BOILER CHEMICAL CLEANING PROCEDURE

DOCUMENT NO: P-T3107 - PROD - 073

ORIGINATED BY

REVIEWED BY

APPROVED BY

DISTRIBUTION - CDCC Original :

- All Div. : Co ! DJUNAEDI BOILER SUPTD. MATHEUS MARYONO GEN. SUPTD.

EFFECTIV E DATE

SIMSON SITUMORANG SITE MANAGER

- All D" #. : Co !

REV. NO

ISSUED DATE

BRIEF OF REVISION

PT. TRUBA JAYA ENGINEERING LABUAN 2 BANTEN 2 300 MW CFSPP BOILER CHEMICAL CLEANING PROCEDURE
Uni# I++$ing : Con+#r$,#ion Boil"r Ar"a A rov"- B! : Si#" Manag"r

DOC. NO P-T3107 - PROD - 060

ISSUANCE DATE: Jan$ar! %&' ())* Pag" ( o. &) RE/ISION : )

TABLE OF CONTENT N!. COVER TABLE OF CONTENT 1 2 3 , . 7 1 2 10 PURPOSE CLEANING SCOPE FLOW OF BOILER CHEMICAL CLEANING PREPARATION CHEMICAL CLEANING PROGRAM RE/UIREMENTS OF THE CONCERNED LABORATORY WOR0S AFTER CHEMICAL CLEANING CHEMICAL CLEANING WASTE TREATMENT SAFETY RE/UIREMENT ATTACHMENT D"#$%&'(&!)# P*+" & ( % % 0 0 1 2 * * * &)

PT. TRUBA JAYA ENGINEERING LABUAN 2 BANTEN 2 300 MW CFSPP BOILER CHEMICAL CLEANING PROCEDURE
Uni# I++$ing : Con+#r$,#ion Boil"r Ar"a A rov"- B! : Si#" Manag"r

DOC. NO P-T3107 - PROD - 060

ISSUANCE DATE: Jan$ar! %&' ())* Pag" % o. &) RE/ISION : )

1. PURPOSE OF CHEMICAL CLEANING 1.1. Completely clean all impurities from inner surface of boiler water wall steam pipe line an! economi"er# suc$ as metal !ebris# o%i!e# &rease# oil# !ust an! metal o%i!e pro!uce! on inner surface !urin& e'uipment manufacture an! stora&e. 1.(. )ay foun!ation for inner boiler $eatin&# surface to &enerate protecti*e coatin& of +e 3O, an! to pre*ent furt$er corrosion of inner wall. 1.3. -ttain eli&ible water steam 'uality in relati*ely faster manner after t$e start up of boiler# ensure t$e unit to put into operation smoot$ly an! reac$ full loa! in relati*ely less time. 2. CLEANING SCOPE (.1. .cope of boiler c$emical cleanin&/ 0oiler proper pipe# economi"er# an! water si!e of steam !rum. (.(. T$e cyclone separator insi!e t$e steam !rum is not installe! !urin& t$is perio!. T$e strainer insi!e t$e lower rin& an! t$e outlet orifice are not installe! !urin& c$emical cleanin&. (.3. 1ater Equipment (Title) 2conomi"er 1ater 1all Full !te" #$lume (m%) 1(., 13, C$emical Cleanin&

4nclu!in& .team Drum an! Down Comer# lower $ea!er rin& pipe Temporary Pipe Temporary Tan5 T$t!l .uper 6eater 7ain .team Pipe T$t!l 1ater preser*ation an! bac5was$ 3.3 30 1&&.& 73 3.( '(.2

%. FLO

OF )OILER CHEMICAL CLEANING

PT. TRUBA JAYA ENGINEERING LABUAN 2 BANTEN 2 300 MW CFSPP BOILER CHEMICAL CLEANING PROCEDURE
Uni# I++$ing : Con+#r$,#ion Boil"r Ar"a A rov"- B! : Si#" Manag"r

DOC. NO P-T3107 - PROD - 060

ISSUANCE DATE: Jan$ar! %&' ())* Pag" 0 o. &) RE/ISION : )

T$e boiler c$emical cleanin& process flow/ 1ater flus$in& 8 -l5ali circulation 8 Cleanin& 8 1ater flus$in& after al5ali circulation cleanin& 8 6y!roc$lori!e aci! circulation cleanin& 8 1ater flus$in& 8 Rinsin& an! Passi*ation. +ill water to boiler an! flus$ boiler wit$ c$emical cleanin& pump. *. PREPARATION )EFORE CHEMICAL CLEANING ,.1. T$e +ollowin& system must normally be put into operation separately an! $a*e correspon!in& operation measurement. ,.1.1. T$e water treatment system of power plant $as been finis$e! for commissionin& an! coul! be put into normal operation. 1ater treatment plant can supply enou&$ an! &oo! 'uality fres$ water an! !ematerialise! water. ,.1.(. .tart up boiler an! start up steam system coul! supply 0.9 8 1.0 7Pa pressure steam. ,.1.3. 1aste water treatment system. ,.(. 0oiler $y!raulic pressure test $as been complete. 0oiler insulation $as been finis$e!: t$e furnace is statisfie! t$e con!ition of sealin&. ,.3. Temporary system re'uirements ,.3.1. +inis$ t$e installation of t$e all temporary pipe an! e'uipments accor!in& t$e !rawin&s. +inis$ t$e trial operation of rotary mac$ineries un!er re&ulation. T$e temporary system $as been ma!e $eat insulation in relation to steam system. ,.3.(. T$e temporary system s$all $a*e a $y!raulic pressure test. ,.3.3. T$e copper core *al*e s$oul!n;t be installe! at t$e c$emical cleanin& system. ,.3.,. +inis$ t$e installation an! commissionin& of all electric an! control system. ,.3.3. <al*e at t$e temporary system s$all be !isassemble! an! c$ec5e!. ,.3.6. T$e temporary le*el &au&e of steam !rum s$all be installe!. T$e temporary le*el in!icator of steam !rum was use! to aci! cleanin& sta&e: t$e temporary le*el &au&e is wit$ ran&e ,00mm 8 300mm. ,.3.7. T$ere are reliable communication e'uipments an! water le*el monitorin& e'uipment between !rum le*el point an! &roun! le*el c$emical cleanin& operation platform. ,.3.9. T$e cyclone separator insi!e t$e !rum is not installe! !urin& t$is perio!. =se t$e emer&ency !rain tube insi!e t$e !rum an! temporary raise t$e tube inlet to position of t$e !rum le*el > ,00 mm as an o*erflow pipe to return li'ui! to t$e cleanin& tan5.

PT. TRUBA JAYA ENGINEERING LABUAN 2 BANTEN 2 300 MW CFSPP BOILER CHEMICAL CLEANING PROCEDURE
Uni# I++$ing : Con+#r$,#ion Boil"r Ar"a A rov"- B! : Si#" Manag"r

DOC. NO P-T3107 - PROD - 060

ISSUANCE DATE: Jan$ar! %&' ())* Pag" 1 o. &) RE/ISION : )

,.3.?. @ame plates for *al*e wit$in t$e scope of t$e cleanin& system $a*e been $un& up. ,.3.10. T$e !emineralise! water containin& @63 an! @(6, an! p6 ?.3 to 10.0 s$oul! be fille! to super $eater. ,.3.11. T$e laboratory test room in site is prepare! rea!y an! coul! be put into operation. -ll t$e instrument an! c$emical analy"ers are 'ualifie! subAect to calibration. ,.3.1(. T$e entire formal control# re&ulation an! measurement e'uipment in t$e c$emical cleanin& loop is installation after t$e en! of c$emical cleanin&. T$ere s$oul! be reliable isolation measurement to t$e formal instrument t$at $as been installe!. ,.3.13. -*oi! cleanin& li'ui! corrosion to all t$e pipes an! e'uipment not ta5e part in t$e cleanin& by closin& *al*e an! blin!in& plates. ,.3.1,. Disc$ar&e facilities for cleanin& li'uor waste $a*e been fi%e!. ,.3.13. Do not install c$ec5 *al*e on t$e fee! water pipe of t$e economi"er# or enforce open t$e c$ec5 *al*e if t$e c$ec5 *al*e $as been installe!. ,.3.16. Close t$e primary an! secon!ary *al*e of boiler samplin& tubes# !osin& tube an! instrument tubes. ,.3.17. T$e *al*e in temporary system is c$ec5e! an! 'ualifie! subAect to !isassemble. +. CHEMICAL CLEANING PROGRAM 3.1. 0oiler 1ater +lus$ +lus$in& process flow/ cleanin& tan5 8 cleanin& pump 8 economi"er 8 !rum 8 water wall 8 lower rin& $ea!er 8 temporary pipes 8 rain water collection plant. 3.1.1. +ill water Bfirst clear water# secon! !emineralise! waterC to cleanin& tan5 to $i&$ le*el location# cleanin& pump fill water to boiler# flus$ economi"er# !rum an! water wall# !rain by openin& *al*es of lower rin& $ea!er !isc$ar&e. 3.1.(. Control t$e !rum le*el abo*e t$e centre scale (30 to 300 mm. 3.1.3. Don;t stop flus$in& until t$e sample from samplin& *al*e reac$es t$e stan!ar! B!eli*ery water sample is *isually clean wit$out suspen!e! substanceC. Close t$e !isc$ar&e *al*e. 3.1.,. Prepare t$e solution of 10m& 1 @63>100m& 1 @(6, in cleanin& tan5. =se c$emical cleanin& pump fill t$e !emineralise! water containin& @63>@(6,p6?.3 to 10.0 to super $eater# a!! about 3 tan5s of water. 3.1.3. Open t$e &eneral !isc$ar&e *al*e. Drain t$e flus$in& water in !rum# economi"er# water wall an! lower rin& $ea!er to rain water collection plant.

PT. TRUBA JAYA ENGINEERING LABUAN 2 BANTEN 2 300 MW CFSPP BOILER CHEMICAL CLEANING PROCEDURE
Uni# I++$ing : Con+#r$,#ion Boil"r Ar"a A rov"- B! : Si#" Manag"r

DOC. NO P-T3107 - PROD - 060

ISSUANCE DATE: Jan$ar! %&' ())* Pag" 3 o. &) RE/ISION : )

3.(. -l5ali Cleanin& 3.(.1. Dissol*e t$e followin& c$emical in t$e cleanin& tan5. T$e first concentration of c$emicals use! in al5ali cleanin& sta&e as t$e followin&/ 0.,D w t triso!ium p$osp$ate. 0.(D w t !iso!ium B$y!ro&enC p$osp$ate. =se t$e clean pump fee! al5ali cleanin& solution from economi"er into t$e boiler. 3.(.(. -!Aust !rum le*el to normal operation le*el strictly after al5ali cleanin& solution was fee! to boiler. 3.(.3. C$ec5 boiler an! temporary system *al*e con!ition is rea!y. 3.(.,. Eeeps al5ali cleanin& time for 9 to 10 $ours temperature/ 90 8 ?00 C 3.(.3. T$e !rum le*el is controlle! at t$e top of le*el Babout > (03 mmC. 3.(.6. Concentration of p$osp$ate in boiler water s$oul! be perio!ically analy"e! !urin& al5ali cleanin& sta&e. 4f t$e concentration of t$e c$emical rea&ent !ecreases to 0.1D w t# t$e c$emical rea&ent can be suitably fille! in. 3.3. 1ater +lus$in& after -l5ali Cleanin& 3.3.1. Completely open !isc$ar&e *al*e !isc$ar&e solution. 3.3.(. -fter t$e al5ali cleanin& lye !raina&e is o*er. =se cleanin& pump fill flus$in& water to boiler. 3.3.3. +lus$ stan!ar!/ until t$e !eli*ery water is clear wit$out colour an! impurity# p6 F ?.0. 3.3.,. -fter t$e flus$in& is o*er# a!Aust t$e !rum le*el below t$e centre point 100mm. 3.,. 0oiler -ci! Cleanin& 3.,.1. +illin& C$emicals 2stablis$ followin& cycle flow/ cleanin& tan5 8 cleanin& pump 8 economi"er 8 !rum 8 boiler water wall 8 lower rin& $ea!er 8 cleanin& tan5. Control water temperature to 30 8 600C. -!Aust !rum le*el below centre point 100mm an! t$e cleanin& tan5 at lower le*el.

PT. TRUBA JAYA ENGINEERING LABUAN 2 BANTEN 2 300 MW CFSPP BOILER CHEMICAL CLEANING PROCEDURE
Uni# I++$ing : Con+#r$,#ion Boil"r Ar"a A rov"- B! : Si#" Manag"r

DOC. NO P-T3107 - PROD - 060

ISSUANCE DATE: Jan$ar! %&' ())* Pag" 4 o. &) RE/ISION : )

+ill in$ibitor 9005& to cleanin& tan5# wait for 1 $our an! t$an a!! 6C4. Ta5e sample from return tube. -naly"e 6C4 concentration control t$e 6C4 concentration is less t$an 3.3D w t. w$en t$e 6C4 concentration in t$e return tube reac$es abo*e 3.0D# be&in t$e time recor! for fillin& aci!# put t$e cleanin& monitorin& system into operation. Control t$e !rum le*el abo*e centre point (00 G 30 mm !urin& fillin& aci! an! after finis$in& fillin& aci!. 3.,.(. -ci! Cleanin& Re'uirements Control t$e !rum le*el abo*e centre point (00 G 30 mm after finis$in& fillin& aci!. -!Aust cleanin& solution temperature at 30 8 600C by au%iliary steam $eatin&. -naly"e solution sample for aci! stren&t$ an! iron concentration in cleanin& pump outlet an! return tube an! reco!e t$e temperature perio!ically. 3.,.3. -ci! Cleanin& 2n! Point 2stimation 2n! t$e aci! cleanin& w$en t$ere is basically no c$an&e of ferrous ion an! 6C4 concentration. 3.3. +lus$ after -ci! Cleanin& -fter confirmin& t$e aci! cleanin& is o*er# t$e followin& wor5 s$oul! be !one. 3.3.1. +irst open t$e blow !own *al*e at t$e bottom of cleanin& tan5. Disc$ar&e t$e cleanin& li'ui! insi!e t$e cleanin& tan5 completely an! flus$ t$e cleanin& tan5 wit$ !emineralise! water until t$e tan5 is clean. Close t$e blow !own *al*e at t$e bottom of cleanin& tan5. 3.3.(. .upply !emineralise! water to cleanin& tan5. 3.3.3. Open &eneral !rain *al*e# economi"er !rain *al*e# lower rin& $ea!er blow !own *al*e an! emer&ency !rain *al*e. Disc$ar&e t$e aci! cleanin& li'ui! to waste water treatment pool. 3.3.,. -fter completely !isc$ar&in& t$e cleanin& li'ui! t$e boiler# flus$ t$e boiler. 3.3.3. .tart cleanin& pump to flus$ boiler# flus$in& flow pass/ cleanin& pump 8 economi"er 8 !rum 8 boiler water wall 8 lower !rum 8 temporary pipes 8 waste water treatment pool. 3.3.6. Control !rums le*el abo*e t$e centre point (30 8 330mm. 3.3.7. Ta5e sample from samplin& *al*e analy"in& p6 an! iron ion flus$in& li'ui!. T$e flus$in& is o*er w$en t$e flus$in& li'ui! p6 H 3.3 8 ,.0# iron ion less t$an 30 m& 1 an! wit$out particle basically.

PT. TRUBA JAYA ENGINEERING LABUAN 2 BANTEN 2 300 MW CFSPP BOILER CHEMICAL CLEANING PROCEDURE
Uni# I++$ing : Con+#r$,#ion Boil"r Ar"a A rov"- B! : Si#" Manag"r

DOC. NO P-T3107 - PROD - 060

ISSUANCE DATE: Jan$ar! %&' ())* Pag" 2 o. &) RE/ISION : )

3.3.9. 7ay ta5e into account t$e flus$in& way of t$e entire boiler fillin& water an! entire boiler !rain alternately t$e flus$in& en!point is same stan!ar!. 3.6. Rinsin& an! Passi*ation 3.6.1. -fter finis$in& t$e flus$in&# t$e cycle way must be as followin&/ cleanin& tan5 8 cleanin& pump 8 economi"er 8 !rum 8 boiler water wall 8 lower rin& $ea!er 8 cleanin& tan5. Control !rum le*el abo*e centre le*el point (00 8 (30mm# control t$e water temperature at ,0 8 ,30C by a!Austin& au%iliary steam pressure. 3.6.(. -!!in& rinsin& c$emicals to cleanin& tan5 to ma5e rinsin& li'uor contain 0.13D w t p$osp$oric an! 0.(D w t so!ium tripolyp$osp$ate. 3.6.3. Rinsin& time/ 1 $our 3.6.,. Passi*ation/ a!!in& @a3PO, an! ammonia# a!Austin& rinsin& li'uor p6 H ?.0 8 ?.3. Put in steam to t$e cleanin& tan5 $eat passi*ation li'uor temperature to 33 G 300C# a!!in& @a@O( contain 1D w t. 2n! t$e passi*ation after maintainin& t$e temperature for , $ours. 3.6.3. Disc$ar&e t$e passi*ation li'uor to waste water treatment pool. Open man $oles of !rum an! lower rin& $ea!er to cool naturally# t$e safety measures must be ta5en after openin& man$oles. ,. RE-UIREMENTS OF THE CONCERNE. LA)ORATOR/ TESTS

NO. PROGRAM 1. 1ater flus$in&

ITEM -ppearance

(. 3. ,.

-l5ali cleanin& +lus$in& after al5ali boil-out -ci! cleanin&

@a3PO,.1(6(O @a(6PO,.1(6(O -ppearance p6 6Cl +e3> +e(> 0 C -ppearance p6 +e p6

STAN.AR. INTER#AL Deli*ery water is 10 min clear wit$out colour an! impurity 0.1 8 0.(D w t 60 min Deli*ery water is (0 min transparent I?.0 3.3 8 ,.3D (0 min 30 8 600C @o particles basically 3.3 8 ,.0 ?.0 8 ?.3 (0 min 30 min

3. 6.

+lus$in& after aci! cleanin& Passi*ation

PT. TRUBA JAYA ENGINEERING LABUAN 2 BANTEN 2 300 MW CFSPP BOILER CHEMICAL CLEANING PROCEDURE
Uni# I++$ing : Con+#r$,#ion Boil"r Ar"a A rov"- B! : Si#" Manag"r

DOC. NO P-T3107 - PROD - 060

ISSUANCE DATE: Jan$ar! %&' ())* Pag" * o. &) RE/ISION : )

'.

OR0S AFTER CHEMICAL CLEANING 7.1. C$ec5 t$e c$emical cleanin& 'uality of !rum# lower rin& $ea!er an! monitorin& tube. 7.(. Cleanin& carefully t$e sla& an! splas$in& materials in t$e !rum an! lower rin& $ea!er. 7.3. Remo*e t$e temporary system connectin& wit$ t$e permanent system an! restore t$e permanent system wit$in 7 !ays. 7.,. 1$en t$e internal is more t$e (0 !ays between finis$in& t$e c$emical cleanin& an! first fire# t$e followin& corrosion pre*ention measures must be ta5en/ +ill t$e boiler wit$ !emineralise! water containin& 10 ppm of ammonia an! (00 ppm of $y!ra"ine. T$e p6 of t$e solution s$oul! be appro%imately 10.0.

(. CHEMICAL CLEANING

ASTE TREATMENT

-l5ali cleanin&# aci! cleanin& an! rinsin& passi*ation waste are !isc$ar&e! to waste water treatment pool for neutrali"ation treat. &. SAFET/ RE-UIREMENT ?.1. T$e c$emical cleanin& personnel must be 'ualifie! after trainin&. Complete an! enou&$ in!i*i!ual &uar! &oo!s are prepare!. T$e in!i*i!ual &oo!s are mainly inclu!es/ rubber &lo*es# rubber s$oes# protecti*e &lasses an! protecti*e mas5. ?.(. T$e temporary flus$ water pump an! 1000 5& lime pow!er s$oul! be prepare! in site. ?.3. 2lectric wel!in&# fire source an! smo5in& are pro$ibite! on t$e boiler an! in fiel! !urin& c$emical cleanin&. 6i&$ altitu!e wor5 is pro$ibite! abo*e cleanin& panel# temporary laboratory test an! !uty room to pre*ent matters !roppin& from $i&$ place. ?.,. 2nou&$ foam an! fire e%tin&uis$ers s$oul! be prepare! for c$emical cleanin& in fiel!. T$e material an! tools for ur&ent repair an! eliminatin& !efects suc$ as steel wire# anc$or ear an! aci! resistant rubber plastic clot$es s$oul! be prepare!. ?.3. T$e li&$tin& is enou&$ in fiel!. ?.6. 7a5e fence by belt aroun! boiler# pump an! cleanin& tan5 an! t$e alarmin& si&ns wit$ notable writin& of 1N$ 2m$3in4 !n5 6i"e78 1N$ !5mitt!n9e e:pe9t $n ;u2ine2278 1.!n4e"$u2 !9i5 liqui57 etc. ?.7. Remo*e t$e &roceries an! useless e'uipment remaine! near t$e systems an! in t$e access or stairs after t$e completions of installation to &uarantee unbloc5s access. ?.9. C$ec5 t$e con!ition on &roun! le*el layer to ensure safe mobile transportation an! personnel operation.

PT. TRUBA JAYA ENGINEERING LABUAN 2 BANTEN 2 300 MW CFSPP BOILER CHEMICAL CLEANING PROCEDURE
Uni# I++$ing : Con+#r$,#ion Boil"r Ar"a A rov"- B! : Si#" Manag"r

DOC. NO P-T3107 - PROD - 060

ISSUANCE DATE: Jan$ar! %&' ())* Pag" &) o. &) RE/ISION : )

?.?. T$e personnel contactin& aci! an! ammonia s$oul! be instructe! in a!*ance an! wear aci! resistant clot$es wit$ rubber $oo!# rubber s$oes# rubber &lo*es# protecti*e &lasses an! protecti*e mas5. ?.10. T$ere s$oul! $a*e rescuin& person on !uty in file! for first an! treatment. T$e followin& &oo!s s$oul! be prepare! also. Towel 2yecup -bsorbent cotton 0urns ointment (D @6,6CO3# wit$ w$ic$ to neutrali"e after was$in& wit$ water w$en t$e aci! li'ui! sprays on s5in an! apply <aseline ointment 0.3D @a6CO3# wit$ w$ic$ to neutrali"e after was$in& wit$ water w$en t$e aci! li'ui! sprays in eyes an! flus$ clean by water. C$emical for curin& aci! or al5ali burns !eeme! by !octor ?.11. -ll c$emicals are 'ualifie! subAect to c$ec5. T$e in$ibitor is 'ualifie! subAect to small-scale test in fiel!. 1<. ATTACHMENT - +low Dia&ram for 0oiler C$emical Cleanin& - Or&ani"ation C$art