordingly so that a safe silent blowing operation is
ensured.

BLOWING THE LINE:

After warming up the line, the source valve is opened to get the required flow for steam blowing. During
this first blow, the dust and other dirt particles are removed from the steam line. But besides these

CHECKED BY: PAGE : 4 OF 19

JLB RELIANCE, JAMNAGAR REV : 00
CAPTIVE POWER PLANT ISSUE : 01
APPROVED BY: DATE : 15.02.2007
NKM AUTHOR : JKP
 CPP Steam & BFW System Position : SFE (SG & D)
Commissioning Methods

things, there are other major detrimental things present in the steam line such as weld slag, mill scales
etc. During this first blow, these things expand due to the high temperature of the steam.

THERMAL CYCLING
Thermal cycling of steam lines is used to assist with removal of strongly adherent debris such as mill
scale. This reduces the blowing time required to achieve acceptable target plates. During a thermal
cycle the temperature of the line being steam blown is reduced to the minimum safe value then allowed
to rise back to the normal steam temperature. Thermal cycling is achieved by varying the temperature
of the steam flowing in the line. Temperature variation causes the metal line to contract during cooling
then expand as the temperature rises. Provided that the oxide scales on the pipe surface have a
different coefficient of thermal expansion compared to the underlying metal, this movement of the pipe
surface relative to the scale will cause the scale to detach from the metal surface. The loosened scale
is then readily removed during the steam blow.
Thermal cycling can be achieved either by natural cool-down or by forced steam cooling during steam
blowing. If the steam blowing is restricted to blowing for a set period each day, e.g. blowing during
daylight hours only, and is continued over at least 3 days, then normally sufficient thermal cycling will
be achieved by natural cooling. Where steam blowing is on a 24 hour per day basis, forced steam
cooling is used for inducing thermal cycles. In this method a thermal cycle is effected by injecting
suitable quality water, normally boiler feed water, into the steam flow at or before the inlet to the section
of line being steam blown. For thermal cycles,
The steam temperature is varied by about 200 C. During a thermal cycle, the steam temperature
should not be reduced to less than 30 C above the saturation temperature for the steam to avoid the
possibility of condensate slugs forming.
If permanent attemperation equipment is not available, temporary facilities can be provided. Normally
this will require injecting dematerialized water at a controlled rate into the steam line either upstream of
the inlet or as close as possible after the inlet. The water can be injected via a spray nozzle if a suitable
flanged connection exists or more commonly, directly into a steam line mud boot (drip leg) drain. The
water supply needs to be at a higher pressure than the line pressure during blowing, typically about 5
bar above the line pressure.

Steam Flow Calculations

The primary calculation is to estimate the steam flow required during steam blowing to achieve a
specified Cleaning Force Ratio (CFR). CFR is a ratio of the steams mass velocity head or momentum
during cleaning with that developed during maximum steam flow. CFR value greater than one ensures
that the mass velocity head during cleaning is greater than at maximum flow conditions.
The operating conditions were used to calculate the mass flow rate required for steam blowing
as follows:

CFR = Mb2 x Vs / Mo2 x Vo

Where,
CFR = Cleaning Force Ratio
Mb = Mass Flow rate required for blowing
CHECKED BY: PAGE : 5 OF 19
JLB RELIANCE, JAMNAGAR REV : 00
CAPTIVE POWER PLANT ISSUE : 01
APPROVED BY: DATE : 15.02.2007
NKM AUTHOR : JKP
 CPP Steam & BFW System Position : SFE (SG & D)
Commissioning Methods

Vb = Specific Volume [steam blowing condition]

Mo = Operating Mass Flow rate
Vo = Specific Volume [operating condition]

In the above equation, the values of Mo, Vo, Vs & CFR are known. From these values the value of Mb
can be determined using the above equation. The values of Mo and Vo can be obtained with the help
of LDT [Line Designation Table]. A sample calculation is given below.

In order to calculate the mass flow of steam required for steam blowing to achieve a specified value of
CFR it is necessary to estimate the steam pressure during steam blowing. During continuous steam
blowing the steam pressure at the inlet to the line is determined only by the pressure drop due to the
flow of steam during blowing. This is because the exit piping is open to atmosphere at its termination
and the steam velocities during blowing are always sub-sonic, hence choked flow does not occur.

Various methods are used to estimate pressure drops for flow of superheated steam. For complex
systems normally software used are Flow master, a commercial one dimensional CFD software
package or Crane Software.
Sample calculation for blowing steam requirement

BLOW NO: 1 [ 951 Area HHP line at West end]

Reference P&ID No.: G42-EE951-030
SOURCE: HHP Steam from HHP Steam Header.
[951-ZS-200-20-EKL2ER-HC-140]

Approx. Duration: 24 hrs.

CFR = Mb2 x Vs / Mo2 x Vo

Taking CFR= 1.8, Mo and Vo values from the LDT & Vs value from the steam table at 6

kg/cm2 a and 510 deg C, we obtain

1.8 = Mb2 x 0. 576 / (180) 2 x 0.030

Hence

Mb = 55 tph

The same procedure was followed to establish the flow rates of all the lines.
Raw Water Supplies
Raw water supplies are required for operation of the quench attemperation system, used to reduce the
CHECKED BY: PAGE : 6 OF 19
JLB RELIANCE, JAMNAGAR REV : 00
CAPTIVE POWER PLANT ISSUE : 01
APPROVED BY: DATE : 15.02.2007
NKM AUTHOR : JKP
 CPP Steam & BFW System Position : SFE (SG & D)
Commissioning Methods

discharge noise of the steam during steam blowing. Fire water shall be used for the purpose.
Discharge Noise
The quench attemperation system is very effective at reducing the steam discharge noise. Discharge
noise levels are typically around 85 dBA at one metre from the discharge point .
Target Insertion Equipment
The target insertion equipment comprises a pneumatically operated isolation valve, a pneumatically
operated insertion ram and a control panel.
Engineering Design
In order to perform the detailed engineering design, the following information is required.
Accurate piping & instrumentation diagrams (P&ID) for all lines to be cleaned. These
will be used to produce flow diagrams for steam blows.
Accurate isometric construction drawings (ISO) and/or piping plans drawings for all
lines to be cleaned including boiler details. These drawings will be used during the detailed design
calculations.
Stress and movement design information on the lines to be blown to carry out a
stress analysis on the temporary piping.
Accurate information on the type, dimensions and Cv values for all valves in the lines
to be cleaned.
Maximum pressure and temperature limitations for all lines to be blown.
Maximum continuous rating (MCR) values for steam mass flows, pressures and
temperatures for all lines to be blown.

Execution Plan
This would include the following:
Detailed Engineering Design for steam blowing
Detailed Method Statement for steam blowing
Site Risk assessment.

GENERIC STEAM BLOW PROCEDURES

CHECKED BY: PAGE : 7 OF 19
JLB RELIANCE, JAMNAGAR REV : 00
CAPTIVE POWER PLANT ISSUE : 01
APPROVED BY: DATE : 15.02.2007
NKM AUTHOR : JKP
 CPP Steam & BFW System Position : SFE (SG & D)
Commissioning Methods

Preliminary Checks.
Line Warming Procedure.
Targeted Steam Blow Procedure.

Preliminary Checks
Verification
Action
Step Action
by Initial Date & time

Make sure all the inline instruments like FT, PT are

1.1
isolated. TT thermowels are removed and blinded.
1.2 PSVs are removed and blinded.

1.3 Safe access to all drip legs & isolation valves available.

1.4 Safety barricades around exit piping in position

1.5 Warning notices in position

1.6 Steam line insulation completed as required

1.7 Exit piping fully supported

1.8 Exit piping lagged in required areas

1.9 Safe access to target inserter

1.10 Attemperation water (fire water ) connected as required

1.11 Fire water header charged and hydrant functioning.

1.12 Air supply to target inserter connected

1.13 Target inserter functioning

No flammable materials in close proximity to steam
1.14
lines or exit piping
1.15 Effluent water (Muzzler drain) drain to safe location
DM water or cold condensate connection is available
1.16
near the steam source points for thermal cycling.

Line warm up procedure

CHECKED BY: PAGE : 8 OF 19
JLB RELIANCE, JAMNAGAR REV : 00
CAPTIVE POWER PLANT ISSUE : 01
APPROVED BY: DATE : 15.02.2007
NKM AUTHOR : JKP
 CPP Steam & BFW System Position : SFE (SG & D)
Commissioning Methods

Verification
Action
Step Action Initial Date &
by
time
Note On commencing steam blowing it is important to control the steam flow and temperature
of the exit line, to prevent water hammer and excessive line stresses.
The requirement is to slowly heat the steam line using a controlled flow of steam,
gradually increasing the flow rate if necessary. It is essential to drain water condensed
during the heating process.
This controlled operation also provides time to check the exit line for leaks or other
problems due to thermal expansion.
All drip leg drains between steam source and the main
2.1
steam stop valves to be opened.
2.2 Open Bypass valve on steam header isolation valve
If no bypass is present then crack open the main stop
2.3
to warm up steam lines.
Walk line closing all drip leg drains and checking all
flanges for leaks and for any problems due to thermal
expansion. Rectify as required.
2.4
When the exit pipe temperature, as shown on
Temperature Gauge, has reached 100C, line warming
is complete.

Targeted Steam Blow Procedure

Action Verification
Step Action
by Initial Date & time
Note The following procedure is generic for all Target Steam
Blows. For individual blow processes see Step by Step
Procedure.
3.1 Establish flow required as mentioned in blow work sheet
provided in engineering package.
3.2 Continue blowing for 2 hrs.
3.3 Reduce flow to half of the total blowing flow.
3.4 Perform thermal cycling (TC) by spraying DM water or
cold condensate at nearest point of source. Allow
temperature to drop by 150 deg C.
3.5 Continue TC for around 1.5 hrs.
3.6 Stop TC and establish normal blowing flow.
3.7 Continue blowing for 1 hr.
3.8 Starting from the drains nearest to the steam source,
sequentially blow down all steam line drains. Fully open
CHECKED BY: PAGE : 9 OF 19
JLB RELIANCE, JAMNAGAR REV : 00
CAPTIVE POWER PLANT ISSUE : 01
APPROVED BY: DATE : 15.02.2007
NKM AUTHOR : JKP
 CPP Steam & BFW System Position : SFE (SG & D)
Commissioning Methods

each drain valve and allow the drain to blow until clean,
then close drain valve.
3.9 Insert a reference target. Keep target exposure for 20
minutes.
3.10 Remove the target safely by operating the Ram.
3.11 Note the following in the target plate log:
(a) Line number
(b) Plate number
(c) Time of insertion
3.12 Examine for impression when plate is cool.
3.13 Store the plate for future reference.
3.14 Repeat step from 3.1 to 3.13 till target meets the criteria.

Note Target acceptance criteria may be different for

different turbine vendor. Refer to turbine vendor.
Hydrochem standard specifies following criteria.

Target exposure of 20 minutes shall result in no impacts

larger than 0.4mm diameter and fewer than 10 impacts
on two successive occasions. The top and bottom half
inch of the target surface should be disregarded, due to
the effects of its attachment on the Target inserter ram.

NON CONVENTIONAL CLEANING METHODS

Apart from silent steam blowing there are various other Non conventional cleaning methods
CHECKED BY: PAGE : 10 OF 19
JLB RELIANCE, JAMNAGAR REV : 00
CAPTIVE POWER PLANT ISSUE : 01
APPROVED BY: DATE : 15.02.2007
NKM AUTHOR : JKP
 CPP Steam & BFW System Position : SFE (SG & D)
Commissioning Methods

as listed below.
Chemical Cleaning.
Hydro Milling
Hybrid Chem steam cleaning

Chemical Cleaning:-
Chemical cleaning uses the most cost effective and environmentally sound means to reach
the desired objective whether it is simply degreasing or removal of mill scale. The chemical
mixture is formulated to remove hard deposits or soft films from virtually any type of
metallurgy. Chemicals used are environmental friendly. The process injects proven
chemistries into saturated steam. By not filling with liquids the chemistry is able to act directly
on the surface of the pipe. Continuous monitoring of the condensate product controls pH and
iron content. The vapour is condensed at the outlet point and neutralized for disposal to plant
waste system. After mill scale removal a final blow for 4 hours is given at calculated flow to
remove the construction debris. Total time required is around 18 hrs in place of 36 hrs for
conventional silent steam blow. The process reduces considerable steam consumption.

Fig.-1 Chem Steam cleaning process- Effluent collection.

Hydro Milling
Hydro Milling is high pressure water jetting process where all debris an mill scale removed
from the pipe surface is transported out of the pipe when the high pressure nozzle is retracted.
This is accomplished via a pusher/flusher orifice built into the cleaning nozzle, utilizing a typical
CHECKED BY: PAGE : 11 OF 19
JLB RELIANCE, JAMNAGAR REV : 00
CAPTIVE POWER PLANT ISSUE : 01
APPROVED BY: DATE : 15.02.2007
NKM AUTHOR : JKP
 CPP Steam & BFW System Position : SFE (SG & D)
Commissioning Methods

working pressure of 12,000 psi for mill scale removal and an average water flow of 40 GPM.
All resulting debris and mill scale may be contained and/or collected for proper disposal. This
proprietary pipe cleaning system is capable of handling changes of direction including multiple
90 degree turns and pipe offsets to distances of 100 mtrs vertically or 30 mtrs horizontally from
the point of entry with precise tracking capabilities. The hydro milling process is capable to all
pipe sizes from 2 dia meter and up. This process is best suited for De aerator lines, PRDS
lines.

HYBRID CHEMSTEAM PROCESS

Gulf Strategic Partners has combined three methods of cleaning to form the Hybrid
Chem Steam cleaning process (HCS Process) to meet the stated objectives

Hydro Milling
Vapor Phase Chemical Cleaning
Steam blow

With the advent of much larger piping systems the previous methods of chemical cleaning, line
flushing, and steam blowing have become cumbersome, expensive, time consuming, and in
some cases impossible to perform utilizing the previous methods. In addition traditional
methods often create large quantities of waste effluent creating disposal problems.

The above stated cleaning methods are combined with the following objectives:

Cleaning meets or exceeds the required standards and specifications

Reduces Commissioning Cleaning time requirements
Engineered pre timed cleaning cycles for realistic scheduling
Adds flexibility to Commissioning Cleaning Schedule
Minimizes waste disposal requirements and liability
Minimizes water and steam consumption
Flexible application and combination of the processes to suit site conditions
Reduces overall costs

Hybrid Chem Steam blow time is 10-20% of normal silent steam blow duration and 2-5% of
conventional steam blow duration.

CHEMICAL CLEANING OF PIPE LINES

INTRODUCTION

CHECKED BY: PAGE : 12 OF 19

JLB RELIANCE, JAMNAGAR REV : 00
CAPTIVE POWER PLANT ISSUE : 01
APPROVED BY: DATE : 15.02.2007
NKM AUTHOR : JKP
 CPP Steam & BFW System Position : SFE (SG & D)
Commissioning Methods

The object of chemical cleaning of carbon steel piping is to remove the loose rust, dislodging the burs,
welding slag & mill scales adhering to the internal surface of the pipelines. The procedure specifies the
method of cleaning & passivation with sodium nitrite prior to taking in service for the first time after
installation of pipeline.
This cleaning enables to remove

a) Grease or oil
b) Mill scales
c) Loose rust
d) Welding slag
e) Paint or varnish if used for protective purposes
f) Any loose foreign particle during flushing of system
The sequence of operations includes flushing by cold & hot water, degreasing, acid pickling, citric rinse,
passivation, drying & preservation. In between this processes different parameters like pH, Alkalinity,
temperature, acid concentration, total iron & clarity of water to be monitored. Various chemicals used in
chemical cleaning process includes Soda ash, Caustic soda, Sodium nitrite, Wetting agent, CORONIL
92B, citric acid & ammonia.

CONTENTS

CHECKED BY: PAGE : 13 OF 19

JLB RELIANCE, JAMNAGAR REV : 00
CAPTIVE POWER PLANT ISSUE : 01
APPROVED BY: DATE : 15.02.2007
NKM AUTHOR : JKP
 CPP Steam & BFW System Position : SFE (SG & D)
Commissioning Methods

Sr. No. PARTICULARS

1 Temporary Arrangements

2 Leak Test

3 Cold Water flushing

4 Hot Water flushing

5 Degreasing

6 Water flushing

7 Acid Pickling

8 Water flushing

9 Citric Rinse & Passivation

10 Drying & Preservation

11 Testing Procedure

Chemical Cleaning Sequence

1. Temporary Arrangements

For starting & smooth operation of chemical cleaning following arrangements has to made before
CHECKED BY: PAGE : 14 OF 19
JLB RELIANCE, JAMNAGAR REV : 00
CAPTIVE POWER PLANT ISSUE : 01
APPROVED BY: DATE : 15.02.2007
NKM AUTHOR : JKP
 CPP Steam & BFW System Position : SFE (SG & D)
Commissioning Methods

starting of job

(a) Scaffolding for all the valves operations. (For vents, Hot tap connections & water supply valves
etc.)
(b) Motor connection to be made either from DG set or through Reliance system depending upon the
conditions. For this permit, isolation tag etc to be provided in consultation with electrical personnel.
(c) Return Hose connection from all valves to pump suction.
(d) Hose connection for DM Water, utility water, LP condensate etc from header valve to chemical
circulation tank.
(e) Chemicals storage at predefined place.
(f) Tie in between chemical circulation tank & effluent tank.
(g) Hose connection from effluent tank to tanker, to discharge effluent after conditioning in Effluent
tank.
(h) Tanker arrangement to dispose effluent at proper place.
(i) All control valves, flow meters & other instruments removal.
(j) Spool fixing in place of Control valve & NRV if required.
(k) Suction strainer removal.
(l) Danger Tags & Barrication in whole area.

2. Leak Test

This is to be done to avoid any leakage in between the process & to avoid any hazard because of
that.
a) After circuit completion, the system will be filled with utility water.
b) Water circulation for 30 min. to check the leakages in system & leakages to be rectified if found
any.
c) Water drain in storm water channel.

End of leak test:

No leakage from any joints
3. Cold Water flushing

To remove loose slag, dirt, foreign particles etc from the system
a) Continuous system flushing with utility water for approx 1 hour.
b) Water filling & circulation in system and drainage in storm water channel till drain water will be
clear.

End of cold flushing:

Clarity of water is good (visual checking )

4. Hot Water Flushing

To remove loose slag, dirt, foreign particles etc from the system while giving a thermal shock
System flushing with hot water.
a) Water filling, circulation in system and raise the temperature up to min. 50 c
c) Drainage in storm water channel till drain water will be clear.
CHECKED BY: PAGE : 15 OF 19
JLB RELIANCE, JAMNAGAR REV : 00
CAPTIVE POWER PLANT ISSUE : 01
APPROVED BY: DATE : 15.02.2007
NKM AUTHOR : JKP
 CPP Steam & BFW System Position : SFE (SG & D)
Commissioning Methods

End of hot flushing

Turbidity of water is good (Visual checking)
5. Degreasing

Process (Oil & Grease removal)

CH2 COOR CH2 - COONa
70 c
CH COOR + 3 NaOH CH COONa + 3 H2O

CH2 COOR CH2 - COONa
Oil & grease (Fatty acid)
a) System filling with condensate or DM water & circulation.
b) Temperature rise to 70 c
c) Chemicals addition
(i) Soda Ash - 3000 ppm
(ii) Caustic Soda - 3000 ppm
(iii) Sodium Nitrite - 500 ppm
(iv) Wetting Agent - 200 ppm
d) Total alkalinity & pH monitoring in every hour.
e) Circulation till the stabilization of total alkalinity & pH (normally 2 to 3 hrs)
f) Drain of effluent in Effluent tank.
g) Neutralize the effluent with water & Hydrochloric acid before discharge in tanker.

Parameter to be monitored
pH & Total Alkalinity

End of degreasing-
pH and Total alkalinity of system at inlet and outlet of cleaning loop is equal and stabilized.

6. Water Flushing

a) System flushing by DM water

b) Stop flushing when pH of system in inlet & outlet points are equivalent to the pH of water being
used.
c) Complete drainage of water.

End of water flushing after degreasing:-

pH of the system at inlet and outlet of cleaning loop is equal to DM water used and stabilized.

7. Acid Pickling

CHECKED BY: PAGE : 16 OF 19

JLB RELIANCE, JAMNAGAR REV : 00
CAPTIVE POWER PLANT ISSUE : 01
APPROVED BY: DATE : 15.02.2007
NKM AUTHOR : JKP
 CPP Steam & BFW System Position : SFE (SG & D)
Commissioning Methods

Process (Iron Removal)

70 c
Fe2O3 + 2 H3 Citrate 2 Fe Citrate + 3 H2O

Ferric Oxide Citric Acid Ferric Citrate

a) Refill the system with condensate or DM water, circulate & raise temperature to 70 c
b) Add 0.2% of corrosion inhibitor Coronil 92 B & circulate for one hour.
c) After 1 hour add 3% of Citric Acid into the solution.
d) Maintain pH of solution between 3.5 to 4 using Ammonia.
e) Monitor concentration of acid, pH & total iron in every hour.
f) Circulate till the acid concentration & total iron remains constant.
g) After stabilizing drain the solution to effluent tank. (If possible under nitrogen)
h) Neutralize the solution with water & burnt lime before discharge in tanker.

Parameter to be monitored pH, Acid concentration & Total iron

End of acid pickling:
Iron amount in ppm at system inlet outlet should be equal and stabilized at maximum level.
8. Water flushing

a) System flushing by DM water

b) Stop flushing when pH of system in inlet & outlet points are equivalent to the pH of water being
used.
c) Complete drainage of water.

End of water flushing after acid pickling :

Iron amount in ppm at system inlet outlet should be equal and stabilized at maximum level

9. Citric Rinse & Passivation

Process -
NH3
Fe2O3 + C6H8O7 FAC (Ferrous ammonium citrate)

pH 9 - 9.5
C6H8O7 + NH3 + NaNO2 Fe3O4
60 c Magnetite Layer

a) Refill system with condensate or DM water, circulate & raise temp. to 70 c.

b) Add Citric acid into the system & circulate for 1 hour.
c) Raise the pH of the solution to 9 9.5 by adding ammonia.
d) After attaining the pH add 1% OF sodium nitrite into same solution.
CHECKED BY: PAGE : 17 OF 19
JLB RELIANCE, JAMNAGAR REV : 00
CAPTIVE POWER PLANT ISSUE : 01
APPROVED BY: DATE : 15.02.2007
NKM AUTHOR : JKP
 CPP Steam & BFW System Position : SFE (SG & D)
Commissioning Methods

e) Circulate the solution for 3-4 hours.

f) Drain the total solution & neutralize the effluent.

End of citric rinse and passivation:

pH should be around 9.0-9.5 and get stabilized.
10. Drying & Preservation

a) Dry the system using instrument air / Nitrogen.

b) The passivated line should be preserved in clean & dry condition with slight positive pressure
using nitrogen to prevent entry of moisture, dust or foreign particles.
c) To prevent re-oxidation, passivation solution must be introduced immediately after flushing the
system.

11. Check passivation layer, remove temporary arrangement, normalize the system & restore the
area after housekeeping.

TESTING PROCEDURE

1. Total Alkalinity: -

10 ml sample + 3 to 5 drops of mixed indicator, titrate against 0.1 N H 2SO4

End Point Green to Red colour

Total Alkalinity as CaCO3 (%) = Total Volume * 0.1 * 50 * 100 / (10 * 1000)
= Total Volume * 0.5

2. Citric Acid Strength: -

10 ml sample + 3 to 5 drops of Phenolphthalein indicator titrate against 0.1 NaOH.

End Point Colourless to Pink Colour

Citric Acid Strength (%) = Total Volume * 0.1 * 70 * 100 / (10 * 1000)
= Total Volume * 0.07

CHECKED BY: PAGE : 18 OF 19

JLB RELIANCE, JAMNAGAR REV : 00
CAPTIVE POWER PLANT ISSUE : 01
APPROVED BY: DATE : 15.02.2007
NKM AUTHOR : JKP
 CPP Steam & BFW System Position : SFE (SG & D)
Commissioning Methods

3. Total Iron Content: -

10 ml sample + 1 gm Sodium Acetate + 1 gm Chloro Acetic Acid + 1 gm Sulpho Salicylic acid + 1 gm

Potassium Persulfate , titrate against 0.01 M EDTA

End Point Red to Pale Yellow

Total Iron as Fe (mg/L) = Total Volume * 0.01 * 55.85 * 1000 / 10

= Total Volume * 55.85

CHECKED BY: PAGE : 19 OF 19

JLB RELIANCE, JAMNAGAR REV : 00
CAPTIVE POWER PLANT ISSUE : 01
APPROVED BY: DATE : 15.02.2007
NKM AUTHOR : JKP