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Appendix A
The Operational and Safety Aspects

of Chemical Cleaning of Thermal
Power Plants
1.0 General Guidelines of Pre and Post-Operational Cleaning of

Drum-Type Boilers, Economizers, Super Heaters, Reheaters,
Condensate and Feed Systems
1.1 Introduction
Damage can occur in the water/steam circuits of an operating plant if
the internal surfaces are coated with foreign matter such as adventitious
metal oxides, grease, oil, and dirt or have excessively thick grown
oxides. These can be removed after erection and prior to commission-
ing, and be controlled during subsequent operation by chemical
cleaning.
1.2 Scope
This covers the objectives and criteria for the chemical cleaning of
drum-type/drumless boilers and surface conditioning of the water/steam
circuit of conventional power plants using suitably inhibited ammoni-
ated citric, hydrochloric, sulphamic and hydrofluoric acids; it also
determines the protection of the plant after cleaning.
The requirements of “safety aspects”, to be applied for the pre-
and post-service cleaning of boilers, economizers, super heaters,
reheaters, condensate, and feed systems.
1.3 Objectives of Cleaning
The aim is to commission and operate the plant with the internal
surfaces of the water/steam circuit as free as practicable from foreign
matter, and to establish a satisfactory basis for the growth of a
protective magnetite film, by removing debris and thick oxides
accumulated during construction and operation.
© Springer India 2016 147

P. Chanda and S. Mukhopaddhyay, Operation and Maintenance
of Thermal Power Stations, Energy Systems in Electrical Engineering,
DOI 10.1007/978-81-322-2722-9
148 Appendix A: The Operational and Safety Aspects of Chemical Cleaning …
1.4 Criteria for Chemical Cleaning

1.4.1 Pre-service Cleaning of Boiler Furnace and Economizer Tubes
Along With Condensate and Feed System
As a result of the application of clean working conditions, the
condensate and feed systems of drum boilers, super heaters, and
reheaters do not require pre-service chemical cleaning. Instead, they
shall be either water flushed or steam purged. However, if the clean
conditions are not met, alkaline washing of condensate and feed system
as given in Appendix 1A.II shall be practiced.
The furnaces of drum boilers still require to be cleaned and suitable
processes, as given in Appendix 1A.-I, are an alkaline boil-out/alkaline
flushing to remove grease and protective coatings followed by a citric or
hydrofluoric or hydrochloric acid stage to remove oxides and other
debris originating during construction, and finally passivation using
ammonia and hydrazine or sodium nitrite and ammonia.
1.4.2 Post-operational Cleaning of Boiler Furnace Tubes (and
Economizer Where included)
Factors that need to be considered in determining the need for cleaning
are:
(i) Changes in operational chemistry (e.g., the occurrence of
“hide-out” or incidence of persistent condenser leakage).
(ii) The presence of large amounts of water-side debris, revealed by
periodic examination or by indirect instrumental methods.
(iii) The occurrence of on-load corrosion, particularly when there has
been extensive retubing.
(iv) The type of boiler-tube geometry, operating pressure, heat flux
(i.e., the sensitivity of the boiler).
(v) Mode of operation-base load/cycling/number of start-ups.
(vi) Lay-up practices of feed trains and boilers that have been applied.
(vii) Post-acid clean history of the specific plant.
1.4.2.1 The Case for Routine Cleaning
Routine cleaning is often considered because if unduly thick oxides are
allowed to accumulate, they are less easily removed and can concentrate
salts which can intensify corrosion. The aim of periodic cleaning is to
preempt the development of such conditions and the cleanings can be
carried out on the basis of either oxide thickness or time. Severe
problems such as heavy oxide deposition would be one indication of the
need to clean. Super heaters and reheaters are not normally included in
the circuit for routine chemical cleaning.
Appendix A: The Operational and Safety Aspects of Chemical Cleaning … 149
1.4.2.2 Oxide Thickness as a Guide to Cleaning

Oxide thickness provides the most reliable guidance on the need to
clean. Measurement for this purpose should be made periodically on
samples taken from the higher heat flux zones of the boiler or from
areas known to be most susceptible to deposit formation. Normal oxide
growth rates tend to be in the range of 1–2 m/kh. A general review has
shown that for coal-fired plants (160 bar), an oxide thickness of 100 µm
has been experienced without any evidence of detrimental corrosion
damage to the underlying metal surfaces. However, the projected
influence of site-specific factors needs to be considered to establish an
allowable maximum oxide thickness for individual units. Risks of
corrosion beneath deposits are dependent on the heat flux experienced
by the plant and oil-fired plants typically have higher heat fluxes and a
limit of 50 µm is recommended for these stations. In the absence of
reliable oxide thickness data, routine cleans should be carried out at
intervals of time determined empirically, a typical frequency for
160 bar plant being 4–6 years to be compatible with the plant’s major
outage frequency.
1.4.3 Post-operational Cleaning of Super heaters, Reheaters,
Condensate, and Feed Systems
1.4.3.1 Super heaters, reheaters, condensate, and feed systems are not normally
cleaned for the purpose of removing iron oxide during their service life.
1.4.3.2 If an abnormal requirement for the post-service cleaning to remove iron
oxide deposits from any of these plant items arises, it could probably be
met by employing a modification of Appendix 1E.
1.5 Available Cleaning Processes and Their Application
1.5.1 Process Details
Details of the on-site cleaning processes are given in the Appendices.
Suitable methods of chemical analysis for controlling the cleaning
processes are given in Sect. 4, ‘Analytical Methods’ and safety
precautions are given in Sect. 5, ‘Safety Aspects’.
Wherever pH value or conductivity is quantified, measurement at 25 °C
is implied.
1.5.2 Furnace and Economizer Tubes of Drum Boilers
1.5.2.1 Pre-operational Cleaning
The specified procedure is a preliminary alkaline boilout/alkaline
flushing using trisodium phosphate, followed by hydrofluoric acid/HCl
or ammoniated citric acid, citric acid rinse, and high temperature
passivation, according to Appendix 1A.
1.5.2.2 Post-operational Cleaning

Selection of the chemical cleaning process should be made by
referencing Appendix 1C. The procedures are given in Appendix 1D.
Hydrochloric and hydrofluoric acid are specified as alternatives to
ammoniated citric acid and have advantages if the boiler is especially
dirty or corroded.
The choice of acids is discussed in more detail in Sect. 1.5.4.2.
1.5.3 Super Heaters and Reheaters
1.5.3.1 Pre-operational Cleaning
This area of the plant does not require being chemically cleaned if
erected according to standard practices. However, the plant requires
steam purging, as specified in Appendix 1B.
1.5.3.2 Post-Operational Cleaning
Post-operational cleaning of super heaters and reheaters is covered in
Sect. 1.4.3.
1.5.4 Supplementary Notes
1.5.4.1 Before commissioning, removal of debris by physical cleaning
processes such as flushing shall be used irrespective of any chemical
cleaning. Steam purging (see Appendix 1B) of the super heater,
reheater, and associated pipework is used to remove material which
may remain after erection.
1.5.4.2 Acids Available for Cleaning
The formulations conventionally used for iron removal in chemical
cleaning are 5 % hydrochloric acid, 1–2 % hydrofluoric acid, or 3 %
ammoniated citric acid, each appropriately inhibited as detailed in
Appendix 1F. Compared with ammoniated citric acid, hydrochloric acid
is cheaper, quicker, and holds more iron, but has a greater risk of
pitting. Hydrofluoric acid is very fast and also holds more iron and can
be inhibited to reduce ferric ion corrosion, but particular care must be
taken in its use and disposal. The capacities for iron of 5 %
hydrochloric acid, 2 % hydrofluoric acid, and 3 % ammoniated citric
acid are 2.5, 1.9, and 0.9 %, respectively. However, citric acid is quite
suitable for the majority of cleaning applications and, in some instances,
is the only available option.
1.5.4.3 Choice of Acid for Iron Oxide Removal
1.5.4.3.1 Guidance on selection of chemical cleaning processes for
post-operational cleaning is given in Appendix 1C. 3 % citric acid is
suitable unless the boiler is either very dirty or corroded. With dirty
boilers, extra acid can be used but where corrosion is present,
hydrochloric acid or hydrofluoric acid may be required. However,

severely scabbed tubes are not susceptible to any acid cleaning process
and some tube replacement is necessary. For boilers with a satisfactory
history of routine cleaning with hydrochloric acid, there is no good
reason to change from the reagent. However, it should be noted that
local corrosion of heat-affected weld zones could occur with
hydrochloric acid, but to a much lesser extent, in citric acid. The effect
has occurred so far only with steels of 0.3 % carbon and while the bulk
of boiler tubes are 0.18 % or less, there is an increasing tendency to use
steels with higher carbon values which tends to mitigate against the use
of hydrochloric acid.
1.5.4.3.2 Work has shown that if 0.5 % formic acid is added to the conventional
citric acid formulation, the capacity for iron is increased by about 20 %
and oxide dissolution occurs more rapidly. Potentially, therefore, this
modification presents another option for iron removal.
1.5.4.4 Fluoride
1.5.4.4.1 The presence of fluoride 0.25–0.5 % ammonium bifluoride increases
the rate of dissolution of iron oxide slightly in hydrochloric acid and
more substantially in citric acid, although in both cases, the solubility of
iron is virtually unchanged. Fluoride additions also improve the
dissolution of siliceous material in hydrochloric acid but in citric acid
this effect of fluoride varies according to the form(s) of silica present.
1.5.4.4.2 Flouride/NH4HF2 should not be added to the citric or hydrochloric acid
solution until the circuit is leak free. There is no test data yet available
to demonstrate that fluoride can be used safely with austenitic stainless
steels.
1.5.4.5 Circulation
Circulation of acid is necessary both to avoid local depletion of effective
strength of acid and inhibitor, and to facilitate the use of analysis to
control the process. For drum-type boilers, the aim should be to obtain
an average rate of circulation of 0.3 m/s in the generator tubes with a
maximum rate of 1.5 m/s. Clearly, the target rate may be exceeded in
some parts of the circuit and experimental work has shown that flow
rates of 1.5 m/s double the corrosion rate found at 0.3 m/s. The effect of
velocity is much more pronounced with inhibited hydrofluoric acid,
albeit from a very low corrosion rate at the low velocity.
1.5.4.6 Copper Removal
In certain situations, economies can be introduced in the copper removal
stages of chemical cleaning, for example, where local experience has
shown that only small amounts of copper are removed on cleaning. In
such cases, only one copper removal process needs to be utilized and it is
advantageous to use it after iron removal. Furthermore, it may be possible
to divide in half the chemical concentrations of sodium bromate and citric
acid, the pH still, however, being adjusted to 9.5. Work has shown that
sodium nitrite is a less acceptable alternative to sodium bromate for the
oxidizing agent in copper removal, despite its apparent advantage for the
secondary purpose of short-term passivation. If gas-induced circulation is
being used, air is an acceptable medium during copper removal, but does
not obviate the need for sodium bromate.
1.5.4.7 Passivation After Cleaning
To minimize deterioration of the active surfaces produced by acid cleaning,
a final passivation stage is an essential part of the overall cleaning process.
Details are included in Appendices 1A, 1D, 1E and supplementary notes
are given in Sect. 1.8, ‘Protection of Plant After Cleaning’.
1.5.4.8 Protection of Plant When the Cleaning Process is Interrupted
Special situation could arise if it were necessary at any stage to curtail
or suspend a cleaning. Guidance on the available courses of action in
such circumstances is given in Appendix 1G.
1.6 Practical Considerations
1.6.1 Planning
1.6.1.1 Coordination
Experience has shown the need for full consultation between the
Engineering, Design and Construction, Plant Engineering, and
Operation Services before carrying out pre-operational chemical
cleaning.
1.6.1.2 Operational Water Requirements
During cleaning, there is a requirement for very large quantities of
clarified and DM water. Careful programming of the installation and
commissioning of the water treatment plant and water storage tanks is,
therefore, required before commencing pre-commissioning cleaning.
For post-operational cleaning, application of the complete Appendix 1D
may use up to 12 boiler volumes of DM water.
1.6.1.3 Effluents
It is essential that all statutory requirements covering effluent disposal
from the station are established and met. In some circumstances, citric
acid waste can be disposed of by burning in an adjacent boiler.
Hydrofluoric acid waste can be disposed of in the ash lagoons by

neutralizing the acid with lime and precipitating residual fluoride with
calcium chloride solution. With all chemical cleaning solutions, care
shall be taken to avoid contravening Pollution Control Board discharge
limits. Where effluent removal is by tanker, adequate tanker capacity
must be available so that the cleaning program is not delayed or the
plant put at risk.
1.6.2 Supervision
Supervision of cleaning processes requires suitably trained staff to be
present at all times. In addition to the overall supervision provided by
the contractor, a complete post-operational cleaning of one boiler may
take 100–200 h depending mainly upon the rigging time.
1.6.3 Engineering Aspects
1.6.3.1 Permanent Points for Post-operational Cleaning
Recommendations are given.
1.6.3.2 Circuit Integrity
The integrity of the circuit to be cleaned must be tested by filling with
water before introducing chemicals.
1.6.3.3 Station Pumps
Subject to the manufacturer’s approval, boiler circulation pumps may
be used for pre- and post-operational cleaning, or gas-induced
circulation. Where permanent points are fitted, the economizer is
included in the boiler circuit for cleaning. If it is considered necessary to
clean the economizer as well as the boiler furnaces when gas circulation
is used, an auxiliary pump will be required. The neck weals of idle
circulation pump motors should be protected from contact with
chemical cleaning solutions by back-flushing with de-mineralized
water.
1.6.3.4 Flexible Pipework
While the use of flexible pipework is not prohibited, all temporary
connections should be made in rigid material, wherever practicable. All
pipework, flexible or rigid, must be sufficiently reliable for the whole of
the operation. With flexible pipework, suitably placed valves must be
provided for isolation in case of failure.
1.6.3.5 Drum Furniture
The removal of drum internals for cleaning is desirable to facilitate
circulation of reagent and inspection, and for the removal of debris, but
their replacement is time consuming. Program considerations usually
dictate that both pre- and post-operational cleaning are carried out with
most of the drum internals in place.
1.6.3.6 Stagnant Areas
Particular attention must be given to stagnant areas, instrument
connections, and similar items to ensure that they are properly cleaned
and flushed. Temperature measurement points should be installed to
show uniformity of circulation, although an infra-red TV camera is
preferable for this purpose. Adequate sampling facilities should be
available to check reagent strength and circulation.
1.6.3.7 Water-Plugging of Super heaters
To prevent cleaning solutions entering the super heater while only the
boiler circuit is being cleaned, the super heater shall be water-plugged
before any circulation of cleaning solution commences and
back-flushed between the various stages of the process. Care must be
taken to ensure that the super heater can be adequately back-flushed. In
addition, as discussed in Appendix 1H, a constant head overflow device
shall be fitted to the boiler drum, and suitable arrangements made to
indicate drum level during cleaning. Make-up water should be adjusted
to a Ph OF 8.8–9.2, and ammonia should be used for this purpose.
1.6.3.8 Venting
While chemical cleaning operations are in progress, venting of the
boiler, including the vent from the constant head overflow, should be to
the outside of the building into an area inaccessible to personnel.
1.6.3.9 Inspection
Thorough inspection of the plant, as far as practicable, shall be carried
out at the end of the cleaning process, giving due regard to the
precautions given in Sect. 5, ‘Safety Aspects’.
1.6.4 Chemical Aspects
Given that there have been problems of degradation of inhibitors in
storage, it would be advisable to check the age and batch number of the
chemical used. Apply the inhibitor efficiency test before use.
1.6.4.1 Chemical Requirements
As some cleanings require additional amounts of chemicals (principally
for iron removal), a sufficient reserve should be available locally to
minimize delay to the program. This is particularly important for the
first cleaning in a boiler’s history or after a change of operating regime
(e.g. from base-load to two-shifting).
1.6.4.2 Chemical Addition

All chemicals shall be added to the cleaning solution in such a manner
as to avoid localized concentrations in the cleaning solution or dilution
tanks by addition at a continuous constant rate while the solution is
being circulated. Avoiding higher acid concentration than specified is
necessary to avoid corrosion. Careful control is necessary when
ammonia is being added to acid solutions containing inhibitors, to avoid
any possibility of inhibitor precipitation.
1.6.4.3 Addition of Inhibitors to Cleaning Solutions
1.6.4.3.1 The approved inhibitor must be present under acid conditions at all
times to ensure that it is fully dissolved and not subsequently
precipitated. It must always be added direct to an acid solution and
not be previously diluted with water or added to water to which the acid
is added later. This requirement can be met by injecting the acid and the
inhibitor simultaneously at the suction of the pump used for injecting
chemicals into the cleaning circuit.
1.6.4.3.2 Some constituents of inhibitors have very limited solubility and,
therefore, must be added to the cleaning solution in a controlled
manner, pro-rota with the acid injection. The inhibitor must be added at
a constant rate over that period of time required for complete circulation
of the cleaning solution, by using either a metering pump or a drip-feed
arrangement.
1.6.4.3.3 The most critical of all chemical additions is that of the inhibitor which,
in some instances, has a very limited solubility (e.g., stannine LTP), and
its addition to the solutions must be made in accordance with Sect. 5,
‘Safety Aspects’. Strict observance of these requirements, in conjunc-
tion with ventilation of the plant and meeting temperature requirements
before entry, have enabled the breathing equipment previously required
for plant inspection after chemical cleaning to be waived in certain
circumstances. The precautions required under such condition are given
in Sect. 5, ‘Safety Aspects’.
1.6.4.3.4 Following the inhibitor addition and at regular intervals during the acid
cleaning stage, a ‘wire wool’ ball test for inhibitor effectiveness should
be used. In this test, a small ball of steel wool (about 0.1 g) is degreased
and added to a sample of the iron removal solution. Inhibition is judged
to be adequate if the wire wool ball does not float after 1 min in
ammoniated citric acid or 2 min in hydrochloric acid. The test is rapid,
but can be affected by a number of factors including temperature,
therefore, the test must be carried out at the same temperature as the
cleaning solution in the boiler or coupon test is done in laboratory by
taking polished metal coupon and subjecting it to test conditions of
temperature and various concentrations of acid and inhibitor.
1.6.4.4 Water Quality for Super heater Flushing

Contaminated water containing significant quantities of chloride has been
found in the super heaters and reheaters of new drum-type boilers after
erection, presumably being present as a result of the use of unsuitable
water for hydraulic testing. To avoid any risk of stress-corrosion of
austenitic material arising from this source, especially during the
pre-commissioning alkali boil-out, flushing of the super heaters and
reheaters with deionized water shall be carried out before the alkali boil.
Intermittent flushing shall be used until the conductivity of the effluent
water is less than 5 us/cm and the chloride is below 1 mg/kg.
1.7 Water Flushing
Flushing of the plant with water will be required for the following
purposes:
(i) To remove any contaminant which has entered the plant during
erection and any loose corrosion products.
(ii) To remove volatile corrosion inhibitors if used for protection of
the plant during storage and erection.
(iii) To remove chemicals and residual sludge after site cleaning
processes.
Notes:
1. This procedure may be unsuitable for large vessels (e.g., DC heaters) because
of weight support limitations.
2. After water flushing has been completed, the plant shall either be dried out or
put in wet storage, unless the flushing immediately precedes a further stage of
cleaning.
3. Water flushing shall be carried out using deionized water if austenitic
components are present or for once-through boilers. If any other plant is given
a preliminary flush with filtered water, it shall be thoroughly flushed out
afterward with deionized water, except where it is to be followed by a chemical
cleaning process.
1.8 Protection of the Plant After Cleaning
1.8.1 The Need for Passivation
After the steel surfaces have been chemically cleaned, they are very
‘active’ and subject to rapid rusting. It is, therefore, necessary to passivate
the cleaned metal surfaces to prevent their deterioration. Operation
immediately after passivation is the best means of establishing the
protective oxide film.
1.8.2. Passivation at 40 bar

Good passivation can only be achieved under high-temperature and
high-pressure conditions (40 bar is recommended) and for preservation of
the passive film, the boiler should be emptied while hot and at 3–5 bar
pressure, or if operationally acceptable, from 28 bar, to ensure that the
surfaces dry out.
1.8.3 Passivation at 7 bar and Below
In certain situations (e.g., feed systems) it is not possible to obtain
high-pressure passivation conditions immediately after the
pre-commissioning chemical cleaning. It is then necessary to resort to
the circulation of a hydrazine/ammonia solution at 95 °C which confers a
limited resistance to rusting. Passivation may be carried out using
trisodium and disodium phosphate at 70 °C. Some contractors use sodium
nitrite and ammonia solution at 70 °C for preliminary passivation and then
hydrazine and ammonia for final passivation at 90–95 °C.
1.8.4 Storage After Passivation
Where passivation at 90 °C has been utilized, it is recommended that the
plant be either thoroughly dried out, which is the preferred method, or
stored wet using corrosion inhibiting solutions which are specified.
Appendix 1A-I Pre-operational Cleaning of Boiler Furnace and Economizer

Tubes
1A-I.1 Introduction
The following stages constitute a complete cleaning and must be
carried out consecutively and with minimum delay. The steps can
be alkali flushing or alkali boil-out followed by acid cleaning and
passivation.
1A-I.2 Precautions
Precautions must be taken to ensure that the chemical cleaning
solutions used in stage 1A-I.3.3 and 1A-I.3.5–1A-I.3.8 do not
enter the super heater. During stage 1A3.3, the water level shall
not be above normal working level. During stages 1AI3.5–
1AI3.8, the super heater shall be filled with deionized water
(treated with 200 ppm N2H4 and pH around 10) to form a water
plug and back flushing should be carried out periodically. In
addition, during stages 1AI3.5–1AI3.8, a constant head overflow
device should be fitted to the drum (see Appendix 1H).
1A-I.3 Sequential stages

1A-I.3.1 Hot Water Flushing
Fill and drain the boiler as far as possible using DM water to
remove foreign matter and check for leakages and blockages.
Flush the super heaters and reheaters intermittently using
deionized water until the water leaving the super heater and
reheater has a conductivity of less than 5 us/cm and a chloride
content of less than 1 mg/kg chloride.
1A-I.3.2 Alkali Boil Out
Fill the boiler to working level with demineralized water
containing 1000 mg/kg trisodium phosphate.
Raise the pressure to 40 bar with intermittent blowing down for 30 s
during every hour. The final pressure should be reached in 8–10 h.
Maintain the boiler at 40 bar pressure with the specified chemical
concentration for at least 24 h. Drain while the boiler is still as
hot as practicable and if possible, while under pressure.
Cool the boiler drum to 90 °C metal temperature and open the
boiler drum and distribution drum’s (if any) manhole for
examination/chemical addition and remove any loose deposits.
1A-I.3.3 Alkali Flushing
*The boiler is filled with a solution containing 2000 mg/kg
TSP and
2000 mg/kg DSP
4000 mg/kg Na2CO3
and a suitable surface active agent at 90 °C.
Circulate for 24 h and drain.
1A-I.3.4 Acid Cleaning
1A-I.3.5 Circulate a solution in deionized water containing one of the
following chemicals through the boiler
(i) 3 % W/W citric acid with an approved inhibitor (see
Appendix 1F) and ammonia to give pH 3.5–4.0.
Initially, circulate at not less than 90 °C (maximum
105 °C) and continue until the iron content is constant
(Note 1). The concentration of free citric acid should be
maintained at not less than 0.5 % W/W during circulation,
otherwise basic citrates might precipitate.
(ii) 5 % Hcl acid with 0.25 % ammonium bifluoride and 0.2 %
inhibitor (Rodine-213 Sp) at a temperature of 70 °C
(Appendix 1A-III).
(iii) 1 % W/W hydrofluoric acid with an approved inhibitor

(Appendix 1A-IV).
Circulate at 55 °C until the iron concentration is constant (Note
1). The concentration of free hydrofluoric acid should be
maintained at not less than 0.2 % W/W during circulation.
1A-I.3.6 Raise the pH to 5.0 by careful addition of ammonia added slowly
during circulation to avoid high pH values (Note 2)
1A-I.3.7 Drain the boiler, and when using ammoniated citric acid, rinse
with a solution containing 0.2 % W/W citric acid with ammonia
to give pH 3.5–4.0
1A-I.3.8 Flush the plant with deionized water until pH remains above 6.0
and conductivity <20 micro Siemens/cm
1A-I.3.9 Fill the plant with deionized water containing:
100 mg/kg N2H4 and with 100 mg/kg ammonia for interim
passivation.
Or, 50 mg/kg hydrazine with 50 mg/kg ammonia for final
passivation.
Maintain a minimum pH of 10.0.
Raise the pressure to 40 bar and maintain for not less than 24 h.
No further additions of hydrazine to the boiler are required
because this has been shown to be unnecessary. However,
50 mg/kg hydrazine and 50 mg/kg ammonia shall be added to
the make-up water to the boiler to react with dissolved oxygen.
On completion of stage 1A-I.3.9, blow the boiler empty at the
highest possible pressure, but in any event, not less than 4 bar.
Notes:
1. Experience shows that provided the system has been lagged, the temperature
should not have fallen below 75 °C before cleaning has been completed, when
using ammoniated citric acid, or 50 °C with hydrofluoric acid/hydrochloric
acid.
2. The reasons for raising pH above 5.0 are:
(i) To minimize corrosion of the plant after cleaning, but before displace-
ment of acid.
(ii) To avoid corrosion in discharge points and culverts.
Appendix 1A-II Pre-operational Cleaning of HP Feed Systems

1A-II.1 Introduction
Generally, if cleaning conditions are met during the course of
preparation, the pre-boiler system shall be water flushed only.
However, some vendors suggest an alkaline wash or alkaline
wash followed by acid cleaning and passivation of the feed
system, which are detailed below.
1A-II.2 Precautions
Precautions must be taken to ensure that all the instrument
tappings are isolated, HP heaters and BFP are blanked off,
internals of all the regulating valves are removed or they are
replaced by spool pieces, all orifices and flow nozzles are
removed, and feed line connections to HP heaters are isolated or
blanketed. Pipeline portions which cannot be included in the
flushing operations shall be mechanically cleaned and inspected
before erection.
1A-II.3 Sequential Stages
1A-II.3.1 Flush the system with filtered water at an ambient temperature to
remove foreign matter.
1A-II.3.2 Fill the system with DM water at 70–80 °C. Circulate the water
and drain. The process of filling, circulating, and draining is
continued until the outlet water quality matches the inlet water
quality in turbidity and color.
1A-II.3.3 Chemical solution in demineralized water for alkali flushing of
trisodium phosphate 5000 ppm as Na3PO4 12H2O along with a
suitable wetting agent are filled in the system and the
temperature is raised to 80–95 °C. Samples are taken every
hour and analyzed for oil impurities, iron, and pH values. The
process is deemed to be complete when there are no traces of oil
impurities when the iron content and pH stabilizes in inlet and
outlet, or after 12 h of circulation. The system is drained.
1A-II.3.4 The system is rinsed with DM water to remove alkalinity left on
the surface. Hourly samples are compared for phosphate,
alkalinity content, and conductivity. When conductivity and
pH are the same as that of DM water, the operation is complete
and the system should be drained.
1A-II.3.5 For acid cleaning, fill the HP feed system with demineralized
water.
1A-II.3.6 Raise the water temperature to 95 °C.

1A-II.3.7 While maintaining the circulating flow, add chemicals to give
the following final solution:
3 % W/W citric Acid
0.05 % W/W stannine LTP inhibitor
Ammonia for a of pH 3.5–4.0.
1A-II.3.8 Circulate the solution for 6–8 h until leveling out of iron and
acid concentration in inlet and outlet.
1A-II.3.9 Drain the system.
1A-II.3.10 Rinse the system with 0.2 % W/W solution of citric acid
ammoniated to a pH of 3.5/4.0 by filling and circulating briefly.
1A-II.3.11 Flush the system using demineralized water until the conduc-
tivity is 30 us/cm or less.
1A-II.3.12 Fill the HP feed system with demineralized water.
1A-II.3.13 Raise the temperature of the circulating water flow to 95 °C.
1A-II.3.14 While maintaining the circulating flow, add chemicals to give
the following final solutions:
300 ppm hydrazine
Ammonia to give pH 10.
1A-II.3.15 Circulate the solution for 12 h.
1A-II.3.16 Drain the system while hot. Preserve the HP feed heater by N2
capping if not used immediately.
Appendix 1A-III Pre-operational Cleaning of Boiler Furnace and

Economizer Tubes with Hydrochloric Acid
1A-III. 1.0 Hydrochloric acid cleaning.
1A-III. 1.1 Ammonium bifluoride 0.25 % may be added to the inhibited
acid solution for the intensification of the reaction and its
effective silica removal.
1A-III. 1.2 Boiler is drained under nitrogen capping.
1A-III. 1.3 Boiler is filled with DM water at 65 °C to a level slightly higher
than the acid level and is completely drained under nitrogen
pressure. The superheater is back flushed simultaneously.
1A-III. 1.4 Citric acid rinse is carried out using 0.1 % W/W citric acid with
a of pH 3.5–4.0. The second rinse with citric acid is done at a
temperature of 65 °C. This step is to ensure a more thorough
iron removal.
1A-III. 1.5 Drain the citric acid solution under nitrogen capping.
1A-III. 1.6 Carry out neutralization using a neutralizing solution contain-
ing 8000 ppm of trisodium phosphate, (Na3PO4 12H2O) and
4100 ppm of disodium phosphate (Na2HPO4 7H2O) at a
pressure of 7 kg/cm2. Hold the pressure for about 2 h
Neutralization can also be done using 1 % soda ash solution at
85–90 °C for about 6 h.
1A-III. 1.7 Switch off the fires. Allow boiler to cool gradually. Open the
drum vents when the drum pressure drops to 1–2 kg/cm2. Drain
the boiler when the drum temperature drops to below 100 °C.
Appendix 1A-IV Pre-operational Cleaning of Boiler Furnace and

Economizer Tubes–Hydroflouric Acid Cleaning
1A-IV. 1.0 Hydrofluoric Acid Cleaning
1A-IV. 1.1 Both once-through and circulating methods can be utilized for
cleaning, In the once-through method, the system is filled with
hot water at approximately 70 °C and the acid and inhibitor are
dosed in such a way that a concentration of 0.15 % inhibitor
and 1 % HF are achieved in the feed water line. The dosing
shud be continued until concentration at the outlet reaches
approximately 1 % HF and the iron values are decreasing down
to 2g Fe/l. All pumps are stopped and the acid remains
approximately 2 h in the system for a static treatment.
1A-IV. 1.2 Then the acid is replaced by DM water. The super heaters are
back flushed. Flushing is continued until the conductivity
difference between inlet and outlet water is less than 10 us/cm.
1A-IV. 1.3 Passivation is done by using ammonia to bring the pH up to
10.2 and by hydrogen peroxide at a concentration of 0.1 % at
an ambient temperature.
Appendix 1B Pre-operational Steam Purging of Super Heaters and

Reheaters
1B-1 Effective steam purging requires extensive temporary pipework
and involves complex theoretical considerations which must be be
studied for each individual design. To be fully effective, it is
necessary to achieve a scouring action at least equivalent to that of
full load steam flow. ASME PTC 4.1/BS-2885 gives a method for
calculating sizes of pipework, and pressure and temperature
conditions necessary for steam purging the super heater, reheater,
and steam pipework together with the necessary chart. Because
there is now a computer program available for carrying out the
required calculations, practical guidance, based on experience on
steam purging at many stations, is also included.
1B-2 During steam blowing, there is an increased risk of water carryover
because the pressure drop which occurs is higher than during
normal operation. To minimize the risk of stress corrosion, sodium
hydroxide must not be added to the boiler water during steam
blowing. The boiler is initially filled with 50 mg/kg hydrazine and
50 mg/kg ammonia. No further additions of hydrazine are required,
but 50 mg/kg hydrazine and 50 mg/kg ammonia should be added to
the make-up water to the boiler to react with dissolved oxygen.
Before commencing the steam blowing process, it must be proved
that all cleaning chemicals have been thoroughly flushed from the
boiler water circuit. The boiler water should not contain more than
0.1 mg/kg chloride (as Cl−) or 0.2 mg/kg sodium (as Na+).
Appendix 1C Post-operational Cleaning of Furnace and Economizer Tubes:

Selection of Chemical Cleaning Processes
Principle deposition during operation of a boiler

1. Mill scale.
2. Oxides of iron and copper.
Tube samples (approximately 600 mm length) to be collected from high heat
flux area (around 3 m above wind box). The following criteria are considered for
depositions.
Boiler type Internal deposits

Clean surface Dirty surface Very dirty surface
(mg/cm2) (mg/cm2) (mg/cm2)
Sub critical <15 15–40 >40
Super critical <15 15–25 >25
All measurement to be done on the furnace side of the tube samples.

Criteria for deciding chemical cleaning are as follows.
Pressure (kg/cm2) Drum type Once-through type

140 140–180 180 Super critical
Quantity of deposits (mg/cm2) 50–70 40–50 30–40 20–30
Common solvent used is HCL (5 %) at 75 °C. Inhibitor used:

• Ammonium bifluoride if large amount of silica is present.
• Ammonium bromate if large amount of copper is present.
Additionally, the following chemicals are also used:
• Phosphoric acid (3 %) at 100 °C
• Ammonium citrate (5 %) at 105 °C
• Formic hydroxyacetic acid (3 %) at 7 °C
• Ammonium EDTA (3 %) at 150 °C.
Circulation speed should be between 0.3 and 1.0 m/s.
Appendix 1D Post-operational Cleaning of Furnace Tubes in Drum-Type
Boilers (And Economizers, Where Necessary)
1D-1 Introduction
The following stages constitute a complete cleaning and must be
carried out consecutively and with minimum delay (Note 1).
1D-2 Precautions
Precautions must be taken to ensure that the chemical solutions do
not enter the super heater. The super heater must be filled with
deionized water to form a water- plug and back-flushing shall be
carried out periodically. In addition, a constant head overflow
device must be fitted to the drum (see Appendix 1H).
1D-3 Sequential Stages
1D-3.1 In some circumstances, the copper removal stage may be
unnecessary (Note 2) and in others, it may be carried out at
reduced strength (approximately 50 %) of the solution specified
below. Otherwise, fill the boiler with a solution containing 1 %
W/W citric acid with 0.5 % W/W sodium bromate and ammonia
for a pH of 9.5.
Approximately 0.5 % W/W of 0.880 ammonia will be required,
the bulk of which must be added before the citric acid is
introduced. Deionized water must be used for the solution.
Circulate at a temperature of 50 °C, until the concentration of
copper is constant (approximately 4–6 h). Drain the boiler and

back flush the super heaters with deionized water.
1D-3.2 Achoice must be made in any given case between hydrochloric,
hydrofluoric, and ammoniated citric acids for iron oxide removal
(see Appendix 1C). The boiler is filled with a solution of either:
3 % W/W citric acid with an approved inhibitor (see Appendix 1F)
and ammonia for a pH of 3.5–4.0.
Or
5 % W/W hydrochloric acid with 0.5 % W/W ammonium
bifluoride and an approved inhibitor (see Appendix 1H).
Circulate at 90 °C (Note 3) until the iron and nickel concentrations
are constant (normally 6 h).
Or
1 or 2 % W/W hydrofluoric acid with an approved inhibitor (see
Appendix 1F).
Circulate at 55 °C (Note 3) until the iron concentration is constant
(Normally 3–4 h).
Initially circulate the solution at 90 °C (Note 3) and continue until
the iron concentration is constant (normally 6–8 h). The iron
removal solution will be drained away under nitrogen capping.
1D-3.3 Drain the boiler and when using ammoniated citric or hydrochloric
acid, rinse with a solution containing:
0.2 %t W/W citric acid and ammonia for a pH of 3.5–4.0.
This solution will be drained under nitrogen capping.
1D-3.4 Copper removal may frequently be required at this stage unless the
water/steam circuit contains no copper alloys. The standard
formulation and procedure is given in 1D3.1.
The full strength solution need only be used when the boiler is
known to be heavily contaminated with copper and its oxides.
Where it is judged that copper contamination is not great, a 50 %
solution may be utilized.
1D-3.5 Drain the boiler and thoroughly back flush the super heaters with
deionized water which has conductivity less than 0.5 us/cm. Rinse
the boiler with deionized water to remove the cleaning solution.
1D-3.6 Interim Passivation—50 mg/l hydrazine and 50 mg/l ammonia to
be circulated at 95 °C for 24 h then drained under nitrogen
capping.
Final Passivation—Refill the boiler with deionized water and add
50 mg/kg hydrazine and 50 mg/kg ammonia, maintaining a
minimum pH of 10.0. Raise the pressure to 40 bar and maintain
for at least 24 h. No further additions of hydrazine to the boiler are
required to maintain a reserve in the boiler water because this has
been shown to be unnecessary. However, 50 mg/kg hydrazine and

50 mg/kg ammonia must be added to the make-up water to the
boiler to react with dissolved oxygen.
1D-3.7 On completion of the passivation process, the boiler should be
blown empty at the highest possible pressure, but in any event, not
less than 4 bar.
Notes:
1. No alkali boil-out is generally necessary for the post-commis-
sioning cleaning of boilers, on the assumption that oil and
siliceous materials will not be present. Where this assumption
is unjustified, stage 1D3.1 shall be preceded by an alkali
boil-out as specified in Appendix 1A-I.
2. The capacity for copper of the formulation given in stage
1D3.1 is 6.3 g Cu/kg. Only rarely is more than 30 % of this
capacity required. Depending on local judgment as to the
amount of copper in any boiler, it may be possible to omit
stage 1D-3.1.
3. Cleaning rates fall with decreasing temperature. Experience
shows that typical temperatures at the end of the iron removal
stage are 70 °C with citric acid, 60 °C with hydrochloric acid,
and 50 °C with hydrofluoric acid.
Appendix 1E Post-operational Cleaning of Once Through Boilers, Super

Heaters, Reheaters, Condensate, and Feed Systems
1E-1 Introduction
The following stages constitute a complete clean and must be
carried out consecutively and with minimum delay.
1E-2 Sequential Stages
1E-2.1 Flush with deionized water at a velocity greater than 1.5 m/s in all
Sect. of the plant.
1E-2.2 Circulate a solution in deionized water containing:
3 % W/W citric acid (Note 1) with 0.5 % W/W formic acid (Note 2)
and an approved inhibitor (see Appendix 1F) and ammonia for a pH
of 3.5–4.0.
The solution is initially circulated at not less than 90 °C and
continued until the iron content is constant. The concentration of
free citric acid should be maintained at not less than 0.5 % W/W
during circulation.
1E-2.3 Raise the pH to 5.0 by careful addition of ammonia, added slowly
during circulation to avoid local high pH values (Note 3).
1E-2.4 Drain and rinse with a solution in demineralized water containing:

0.2 % W/W citric acid with ammonia for a pH of 3.5–4.0.
1E-2.5 Flush with deionized water at a velocity greater than 1.5 m/s until
the pH remains above 6.0.
1E-2.6 Circulate solution in deionized water containing:
300 mg/kg hydrazine with 50 mg/kg ammonia.
Raise the temperature of the solution to at least 90 °C and circulate for
not less than 24 h. Furthermore, additions of hydrazine should be made
if necessary to maintain a concentration of not less than 25 mg/kg.
1E-2.7 On completion of stage 1E.2.6, drain the plant at the highest
possible temperature.
1E-2.8 After stage 1E.2.7, the plant should be dried out or wet stored.
Notes:
1. The chloride content of the citric acid used should be such that a 3 %
W/W solution does not contain more than 2 mg/kg chloride as C1.
2. Formic acid is required to obtain an acceptable rate of reaction for
dissolving the outer layer of duplex oxides from super heaters.
3. The reasons for raising the pH to 5.0 are:
(i) To minimize corrosion of the plant after cleaning, but
before displacement of acid and subsequent flushing.
(ii) To avoid corrosion in discharge points and culverts.
4. In the event of the need to post-operation clean condensate or feed
systems, the processes required should be based on this Appendix.
Appendix 1F Recommended Inhibitors

1F-1 The inhibitors which are to be used during acid cleaning processes
and the recommended concentrations are:
(i) For 5 % W/W hydrochloric acid, use 0.25 % W/W armohib
28. or 0.1–0.2 % v/v rodine 213 (sp) or equivalent at 65 °C.
(ii) For 1 or 2 % W/W hydrofluoric acid, use 0.1 % W/W
dodigen 95 (Note 1) or lith solvent, CL-4
or 0.1–0.5 % rodine 31A or equivalent.
(iii) For 3 % W/W citric acid, use, preferably, 0.05 % W/W
dodigen 95 or rodine 215 or equivalent (Note 2). If this is
not available, 0.05 % W/W stannine LTP can be used with
appropriate additional safety precautions.
The inhibitor concentration selection will be based on the
manufacturer’s recommendations and should have mutual
acceptance.
1F-2 The approved inhibitors must be present under acid conditions at

all times to ensure that they are fully dissolved and not
subsequently precipitated. They must always be added directly to
an acid solution and should not be previously diluted with water or
added to water to which the acid is added later. The requirements
for the addition of inhibitors to the cleaning solution as given in
Sect. 5, “Safety Aspects”, shall be strictly observed.
1F-3 Storage and handling of the approved inhibitors must be in
accordance with Sect. 5, “Safety Aspects”.
Notes:
1. With hydrofluoric acid, the material must be brought onto site
as a solution (typically 15 % W/W) to which the inhibitor has
already been added, to eliminate the need to dilute concen-
trated solutions before injecting into the boiler.
2. Dodigen 95 is preferred because its chemical composition is
such that it is incapable of producing the hydrolysis product
which has been associated with eye toxicity when using
stannine LTP.
Appendix 1F-1 Inhibitors for Acid Cleaning (For Information)

Inhibitor Type Cleaning agent Metallurgy Normal Temp
conc. range (°C)
Rodine Liquid, HCl Copper, Brass, M. 1–2 %, 65–93
213 Spl. semi-foaming S., S.S., admiralty V/V of
metal conc. acid
Rodine Liquid HF, Chloride free Any 0.1–0.5 % Room
31A solvents of diluted temp. to
acid 105a
Rodine Liquid HCl Copper, brass M. 1–2 %, v/v 65–80
212 semi-foaming S., S.S., admiralty of conc.
metal acid
Rodine Liquid H2SO4, H3PO4, Any 1–2 %, v/v Room
92B AcOH, NaHSO4, of conc. temp. to
Citric acid 100
Rodine Powder Sulphamic, citric, M.S., S.S., brass, 1–2 %, Room
130 tartaric, oxalic acid copper W/W of temp. to 65
and NaHSO4 conc. acid
a
Varies depending on type of acid
Inhibitor Type Cleaning agent Metallurgy Normal Temp

conc. range (°C)
Coronil 213 Liquid HCl (also in Standard steel, M.S., 0.1–0.2 % Ambient
(Spl) combination with HF) high carbon steels, v/v of to 90 °C
etc. copper and Cu super heated steels diluted
alloys acid
Coronil-92B Liquid Citric acid – 1–2 % v/v Ambient
and of conc. to 100 °C
powder acid
Coronil-130 Powder Sulphuric, sulphamic Carbon-steel, S.S., 1.5 % –
acid copper and brass. W/W of
acid
1H Constant Head Overflow and Temporary Gauge Glass

1H-1 Constant Head Overflow
1H-1.1 In addition to water plugging and back flushing the super heater, a
constant head overflow device must be fitted to the drum to ensure that
chemical cleaning solutions do not enter the super heater.
The degassifying header has been placed inside the boiler drum and
generated H2 passed through it during the acid cleaning step.
1H-1.2 The overflow device may be fitted using a temporary drum door. It is not
envisaged that the overflow would be required to take full flow of the
chemical circulation pumps and a 100-mm line should be adequate.
Particular care will be necessary when initially adding the acid to the
water in the boiler so as not to exceed the working level. In this context, a
temporary gauge glass extending the full height of the drum should be
provided.
1H-1.3 In the event of a stoppage of the acid circulation pump, the level in the
drum may rise due to water draining back from the tubes. Thus, the height
of the overflow should be positioned 75–100 mm above the required
working level.
1H-1.4 The valve must be open at all times except when it is required to rinse the
upper surfaces of the drum. Before such rinsing is carried out, ensure that
the solution contains less than 2 mg/kg chloride.
1H-1.5 Provision must be made at the overflow outlet for the boiler to be vented
outside the building in a position inaccessible to personnel and for any
liquid overflowing to be led to a convenient sump where it may be
neutralized, if necessary. This may be achieved by leading the overflow
outlet into a small tank from which the liquid can be drained and the
vapor vented outside the buildings.
1H-2 Temporary Gauge Glass

1H-2.1 A temporary gauge glass is required because the normal means of level
indication cannot be used.
1H-2.2 Experience shows that the boiler drum becomes slightly pressurized
during temperature raising and with an open-ended temporary gauge
glass, a false indication of the drum level is obtained. Both links of the
indicating column must be connected to the drum. It is therefore required
that permanent tapping points are provided for drum-level indication
during chemical cleaning. Each tapping point must be fitted with
double-isolating valves and a blanked flange suitable for full boiler
pressure. Preferably, the lower tapping point should be from a line other
than the permanent gauge glass impulse line (e.g., the boiler dosing or
sampling line). The top tapping point may be led into a drum air release
line before the normal air valve.
2.0 Post-Operational Cleaning of Condensers
2.1 Introduction
Adverse performance due to fouling may justify chemically cleaning
the main steam condenser-side (i.e. the cooling water [CW]) and/or the
steam side according to circumstances.
At some power stations, usually those with recirculating CW systems, it
has been the practice to remove CW side (hardness) scale periodically
by chemically cleaning.
Experience has shown that deposits on the steam side of condenser
tubes can also cause significant efficiency losses. Improvements in back
pressure of 6–12 mbar have resulted from the chemical removal of such
deposits.
Investigational work has been carried out over a number of years into
various aspects of the chemical cleaning of both the CW and steam side
of condenser deposits. It is intended to provide general guidance to
power stations on condenser cleaning, but detailed advice on any
specific case should be sought.
The requirements given in Sect. 5, “Safety Aspects” must be
applied for the post-operational cleaning of condensers.
2.2 Objective of Cleaning
The objective of cleaning is to remove material (whether on the CW
side or steam side) impeding heat transfer and restore the thermal
efficiency.
2.3 Criterion for Cleaning

2.3.1 The criterion for cleaning is an unacceptable fall in condenser
efficiency. If, after allowing for any air-in leakage, the losses attributed
to the fouling of the CW or steam side are judged to be worth retrieving,
then CW or steam side cleaning should be considered. The potential
financial benefit of cleaning is best judged on the basis of estimates of
the fouling burden and the fouling resistance to heat transfer.
2.3.2 The fouling burden on individual tubes can be determined chemically.
Tubes extracted from the condensers for this purpose must always be
removed by cutting between sagging plate positions and removing
sections from the steam side. Extracting tubes will lead to dislodgement
of the steam-side deposit.
2.3.3 In situ deposit thickness measurements on accessible tubes will give an
indication of the extent of fouling. Deposit thickness can be measured
nondestructively using commercially available impedance measuring
instrumentation.
2.3.4 Fouling resistance data can be obtained by externally cleaning selected
tubes, in situ, with emery cloth and comparing the cooling water
temperature rise for pairs of dirty and clean tubes. When using this
technique on power stations where Taprogge is not installed to offset
water-side deposit accumulation, allowance should be made for
water-side losses.
2.3.5 Fouling resistance data can also be obtained from heat transfer tests
carried out, on extracted segments of tubing, by an approved
mechanical engineering laboratory.
2.4 Cleaning the CW Side of Condensers.
2.4.1 Available Cleaning Processes.
2.4.1.1 There are three distinct methods for condenser cleaning, all of which
depend on the use of acid to dissolve he scale. The methods available
are termed ‘off-load’, ‘reduced-load,’ ‘on-load,’ and details are given in
Appendices 2A–2C, respectively. Prior to chemical cleaning the
mechanical cleaning of condenser tubes may be carried out to remove
physical debris like CT fill material, sponge balls, etc., make circulation
path clear, enhance chemical efficiency and reduce chemicals
requirement.
2.4.1.2 In the off-load method, the acid solution is introduced into the
condenser and circulated until monitoring shows scale dissolution to be
effectively complete. The reduced-load method differs in that it is
applied to one shell of the condenser, isolated for the purpose, while the
other is still operating.
2.4.1.3 In the on-load method, the pH of the cooling water entering the
condenser is decreased by acid dosage to about 2–2.5. The buffering
capacity of the cooling water, together with the large volume of the
system restrict the change of pH elsewhere in the circuit.
2.4.2 Choice of Acid
While in principle any of a large number of acids may be used to
remove the scales found in condensers, hydrochloric and sulfuric acids
are recommended because in addition to being inexpensive and readily
available, they were used satisfactorily in investigational studies of this
subject. Of these two, hydrochloric acid is recommended only when the
whole condenser is isolated, (i.e., in an off-load cleaning). Where there
is any possibility of contamination of the feed water by the cleaning
solution, as in reduced-load or on-load methods, then only sulfuric acid
is to be used. For SS tubes, sulphamic acid, although costly, is also
being used.
2.4.3 Inhibition
2.4.3.1 The three basic methods of cleaning impose quite different requirements
for inhibition and these are influenced by the materials of construction
of the plant and by the estimated long-term frequency of cleaning. By
the use of inhibitors, acceptable conditions can be achieved in respect of
the corrosion of water boxes and tubes, as well as restraint of galvanic
attack and copper deposition and dezincification. The use of either
recommended inhibitors. Armohib 28 or Armohib 533 or equivalent
suppresses copper deposition in the water box and also counteracts
galvanic corrosion. Recommendations for inhibitor requirements are
given in Appendix 2D.
2.4.3.2 The degree of risk to condenser integrity is related to the frequency of
cleaning.
2.4.4 Selection of Cleaning Processes
To aid in the selection of a suitable cleaning process, logic is given in
Appendix 2E.
2.4.5 Practical Considerations
2.4.5.1 Terminal Points
Suitable terminal points can be made as branch connections, so that
rigging can be carried out on-load and subsequent flushing can take
place without delay.
2.4.5.2 Circuitry
Where appropriate, the water boxes should be connected in series into a
circuit containing a tank and pump, the water box vents being fitted
with temporary connections back to the chemical mixing tank.
2.4.6 Protection of Plant After Cleaning

In contrast to boiler plant, there are no special requirements for the
protection of condensers after cleaning provided that the cleaning
solution has been flushed away adequately.
2.5 Cleaning the Steam Side of Condensers
The process described below is not suitable for pannier condensers and
even conventional condensers may need support to take the additional
weight of the cleaning solution.
2.5.1 Available Cleaning Processes
2.5.1.1 Studies have shown that steam-side deposits which foul condensers are
principally a porous mixture of hydrated iron oxides (nominally
Fe2O3 2H2O) together with the corrosion products tenorite (CuO) and
zincite (ZnO) formed in service. In some instances, oil has been found
incorporated into the deposit.
2.5.1.2 Even a small amount of oil will render the deposit hydrophobic, making
removal by aqueous-based systems impracticable. Therefore, prior to
cleaning, the oil content of the deposit shall be determined as this will
influence the final formulation of the cleaning solvent and the process
requirements.
2.5.1.3 Currently, one basic cleaning process with satisfactory field experience
is available. It can be used in two modes, one for deposits which contain
oil and one for deposits which are oil-free. Cleaning is carried out at
ambient temperatures and cleaning time is typically 40 h. Details of
each method are given in Appendices 2F and 2G.
2.5.2 Constituents of Cleaning Solutions
The available formulations contain up to five constituents which are as
follows:
(i) Reducing agent
(ii) Complexing agent
(iii) Approved degreasant
(iv) Additional surfactant
(v) Additional organic acid to adjust pH.
2.5.2. Reducing Agent
The reducing agent is oxalic acid and provides the driving force for the
dissolution of ferric oxides. For both oil-bound and oil-free deposits, the
concentration of oxalic acid is 0.7 %.
2.5.2.2 Complexing Agent

2.5.2.2.1 The complexing agent which is required to hold iron, copper and zinc in
solution is ethylenediamine-tetra acetic acid (EDTA). The cleaning
solution must be prepared from the tetra-sodium EDTA salt
(Na4EDTA). The use of any other EDTA salt is not permitted.
2.5.2.2.2 The concentration of EDTA used, 3.6–5.5 %, determines the capacity
of the cleaning solution.
2.5.2.3 Degreasant
2.5.2.3.1 The degreasant is based on C9 aromatic naptha. Two commercially
available C9 naptha-based degreasants have been recommended for use
in this application (see Appendix 2H).
2.5.2.3.2 For the removal of oil containing deposits, the formulation may contain
up to maximum of 10 % v/v degreasant. This is the maximum level of
degreasant that can be used when butyl rubber packing is present
without having a permanent deleterious effect on the packing.
2.5.2.4 Surfactant
Although both approved degreasants contain some surfactants
(Appendix 2H), investigations have shown that without the addition
of a supplementary surfactant, separation of the emulsion can occur
during the oxide dissolution process. The supplementary surfactant is
lissopol and it is used at a concentration of 1 % v/v.
2.5.2.5 Additional Organic Acid
Formic acid is used to adjust the pH of the cleaning solution.
2.5.3 Selection of Cleaning Process
2.5.3.1 The choice of cleaning process will be dictated by whether oil is present
and by the estimate of the total mass of metal oxides to be removed. Oil
content determined by solvent extraction from segments of individual
tubes and the metal oxide burden found by laboratory cleaning tests.
Great care should be taken to ensure that representative tube samples
are used for these tests.
2.5.3.2 Once the total metal burden is known, the concentration of EDTA to be
used as such that no more than 60 % of the available capacity will be
consumed (see Appendix 2-I). Dissolution rates diminish if the solution
becomes significantly more than 60 % exhausted. The EDTA concen-
tration should be between 3.6–5.5 %.
2.5.3.3 Experience to date has shown that a solution containing Na4EDTA and
0.7 % oxalic acid has sufficient capacity to cope with most of the
condenser steam side deposits encountered. If oil is present, 10 % v/v
degreasant and 1 % v/v ethomeen S25 has been found to be adequate.
2.5.4 Exclusion of Oxygen
2.5.4.1 Corrosion inhibitors are unnecessary provided air (oxygen) is excluded
from the cleaning circuit.
2.5.5 Practical Considerations
Experience has shown the need for full consultation between cleaning
contractors, stations and if appropriate, specialist advice should be
sought prior to cleaning. Among the factors to be considered are:
2.5.5.1 Water Requirements
2.5.5.1.1 During the cleaning, there will be a requirement for large quantities of
high quality demineralized water for preparing solutions and rinsing.
Water containing a significant concentration of calcium must not be
used, as this would cause a precipitation of calcium oxalate and a
subsequent rise in solution pH.
2.5.5.1.2 Although the clean is carried out at ambient temperatures, if possible, a
supply of high quality hot water (e.g., blow-down) should be available
to facilitate more rapid dissolution of oxalic acid crystals when the
cleaning solution is being prepared.
2.5.5.2 Temporary Holding Tanks
Sufficient temporary holding tanks must be provided to hold the
pre-mixed solution prior to transferring it to the condenser, and to hold
the effluent when the cleaning is completed.
2.5.5.3 Mixing Procedure
2.5.5.3.1 Prior to mixing is necessary to prepare a concentrated (approx. 10 %
v/v) solution of oxalic acid and to add the surfactant to the degreasant.
To save process time, both these procedures may be carried out off site
by the cleaning contractor prior to the cleaning.
2.5.5.3.2 If the degreasant/surfactant mix is prepared on site, this mixture must be
continuously agitated prior to use to ensure complete dispersal of the
much denser surfactant.
2.5.5.3.3 Mixing shall be carried out in the following order:
1. Dilute Na4EDTA concentrate.
2. Carefully add, with further dilution, concentrated oxalic acid
solution.
3. Carefully add, with further dilution and agitation the degreasant in

which the required quantity of surfactant (ethomeen S25) has
already been dissolved.
4. Dilute the solution to 95 % of required final volume. Carefully add
sufficient formic acid to give a final pH of 4.5.
5. Dilute to required final volume and transfer to the condenser.
The following points shall be noted:
(i) The pH of the cleaning solution must always be maintained at
more than pH 3.8 to prevent free EDTA from precipitating out.
(ii) The surfactant must always be added to the degreasant. Direct
contact with water will produce a solid precipitate.
(iii) The degreasant/surfactant must always be added to the
EDTA/oxalic acid mixture. If concentrated oxalic acid solution is
allowed to come into contact with the degreasant/surfactant
mixture, a solid precipitate will be formed.
2.5.5.4 Quality of As-Received EDTA Solution
2.5.5.4.1 It is required that a quality control check be carried out on the
as-received Na4EDTA concentrate prior to its use. The following
parameters shall be checked:
(i) Na4EDTA concentration
(ii) Free sodium hydroxide
(iii) Relative density
2.5.5.4.2 Experience to date has shown that some commercially available grades
of Na4EDTA are variable in quality and may contain free sodium
hydroxide which could increase the pH of the cleaning solution
2.5.5.5 Solution pH
2.5.5.5.1 The optimum pH for the dissolution process is 4.5, A solution
containing 3.6 % Na4EDTA, 0.7 % oxalic acid, if mixed correctly will
have a pH of 4.4–4.6. If an excess of Na4EDTA is present, pH
adjustment is necessary prior to use. Formic acid is suitable for this
purpose
2.5.5.5.2 Both approved degreasants are essentially non-ionic and their presence
has little effect on the solution pH
2.5.5.5.3 It is recommended that an emergency reserve of formic acid be
available to compensate for any adventitious rise in pH. If any pH
adjustment is carried out, the pH of the solution must not be allowed to
fall below 3.8
2.5.5.5.4 The pH of the cleaning solution will rise slightly during cleaning:
normally the rise is not significant
2.5.5.6 Circulation, Agitation and the Exclusion of Air

Thorough out the duration of the clean, external pumps shall circulate
the cleaning solution. Nitrogen purging shall be used to ensure good
mixing and to exclude air. Oxygen ingress caused enhanced corrosion
of brass components.
2.5.5.7 Duration of Clean
2.5.5.7.1 The clean should be allowed to proceed until analysis shows iron
uptake has ceased or the total dissolved metal ions are equivalent to 85
% of the available capacity. If the latter situation is reached, it will
probably be necessary to renew the cleaning solution to complete the
clean. Details to be utilized are given in Sect. 4, ‘Analytical Methods’
2.5.5.7.2 Experience has shown that provided the correct pH is attained for the
levels of fouling, cleaning is completed in about 40 h
2.5.5.8 Effluents
2.5.5.8.1 Once the process is complete, the spent solution must be discharged to
the holding tank prior to disposal
2.5.5.8.2 It is essential that all statutory requirements covering effluent from the
station are established and met. Where tankers remove effluent,
adequate capacity must be available so that the full cleaning program
(e.g., rinsing down) is not delayed
2.5.5.8.3 At the planning stage consideration must always be given to
incineration of the effluent in an operational boiler as an alternative to
discharge via the ash lagoons or removal by tankers
2.5.5.9 Analytical Methods
During the course of the clean, it will be necessary to monitor at regular
intervals, dissolved iron, copper, and zinc together with nickel in the
case of power station where cupronickel tubes are fitted. The
recommended methods are given in Sect. 4, ‘Analytical Methods’.
2.5.6 Engineering Aspects
2.5.6.1 Isolation
2.5.6.1.1 Owing to the complexity of most modern power station condensers,
particular care must be taken to ensure that the condenser steam side is
completely isolated prior to cleaning
2.5.6.1.2 If gas bags are used to seal off pipework, check shall be made to ensure
that the bag material will not be degraded by any degreasant used. Such
bags shall always be maintained under positive pressure by an inert gas
(air must not be used)
2.5.6.2 Air Extraction Pumps

2.5.6.2.1 If air extraction pumps are used to draw off degreasant vapor, steps
must be taken to ensure that the pumps do not draw over any of the
chemical liquor. Any vapor must be discharged to an outside area
inaccessible to personnel
2.5.6.3 Temporary Sight Glass
A temporary sight glass should be provided to indicate the level of
solution in the condenser steam side.
2.5.6.4 Vent
A vent/overflow shall be provided just above the anticipated maximum
solution level.
2.5.6.5 Tube Plugs
Plastic tube plugs fabricated in polythene are not completely resistant to
either approved degreasant and will fail at the nose either during a clean
or on return to service. Such plugs must be replaced with brass plugs
prior to cleaning.
Appendix 2A Hydrochloric Acid Process for Off-load Post-operational

Cleaning of the Water Side of Condensers and Sulphamic
Acid Cleaning for SS Tube Condensers
2A-1 The condenser shall be made available for cleaning with all plant
isolation, depressurizing and draining complete
2A-2 Circulate at ambient temperature a solution containing:
1.5 % W/W hydrochloric acid with an approved inhibitor (see
Appendices 2D and 2E) until the calcium concentration is constant
and an excess of at least 0.5 % W/W of acid still remains. Open the
vents at intervals to release carbon dioxide liberated by the
descaling process.
2A-3 On completion of cleaning, drain the condenser and pass normal
cooling water flow for 30 min. Then, drain and inspect
2A-4 For Stainless Steel Tubes7
Sulphamic acid cleaning has been successfully done, however, at a
higher cost investment.
In practice, inhibited sulphamic acid (2–5 %) has been used at 65–
70 °C without much pressurizing the condenser system. CO2 gas
generated is allowed to leak off from the top vents. The acid
circulation is continued for approximately 8 h and then drained.
The system is refilled with raw water and circulated at 4–5 kg/cm2
pump pressure and drained. Mass flushing is finally done with CW
pumps in service.
Appendix 2B Sulfuric Acid Process for Reduced-Load Post-operational

Cleaning of the Water Side of Condensers
2B-1 The part-condenser to be cleaned shall be made available with
appropriate plant isolators and drained
2B-2 Circulate at ambient temperature a solution containing:
1.5 % W/W sulfuric acid with an approved inhibitor (see Appendices
2D and 2E) until the calcium content is constant and an excess of at
least 0.5 % W/W of acid still remains. The temperature of the cleaning
solution will increase as it takes up heat from the system up to a
maximum of about 40 °C, depending on the particular plant.
2B-3 Open the vents at intervals to release carbon dioxide liberated
2B-4 On completion of cleaning, drain the condenser and return to
service
Appendix 2C Sulfuric Acid Process for On-Load Post-Operational Cleaning

of the Water Side of Condensers
2C-1 As experience of on-load descaling of condensers is successful but
limited, this method should be considered only when off-load or
reduced-load cleaning cannot be applied
2C-2 The method is, therefore, given only in outline in this directive,
and detailed guidance should be sought before undertaking an
on-load cleaning
2C-3 The process consists of adding sulfuric acid to reduce the pH to 2–
2.5 locally within the condenser, yet restricting the total sulphate
concentration of the cooling water to less than 700 mg/kg SO4 and
maintaining the bulk pH above 6.0 to minimize the risk to the
concrete and metals in the cooling water circuit
2C-4 It has been found acceptable, at some locations, to introduce the
acid via the chlorination system with the additional advantage that
the isolating valves facilitate dosage of individual passes of the
condenser
2C-5 For any system, the practical details of on-load cleaning depend upon
the system volume, the severity of scaling, the water analysis and the
individual condenser design. The water quality is kept within the
required limits of sulphate concentration and pH by varying the
duration of acid addition and by purging, when necessary
2C-6 An assessment of the probable effect of dosing on a given cooling

water chemistry shall be carried out in any situation where on-load
cleaning is being considered
Appendix 2D Recommended Inhibitors

2D-1 General
2D-1.1 If condensers are to be cleaned frequently (i.e., more than once per
year-see Appendix 2E), it is necessary to use inhibited hydrochlo-
ric acid or inhibited sulfuric acid
2D-1.2 The inhibitors which are approved for use during condenser acid
cleaning processes and the recommended concentrations are:
(i) For 1.5 % W/W hydrochloric acid, use 0.25 % W/W
Armohib 28 or 0.025 % W/W Armohib 533 (see Note) or
Indian equivalent/[0.1–0.2 % v/v Rodine 213 (sp)]
(ii) For 1.5 % W/W sulphuric acid, use 0.05 % W/W Armohib
533 (see Note) or Indian equivalent
The inhibitor concentrations are based on the manufacturer’s
recommendations.
2D-1.3 The approved inhibitors must be present under acid conditions at
all times to ensure that they are fully dissolved and not
subsequently precipitated. They must always be added direct to
an acid solution and must not be previously diluted with water or
added to water to which the acid is added later.
2D-1.4 The requirements for the addition of inhibitors to the cleaning
solution as given in Sect. 5, ‘Safety Aspects’ must be strictly
observed.
2D-1.5 Storage and handling of the approved inhibitors must be in
accordance with Sect. 5, ‘Safety Aspects’, Appendices 5A and 5B.
2D-2 For Ferrous Metals Specifically
Hydrochloric acid inhibited with Armohib 28 or Armohib 533, or
sulfuric acid inhibited with Armohib 533, may be used, selected in
accordance with the recommendations given in.
2D-3 For Ferrous Metals and Brass Together
Hydrochloric acid or sulfuric acid inhibited with Armohib 533 are
to be used, selected in accordance with the recommendations.
Appendix 2E The Selection of Cleaning Process for the Water Side of

Condensers
Flow of water through condenser tubes gets obstructed mainly due to scale for-
mation or fouling inside the tubes. Condenser water contains dissolved solids that
get precipitated on the inner surface of the tubes. This causes the formation of the
scale. Another way of fouling is due to growth of organic bodies like algae/fungi.
Various cleaning process as given below are adopted depending on the type of
fouling:
On-line
• Mechanical process:
– Taprogge system with sponge rubber balls
• Chemical process:
– scale and corrosion inhibition, dispersants, and biocides
– Lowering pH value of the circulating water.
Off-line
• Mechanical process:
– High pressure water jet
– Molded plastic cleaners/metal cleaners with controlled spring loaded cutting
edge.
• Chemical process:
– Acid or chelate dissolution.
Chemical scale removal is very effective if the scale is silica based.
Appendix 2F Cleaning Method for Removal of Oil-Free Deposits from the

Steam Side of Condensers (see Note)
2F-1 The condenser must be made available for cleaning with all plant
2F-2 Circulate at ambient temperature a solution containing:
(i) 3.6–5.5 % EDTA (added as the Na4 EDTA salt)
(ii) 0.7 % oxalic acid
(iii) Formic acid to give pH of 4.5
Until the iron concentration is constant or until the total metal ion
concentration is 85 % of the available capacity, when further
dissolution rates are minimal.
2F-3 On completion of cleaning, drain the condenser, rinse, and inspect
Note: Deposits containing less than 5 % oil.
Appendix 2G Cleaning Method for Removal of Oil Containing Deposits from

the Steam Side of Condensers (see Note)
2G-1 The condenser must be made available for cleaning with all plant
2G-2 Circulate at ambient temperature a solution containing:
3.6–5.5 % EDTA (added as the Na4EDTA salt), 0.7 % oxalic acid,
up to 10 % v/v approved degreasant (see Appendix 2H), 1 % v/v
Ethomeen S25 and formic acid to give pH of 4.5.
Until the iron concentration is constant or until the total metal ion
concentration is 85 % of the available capacity, when further
dissolution rates are minimal.
2G-3 On completion of cleaning, drain the condenser, rinse, and inspect
Note: Deposits containing more than 5 % oil.
Appendix 2H Recommended Degreasants

2H-1 Commercially available degreasants suitable for use in the steam
side cleaning of condensers are based on C9 Naptha. As supplied,
the degreasants normally contain C9 Naptha nonylphenyl surfac-
tants and dodecylbenzene sulphonate surfactants
2H-2 A number of commercially available degreasants have been
evaluated, and two have been approved for use in this application
There are:
(i) Industrial polyclenes.
(ii) Banner slove H536.
With both these degreasants, it is necessary to add the
additional surfactant, Ethomeen S25 to obtain the required
emulsion stability for the duration of the clean.
(iii) Non-ionic detergent (SNID-PGN) (Conc. 0.05 %).
Appendix 2-I Selection of Cleaning Process
Let: Cu = average copper burden (g/m2)

Fe = average iron burden (g/m2)
Ni = average nickel burden
(applicable only if cupronickel

tube fitted) (g/m2)
Zn = average zinc burden (g/m2)
(Cu, Fe, Ni and Zn are determined by chemical cleaning tests)
V = volume of solution required to fill the condenser steam side (liters)
A = total surface area of condenser tubes (m2)
B = total metal ion burden (moles)

B ¼ A Cu þ Fe þ Ni þ Zn mol
63:5 56 59 65:4
If: B < 0.048 V use 0.08 M EDTA.

B > 0.048 V use upto 0.13 M EDTA (required concentration = 1.73)
If B > 0.078 V seek specialist advice.
The requirement for a degreasant can be established by solvent extraction and
comparative cleaning tests. Normally, even the presence of a small quantity of oil
will necessitate the use of degreasant. It is extremely important (see 2.5.3) when
determining/fouling burden to ensure that representative tube samples are used.
When establishing the volume of solution required to fill the steam side of the
condenser, consideration should be given (subject to the design of the condenser) to
blanking-off or filling with gas bags ‘dead’ areas thereby reducing solution
requirements.
3.0 Post-Operational Cleaning of the Water Side of Feed Heaters
3.1 Introduction
Pre-operational cleaning of feed heaters was formerly carried out using an
acid/neutralization/passivation sequence much the same as that currently
available for boilers. However, the introduction of ‘at works’ cleaning
followed by preservation of the heaters, by means of vapor phase
inhibition or dehumidification, largely supersedes on-site cleaning, which
was only carried out if there were shortfalls in the performance of the
newer technique.
Where post-operational chemical cleaning of feed heaters is required
solely for the removal of inorganic constituents, this shall be accom-
plished by employing appropriate stages from Appendix 1E. The situation
becomes more complicated, however, when organic contamination is
present due, in particular, to the ingress of turbine lubricating oil to the
feed-water. In passing through the feed system, the oil appears to undergo
progressive degradation. In the LP heaters, it is easily removed by
alkali/detergent treatment, but in the HP system, the deposits may
comprise a mixture of ‘baked’ organic matter and metallic oxides and
resist this treatment. A process has been developed to deal with this,
which is described in Appendix 3A.
The requirements given in Sect. 5, ‘Safety Aspects’, must be applied

for the post-operational cleaning of feed heaters.
3.2 Objective of Cleaning
The objective of feed-heater cleaning is the restoration of the thermal
performance of feed heaters by removal of contaminant material within
the tubes.
3.3 Criterion for Cleaning
The criterion for cleaning is the loss of heater efficiency due to water-side
fouling. Examination of the samples removed provides a useful check,
especially where there is a history of oil ingress into the feed system.
3.4 Available Cleaning Process
3.4.1 LP Feed Heaters
Deposits of an oily nature present in the LP feed heaters can be readily
removed by using one of the many proprietary alkali/degreasant
treatments which are available.
3.4.2 HP Feed Heaters
3.4.2.1 The processes currently available for post-operational cleaning of HP feed
heaters include:
(i) A chemical process incorporating degreasant and acid stages, fol-
lowed by flushing at full feed water flow, the objective being to
remove both organic and inorganic contaminates. If full feed flow
cannot be achieved, then the chemical cleaning process should not
be used.
(ii) A physical process using high-velocity water jetting.
3.4.2.2 High-velocity water jetting, being a purely mechanical process, is not
covered in this directive, only details of the chemical process are given. It
should be recognized that experience of high-velocity water jetting and its
application is limited and, therefore, due attention shall be given to
Sect. 3.5, ‘Practical Considerations’.
3.5 Practical Considerations
3.5.1 Plant to be Included
The process given in Appendix 3A has been applied to both full HP feed
heater trains and single HP feed heaters. The former can give problems in
ensuring correct and complete circulation in all areas of the plant being
cleaned. Consequently, it may be preferable to clean HP feed heaters
either single or in pairs, if practicable, particularly if the contamination is
localized. Such an approach is justifiable on economic grounds.
3.5.2 Examination of Tubes Prior to Cleaning

The nature of deposits present on the HP feed heater surfaces will vary
considerably according to the source and extent of contamination. The
process given in Appendix 3A has been formulated to deal with a wide
combination of likely contaminant. However, wherever possible, tube
samples should be removed for laboratory trials to assess the effectiveness
of the process, prior to its application. In extreme cases, the cleaning
process may not be completely effective.
3.5.3 Prevention of Ingress of Cleaning Solution to other Plant Items
3.5.3.1 Care must be taken to minimize the risk to other sections of the plant by
secure isolation of the feed system from the boiler and disconnection from
the condenser.
3.5.3.2 Care must also be taken to ensure that all the cleaning solution has been
removed from the plant by full feed flow water flushing before it is
reconnected to the condensing or boiler plant. Particular attention should
be paid to the boiler water analysis when returning the plant to service to
confirm the absence of contamination from the cleaning solution.
Appendix 3A Degreasant/Hydrochloric Acid Process for Post-Operational

Cleaning Of HP Feed Heaters (See Note 1)
3A-1 Circulate a solution of a 50 %, v/v ‘Applied Chemicals 4–43’ (see
Note 2), at a temperature of 80–90 °C for 10 h.
3A-2 Flush to waste at a flow equivalent of full feed flow until a
conductivity of <200 ms/cm is recorded.
3A-3 Circulate a solution of 5 % W/W hydrochloric acid inhibited with
0.25 % W/W armohib 28 at a temperature of 75 °C for 2 h.
3A-4 Flush to waste at a flow equivalent to full feed flow until a
conductivity of <200 us/cm is reached.
3A-5 Repeat 3A.3
3A-6 Repeat flush to waste at a flush equivalent of full feed flow until a
conductivity of <5 ms/cm is reached.
Notes:
1. If the HP feed heaters being cleaned are heavily fouled, it may
be necessary to repeat 3A.1–3A.6
2. An equivalent alkaline detergent may be used if Applied
Chemical 4.-43 is not available.
4.0 Analytical Methods

4.1 Introduction
The section deals with the analytical methods required for monitoring the
pre- and post-operational cleaning of boilers, super heaters, reheaters, and
the feed system described in clause 1 (4.2) and the post-operational
cleaning of condensers described in clause 2 (4.3).
A list of the methods is given in Appendix 4A. There are a number of
other methods that may be required and although not fully evaluated,
recommended procedures are given below.
4.2 Methods of Analysis to be Used During the Chemical Cleaning of
Boilers, Super Heaters, Reheaters, and Feed Systems
The following methods are to be utilized during various stages of the
chemical cleaning. This sample must be filtered before any analysis is
carried out.
4.2.1 pH
Use method 2 given in BS 1427/ASTM/IS/
4.2.2 Concentration of Hydrochloric Acid or Hydrofluoric Acid
Take 1 mL sample and add 50 mL of demineralized water. Add pH 4.5
indicator and titrate with 0.1 M NaOH.
g/kg Hcl = Titre × 3.65.
g/kg HF = Titre × 2.0.
4.2.3 Total Citrate
4.2.3.1 Take 2 mL sample, make up to 200 mL with distilled water and pass
through a strongly acidic cation exchange column. Discard the first
100 mL and titrate the second 100 mL with 0.1 M NaOH using
phenolphthalene indicator
% total citrate (as citric acid) = Titre × 0.64.
4.2.3.2 Where sodium bromate has been used, an allowance must be made for the
presence of bromic acid after cation exchange. For the addition of 0.5 %
sodium bromate, the calculation becomes:
% total citrate (as citric acid) = (Titre-0.3) × 0.64.
4.2.4 Free Citric Acid
The free citric acid is obtained by deducting from the total citrate
concentration the equivalent of the total iron found in solution.
% free citric acid = % total citrate (3.4 × % total iron).
The dimensions of a suitable ion exchange column are: internal diameter
15 mm, height 200 mm. The resin is in the hydrogen form and the diluted
sample is passed through the column at a rate of about 10 mL/min.
4.2.5 Fluoride
Determine using a fluoride ion selective electrode and an epoxy bodied
reference electrode.
4.2.6 Alkalinity
Take a 100-mL sample, add pH 4.5 indicator and titrate with 0.1 M nitric
acid.
g/kg NaOH = Titre × 0.4.
4.2.7 Sodium
Sodium may be measured flame photometrically. Instruments giving a
full scale deflection for 5 mg/kg or less of sodium will be satisfactory, and
should be operated in accordance with the manufacturer’s instruction.
4.2.8 Total Iron in Citric Acid, Hydrochloric Acid, or Hydrofluoric Acid
4.2.8.1 Dilute the sample to give a final iron concentration in the range
0–60 mg/kg (3 % citric acid saturated with iron will have an approximate
iron concentration of 8500 mg/kg). For most analysis, a hundred-fold
dilution will be adequate. With hydrofluoric acid, dilute with 2 % boric
acid to protect glassware.
4.2.8.2 Determine the total iron by atomic absorption directly on the diluted
sample or take 50 mL of the diluted sample, add 0.5 thioglycollic acid
and 5 mL excess of 0.880 ammonia. Make up to 100 mL. Measure the
colour using a 10 mm cuvette and a 605 filter. Read off the total iron
concentration from a calibration graph prepared under identical
conditions
Total iron and total copper may also be determined by titration method.
For iron 5 mL of filtered sample and dilute with 25 mL of DM water.
Add 2 % KMnO4 solution dropwise till permanent pink colour appears.
Add 15 % hydrazine sulphate solution dropwise till pink colour
disappears. Add 2 drops in excess. Add 5 g of KI crystals and stopper
the flask. Allow to stand for 5 min. Titrate the liberated iodine with 0.1 N
sodium thiosulphate solution using starch indicator.
The method for copper determination is same as for iron except that
before the addition of KI crystals 5 g of ammonium bifluoride is to be
added and mixed well.
4.2.9 Ferric Iron in Citric Acid or Hydrochloric Acid
4.2.9.1 Take 25 mL sample and adjust the pH to 2.5 with approximately normal
Na2C03 solution
4.2.9.2 Dilute the solution to 100 mL and add five drops of 5 % sulphosalicylic
acid solution. Titrate with 0.1 M EDTA until the pink colour just
disappears. Add a further five drops of indicator and continue the titration
until the pink color disappears
g/kg Fe 3+ = Titre × 223.
4.2.10 Nickel
Place 2 mL of the sample in a separating funnel, add four drops of 10 %
hydrogen peroxide solution, and two drops of phenolphthalein solution.
Then, add 5 mL of 10 % sodium potassium tartrate and mix the contents.
Add 2.5 N sodium hydroxide solution drop-wise until the phenolph-
thalein just turns pink and then add 0.1 N hydrochloric acid drop-wise
until the colour is just discharged. Add 5 mL of 0.15 %
furil-alpha-dioxime followed by 25 mL of 2 N ammonia solution. Swirl
the contents of the flask to mix, and add 15 mL of the chloroform through
a filter paper and measure the absorbance in a suitable size cuvette.
Determine the nickel content from a calibration curve.
4.3 Methods of Analysis to be Used During the Post-operational Cleaning
of Condensers
The iron, copper, zinc, and nickel content of samples of the chemical
cleaning liquor can be determined by atomic absorption
spectrophotometry/suitable equipment available at site using standard
instrument operating conditions.
4.3.1 Instrument Calibration
4.3.1.1 Prepare separate series of calibration standards by appropriate dilution of
1000 mg/kg stock containing:
(i) Iron: 0, 10, 20, 30, 40 and 50 mg/kg Fe
(ii) Copper: 0, 5, 10, 20, 30 and 40 mg/kg Cu
(iii) Zinc: 0, 0.5, 1, 2, 3 and 4 mg/kg Zn
(iv) Nickel: 0, 2, 4, 6, 8 and 10 mg/kg Ni
in 2 % v/v ‘AR’ nitric acid
4.3.1.2 Measure the absorbance of each standard, using the manufacturer’s
recommended instrument conditions, at the following wave lengths:
(i) Fe: 372.0 nm
(ii) Cu: 217.9 nm
(iii) Zn: 213.9 nm
(iv) Ni: 232.0 nm
and construct calibration curves for reference purposes.
4.3.1.3 When used in conjunction with the following analytical procedure, the
above concentrations will correspond to 0–2500 mg/kg Fe; 0–2000 mg/kg
Cu; 0–200 mg/kg Zn, and 0–500 mg/kg Ni in the original cleaning liquor.
Two procedures are available, one for determining total metal removed in
a clean and the other for following the progress during the chemical
cleaning operation
4.3.2 Determination of the Total Amount of Iron, Copper, Zinc, and Nickel
Removal in a Cleaning
Mix the final cleaning liquor sample well. Transfer 5 mL of the sample to
clean dry 50 mL conical flask. Add 5 mL concentrated nitric acid (AR).
Heat to boiling on a moderate hot plate and gently reflux for 15 min with
occasional swirling of the flask. Allow to cool and add approximately
30 mL deionized water. Warm the solution on a hot plate and transfer the
contents of the flask quantitatively to a clean 250 mL graduated flask.
Dilute to the mark with deionized water and mix the solution well.
Determine the Fe, Cu, Zn, and Ni content solution by atomic absorption
spectrophotometry using the instrument operating conditions and cali-
bration procedure previously described.
4.3.3 Rapid Method for Following the Progress of the Chemical Cleaning
Operation
Transfer 5 mL of the chemical cleaning liquor (free from suspended
matter) to a clean 250 mL graduated flask. Add 5 mL ‘AR’ concentrated
nitric acid, dilute to the mark with deionized water and mix well.
Determine the Fe, Cu, Zn, and Ni content of the sample by atomic
absorption using the instrument conditions and calibration procedure
described above.
Appendix 4A List of Analytical Methods used IN Analysis of Chemical

Cleaning Solutions
Determinant Solution Method
Free citric acid Acid cleaning Selective ion electrode
Fluoride Acid cleaning Selective ion electrode
Fluoride Flushing Colorimetric
Chloride 3 % citric acid Selective ion electrode
Chloride 50 % citric acid Turbidimetric
Chloride 0.880 sg. ammonia Selective Ion electrode
Chloride Water Selective Ion electrode
Chloride Water/hydrazine Colorimetric
Chloride Flushing Selective ion electrode
Chloride Flushing Colorimetric
Silica Acid cleaning Colorimetric
Silica Acid cleaning Atomic absorption
Stannine LTP Acid cleaning UV absorbance
Active inhibitor Extract from 5A Colorimetric
(continued)
(continued)
Determinant Solution Method
Armohib 28 Acid cleaning Colorimetric
Bromate/copper Alkali cleaning Titration
Nitrite Copper stripping Colorimetric
Nitrite Flushing Colorimetric
Copper Alkali cleaning Colorimetric
Trisodium phosphate Alkali boil-out Titration
Phosphate Cleaning Colorimetric
Phosphate Alkali boil-out Colorimetric
Hydrazine Water Colorimetric
5.0 Safety Aspects

5.1 Introduction
This section describes the precautions necessary for the safe handling,
storage and use of chemicals used in the cleaning processes and also
describes the procedures for entry into the plant after cleaning and
disposal of residues. The recommendations contained in this Section shall
be considered in conjunction with the (then) CEGB Safety Rules, the
National Safety Code of Practice GS-EH162. “The implementation of
Control of Substance Hazardous to Health (COSHH) Regulation 1988”,
and the other Sections of this directive.
The storage used and handling of the chemicals required for the chemical
cleaning process are potentially hazardous to the personnel involved.
These hazards are listed along with storage requirements, in Appendix
5A. The officer responsible for the safety aspects of chemical cleaning
and for ensuring that safety precautions are strictly observed shall make
himself familiar with appropriate (then) CEGB safety documentation.
A summary of suitable protective equipment is given in Appendix 5B, but
this should not discourage reference to the documentation itself.
Emergency provisions and first-aid treatment are given in Appendix 5C.
5.2 All Items of Plant
5.2.1 Supervision
5.2.1.1 The officer responsible for the overall safety aspects of chemical cleaning
shall be the Project Site Manager in the case of pre-commissioning
cleaning, and the Location Manager where post-commissioning cleaning
is being carried out. In both circumstances, the Station Chemist or a
nominated deputy shall act as adviser to the officer responsible for safety
and shall be the Supervising Officer in so far as it is necessary to ensure
that the safety precautions are strictly observed and to ensure that suitable
hygiene and first-aid facilities are available. The Supervising Officer shall
consult with the medical service (normally the Nursing Officer) with
respect to first-aid facilities. Supervision of the required safety precau-
tions by the Station Chemist shall also include supervising the chemical
cleaning contractor’s employees and any failure to comply with the safety
requirements shall be notified immediately to the Project Site Manager or
Location Manager as appropriate. The Supervising Officer or his deputy
shall be present at the scene of operation whenever chemicals are being
received or are in the cleaning system or during subsequent inspection
5.2.1.2 The Station Chemist shall ensure that chemicals are introduced in the
correct manner to the cleaning circuit and that the ventilation and
temperature requirements before entry into the plant for inspection or
working have been complied with (see 5.2.6)
5.2.2 General Philosophy
5.2.2.1 The manual handling of chemicals should be avoided as far as practicable
and wherever possible, mechanical methods should be used for
transporting, dispensing, and transferring chemicals
5.2.2.2 Protective clothing for skin and eye protection must be worn and if not
adequately ventilated, breathing apparatus must be worn when:
(i) Mixing chemicals
(ii) Dealing with leaks, spillages, splashes and
accumulated vapors
(iii) Approaching the plant
(iv) Post-cleaning inspection is carried out
5.2.3 General Precautions and Personal Hygiene
Wherever and whenever there is danger of contact with chemicals, all
personnel must:
(i) Be warned of the nature of the potential hazards and the necessary
precautions and be instructed in the correct use of protective
clothing and equipment by the Supervising Officer
(ii) Observe a high standard of personal hygiene avoiding contact with
chemicals, their vapors or contaminated residues
(iii) Not eat, drink, or smoke
(iv) Avoid wiping nose, eyes or face other than with clean paper tissues
(v) Place all debris and chemical residues removed from the plant in
clearly labeled polythene bags for subsequent disposal
(vi) On leaving the plant, remove their protective clothing for cleaning
before re-use, and clean themselves and their equipment, using
disposable materials
(vii) Wash thoroughly as soon as possible after leaving the operational
area (see 5.2.8)
5.2.4 Storage of Chemicals

Chemicals shall always be stored in a cool, well ventilated and secure
building which, as far as possible, is free from fire. Because of their risk,
particular properties and in some cases, their incompatibility, some
chemicals require special storage precautions to be taken; these are given
in Appendix 5A. If any chemical not listed there is to be used, then the
advice of the Chief Medical Officer must be sought and the ‘Head of
Industrial Safety Management Group’ notified so that Appendix 5A can
be accordingly modified. Chemical containers must be clearly labeled at
all times.
5.2.4.2 The Supervising Officer must ensure that notices detailing the action to be
taken in the event of spillage, the emergency provisions and first-aid
treatment, are prominently displayed in the chemical storage and
operating area. The notice must state the location of equipment necessary
to deal with spillage or personal contamination
5.2.4.3 An adequate water supply must be available to deal with any leakage or
spillage of chemicals
5.2.4.4 Stock control shall be implemented so that there is a sequential turnover
of chemicals
5.2.4.5 The chemical cleaning contractor must provide equipment and chemicals
for the treatment of spillages or personal contamination, which is readily
available and properly maintained
5.2.5 Precautions during the Cleaning Process
5.2.5.1 The chemical handling, mixing and temporarily hazardous areas must be
roped off, cleared of extraneous matter, and have proper warning notices
erected and authorized by the Supervising Officer. Persons not concerned
with the cleaning process must be excluded from the area. Whenever
chemical solutions are in the plant, the entire circuit both temporary and
permanent, must be periodically examined for leaks. Any leaks should be
stopped as quickly as possible and the contaminated area thoroughly
sluiced down. If the Supervising Officer deems the leak to be dangerous
to personnel, the process must be suspended and the affected circuit
drained and flushed prior to repair. Appropriate protective clothing must
be worn while checking for leaks and when using appropriate equipment
for dealing with leaks (see Appendix 5B)
5.2.5.2 Entry into any confined space into which solutions or vapor can leak from
the cleaning circuit during the process should be avoided as far as is
reasonably practicable. If entry into such spaces must be made, the
precautions given in 5.2.7 shall be observed
5.2.5.3 Whilst chemical cleaning operations are in progress, venting of the boiler,
including the vent from the constant head overflow, must be to the outside
of the building, inaccessible to personnel and well away from other vents
or intakes to avoid the possibility of vapor reentering the building
5.2.6 Approach to the Plant (Excluding Bodily Entry) After any Stage of
the Cleaning Process
5.2.6.1 When the plant is to be opened up after the passivation stage or after any
acid stage during the process, the precautions given in 5.2.6.2–5.2.6.6
shall be observed
5.2.6.2 The chemical cleaning circuits must be drained to the approved disposal
point taking care to minimize spillage, splashing of solutions or
accumulation of vapor. If chemicals are drained into a holding vessel,
care must be taken that mixing of chemicals from different stages does not
occur in the vessel. It is particularly important to avoid acidifying
solutions containing nitrite or bromate, or mixing strong acids and alkalis
or strong oxidizing and reducing agents
5.2.6.3 Vapors issuing from plant openings should be dispersed by blowing clean
air through the access point using the best possible ventilation to obtain a
high dilution rapidly. The breaking open of access points should be
carried out by personnel wearing an approved type of overall and gloves
and breathing apparatus incorporating a hood to give a full protection to
the head. Suitable equipment is given in Appendix 5B. Contact with
surfaces which are or have been wetted by chemicals should be avoided
as far as is reasonably practicable
5.2.6.4 Components which are contaminated with chemicals should be placed on
impervious sheets for cleaning prior to replacement
5.2.6.5 Personnel should not expose themselves to risk by making a quick
observation of the plant interior (without bodily entry) when the access
points are first opened
5.2.7 Entry of Personnel into Plant That has been Chemically Cleaned
5.2.7.1 The precautions given in 5.2.7.2–5.2.7.5 are necessary if entry is to be
made into the plant after any acid cleaning or passivation stage in the
process
5.2.7.2 Entry to the plant shall be restricted to the minimum number of people
necessary. During the time that personnel are inside the plant, a stand-by
man must be positioned at the point of entry
5.2.7.3 Before entering the plant after chemical cleaning, either after the
passivation stage at the end of the process, or after any acid stage during
the process, or to carry out reinstatement work such as the removal of
flow restrictors, there must be an absolute minimum delay of 3 h after
opening all entry points, unless full protective clothing is worn and an
air-line breathing apparatus is used. During this period, ventilation of the
plant should be carried out at a rate of at least ten air changes/h using a
filtered air supply. It is essential that this 3-h delay period is observed,
even if a higher ventilation rate is adopted. Ventilation of the plant at a
rate of at least 10 air changes per hour should be continued while
personnel are in the plant for inspection or to carry out reinstatement work
such as removal of flow restrictors
5.2.7.4 Additionally before personnel enter plant, the temperature should be
ambient temperature. If the conditions above in 5.2.2 and 5.2.5 have been
fully complied with personnel can enter the plant wearing coveralls,
gloves, and carefully fitted eye-goggles as detailed in Appendix 5B.
Where such conditions have not been fully complied with, personnel
entering the plant must wear overalls, PVC gloves, rubber boots, a
breathing apparatus, and hood attachment giving full protection to the
head as detailed in Appendix 5B
5.2.7.5 Removal of debris or chemical residues from the plant must be carried out
by personnel wearing full protective equipment and in such a manner as
to avoid contamination of external surfaces. The residues should be
extracted into impervious containers which are then passed to persons
wearing gloves and goggles, as detailed in Appendix 5B
5.2.8 Exit of Personnel and Materials from Plant Containing Hazardous
Residues After Chemical Cleaning
5.2.8.1 The personnel collecting debris and chemical residues must place them in
clearly labeled polythene bags within the plant
5.2.8.2 For disposal, debris and chemical residues must be washed into a system
where considerable dilution can be achieved. Equipment used for
handling chemicals and the inhibitor must also be cleaned after use by
washing into a disposal system where considerable dilution can be
achieved (see 5.2.9)
5.2.8.3 The same personal clothing should be used until the end of the work
period on which a particular operator is engaged and then thoroughly
cleaned. Upon leaving the plant, the operator should remove the
protective clothing for subsequent cleaning before re-use and proceed
directly to the showers, paying particular attention to washing the hands
and face
5.2.9 Disposal of Chemical Waste
Disposal of all surplus solutions and chemical waste must be by an
approved route. The appropriate waste disposal and water authorities
should be consulted.
Notes:
1. Where Emergency Action is Required For Dealing With Spillage Or
Escape Of Chemicals, Maximum Ventilation and Water-Washing
Facilities Must Be Used
2. Personnel using self-contained and air-line breathing apparatus must
be properly trained and experienced in the use of such apparatus
3. The standard procedure outlined in documents with regard to the
removal of protective clothing must be strictly observed
4. Particular care must be exercised when opening drums of 0.880
ammonia solution, particularly where these have been in a warm
atmosphere, because the contents are likely to be under pressure
5.3 Boilers, Super Heaters, Reheaters, and Feed Systems
Where there is a choice, preference should be given in using inhibitors
having a lower perceived risk.
5.3.1 In addition to the safety considerations given for all items of plant, the
following specific provisions apply to the chemical cleaning of boilers,
super heaters, reheaters, and feed systems
5.3.2 The substituted thio-ureas present in some inhibitors specified in
Appendix IF can lead to the formation of carbodiimides, which cause
temporary blindness and sensitivity to light. To minimize the risk of eye
toxicity, it is essential to adhere to the recommendations in Sect. 5.2, ‘All
Items of Plant’, particularly regarding the addition of the inhibitor to the
cleaning solution (5.2.5) and approach and entry into the plant (5.2.6 and
5.2.7). The recommendations on supervision (5.2.1) handling, storage,
and disposal of chemicals (5.2.2, 5.2.4, 5.2.5 and 5.2.9) must be strictly
observed
5.4 Condensers
5.4.1 Cooling Water Side
5.4.1.1 The provisions given in Sect. 5.2 also apply to the chemical cleaning of
the CW of the condensers
5.4.1.2 While it is believed that eye toxicity due to carbodiimide is not possible
with the inhibitors currently specified for condensers in Appendices 2D
and 2E, it is nevertheless essential to flush out all traces of inhibitor using
the full flow of the main CW pumps for at least 3 h before entering the
plant. The precautions during cleaning (5.2.5) and the approach and entry
into the plant (5.2.6 and 5.2.7) must be strictly applied
5.4.1.3 The health precautions stated in the IS Safety Code of Practice on the
maintenance of cooling water and other auxiliary water must be followed
to minimize the risk of infection from Legionella
5.4.2 Steam Side
Inhibitors are not used in current practice for cleaning the steam side of
condensers, therefore, no special precautions are required in this respect.
5.4.2.2 However, large volumes of acid cleaning liquids and solvents are used
and the provisions given for supervision (5.2.1). Handling storage and
disposal of chemicals (5.2.2, 5.2.4 and 5.2.9) must be applied. Some
solvents are flammable and/or toxic, and precautions must be taken to
ensure that no explosion hazard or toxicity risk can arise. Ventilation
equipment should be selected and positioned taking into account risks to
personnel and explosion risks in accordance with ‘National Power Safety
Rules Code of Practice in Confined Spaces’
5.5 Feed Heaters
The provisions given for supervision (5.2.1); the addition of inhibitors to
the cleaning solutions (5.2.5); approach and entry into the plant (5.2.6 and
5.2.7), and the handling, storage, and disposal of chemicals (5.2.2, 5.2.4
and 5.2.9) must be strictly observed. Solvents are also used and
precautions must be taken to ensure that no explosion hazard can arise
and that the plant is suitably ventilated to prevent risks to personnel (see
5.4.2.2).
Appendix 5A Summary of Main Chemical Hazards and Special Storage

Requirement
Chemicals OEL (note 1) Main hazards Special storage

requirements
Acetic acid 10 ppm Corrosive, irritant can cause severe Store away from
burns flammable chromic and nitric acids
Ammonia 25 ppm (as Corrosive, severe irritant Store away from acids
NH3) and/or bromate
Ammonium bifluoride Corrosive, reacts with mineral acids Avoid contact with
to produce HF gas. Highly irritating acids and fire risk
to skin, eyes and nose
Applied chemicals 4–43 Can cause skin and eye irritation; if Store away from
swallowed gastro-intestinal irritation sources of heat or strong
acids
C9 Naphtha degreasant Flammable (see supplier's data Store away from fire
sheet) risk in a well ventilated
area
(continued)
(continued)
requirements
Citric acid Powder and solution can cause eye Store away from
injury oxidizing agent
Chromic acid 0.05 mg/m3 Can cause severe burns Store away from
(as Cr) Can cause violent oxidizing agents and
explosion in contact with reducing any fire risk
agents
Dipotassium hydrogen Produces toxic, irritant fumes when
phosphate heated
Disodium hydrogen Produces toxic, irritant fumes when
phosphate heated
Ethomean S25 – Skin and eye irritant (See Supplier's
data sheet)
Formic acid 5 ppm Corrosive. Can cause severe burns Store in a
well-ventilated area
Inhibitors (Armohib 28, Can cause skin and eye irritation –
Hibron armohib 533, (some severe). Some combus-
Stannine LTP, Dodigen Tible/toxic/corrosive
95, etc.) Rodine, Lith
solvent, coronil. etc.
Hydrazine 0.1 ppm Strongly caustic. Irritant Store separately. See
May cause damage to liver and national safety code of
kidneys practice GS-C1 0.15
Hydrochloric acid 5 ppm Corrosive and irritant. Store in a
well-ventilated area
Hydrogen peroxide 1 ppm Oxidizing and corrosive Store separately, and
Can cause severe damage to eyes away from all
and skin combustible materials in
May explode in contact with dust a cool area
Hydrofluoric acid 3 ppm Toxic and corrosive. Can cause Store in a
severe burns well-ventilated area
Nitric acid 2 ppm Oxidizing and corrosive can cause Store away from acetic
severe burns acid, ammonia and
combustible materials
Oxalic acid 1 mg/m3 Corrosive. Avoid breathing dust or Store away from
vapor oxidizing agents
Potassium hydroxide 2 mg/m3 Highly corrosive. Irritant. Inhalation Severe store away from
(caustic potash) (Note 2) of dust or mist causes intense acids
irritation
Potassium or sodium – Eye/skin irritant, with acid solutions Store away from acids
dichromate toxic gases can be produced and combustible
materials
Possible explosion hazard on contact
with organic materials
(continued)
(continued)
requirements
Potassium or sodium – Oxidizing agent. Eye/skin irritant. Store away from acids,
bromate With acid solutions toxic gases are combustible materials
produced and ammonia
Possible explosion hazard with
ammonia and contact with organic
materials
Potassium or sodium – Eye/skin irritant. With acid solutions Store away from acids
chromate toxic gases can be produced. and combustible
Possible explosion hazard on contact materials
with organic materials
Potassium or sodium Eye skin irritant with acid solutions Store away from acids
nitrite nitrons fumes are produced. Possible and combustible
explosion hazard on contact with materials
organic materials
Sodium carbonate (soda Skin irritant. Dust or mist, irritating Store away from acids
ash) to upper respiratory tract
Sodium fluoride 2.5 mg/m3 If heated or in contact with acids, Store away from acids
(as F) emits highly toxic fumes and combustible
materials
Sodium hydroxide 2 mg/m3 Highly corrosive. (note 2) irritant. Severe store away from
(caustic soda) Dust acids
or mist can cause irritation to upper
respiratory tract
Sulphamic acid – Emits toxic fumes when heated. Store away from heat
Irritant
Sulphuric acid 1 mg/m3 Extremely irritant and corrosive. Store away from alkalis
Cause severe burns
Tetra sodium ethylene – Concentrated solution is caustic. Store away from acids
diamine tetra Skin
acetate and eye irritant
Tripotassium phosphate – Skin irritant. If heated highly toxic –
fumes
Trisodium phosphate – Skin irritant. If heated emits highly –
toxic fumes.
Wetting agents – May cause eye and skin irritation –
(Dissapol, Teepol, etc.)
Notes
1. OEL—Occupational Exposure Limit (8-h TWA value)
2. Confirm by reference to the most recent HSE Guidance Note eH 4016
Appendix 5B Summary of the Protective Equipment to be Used When

Handling Chemicals
Conditions Protective equipment
B-1 Normal handling of the following chemicals:
Ammonia a. Chemical safety goggles.
Ammonium bifluoride b. PVC apron.
Applied Chemicals 4–43 c. PVC gloves.
Armohib 28 d. Rubber boots (molded).
C-9 Naphtha degreasant
Citric acid In addition, for particulate chemicals
Diaminetetra acetic acid
Ethomeen S 25 e. Dust respirator
Formic acid
Hydrazine In addition, for formic acid, hydrochloric
acid and sulfuric acid
Hydrochloric acid
Hydrofluoric acid
Lissapol C
Lissapol N f. Vizor.
Oxalic acid
Sodium bromate
Sodium hydroxide
Sodium nitrite
Stannine LTP
Sulfuric acid
Tetra sodium ethylene
Trisodium phosphate
5B-2 (i) For entry into plant chemical cleaning a. Chemical safety goggles
in which the requirements for inhibitor b. One-piece cotton/polyester overall with
additions and ventilation and temperature hood or one-piece disposable overall in
have been fully complied with PE-coated tyrek
c. PVC gloves
d. Rubber boots (molded).
(ii) For handling debris and chemical As for 5B.2(i) above.
residues removed from chemical cleaned
plant
(continued)
(continued)
Conditions Protective equipment
5B-3 (i) For entry into plant after chemical a. Compressed air-line breathing apparatus
cleaning in which the requirements for b. One-piece cotton/polyester overall with
inhibitor additions and ventilation and hood or one-piece disposable PE-coated
temperature have been fully complied with tyrek
c. PVC gloves
d. Rubber boots (molded)
(ii) When breaking open access points a. Compressed air-line breathing apparatus
after chemical cleaning (if entry also required).
b. Open-circuit self contained breathing
apparatus (if entry not required)
c. One-piece cotton/polyester overall with
hood or one-piece disposable Tyrek
d. PVC gloves
e. Rubber boots (molded)
(iii) Where contact with vapor and As per 5B.3 (ii)
merging from drains or vents during a
chemical process is unavoidable
(iv) Where severe spillage or escape of the a. Open-circuit self-contained breathing
following chemicals has taken place: apparatus
Sodium bromate, Nitrous fumes, b. Compressed air-line breathing
Stannine LTP and Armohib 28
c. PVC gloves
d. Rubber boots (molded)
e. One-piece cotton/Polyester coverall
with hood or one-piece disposable overall
in PE-coated tyrek (alternatively, PVC
chemical splash suit)
Appendix 5C Emergency Provisions and First-Aid Treatment

5C-1 Emergency Provisions
Flushing and washing (i) Ample supplies of tepid flushing and washing water shall be provided
water supplies at all possible points of discharge, spillage or escape of chemicals
(ii) Adequate provision shall be made for emergency treatment of the
eyes, comprising eyewash bottles, located conveniently to places where
discharge, spillage, or escape of chemicals can occur
First-aid room A suitable first-aid treatment room with outside telephone facilities shall
be provided within a reasonable distance of the place where chemicals
are being used
Store room A suitable room shall be provided for housing the protective clothing and
apparatus required for emergency use
5.C-2 First-Aid Treatment

Injury Chemicals Treatment
Splashes in All chemicals (i) Immediately flood the eye with water. To be effective,
the eye the eye must be opened
After a quick preliminary swill to wash away fluid
around the eye, the eyelids should be pushed apart using
the thumb and index finger of the left hand. The casualty
will probably not be able to open the eye themselves
because of painful spasms
If an eyewash bottle is used, the jet would not be directed
at the front of the eye but should be directed in from the
side, so that flow is over the surface of the eye
(ii) Irrigation should be continued for 5−10 min, after
which the casualty should be taken to the first-aid room
(iii) Irrigation should be continued in the first-aid room.
Remember, vision is saved by thorough irrigation, no
other treatment can prevent damage if this is omitted
(iv) After thorough irrigation, the eye should be covered
with a pad: the patient should be referred for medical
opinion
Irritation of All chemicals If signs of skin irritation occur, the person should be
the skin removed from contact and referred for medical opinion
In the event of splashing of the skin with chemicals, the
affected area should be washed thoroughly avoiding
spreading contamination to the face and eyes
Gassing All chemicals Bring person to fresh air, remove contaminated clothing,
cover with blanket and keep person still and under
observation. Refer for medical opinion
Ammonia or In addition to the above, if breathing is distressed, give
nitrogen. Bromine oxygen. If breathing fails, give artificial respiration.
from sodium Summon doctor to site. dioxide from sodium nitrite
bromate. Nitrogen
N.B. Oxygen can only be issued by a doctor or an occupational first-aider

holding the appropriate certificates
Appendix 5D Inhibitor Efficiency Test Procedure
5D-1 The selected inhibitor for acid cleaning of pre-boiler and boiler
parts is to be checked for its efficiency. This can be done in two
ways. The first is the laboratory test method, which confirms the
efficiency of the inhibitor and also helps in arriving at the desired
concentration of inhibitor required for effective results. The second
is a field test method which can be used during acid cleaning at
intermediate intervals so that necessary changes, if any in the
inhibitor concentration may be made from time to time
5D-2 Laboratory Test Method

The relative corrosivity of inhibited solutions used for chemical
cleaning can be checked in laboratory under static conditions at
temperature of 65–70 °C. The test can be conducted on metal
coupons, preferably water wall tube samples, under clean condi-
tions. The test consists of exposing metal coupons to cleaning
solvent under controlled conditions. The coupons are weighed
before and after the test and the corrosion rate is calculated from
the weight loss method. Reagent grade chemicals and DM water
should be used in all tests.
5D-2.1 Metal Coupon Preparation
A convenient metal coupon dimension is 13 × 100 × 3 mm
(0.5 × 4.0 × 0.125 in.). Other shapes and sizes of test coupons are
acceptable provided the total area is about 2600 mm2 (4 in2) or
greater. The principal requirement is to keep the flat surface area
large when compared with the edge area. The surface finish of the
metal coupons should be carried out with No. 120 abrasive paper
or cloth of the equivalent grit grade unless the surface is to be
tested in the mill finished condition.
5D-2.2 Surface Area-Volume Ratio
Specific coupon surface area to solution volume ratio is to be
maintained for the test. For comparative results, a recommended
ratio of surface area to solution volume (S/V) is 0.35 cm2/cm3.
Other S/V ratios may be used to match the S/V ratio of a test to a
specific application for which the cleaning solution is intended. For
example, chemical cleaning solutions may also be tested at a typical
S/V ratio of 0.6 cm2/cm3 for drum-type boilers or 1.3 cm2/cm3 for
once-through boilers. The S/V ratio for specific equipment can be
calculated by the examiner. It is important that the test S/V ratio be
recorded and maintained during the test.
5D-2.3 Test Procedure
5D-2.3.1 Prepare a sufficient quantity of solution to conduct all the planned
tests for one day. Place the solution in individual glass or plastic
test vessel (plastic test vessels must be used if the solvent contains
fluoride). The test vessel should be resistant to both the chemical
cleaning solution and the test temperature. Note that the corrosion
inhibitor should be added to the solution just prior to testing.
5D-2.3.2 Add the amount of solution to the test vessel and record the S/V
ratio and maintain it during the test.
5D-2.3.3 Place the test vessel in a constant temperature bath and allow it to
equilibrate to the test temperature.
5D-2.3.4 Weigh the coupon to the nearest tenth of a milligram. The coupon
should not be added to the test vessel containing the solution until
the solution reaches the test temperature. Totally immerse the
coupon in the test solution. Any supports or hangers used should
be electrically nonconductive material.
5D-2.3.5 The duration of test should be 6 h.
5D-2.3.6 Duplicate tests must be performed to confirm results and to
minimize the possibility of random errors. Duplicate tests should
be conducted separately so that any errors made in one test will not
be repeated in duplicate.
5D-2.3.7 After completion of the test, rinse the coupons in DM water and
then rinse them with acetone or methanol to remove the inhibitor
film. Scrub the test coupons using a nylon brush and soap solution.
Rinse with DM water and follow with an acetone or alcohol rinse
to replace the water and dried in oven at a temperature of about
105 °C for about 15 min. Store the coupons in a desiccator for a
minimum period of 1 h prior to re-weighing.
5D-2.3.8 Calculation of Corrosion Rate
After cleaning, the coupon should be re-weighed to the nearest
tenth of a milligram. The corrosion rate, as on average penetration,
based on weight loss should then be calculated in the units of
mg/cm2/h.
5D-2.3.9 Criteria for Acceptance
The weight loss should not be more than 0.1 mg/cm2/hr at 65 °C
for carbon steel and mild steel sample.
5D-3 Field Test Method
A small ball of steel wool (about 0.1 gm) is degreased with
acetone and added to a sample of inhibited acid solution in the acid
tank solution during cleaning process.
5D-3.1 Criteria
Inhibitor efficiency is judged to be adequate if the wire wool ball
does not float after 1 min in ammoniated citric acid or after 2 min
in hydrochloric acid.
5D-4 Notes:
1. The expiration date of the inhibitor is to be checked before
starting use.
2. In the event that the test fails, the test is to be conducted at a
higher concentration so as to conclude at what concentration
the efficiency is acceptable and accordingly concentration of
inhibitor in acid cleaning procedure is to be adopted.
Appendix B
Fire Protection of Power Stations
1.0 Introduction
Plant is exposed to onerous operating conditions and the combinations of
flammable material in large quantities and ignition sources which can lead to
the incidence of fires. This Guidance Note applies the principles and gives
specific recommendations to achieve a satisfactory level of protection,
methods to prevent fires, and routine checks/maintenance jobs for operational
station at risk from fire.
2.0 Any previous Guidelines
Nil
3.0 Scope
This Guidance Note is specifically geared at fixed fire detection and
protection systems. The provision and use of portable equipment, such as
hose pipes/reels and extinguishers by a fire fighting team is covered by the
TAC/CISF Fire Manual.
Recommendations are made for prevention/detection/protection against fire,
for inspection, for testing and maintenance, and for operational needs
pertaining to the fire detection and protection equipment.
4.0 Fire Hazards and Prevention
The various hazards in a power station and the methods to prevent these are
given in the following table.

DOI 10.1007/978-81-322-2722-9
206 Appendix B: Fire Protection of Power Stations
S. No. Area Fire hazard Fire prevention

4.1 Coal stockyard Self-ignition due to coal air 1. Coal to be visible as wet while
interaction (dry coal-wet air stacking
from the period of March to 2. Fresh coal not to be stacked over
June is the most critical old coal
combination and moist coal-dry 3. Coal to be stacked layer by layer
air the most favorable (each of 1–1.5 M height) with
combination) compaction of each layer
4. Regular spray of water over coal
yard to be done
5. Stacking to be done in
trapezoidal stockpile and not in
conical form
6. Proper records of period of
stacking to be maintained and the
principle of FIFO (First In First
Out) to be adopted
4.2 Bulldozers, Coal dust and oil deposits Regular cleaning of engine
pay-loaders, etc. combined with hot exhaust compartment, inspection to check
pipes, fuel oil tank, fuel oil for any fuel leakage
leakages, cables
4.3 Coal conveyors 1. Maintenance activities 1. Regular cleaning and inspection
involving welding/gas cutting of all areas of CHP
leading to weld spatter on 2. Chute block switches to be kept
coal/conveyor in service to alarm chute choking
2. Friction caused by 3. Pulley, idlers, gear boxes, fluid
(a) Belt with steel frame couplings not to be over
(b) Jammed idler greased/over filled
(c) Jammed conveyor belt 4. System of hot work permit to be
due to choking of chute but followed during welding/cutting job
pulley rotating in bunker floor. CISF man to be
3.Fluid coupling failures present along with portable
4. Overfilled gear box extinguishers, ready hose, etc
5. Self-ignition of accumulated 5.Only fire retardant (FR grade) belt
coal dust at concave contours of to be used including bunker sealing
conveyors belt, ILMS belt
6. Loosely laid 6. Belt not to rub steel work
wires/cables/welding cables 7. While welding any chute/hopper
with exposed joints lined with rubber/polymer liners,
special care to be taken to cool the
liner
8. Adequate illumination in all areas
of CHP
9. Coal dust accumulation on
magnets and its cleaning belt to be
avoided as temperatures are high
there
10. Loose wires/cable/welding
leads with open joints to be avoided
11. Belt flapping to be avoided by
installing rollers mounted on
carrying side
(continued)
Appendix B: Fire Protection of Power Stations 207
(continued)
4.4 Coal bunkers 1. Feeding of hot coal from 1. Residual, compacted coal should
stockyard, which may be about be avoided in bunkers and bunkers
to burn should be emptied and cleaned
2. Residual coal sticking to thoroughly during overhaul of unit
bunker walls for a long periods 2. Bunker gates to be maintained to
resulting in self-ignition ensure that they close properly
3. Any draught of air through when bunker is not in use
the coal in bunkers, particularly 3. Hot coal should not be fed into
compressed air from air blast the bunkers from stockyard
equipment 4. System of hot work permit to be
4. Low bunker level coupled followed during welding/cutting job
with unsatisfactory isolation in bunker floor
from feeder/mill with 5. Availability of bunker level
subsequent pressurization of indication along with annunciation
furnace causing hot gases to for low bunker level to be ensured
pass through the bunker
5. Bunker conveyor fires
4.5 Coal feeders 1. Hot or burning coal passing 1. Routine cleaning of feeder from
from coal bunkers inside to reduce extent of residual
2. Fires in mills particularly coal left compacted in dead spaces
during start-up or shut-down within the feeder
periods 2. Bunker gates and mill dampers to
3. Friction due to mechanical be maintained to prevent passage of
failure combustion products from fires into
4. Welding/gas cutting etc. the feeders or elsewhere in the
5. Residual coal in pockets of system
feeder 3. The system of hot work permit to
be strictly followed during
welding/gas cutting jobs
4. Periodic checking of feeder
protection on “No coal on belt” to
be ensured
4.6 Coal mills and P. 1. High mill outlet temperature 1. Appropriate fire detection system
F. piping due to coal flow interruption to be maintained in both running
2. Low level of coal in ball and standby mills
mills 2. Instrumentation of
measuring/maintaining level of coal
in ball mills and of measuring
sound level to be maintained
3. Proper start-up and shut-down
procedures to be maintained
4. Mill inerting system to always be
kept in service
5. Auto closing of HAG from mill
outlet temperature high protection
is to be kept in service
(continued)
(continued)
4.7 Boiler burner 1. Ignition of preheated fuel oil 1. Steam pipes for oil atomization
fronts on hot boiler casing/steam pipes are to be thoroughly insulated
2. Rupture of flexible hoses 2. Prompt attention to defects on
3. Leakage of PF pipes burner connecting hoses and pipe
4. Faulty ignitors coupled with work
leaking oil 3. No spillage of oil around burner
area during removal of burner
carrier for tip cleaning. In case of
oil leakage, soaked insulation to be
removed and re-insulation to be
completed
4. Minimum electrical
equipment/cables/junction boxes
near burners to be located
5. Ignitor faults to be immediately
attended
6. Oil waste, rag, and combustible
materials should not to be allowed
to accumulate
7. Periodic checking of igniter
effectiveness to be done
4.8 Fuel oil storage 1. Greater risk during venting, 1. Precautions to be taken during
tanks gassing, and filling operations tank emptying, cleaning, tank
of light fuel oil inspections, vent inspections, and
2. Leakage of tank other maintenance work (including
3. Dry grass around tanks electrical/lighting work).
4. Oil spillage Welding/cutting to be avoided. If
5. Unclean surroundings carried out, all precautions must be
6. Soaked insulation taken
7. Electrical tracing 2. Entry to bunded area to be
restricted to authorized persons
only
3. Filling lines to be purged and
road tanker connections should be
kept secure when not in use
4. Recycled oil to be cooled to
below the flash point before
returning to storage tanks
5. Excess temperature safety
systems and alarms to be installed
on heater banks
6. All areas within the bund walls
must be free of vegetation and other
combustible materials
(continued)
(continued)
4.9 Fuel Oil unloading 1. Oil spillage or leakage due to 1. There should be adequate
and transfer pump failure of joints or of venting ventilation in the enclosed pump
house due to overheating or house to keep the concentration of
restrictions in system oil vapors within safe levels
2. Heaters 2. Proper smoke vents and
3. Loosely laid electrical adjustable louvers at high and low
cables/welding cables level
4. Drain oil stagnant in 3. Proper earthing of all electrical
unloading pipe trenches and systems
surface drains 4. Use of flame proof
lighting/electrical appliances only
in the pump house
5. Trenches to be filled with sand
and PCC on top to prevent
contamination with oil
6. Oil waste, rag, other combustible
materials not to be allowed to
accumulate
7. No spillage of oil
8. Prompt attention to defects on oil
pipes and heaters etc.
9. If used, oil absorbing granules
should be removed immediately
after use. Wood dust not to be used
as it is an oil-absorbing medium
4.10 Naphtha tanks and 1. Leak in the system, whether 1. Gas leak detection system to be
piping from bulk storage, the kept operational
distribution network, control 2. Entry to storage areas should be
valves, or naphtha pipelines at restricted to authorized persons
combustion chambers only
2. Venting or leaking Naphtha 3. Areas around tanks to be kept
gas getting ignition due to free of vegetation and any other
discharge of static electricity combustible materials
during tank filling 4. Earthing of tanks, other
equipment to be checked regularly
5. Filling lines to be purged and
road tanker connections to be kept
secure when not in use
6. Prompt attention to leakage
defects
4.11 Regenerative Air 1. Carry over of unburnt liquid 1. Frequent inspection and water
Heaters fuel onto the internal heat washing of air heater
exchanger surfaces during cold 2. Soot blowing of air heaters
start-up specially during start-up
2. Slow build-up of deposits of immediately after bringing boiler
unburnt fuel in the absence of into service and cleaning regularly
soot blowing for a period of at least once per shift at a minimum
time 3. Oil to be burnt with maximum
attainable efficiency in the furnace
by appropriate cleaning and
adjustment of burners to minimize
the quantity of unburnt particles,
elimination of tramp air, and
consequent chilling of the flame and
(continued)
(continued)
by ensuring that combustion
chambers are gas tight
4. Air heaters can be put under
observation during light up with the
help of digital camera
5. Regular cleaning, maintenance
and testing of oil burners
6. Thermo-couple type fire
detection system which has been
found to be more reliable to be kept
in service for monitoring air heater
temperatures
7. Infra-red fire detection system,
wherever provided, also to be
maintained for prompt hot spot
detection
8. Burner flushing and testing for
their sprayer leakage and
atomization to be done
4.12 Turbine-generator 1. Minor leakage of lubricating 1. Oil leaks, if any, should be
and control fluids into collected nearest to the leak
inaccessible areas, lagging, 2. Prompt attention to oil leakages
drain trenches and coming in 3. Good housekeeping.
contact with hot surfaces Accumulation of rubbish should be
2. Heavy oil leakage in the form avoided
of spray onto bare hot metal 4. Dispensing point of flammable
caused by bursting of liquid to be kept away from turbine
pipe/flange hall
3. Leakage of hydrogen to 5. Seepage of oil into insulation
atmosphere should be avoided
4. Leakage of hydrogen into 6. Any increase in consumption of
bus duct coupled with choking hydrogen to be thoroughly
of vents of bus duct investigated and rectified
5. Cables laid near hot 7. Adequate ventilation of TG hall
equipment 8. Any welding/gas cutting work to
6. Looseness of current carrying be done only after issue of hot work
bolts, carbon brushes permit
9. Steam pipes to be thoroughly
insulated
10. In case of oil leakage, soaked
insulation to be removed and
re-insulation to be done
4.13 Mineral oil filled 1. Electrical faults inside the 1. Oil leakages to be promptly
transformers transformers including tap attended to
changer failures 2. Vegetation, rags, etc. should not
2. Oil leakage from be allowed around transformer
transformers 3. Routine checking of cooling fans
3. Bushing failure and pumps, operational parameters
4. Rupture of transformer tank 4. Soaking pit to be inspected
body caused by internal faults regularly and cleared as necessary
so as to avoid saturation
5. DGA (dissolved gas analysis) to
be done regularly for transformers,
(continued)
(continued)
and any defect indicated should be
attended to as early as practicable
6. Condition monitoring of
transformers by thermo-vision
cameras, acoustics methods should
be done
4.14 Cable 1. Overheating of cables/cable 1. Cable galleries/vaults to be kept
(a) galleries/vaults joints up to temperature clean and free of all extraneous
conditions high enough to bring combustible materials and not to be
the plasticizers of PVC used as storage and office areas
compound into a volatile state Regular inspection of cable
2. Short-circuit creating galleries
sufficient heat 2. Access to cable galleries to be
3. Accumulation of coal dust, restricted
flammable debris, cardboard 3. Proper ventilation to be provided.
packages, fuel and lubricating 4. All cable entry points to cable
oils gallery to be fire sealed
4. Welding/cutting inside cable 5. Fire barrier walls to be provided
gallery between cable tunnels of units and
5. Heating during installation of fire doors to be kept closed
heat-shrinkable cable joints 6. Loosely laid wires to be avoided
7. Lighting fittings, lighting wires to
be inspected regularly
8. No welding work to be done in
cable galleries
9. Any leakage of fuel/lubricating
oil into cable gallery to be
immediately attended
10. Ingress of coal dust from boiler
side must be avoided
11. Any overheated joint should be
repaired at the earliest
12. Proper illumination in the cable
gallery to be maintained
4.14 Cables in trays in 1. Accumulation of coal dust, 1. Cable trays to be covered with
(b) boiler area flammable debris, cardboard aluminum sheet from top
packages, fuel, and lubricating 2. Cable trays to be regularly
oils inspected and cleaned
2. Welding/cutting inside cable 3. Loosely laid wires to be avoided
gallery 4. Care to be taken during gas
3. Hot flue gas/ash from boiler cutting/welding near/above cable
furnace during furnace trays
pressurization 5. Any leakage of fuel
4. Heat radiation/high oil/lubricating oil on cables to be
temperature due to vicinity of immediately attended
furnace, p.c. pipes, hot air ducts
(continued)
(continued)
4.14 Cables in trays 1. Accumulation of coal dust, 1. Cable trays to be covered with
(c) near bottom ash flammable debris, cardboard aluminum sheet from top
hoppers packages, fuel, and lubricating 2. Cable trays to be regularly
oils inspected and cleaned
2. Welding/cutting inside cable 3. Loosely laid wires to be avoided
gallery 4. Care to be taken during gas
3. Hot flue gas/ash from boiler cutting/welding near/above cable
furnace during furnace trays
pressurization 5. Any leakage of fuel
4. Heat radiation/high oil/lubricating oil on cables to be
temperature due to vicinity of immediately attended
furnace, p.c. pipes, hot air ducts 6. Cables trays can be insulated
5. Hot bottom ash falling on with refractory material for limited
cables during abnormal lengths keeping in view derating
operation factors as per cable manufacturers
(Cables may have to be replaced by
higher size)
4.15 Switch-gears 1. Insulating oil of circuit 1. Switchgear rooms to be kept
breakers clean and free of flammable debris
2. PVC cables, epoxy resin 2. Regular inspection of switchgear
based and paxolin/melamine rooms to be done
insulating material, PVC 3. Switchgear rooms not to be used
wiring, solenoids, and plastic as storage areas or office space
encased relays 4. Proper maintenance of
switchgears and regular testing of
protection relays
5. Proper ventilation of switchgear
rooms
4.16 Gas turbines 1. Leakage of gas, Naphtha 1. Gas leak detectors to be kept in
from joints, covers etc. service always and to be regularly
2.Improper burning of liquid tested
fuel leading to its accumulation 2. Gas/liquid fuel leak should be
in the duct promptly given attention
3.Leakage of 3. Lubricating oil/jacking oil leak
lubricating/jacking oil should be attended at the earliest
possible time
4. No flammable materials should
be allowed to be stored in the
turbine hall
5. Liquid fuel should be fired to
maximum attainable efficiency
6. Good housekeeping.
Accumulation of rubbish to be
avoided
7. Dispensing point of flammable
liquid to be kept away from turbine
hall
8. Any welding/gas cutting work to
be done only after issue of hot work
permit
9. Seepage of oil into insulation to
be avoided
10. Adequate ventilation of TG hall
(continued)
(continued)
4.17 Diesel Generators 1. Leakage of fuel oil 1. Permanent natural ventilation
and Diesel 2. Lubricating oil getting should be provided in the diesel
Engines Driven overheated and leaked engine room at high and low levels
Fire Pumps 3. NRV of diesel return line to to disperse vapors and fumes
tank not working 2. Exhaust pipes should be suitably
insulated to prevent ignition of
flammable materials
3. Fuel, lubricating oil leakages
should be immediately attended to
4. Fuel tanks should preferably be
positioned outside the building
5. Instrumentation and controls of
diesel engine to be regularly
checked and maintained
6. Overloading should be avoided
7. NRV of diesel return line to tank
to be checked regularly
8. Engine oil sample to be tested
regularly
9. Battery and diesel tank should be
sufficiently apart
5.0 Fire Detection and Protection Systems

Power stations must be provided with fire detection and protection systems in
all hazardous areas. There are certain variations with regard to the type of
systems due to change of technology from time to time. Common types of fire
detection and protection systems are described in the following table
Fire Detection and Protection System
SN Area Detection system Protection system Remarks

5.1 Main plant TG building/block
a. Unit Turbine lube oil Quartzoid bulb type Automatic HVW
tanks, coolers and heat detectors (with spray system and fire
purifiers hydraulic detection extinguishers
pipe network)
b. (i) Gas turbine enclosures Heat detectors and Automatic carbon
(If any enclosures are vapor detectors as dioxide gas
provided) per manufacturer’s extinguishing system
(ii) Gas turbine practice or automatic inert gas
combustion chambers extinguishing system
(continued)
(continued)
c. (i) Unit Turbine lube oil Quartzoid bulb type Automatic HVW
tanks, coolers, and heat detectors (with spray system and fire
purifiers hydraulic detection extinguishers
(ii) Turbine lube oil tank pipe network)
assembly in auxiliary
compartment of gas
turbines (design without
GT enclosure)
d. Central lube oil tanks - do - - do -
assembly and purifiers
e. Turbine lube oil pipes (in - do - (optional) Automatic HVW Feasibility to be
oil canal) spray system checked as per
(optional) layout for each
project
f. Lube oil system (tanks, - do - Automatic HVW
piping if any) of TD- spray system and fire
boiler feed pump extinguishers
g. Generator seal oil system - do - - do -
h. Cable galleries/cable vault (a) Linear heat (a) Automatic MVW (b) Not being
sensing cable type spray system and fire provided in new
heat detectors; extinguishers projects
ionization and (b) TES type water
photoelectric type spray system
smoke detectors
(b) - do - plus TES
type
sprinkler bulbs (for
local/auto spray)
i. Cable vault (above false Linear heat sensing Fire extinguishers; Indicator of the
roof and below false cable type heat automatic carbon photo-electric
flooring of unit control detectors; ionization dioxide gas and ionization
rooms) and photoelectric extinguishing system type smoke
type smoke detectors or automatic inert gas detectors to be
extinguishing system mounted at false
roof
j. Battery rooms (C&I and Electrical spot type Fire extinguishers
electrical) heat detector and
ionization type
smoke detectors
k. Steam turbine bearing (a) Quartzoid bulb (a) Manual HVW To be provided in
housing, turbine type heat detectors spray system and fire consultation with
enclosure (with hydraulic extinguishers manufacturer
detection pipe (optional)
network) (optional) (b) Automatic inert
(b) Flame detectors, gas extinguishing
gas detectors system
(continued)
(continued)
l. All MCC and Switchgear Ionization type Fire extinguishers
rooms (LT/HT) smoke detectors
m. UCB and its adjoining Ionization and photo Automatic Inert gas
office space, Control electric type smoke (‘INERGEN’ or
equipment rooms, UPS, detectors ‘ARGONITE’)
inverter rooms, extinguishing system;
marshalling cabinet area automatic inert
system
n. SWAS rooms – Fire extinguishers
o. Service building/facilities Smoke detection Sprinkler system, fire
building system extinguishers
p. Along the periphery – Hydrant system Hydrant valves
and individual
hose boxes/hose
reels
q. Stair cases – Hydrant system and Landing valves
fire extinguishers and individual
hose boxes
5.2 Main plant boiler/WH RB block
a. Electro-static-precipitator – Hydrant system, Landing valves
water monitors and individual
around ESPs and hose boxes, hose
WHRB reels
b. Gas turbine fuel syst. Quartzoid bulb type Automatic HVW
skids heat detectors (with spray system and fire
(gas/Naphtha/NGS/HSD) hydraulic detection extinguishers
for metering/filtering etc. pipe network)
c. Boiler burner front Quartzoid bulb type Automatic HVW
heat detectors (with spray system and fire
pneumatic detection extinguishers
pipe network) or
electrical spot type
detector
d. All control rooms, MCC Ionization type Fire extinguishers
and switchgear rooms smoke detectors
(ESP/VFD, ash handling
plant and other buildings)
e. Cable galleries (ESP and Linear heat sensing Automatic MVW
VFD building) cable type heat spray system and fire
detectors; ionization extinguishers
and photoelectric
type smoke detectors
f. Boiler staircases – Hydrant system, Landing valves
water monitors on and individual
either side of boilers hose boxes
and fire extinguishers
(continued)
(continued)
g. Coal Bunkers – Bunker inerting by
CO2/inert gas/steam
(optional)
h. Along the periphery – Hydrant system Hydrant valves
and individual
hose boxes
5.3 Transformer yard area
a. All transformers Quartzoid bulb type Automatic HVW Hydrant valves
heat detectors (with spray system hydrant and individual
hydraulic/pneumatic system and fire hose boxes
detection pipe extinguishers
network)
b. Along the periphery – Hydrant system Hydrant valves
and individual
hose boxes
c. DG set/black start DG Quartzoid bulb type Automatic MVW
area heat detectors (with spray system and fire
hydraulic detection extinguishers
pipe network)
d. All control rooms, MCC Ionization type Fire extinguishers
and switchgear rooms smoke detectors
(compressor house, DG
set area or any other local
MCC/switchgear rooms)
5.4 Coal handling plant
a. Coal Conveyors (a) - (a) Hydrants/monitors Hoses to be
(b) LHS cable type (b) (i) Sprinkler provided in
heats detectors and system central hose
infrared type heat (ii) Solenoid operated houses
detectors automatic MVW
(c) Linear heat spray system and
sensing cable type hydrant system
heat detectors, (c) Automatic MVW
quartzoid bulb type spray system and
heat detectors (with hydrant system
hydraulic/pneumatic
detection pipe
network) and
infra-red type heat
detectors
b. Transfer points and Quartzoid bulb type (a) Automatic MVW
crusher houses heat detectors spray/sprinkler
system and hydrant
system (landing
valves and/or water
monitors)
(b) Hydrants
(continued)
(continued)
c. Coal handling plant Ionization type (a) Fire extinguishers
control rooms, MCC and smoke detectors (b) Hydrants (outside)
switchgear rooms
d. Cable galleries in CHP Linear heat sensing (a) Automatic MVW
control/switchgear rooms cable type heat spray system and fire
(if any) detectors; ionization extinguishers
and photoelectric (b) Hydrants (outside)
type smoke detectors
e. Transformers of rating 10 Quartzoid bulb type Automatic HVW Hoses to be
MVA and above within heat detectors (with spray system and fire provided in
the plant premises hydraulic detector extinguishers hydrant central hose
pipe network) system houses
5.5 Fuel oil handling
a. Fuel oil tanks Linear heat sensing Foam injection
(NAPTHA/NGL/HSD) cable type heat system and
HFO/LDO detectors, quartzoid automatic/manual
bulb type (with MVW spray system
pneumatic detection (for uninsulated
pipe network) heat tanks)
detectors
b. Fuel oil dyke – Hydrant system Hoses to be
(hydrants and water provided in
monitors); central hose
foam water houses
hydrants/monitors
c. Fuel oil pump house ‘Quartzoid bulb’ (a) Automatic
equipment type heat detectors MVW/foam spray
(with hydraulic system
detector pipe (b) Fire extinguishers,
network) foam hydrants
d. Control rooms, Ionization type Fire extinguishers
MCC/switchgear rooms if smoke detectors
any
e. Transformers of rating Quartzoid bulb type Automatic HVW Hoses to be
10 MVA heat detectors (with spray system and fire provided in
hydraulic detector extinguishers hydrant central hose
pipe network) system houses
5.6 All Other off site area
a. All pump – Hydrant system Hoses to be
houses/permanent (hydrants and/or provided in
structure such as WTP, water monitors) fire central hose
PT Plant etc. (other than extinguishers houses
cooling towers)
(continued)
(continued)
b. Miscellaneous Ionization type Hydrant system
switchgear/MCC and smoke detectors (hydrants and/or
control rooms water monitors) and
fire extinguishers
c. Transformers of rating 10 Quartzoid bulb type Automatic HVW Hoses to be
MVA and above within heat detectors (With spray system, hydrant provided in
the plant premises hydraulic detector system and fire central hose
pipe network) extinguishers houses
d. Administration building – Hydrant system Hydrant valves
(periphery) and individual
hose boxes
e. Administration building – Hydrant system and Landing valves
(staircases) rire extinguishers and individual
hose boxes
f. Communication Ionization type Fire extinguishers
building/SATCOM smoke detectors
building if any switchgear
room, control/cubicle
room
g. Communication – Hydrant system Hydrant valves
building/SATCOM and individual
building (periphery) hose boxes
6.0 Inspection, Testing and Maintenance Requirements of Fire Detection

and Protection Systems
The recommended inspection, testing, and maintenance requirements for fire
detection and protection systems are given below.
6.1 Inspection, Testing and Maintenance Requirements for Hydrant System
and Fire Water Pump House
Frequency Checks
Daily 1. Check and record discharge pressure of each electric and diesel driven pump
(including booster pumps) after running it at least for 5 min daily
2. Check and record pressure gauge reading of firewater header
3. Check and record pressure gauge readings of hydrant system at the highest
and farthest points and other strategic points. These should be 3.5 kg/cm2
(minimum)
4. Check level of water in the priming tanks to ensure that the foot valve of the
pump is not leaking
5. Check main firewater header, pipes in the pump house for any
leakage/damage
(continued)
(continued)
Frequency Checks
Weekly 1. All hydrant valves and monitors to be examined systematically to ensure that
all valves and spring catches are maintained in good condition along with
hand-wheels, couplings, lugs, etc.
2. Inspect hydrants for any obstruction of approach to these due to vehicles, etc.
3. Open randomly selected valves one by one and observe flow of water for a
short time. Close the valves. The whole operation of valves should be smooth
and there should not be any leakage
4. Inspect all hose boxes to ensure that these contain the required number of
hoses, branch pipes, and nozzles
5. Open air release valves on the main pipes in order to expel trapped air
6. Inspect hose reel installations and ensure that their isolating valves are closed
7. Inspect isolating valves for valve position and for any leakage
8. Check valve pit for proper cleanliness and ensure that it is not flooded and is
in good repair, readily operable condition
Frequency Checks
9. Check level and specific gravity of electrolyte in the batteries of diesel
engines
10. Check that automatic start sequence of diesel engine-driven pump is
operative. Run each diesel engine for about 30 min under load (not less than
60 % operating load) until the time operating parameters such as exhaust
temperature, closed circuit water temperature, lubricating oil temperature,
lubricating oil pressure, etc. are stabilized. Check whether operating parameters
are within recommended range
Check exhaust pipes of each diesel engine for leakage, chokage, and
overheating when the pump is running
11. Check battery charger panels for proper functioning
12. Check fire pumps control-cum-annunciation panel for proper functioning
and alarm/annunciation
13. Check temperature of pump house
14. Check all auxiliary equipment such as battery charger, compressor, water
pumps, and diesel fuel level
15. Carry out flow test as detailed below:
(a) Select hydraulically most remote hydrant and place a pressure gauge
mounted on a blank cap adjacent to it
(b) Connect two or more hose pipes with nozzles each 30 m long at
hydraulically most remote hydrant and adjacent valves
(c) With a pump running at its maximum pressure, with other hydrant valves
closed, flow water through the hose reels with valves fully open. Note down
readings of pressure gauges mounted adjacent to hydraulically most remote
hydrant valve and in the pump house. The running pressure should be between
3.5–5 kg/cm2. This test should be repeated with different pump next week by
rotation. (Alternatively, the pressure gauge can be mounted at the hydraulically
most remote hydrant also instead of adjacent one). Test should be rotated for
different locations which are hydraulically far or are hazardous
16. Change over to other pumps as per ‘Change Over Schedule’
(continued)
(continued)
Frequency Checks
Monthly 1. Clean strainers of spray pumps (in case of clarified fire water site may change
the frequency of cleaning the strainers)
2. Check that connectors of battery are clean and free from corrosion and
properly connected. Smear a little petroleum jelly on them and on the battery
terminals
3. Top up cells with distilled water, if required
4. Carry out monthly maintenance of diesel engine as per manufacturer’s
recommendation
5. Measure vibrations of pumps and gear boxes
Quarterly 1. Clean and examine pump coupling for signs of wear, general damage,
looseness, and misalignment
2. Carry out quarterly maintenance of pump and motor and diesel engine as per
manufacturer’s recommendations
3. Inspect fan belts of diesel engine for slackness and wear. Adjust/replace if
necessary
4. Clean crankcase breather (use clean fuel for cleaning) by using air
Frequency Checks
5. Remove air filter element and shake out excess dirt by gently tapping on a flat
clean surface
6. Inspect exhaust pipe work for any damage, leakage, or choking and clean it
thoroughly.
7. Check and clean terminals of electric motors. Tighten connections, if required
8. Reassemble air compressors using new gaskets
9. Inspect compressor delivery filter
10. Carry out quarterly maintenance of air compressors as per manufacturer’s
recommendations
11. Adjust the gland assembly by tightening the gland adjusting nuts on either
side of split gland collar. Replace gland packing if it has hardened
Yearly 1. Overhauling of pump and motor to be performed per manufacturer’s
recommendation
2. Yearly maintenance of diesel engine to be done per manufacturer’s
recommendations including:
(a) Inspection and cleaning of fuel injectors
(b) Thorough checking of diesel engine cooling system for leaks, blockages
(flushing, if required, to be done with clean water)
(c) Inspection of starter motor and replacement of carbon brushes, if necessary
(d) Inspection and cleaning of engine exhaust manifolds and pipes and
replacement, wherever necessary
(e) Inspection of air filter and replacement of air filter element, if required
3. Painting of stand posts, overground pipes, and risers is recommended
4. Carry out hydraulic test of pipelines to detect leakages
5. Remove suction filter, cylinder head and valve plate assembly of air
compressors and clean. Inspect valve plates and counter plates. Replace, if
necessary
Every 2 1. All isolating valves to be dismantled and thoroughly overhauled
years 2. Various pressure/temperature switches/gauges to be calibrated
Every 5 Drain, clean, repair, and return to service all pump suction tanks for the systems
years
6.2 Inspection, Testing and Maintenance Requirements for Sprinkler

System
Frequency Checks
Weekly 1. Check water pressure gauge to ensure that required
pressure is maintained
2. Check that sluice valves are strapped to their normal
operating mode
3. Check that alarm(s) is operative
4. Check alarms function correctly
Quarterly (in addition to 1. Check that water supply arrangements (including back-up
weekly requirements) supplies) are in order. Operate valves and carry out a valve
discharge test
2. Operate main stop and zone isolating valves over full
range. A non-hardening packing should be used in valve
glands. Restart valves
3. Check back pressure valves for correct function. Inspect all
sprinkler heads for freedom from corrosion and correct
orientation
4. Painted sprinkler heads should be replaced
Annually 1. Replace a few sprinklers by opening nozzles to start spray.
Measure the running
pressure at the hydraulically most remote point. It should be
more than 1.4 kg/cm2
3. Various pressure/temperature switches/gauges to be
calibrated.
Every statutory outage Pressure vessels should be examined internally and the
opportunity taken to repaint with rust-resisting paint
Every 5 years Drain, clean, repair and return to service all pump suction
tanks for the systems
6.3 Inspection, Testing, and Maintenance Requirements for High- and

Medium-Velocity Systems
Frequency Checks
Weekly 1. Check main water and air/water detection line pressure gauges to
ensure that required pressure is maintained
2. Check that sluice valves are strapped to their normal operating
mode
3. Open air line drain valve and blow out condensate
4. Check tank water level
5. Check that alarm(s) is operative
6. Test alarms
7. Operate drains and main vent valves
8. Check for any leakage of air/water from detection/main lines
9. Check for correct position of local/manual selector switch
(continued)
(continued)
Frequency Checks
Monthly 1. Check for proper functioning of solenoid valves for
remote/manual operation and local/manual operation by energizing
solenoid valves but not allowing spray to take place
2. Check quartzoid bulbs and spray nozzles for proper
positioning/orientation
Quarterly (in addition to 1. Check that water supply arrangements (including back-up
weekly requirements) supplies) are in order and operate valves and carry out a valve
discharge test
2. Operate main stop and zone isolating valves over full range.
A non-hardening packing should be used in valve glands. Restart
valves. Trip and reset deluge valves
3. Test the deluge system by doing actual spray. Where plant
operations prevent routine testing of fixed water sprays,
consideration should be given to conducting a trial of the equipment
during a plant overhaul
4. Check back-pressure valves for correct function. Inspect all
sprays and nozzles for freedom from corrosion and correct
orientation. Painted detector heads should be replaced
5. Examine piping to ensure that it is corrosion free, is properly
supported and is painted
6. All electrical and hydraulic alarms and their initiation devices
should be checked
7. Check spray nozzles for proper orientation
8. Operate water spray system by releasing pressure from detection
line after taking precautionary measures. Observe the spray
coverage and nozzles for any choking, wrong directional mounting
In the case of spray system of transformers, check that the top of
spray cones are below turret of bushings. Reset deluge valve
9. Clean strainers after the spray
Annually 1. Overhaul all control valves, isolating valves and deluge valves
2. Alarm valves, isolating valves to be dismantled and overhauled
3. Various pressure/temperature switches/gauges to be calibrated
4. Flush detection and spray lines and clean all nozzles
Every statutory outage 1. Pressure vessels should be examined internally and the
opportunity taken to repaint with rust-resisting paint
2. Test the deluge system by doing actual spray. Where plant
operations prevent routine testing of fixed water sprays,
consideration should be given to conducting a trial of the equipment
during a plant overhaul
3. Carry out a full flow pump test for a minimum of 6 h
4. Adequate steps should be taken to prevent vulnerable items
suffering damage from water ingress and to ensure that spray
pipework is completely drained afterward
Every 15 years Drain, clean, repair and return to service to service all pump suction
tanks for the system
6.4 Inspection, Testing, and Maintenance Requirements for Foam Systems

Frequency Checks
Weekly 1. Check level of foam in tanks
2. Check position of valves
3. Check for any leakage etc. of foam
4. Check yard foam spray hydrant valves for hand wheel, coupling and its
lug etc.
Quarterly 1. Check all pressure gauges register properly. All control valves should
be properly set and access to valves, pumping in points and proportioning
equipment is maintained. Manipulate and repack valves
2. Inspect and clean strainers, check alarms auto control valves, indicators,
manual tripping devices, vapor seals, piping, level of foam liquid and level
of liquid and level of liquid in any gas cylinders
3. Inspect external surfaces of the foam concentrate tank for signs of
leakage and corrosion
Every 6 months 1. Sample and test foam concentrate
2. Withdraw a sample of foam concentrate from the foam tank and test it
3. Turn foam maker by 180° so that the foam will come out on ground and
open the isolating valve of foam/water line for 5 min. Observe the quality
of foam being made and the rate at which foam is being sucked by
venturi/pump
4. Compare it with designed value
Annually 1. Replace the foam concentrate as and when the life guaranteed by
supplier or as per test, expires
2. Inspect internal surface of foam concentrate tank before replacement of
foam tank concentrate to ensure that it is free from dirt or foreign materials
and the epoxy coating is intact. If required, touch up amounts of epoxy
(not the ordinary paint) may be applied
3. Clean and service all valves, pipes, in-line inductor/pump
5. Various pressure/temperature switches/gauges to be calibrated
Every statutory Discharge test, flush, and reinstate
outage
6.5 Inspection, Testing, and Maintenance Requirements for CO2 Systems

Frequency Checks
Quarterly Check pressure gauges register properly, all control valves are properly set and
access to valves is not obstructed. Examine cylinder contents level and replace
cylinders as necessary
Twice Check that correct number of cylinders are in service; piping, alarms, lock-offs
Annually manual and emergency releases drop curtains etc. are properly located and
function correctly, also that any interlocks operate properly
At 10 Years Deluge test, return cylinders for stretch test and refill
6.6 Inspection, Testing and Maintenance Requirements for Halon Systems

Frequency Checks
Quarterly Check pressure gauges register properly, all control valves are properly set
and access is not obstructed. Examine cylinder content level and replace
cylinders as necessary
Twice Check that correct number of cylinders are in service; piping alarm lock-offs
annually manual and emergency releases, drop curtains, etc., are properly located and
function correctly, also that any interlocks function correctly
5 times a year Withdraw and pressure test cylinders
Discharge Consult Industrial Safeguards Branch
testing
6.7 Inspection, Testing, and Maintenance Requirements for Detection

Systems
Frequency Checks
Monthly 1. Functional test of detection system, if required, as part of the protection
system. Testing in a particular area
2. Inspect physical position of LHS cable, IRD type detection systems for any
damage and test these by simulation and observe annunciation. In case of IRD,
a moving heat source can be used to generate fire signal
Quarterly 1. Functionality test
2. Check better condition, where applicable
3. Check and test all control/annunciation panels, i.e.,
- Main fire alarm panels
- Local fire alarm panels
- Fire station repeater panel
- Coal conveyor belt stooping panel
- Cable gallery TES/Zone operating panel.
Annually 1. Check detectors (except once only detectors) by an in situ test using heat or
smoke as appropriate. Withdraw air heater poles for this test
2. Check system integrity
Every 4 Carry out electrical checks as specified in IEE regulations
Years
Appendix C
System for Plant Modifications
1.0 Purpose
The directive specifies the system for modifications in plant/equipment at
the power station.
2.0 Scope
2.1 This directive shall be applicable to all modifications (or design change)
to plant/equipment/systems/components of existing power stations after
the date of issue of the directive. For modifications made prior to issue of
this revision, procedure described at clause no 5.7 should be followed
2.2 In the case of power stations set up after the date of issue of this directive,
the directive shall apply from the date the PG test is conducted or date of
completion of warranty of the contractor, whichever is later
2.3 The directive shall not be applicable to modifications/design change to be
carried out under contractual obligations of the contractor under the
contract irrespective of the period when such modification is carried out.
However, in such cases where modification is necessary to be carried out
before expiry of the warranty period or before PG Test, whichever is later,
written consent of the contractor for such proposed modification should
be obtained before carrying out the modification. In all such cases, an
approval from the Engineering Department must be obtained, which shall
be routed through Operation Services (OS)
2.4 The reference design or datum for each plant/equipment/system/
component of the power station shall be as per the last document
approved by Engineering or the original design drawings
2.5 The directive shall not be applicable to ‘defects’ or ‘repairs’ which require
equipment to be reinstated to the original condition
2.6 For the purpose of this directive, system, or component shall also include
load-bearing structures

DOI 10.1007/978-81-322-2722-9
226 Appendix C: System for Plant Modifications
3.0 Previous Guidelines

If any
4.0 Records of Revision
The entire document has been redrafted after review by the System
Review Group
5.0 Process
5.1 Definition
5.1.1 For the purpose of this directive, the term modification or design change
shall have the following meaning or interpretation:
5.1.1.1 ‘Modification’ shall include
(i) A repair or replacement of a system/equipment/component where it
involves a change to its reference design or datum, geometry, or
materials.
(ii) Any change to the settings, or mode of operations, of a component
in a control, interlock or protection system (including computer
software).
(iii) Any addition or deletion of a system, component, or of a complete
system or complete equipment.
5.1.1.2 The following shall not be construed as modifications for the purpose of
this directive:
(i) The repair/replacement/modification of minor components or
equipment as may be specified by the Head of the Station in the
Location Management Instruction issued for implementation of this
directive. However, details of these shall be intimated to COS.
(ii) The overriding of any interlock (protection by pass) or any change to
the settings or mode of operation of any component in a control,
interlock, or protection system (including computer software) which
is authorized, implemented, and recorded in accordance with a
Location Management Instruction, provided that no such override or
change remains in place for a period exceeding 72 h. If it is to
exceed 72 h, it will be treated as a modification and will require
registration and assessment in accordance with this directive.
5.2 Need for Modification
The need for modification or design change may arise from:
• Recommendations of an enquiry report/audits.
• Proven best practice elsewhere in the utilities known globally.
• Improvement in efficiency/commercial parameters.
• Statutory/legal requirements.
Appendix C: System for Plant Modifications 227
• Feedback from major failures/trip analysis.

• Constraints faced during plant operation.
5.3 Proposal
5.3.1 In order to maintain a record of all modifications or design changes to
plant/equipment/systems/components, all proposals for modifications
shall be registered with the Station Planning department. Furthermore,
to ascertain the suitability of the modifications, all proposals will be
assessed technically as per the system laid down hereunder:
5.3.2 A format for registration of all proposals for modification or design change
is given in Appendix I (Modification Registration Performa/Design
Change Request).
5.3.3 The proposal for modification/design change may be initiated by the
concerned department at station/engineering/research and development
others, and sent to Incharge O&M of the station for formal initiation. The
proposal shall give sufficient details of modification i.e., name of the
plant/equipment/component/system, its location, name of the
supplier/manufacturer, reasons for modification, approving authority, etc.
The details of modification shall be maintained by the Head of Planning
department of the power station in the Performa (request for design change)
given in Appendix 1. A flow diagram showing the process of the system for
plant modification/design change is shown in Appendix 2.
5.4 Categorization of Modifications
The category of technical assessment required i.e., internal or external to
the station, shall be approved by the appropriate authority based on the note
giving details of modifications received from the head of the power station.
5.4.1 For the purpose of this directive, technical assessment of proposals shall
be of two types, i.e., Category A (requiring external assessment) and
Category B (requiring internal assessment).
5.4.2 Category A assessment will be required in case of all proposals which, if
inadequately conceived or executed, could lead to the following:
• A major safety/environmental implication.
• A major plant failure (boiler, turbine, generator, transformer, cooling
water system, ash disposal system, coal handling plant, switch yard).
Category A assessment will also be required in case of

• Any change in the protection scheme for main equipment i.e., boiler,
turbine, or generator.
• Modifications related to improvement of efficiency commercial
parameters of major equipment.
5.2.3 Category A assessment may not be required:
(i) If repair/replacement of any system or component or equipment is
carried out without changing the original design or datum and using
approved procedures relevant to such repair.
(ii) If replacement of any system or component or equipment is being
done due to age or obsolescence by a modern equivalent with no
change in original design or datum, materials or operating
environment.
5.5 Category A Assessment
The proposals for modification of all Category A proposals as defined
above will be submitted for technical approval to the Engineering
department by the power station. Engineering may seek the comments of
other departments of Corp. Centre e.g., R&D, Safety, etc. Technical
approval from Engineering will be sent to the station. Thereafter, the
proposal should be submitted for approval of Competent Authority by the
power station as per DOP. If required, detailed engineering will be done
by the Engineering department and sent to the station for implementation
of the modification.
5.6 Category B Assessment
Proposals which do not qualify for category A assessment will be
categorized as Category B. The proposals involving category B
assessment will be scrutinized and assessed by a team comprising
representatives of O&M, FQA, and Technical Services departments at the
station in consultation with Operation Services & Engineering, and
approved in accordance with DOP if any costs are involved. After the
modification has been completed, a post facto approval will be sought by
the station in charge from the Engineering department detailing the
requirement for the modification, implementation status, etc. Any
recommendations from Engineering shall be implemented by the Station.
5.7 Modification Made Prior to this Directive

The station will compile the modification with relevant details made prior
to the issue of this document. For all the modifications which have not
been vetted or approved by Engineering, the station will be required to
intimate the same to Engineering with the relevant details, pre- and post
modification assessment and amendment to documents and drawings
wherever applicable. Any recommendations from Engineering shall be
implemented by the station.
5.8 Implementation of the Directive
Each head of the power station is responsible for ensuring that the
directive is implemented at the power station by issuance of location
management instructions (LMI).
5.9 Amendment of Station Documentation
All relevant drawings, operation and maintenance instructions, details in
the stores catalog, and other requirement for modified
equipment/system/component will be amended before the first modified
system or component is commissioned. The amended documentation as
built drawings must be approved by the same authority that initially
approved the documentation/drawing. The master list of documents and
drawings must be revised accordingly. The issue of these modified
documents as stated above shall be controlled and the old version will be
stamped as superseded. Where the modification is to be progressive,
covering various areas of the power station, then care must be taken to
clearly identify the system or component or equipment to which the
amended documentation applies. The necessary records will be updated
in the Modification Register Performa.
5.10 Execution of the Plant Modification
After the receipt of the detailed Engineering report, the Planning
department will find out whether any procurement is required. If
procurement is required, then the Maintenance department will initiate
the procurement. After receipt of the material, the Maintenance depart-
ment will execute the modification with relevant quality checks by the
Field Quality department. Commissioning will be done by the Operations
department. Reports, as required, will be generated and given to the
Planning department for consolidation.
5.11 Post Modification Assessment

After the system or component has been commissioned, an assessment
shall be carried out by the head of O&M of the power station to determine
(i) that the modification has been implemented in accordance with the
approval.
(ii) the resulting change in performance as compared to that proposed
originally.
(iii) that the integrity of plant safety has not been impaired.
5.11.1 Where appropriate, this assessment shall include such tests and trials
specified in the approval.
5.11.2 A report shall be generated by the head of O&M of the station stating the
improvement after the modification with respect to pre-modification status
and shall be sent to the head of Operation Services (OS). Final acceptance
of the modification shall be given by OS in association with Engineering.
In case of non-acceptance of the modification, necessary analysis shall be
done by Planning along with the concerned department(s). Either
corrective action is taken and post modification assessment is carried
out or pre-modification status is restored. The site may also initiate a fresh
proposal for modification.
5.11.3 The Modification Register Performa should then be updated completely
and shall be circulated to all concerned.
5.12 Compliance of Directive
Compliance of this directive shall be verified during the course of internal
and external LMI audits and a technical audit of the station by OS.
5.13 Records
The following records shall be maintained by the Planning department at
the station:
• Records of modifications as per Modification Registration Proforma.
• Records of approval of modification.
• Reports of post modification Assessment.
6.0 Review
The head of Corporate Operation Services will be responsible for
reviewing the document on a 3-year basis or as necessary.
Appendix 1 Modification Register Proforma/Design Change Request
MODIFICATION REGISTER Serial No.:
For Plant, Apparatus and Structure Date Proposed:
1. PROPOSED FOR MODIFICATION AT POWER STATION
Station Code:
Purpose of Modification
Component / System: (State justification)
Manufacturer :
Details of Proposal (including time schedule):

a) Whether the modification suggested is for phasing out Effect on
an obsolete item, if so, details. interchangeability
b) Whether the modification suggested is for
indigenisation, if so, details.
Any identified safety hazard / Environment impact on account of the Plant Modifications
Requirement for amending documents Yes No
Pre-modification Condition (e.g. Operational Performance, Emissions, Plant Life. etc.):
Approval of Head of O&M Date:
Approval Head of Power Station Date:
2. REVIEW BY APPROPRIATE AUTHORITY & CATEGORIZATION

Category of modification as per note ref. no. received.
Date
3. APPROVALS
Final approval from Engineering Note Ref. Date:
i) Not Approved Note Ref. etc. Date:
4. IMPLEMENTATION
(After work has been completed, record the means by
which modification has been achieved. State Contract Signature:
Number, etc.) Concerned Dept. I/C
Date:
5. COMMISSIONING
Confirm that commissioning has been done as per Signature:

procedure and the relevant protocol; has been filled up. Operation Dept. I/C
Date:
6. AMENDMENTS TO DOCUMENTATION
Confirm the completion of amendments to
operating/maintenance Instructions, station manuals, plant Signature:
status records, stores records, drawings, training Concerned Dept. I/C
programmes, etc. Date:
7. POST MODIFICATION DATA
Date of modification
Confirm completion of commissioning and
state the condition after modification Relevant Signature of Initiator of
compared to the original data recorded in Report Ref. Proposal: Date:
Section 1 etc
8. CIRCULATION
TO DATE SIGNATURE
Note:
1. This Directive applies only to modifications; it does not apply to `defects' or
repairs which require equipment to be reinstated to the original condition.
2. Section 2 `Categorization'-The selection of Assessment Category is the
responsibility of the Appropriate authority.
Appendix 2 Flow Diagram for Process of Modification/Design Change

Appendix II

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Appendix A

The Operational and Safety Aspects

1.0 General Guidelines of Pre and Post-Operational Cleaning of

© Springer India 2016 147

1.4 Criteria for Chemical Cleaning

1.4.2.2 Oxide Thickness as a Guide to Cleaning

1.5.2.2 Post-operational Cleaning

hydrochloric acid or hydrofluoric acid may be required. However,

Hydrofluoric acid waste can be disposed of in the ash lagoons by

1.6.4.2 Chemical Addition

1.6.4.4 Water Quality for Super heater Flushing

1.8.2. Passivation at 40 bar

Appendix 1A-I Pre-operational Cleaning of Boiler Furnace and Economizer

1A-I.3 Sequential stages

(iii) 1 % W/W hydrofluoric acid with an approved inhibitor

Appendix 1A-II Pre-operational Cleaning of HP Feed Systems

1A-II.3.6 Raise the water temperature to 95 °C.

Appendix 1A-III Pre-operational Cleaning of Boiler Furnace and

Appendix 1A-IV Pre-operational Cleaning of Boiler Furnace and

Appendix 1B Pre-operational Steam Purging of Super Heaters and

Appendix 1C Post-operational Cleaning of Furnace and Economizer Tubes:

Principle deposition during operation of a boiler

Boiler type Internal deposits

All measurement to be done on the furnace side of the tube samples.

Pressure (kg/cm2) Drum type Once-through type

Common solvent used is HCL (5 %) at 75 °C. Inhibitor used:

copper is constant (approximately 4–6 h). Drain the boiler and

been shown to be unnecessary. However, 50 mg/kg hydrazine and

Appendix 1E Post-operational Cleaning of Once Through Boilers, Super

1E-2.4 Drain and rinse with a solution in demineralized water containing:

Appendix 1F Recommended Inhibitors

1F-2 The approved inhibitors must be present under acid conditions at

Appendix 1F-1 Inhibitors for Acid Cleaning (For Information)

Inhibitor Type Cleaning agent Metallurgy Normal Temp

1H Constant Head Overflow and Temporary Gauge Glass

1H-2 Temporary Gauge Glass

2.3 Criterion for Cleaning

2.4.6 Protection of Plant After Cleaning

2.5.2.2 Complexing Agent

3. Carefully add, with further dilution and agitation the degreasant in

2.5.5.6 Circulation, Agitation and the Exclusion of Air

2.5.6.2 Air Extraction Pumps

Appendix 2A Hydrochloric Acid Process for Off-load Post-operational

Appendix 2B Sulfuric Acid Process for Reduced-Load Post-operational

Appendix 2C Sulfuric Acid Process for On-Load Post-Operational Cleaning

2C-6 An assessment of the probable effect of dosing on a given cooling

Appendix 2D Recommended Inhibitors

Appendix 2E The Selection of Cleaning Process for the Water Side of

Appendix 2F Cleaning Method for Removal of Oil-Free Deposits from the

2F-3 On completion of cleaning, drain the condenser, rinse, and inspect

Note: Deposits containing less than 5 % oil.

Appendix 2G Cleaning Method for Removal of Oil Containing Deposits from

Note: Deposits containing more than 5 % oil.

Appendix 2H Recommended Degreasants

Appendix 2-I Selection of Cleaning Process

Let: Cu = average copper burden (g/m2)

(applicable only if cupronickel

If: B < 0.048 V use 0.08 M EDTA.

The requirements given in Sect. 5, ‘Safety Aspects’, must be applied

3.5.2 Examination of Tubes Prior to Cleaning

Appendix 3A Degreasant/Hydrochloric Acid Process for Post-Operational

4.0 Analytical Methods

Appendix 4A List of Analytical Methods used IN Analysis of Chemical