LARSEN & TOUBRO LIMITED

CLEANING OF THE UNIT - BOIL OUT

1 SCOPE
1.1

Before start-up of a new boiler, it is necessary to remove all foreign matters from
boiler, steam drum and piping after erection and assembly. Moreover, a new
boiler will usually contain grease or oil, which must be removed by boiling out. A
light film of non-conducting oil could very definitely cause overheating the
boiler. To overcome this possibility, boil out the boiler using a chemical charge is
recommended.

1.2

When boiling-out, it is most important to keep the water hot circulating (by
natural circulation) otherwise successful cleaning cannot be accomplished
regardless of the cleaning chemical or the strength of the solution used.

2 MAIN RECOMMENDATIONS
2.1

Before any operation of rinsing or cleaning is started, it is necessary to unmount

or isolate all control accessories such as:
-

Remote and local gauges. Possibly replace them with tubular or other type
glass or mica backing. One Pressure transmitter in-line can be kept in
order to monitor the pressure in the system.

Level alarms and controllers or transmitters.

Safety relief valves.

Manometers (if any).

Silencer on vent nozzle (if any. Isolate silencer when bypass valve
mounted in vent pipe line connected to silencer otherwise silencer can be
left in place without isolating it).

Demister

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2.2

Install temporary gaskets on manholes and other flanges connections. After

cleaning operations and before start-up, remove them and replace by the final
gaskets.

2.3 The internal parts piping, impingement plates will be left in place. Some partition
plates or inspection doors shall be removed after the cleaning is achieved in order to
be sure of the cleanliness of the internal shrouds in the steam drum.

3 CHEMICAL CHARGES
QUANTITIES TO SUPPLY FOR THE COMPLETE CYCLE OF CLEANING
(STAGES 5.2 & 6.2)
3.1 CHEMICAL FOR HOT DEGREASING OPERATION:
(For each cubic meter of water in the system)
- 3 kg: Soda ash.
- 3.2 kg: Caustic soda.
- 0.50 kg: Wetting agent.
3.2

CHEMICALS FOR PRESSURIZED BOIL-OUT OPERATION:

(For each cubic meter of water in the system)
- 3 kg: Sodium phosphate (Na2PO4, 12H2O).

& one of the following chemicals to be used: (Qty based on neat solutions &
considering less than 0.007 ppm dissolved oxygen in the BFW water as given in clause 2.2 of
HTAS Specification doc no: P53200-E REV 1).
-

0.0110 g: Carbohydrazide (O2 Scavenger)

0.009 g: DEHA (O2 Scavenger)
0.007 g: Hydrazine (O2 Scavenger)

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CAUTION
Boil-out chemicals are highly caustic. Caustic soda will produce a violent flash if
introduced too fast in water. All chemicals should be premixed with water in a
large container before they are introduced into the drum. Wear goggles, rubber
apron and rubber gloves at all times while mixing and handling chemicals. Warn
all personnel to exercise due care. Use vinegar or boric acid as antidotes.
4 PRELIMINARY WASHING
4.1

Make sure that all connections are tightly closed.

4.2

Open the drum vent and connect it to a hose pipe.

4.3

Start-up the feed water pump and maintain a large flow through the by-pass of the
feed water control valve.

4.4

Fill-up the system with clean demineralized water until it overflows by the vent
nozzle.

4.5

Stop the filling and drain by all valves at the lowest point.

4.6

Repeat this operation once.

5 HOT DEGREASING
This operation is done at ambient pressure, when starting-up the upstream
equipment and by sending hot gases in the boiler. Its purpose is to eliminate the
grease and oil deposits from the internal surfaces of the unit.
Hot degreasing is done as per following steps:
5.1

Fill the boiler unit to 100mm below normal operating level with demineralized
water. Measure the quantity of water used.

5.2

In a separate tank dissolve and premix the following chemicals in cold water:
(For each cubic meter of water in the system).

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LARSEN & TOUBRO LIMITED

- 3 kg: Soda ash.

- 3.2 kg: Caustic soda.
- 0.50 kg: Wetting agent.
5.3

Add the premixed charge to boiler through the chemical feed connection or a
large opening in the steam drum, safety relief valve nozzle for example.
CAUTION
If the chemical feed line is used to introduce the chemicals, care should be taken
to make sure slugs of chemicals are not pumped in the line as this may plug
the distributor pipe.

5.4

Close-up steam drum and adjust the water level to 100 to 150 mm above drum
centerline. Close main steam stop and non-return valves. Leave drum vent open.
Note: keep the superheater and main steam line vents and drains open. The
purpose of this is to maintain steam flow through the superheater to prevent
damage due to overheating and to increase the recirculation of the boiler water.

5.5

Begin slowly the water heating using hot gases through tube-side and/or the steam
injection in the boiler (through nozzles E1 & E2). Thermal shock of the boiler
tubes is to be avoided at start-up, shutdown and when feed is introduced in the
drum during boil out. Gradually increase the gas flow and/or its temperature and
the steam injection until the water temperature is at 90/95 C. Water temperature
is monitored through a temperature indicator mounted in the downcomer piping
line. If this temperature indicator has not been provided then water temperature
can be measured manually by collecting the water sample from the downcomer
piping line drain arrangement.

5.6

Adjust gas flow and temperature to maintain the boiler temperature for a period of
24 to 48 hours. (Experience has shown that a period of 48 hours at the
recommended temperature and chemical concentration is usually sufficient to
clean the unit). While hot degreasing, testing of Na2CO3, NaOH and pH is carried
out. Samples are taken and tested every alternate hour. Maintain boiler
temperature of 90-950C for 48 hours along with three consecutive stable readings
of
Na2CO3,
NaOH
&
pH.

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LARSEN & TOUBRO LIMITED

5.7

Stop the heating and fully drain the unit. Let the metal be cooled before to re-fill
the unit to rinse it.

5.8

After complete rinsing shut the drain valves.

PRESSURIZED BOILING-OUT
The purpose of this last stage is to achieve the degreasing, to remove scales and to
pickle internal surfaces.

6.1

Fill the boiler with demineralised water to 100/150 mm below the normal
operating level.

6.2

Dissolve and premix the following chemicals in cold water:

(For each cubic meter of water in the system).
- 3 kg : Sodium phosphate (Na2PO4, 12H2O).

& one of the following chemicals to be used: (Qty based on neat solutions &
considering less than 0.007 ppm dissolved oxygen in the BFW water as given in clause 2.2 of
HTAS Specification doc no: P53200-E REV 1).
-

0.011 g: Carbohydrazide (O2 Scavenger)

0.009 g: DEHA (O2 Scavenger)
0.007 g: Hydrazine (O2 Scavenger)

6.3

Add the premixed chemicals charge as indicated at 5.3.

6.4

Close-up the steam drum and adjust the water level to the drum centerline. Leave
drum vents open.

6.5

Heat slowly the water with hot gases and steam injection. Temperature raising for
water will be no more than 50 C/hr.

6.6

Close steam drum vents when 1 kg/cm2 pressure is reached. (If there is a
superheater, leave its vent and drain open).

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LARSEN & TOUBRO LIMITED

6.7

Increase the heating and adjust it until the boiler pressure is approximately 15 to
16 kg/sq.cm. Steam exhaust will be controlled by the vent valves to maintain the
recommended pressure for a period of 48 hours.

6.8

During the desired steaming period, add water slowly to maintain the water level.

6.9

Every 4 hours, using the continuous blowdown line, blowdown until the water
falls to the continuous blowdown connection. From this point, use the intermittent
or bottom blow off connection to further lower the water level to a point 50 mm
above the low level cut off.

6.10

After each blow off, re-fill the boiler to its normal water level.

6.11

Samples of the blowdown shall be taken for:

- Visual inspection for signs of oil or contamination.
- pH measurement : below 9.5.
- Chemical analysis.
When the phosphate content remains unchanged after three blowdown, the boiling
out can be considered as achieved.
Samples of the blow-down will be the guide for ending the process.

6.12

Upon completion of the boil-out, cool the entire system slowly. Drain the unit
while still fairly warm, re-fill and drain once more. Please note that the
temperature difference between rinsing water and metal surface of steam drum
must not exceed 60 C. Metal surface temperature can be measured by using laser
temperature detector.

6.13

Open the boiler and the drum and wash down with a high-pressure hose using
clean warm water. Wash the system thoroughly to remove all traces of wetting
agents and solid deposits.

6.14

Inspect the internal areas of the steam drum carefully and remove dismountable
panels to ensure that no trace of oil remains, and that all foreign material, dirt,
scale, welding spatter and metal chips have been removed from the drums. These
heavier particles will be found in the boilers and downcomer pipes and in pocket

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locations around baffles. Remove them by washing with the high-pressure hose
through hand holes, keeping the boiler drains open or by intermittently opening
and closing the drains (of completely filled boiler) 3-4 times.
6.15

If no trace of oil can be found, the system is ready for operation. If oil traces are
found, repeat the boil-out procedure.

7 PRE START-UP SAFETY REVIEW

It is presumed that all operations and checks for commissioning the plant have already been performed
satisfactorily. The operations described hereafter are those to be performed immediately before actual
start-up of the plant or restart-up.
Ensure that:
- The system is clean and that no foreign substance inside the Reformed Gas Boiler and Steam Drum.
- The drum internals and accessories are correctly mounted.
- The nozzles are not obstructed. Check whether air /water can flow freely inside Risers and
Downcomers.
- All valves are working freely. In particular, the drain valves must be checked carefully to avoid any
obstruction & risk of deterioration. They must be opened, thoroughly rinsed & manipulated before the
valve is filled with water.
- The level gauges are correctly connected and the marks have been placed on level gauges at normal
level. Check visibility and lighting.
- Instruments are correctly installed and operate suitably. Check air and / or power supply.
- Safety valves are operating correctly and set to correct pressure. Ensure that the purge and escape
piping are completely safe to operators.
- All access openings are correctly closed.
- All utilities are available and water treatment is operating smoothly. Check availability of chemicals
and reagents and feed-pump operation.
- Open the steam outlet valve, drain and continuous Blowdown valves.

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- Ensure that refractory lined portion is not insulated, insulation should end 100 mm before the section
where refractory starts.
-

Replace all drum internals and parts removed for washing and rinsing. Check the
good tightness of bolts. Stop all nuts holding panels by stainless steel wire or tack
welds.

Install the Demister on the steam outlet line.

Replace all temporary gaskets by final new ones.

Replace the gage glass with the proper glass for operation.

Make sure that no mud or weld particles are introduced when doing the above steps.

Fill the boiler with treated and deaerated boiler quality feed-water :
For an immediate start-up: 150 mm below the normal liquid level
For a postponed start-up: over-flow. (FILL-UP)
Note : If there is risk of freezing, after overflowing drain the unit after you
have connected a pressurized nitrogen drum to the vent nozzle. Keep the unit
filled with N2 at 0.3 kg/cm2 pressure.

8 REMARKS
8.1

Boiling - out can be performed together with the refractory concrete drying.

8.2

The alternative to this procedure would be to chemically clean the unit. This must
be done with great care and supervision to eliminate any possibility of corrosive
attack. Procedures for these operations should be determined by specialists in the
field in relation to the unit configuration and its operating characteristics.

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LARSEN & TOUBRO LIMITED

SAFETY

9.1. Scope and Summary

The prime consideration in Plant Operation and Management is assumed to be safety of
personnel. The information in this section is intended purely as a guide. It is strongly
recommended that detailed safety instructions and procedure to be developed and implemented
by the Client. It must be stressed that the following notes do not necessarily cover all hazardous
conditions.
9.2

Safety Generally

9.2.1 Regulations
Safety Procedures should be developed taking into account any relevant national or local
regulation or statutory requirements. Where plant is adjacent to existing plant, the Safety
Regulations relating to the existing plant should be reviewed also, and any additional precautions
necessary introduced.
Detailed Fire Precautions and First Aid Procedures should also be developed, and the necessary
liaison established with the appropriate local authorities.
9.2.2 Work Permits
To avoid hazardous situations, it is widely considered essential that a system of Work
Permits be used to control maintenance, repair work or other work of hazardous or potentially
hazardous nature. The Work Permit system should ensure that responsibility and authority for
such work are clearly defined, personnel only acting when holding written clearance permits.
Permits should state what protective clothing and safety equipment is required. Clear
warning notices should be displayed prominently wherever hazards exist, and safety barriers
used where necessary.
Personnel should never be instructed to enter equipment until full clearance backed up
where necessary by chemical tests have been given.
Maintenance work must always be supervised to ensure sparking due to electrical work
or hammering, cannot occur in areas where inflammable materials may exist. Welding should be
similarly supervised.

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9.3

Personnel Protection
Main access routes should always be kept clear to ensure personnel can get away safely
from any unexpected hazard.
Discipline regarding "No Smoking" areas should be strictly enforced.
Electrical equipment in particular should be opened by qualified staff holding valid Work
Permits and then only when properly isolated.
9.4
Training
It is essential that personnel are trained positively "To Stop Accidents". Almost all accidents can
be prevented by systematic consideration of what can happen followed by development and
implementation of suitable training procedures. All concerned with operation of the plant should
be thoroughly aware of potential hazards and capable of initiating the steps necessary to
overcome them without delay.
9.5
Attention to Operating Procedures
Particular care should be taken to observe the Operating Procedures and precautions described
elsewhere in this Manual should be reviewed carefully to ensure unsafe situations are not
allowed to develop.
9.6
Plant Maintenance
Good housekeeping on the plant is essential to safety, and to this end, the plant should be kept
clean and tidy, and leaks attended to promptly.
Unusual noises or conditions should be reported and investigated promptly.

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