PT THERMAX INTERNATIONAL

INDONESIA

BOILER BDFB 350/1004

CHEMICAL BOILING OUT PROCEDURE
DOC.NO : TII/CH/ER/007/JKT-2021

PREPARED BY : REVIEWED BY : APPROVED BY

PT WIKA REKAYASA
GAES GS
KONSTRUKSI

ISSUED EFFECTIVE
REV.NO BRIEF REVISION
DATE DATE

00
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TABLE OF CONTENTS

1. SCOPE
2. PURPOSE
3. MATERIALS
4. WORK METHODE
4.1 Methods of Chemical Boiling Out.
4.2 Preparation of Chemical Boiling Out.
4.3 Procedure of Chemical Boiling Out.
4.4 Acceptance Criteria of Chemical Boiling Out.
5. WORK PERMIT AND SAFETY
5.1 Work Permit
5.2 Safety Requirements

6. REPORTING
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1. SCOPE
This procedure defines the requirement and procedure of Chemical Boiling Out of the Boiler
Pressure Part after all boiler pressure part complete and fur assembly.
2. PURPOSE
The purpose of alkali boil-out is to remove from boiler internals the deposits like oil, grease, mill scale
etc., resulting out of manufacturing, fabrication and erection procedures. Such deposits in the boiler
tube walls severely restrict heat flow across the tube walls, result failure due to overheating.
3. MATERIALS
Materials commonly are used for Chemical Boiling Out as follows:
➢ Coal.

➢ Charcoal.
➢ Demint Water.
➢ Diesel fuel/Solar.

➢ Bed Material/Sand Silica.

➢ Chemical Trisodium Phosphate.
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4. WORK METHODE
4.1 Methods of Chemical Boiling Out
Chemical boiling out is done by applying heat to the boiler so that the pressure on the boiler
pressure part rises and the pressure is controlled so that the chemicals work.

4.2 Preparation of Chemical Boiling Out

In order to commence alkali boil-out of the boiler; following prerequisites/inputs have to be
made available:
➢ Mechanical completion of boiler including auxiliaries and piping.
➢ Completion of boiler hydro test and other commissioning activities including refractory dry out.
➢ Readiness of Electrical and Instrumentation controls.
➢ Adequate illumination in and around the boiler house.
➢ Electrical power for motorised valves, gauge glass illuminator, etc.
➢ De-mineralized water through boiler feed water pumps.
➢ Readiness of sample collection system.
➢ Chemicals required for the process.
➢ Full readiness of Boiler for lighting up and its thermal expansion.
➢ Water testing facilities including pH and oil detection.
➢ Readiness of chemical dosing system.
➢ Inspection and mechanical cleaning
➢ Make visual check of the entire boiler unit and remove all debris.
➢ Remove drum internals (If required) from steam drum as specified by Thermax engineer.
➢ After visual checks, close all access to the boiler unit internals.
➢ Following minimum controls and requirements are necessary for boiler operation.
➢ Good working Drum level gauge glass with illuminator assembly.
➢ Boiler drum pressure gauge.
➢ Safety/relief valves with gags or hydrostatic plugs removed.
➢ CBD and all drain valves in good working order.
➢ Water level control and associated alarms.
➢ Cooling water / air piping.
➢ Furnace pressure gauge.
➢ Temp. indications for flue gas, feed water and steam line.
➢ During alkali boil out, transmitters connected to steam piping and steam drum will be kept
isolated to avoid any damages to transmitters due to alkali.
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4.3 Procedure of Chemical Boiling Out
➢ Ensure that blow down and drain connections are terminated to safe location.
➢ Ensure that all dampers are in good working condition and "OPEN" "CLOSE" positions are
marked correctly..
➢ Ensure that the feed water pumps operate satisfactorily.
➢ Fill specified quality feed water 50 mm below the steam drum manhole rim.
➢ Exact quantity of chemicals is to be carried in dry form up to the drum level platform. The
chemicals are to be dissolved in DM water externally in a container near the drum manhole in
batches. The concentrated solutions so prepared are to be poured into the drum through the
manholes. When the entire quantity of chemical has been so dissolved and poured into the drum,
close the manhole. And fill the drum 50-mm below the normal water level.
➢ Burn like during slowfiring using firewood (All Fan OFF) slowly up to 6-7 Bar then stop
burning (stop adding firewood) before the press reaches 7-8 Bar, (about 4-5 bar) because the
pressure will still rise due to the residual heat of combustion
➢ Control the pressure on the boiler by modulating (open / close) the air vent or open the
Blowdown valve slightly (10-15%) (if the pressure seems to increase more than 7 bar so as not
to over pressure) and close again if the pressure is stable.
➢ Hold the boiler pressure for 12 hours.
➢ Make sure the pressure has dropped to 4-5 bar (if not, lower the pressure to 5 bar slowly through
the air vent and / or perform intermittent blowdown (open and close the blowdown valve) for 10
seconds.
➢ Always make sure the water level in the steam drum is at a level of ± 50% (fill water into the
boiler if the level is <50%).
➢ If the pressure has dropped to 5 bar, do a blowdown and open all drain lines by opening /
closing the valve 10-15% every 10 seconds.
➢ Always make sure the water level in the steam drum is at a level of ± 50%.
➢ Perform the blowdown until the pressure drops to 2 Bar then close the blowdown valve and
drain valve again.
➢ Fully open the air vent until there is no pressure in the boiler.
➢ Leave the air vent valve full always open and do a full drain of water in the boiler (fully open all
boiler drain lines) until all the water in the boiler runs out then close the valve again.
➢ Refill the water into the boiler until it comes out of the venting line and drain it again for
circulation (flushing), cleaning and cooling the boiler.
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➢ Perform the cleaning flushing until the Ph and TDS or the boiler waste water content is equal to
or close to the feed water content (a sign of a good cleaning process).
➢ Also make sure the oil content (oil content) on the boiler is <5ppm.
➢ If everything is in order, close all drain and blowdown valves again and then refill the boiler ±
55-65%.

4.4 Acceptance Criteria of Chemical Boiling Out.

Acceptance criteria for chemical boiling out, the content of waste water from flushing is the same
as demint water as feed water to the boiler.
5. WORK PERMIT & SAFETY
5.1 Work Permit
All of necessary work permits (hot, cold,elevated work permit) shall be obtained prior to start
the work by daily basis. And all of the proposed equipment shall have Zone-I permit by
Client after doing inspection to the equipment them selves.
5.2 Safety Requirements
➢ All construction safety requirements shall comply with Safety, Health and Environmental
Plan Manual Project.
➢ All Tools shall be inspected for fitness and safety before mobilization to site and
commencing testing activity at each location.
➢ All lifting / loading equipment shall be inspected before use by trained and competent
supervisor and shall be recorded and approved by Company.
➢ Testing crew shall be well experienced to carry out the operation following all safety
precautions.
➢ Certified lifting equipment and tools and shackles shall be utilized for loading/unloading
purposes.
➢ No mechanical work shall be carried out near the pipeline under pressure.
➢ Only authorized personnel shall be involved in handling equipment and valves during testing
activities.
➢ Toolbox meeting shall be conducted regularly to discuss environmental, health and safety
measures related to testing activity.
➢ Care shall be taken to minimize soil erosion and environmental impact due to dewatering
activity.
➢ Appropriate PPE (personnel protection equipment) shall be worn by all working personnel.
➢ Risk Assessment Form as enclosed shall be followed.
➢ Water that will be used for hydrotest shall be analyzed by a competent laboratory.
➢ Water disposal shall be properly managed to avoid any destructive effect to the environment.
➢ All connections (hose, fitting, etc.) that have pressure shall be equipped with chain safety
lock.
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6. REPORTING
Chemical Boiling Report shall be sign by all concern Parties i.e., Contractor, Company. And will be
part of Final Record.
➢ Chemical Boiling Out Report.