Pre-Commissioning Chemical Cleaning of Main Boiler & Pre Boiler System.

Chemical Cleaning of 1 x 80 MW at
Sharda Metal & Alloy Ltd
Proposal Ref No: AEPL/SMAL/ST: 082028

Date: 25.08.2022

Submitted To:

M/s. Sharda Metal & Alloy Ltd

Address: D No 50 96 4 1 Floor II III Sri Gowri Nilayam

Seethammadhara NE. City: Visakhatapnam.

The information contained in this proposal is considered to be of a confidential and property nature, the rights to which belong to ARUDRA
ENGINEERS PVT LTD. This information is being furnished to the purchaser to enable the purchaser to evaluate ARUDRA ENGINEERS PVT LTD
Proposal. If contract is awarded to ARUDRA ENGINEERS PVT LTD based on this proposal, then the information is to be included in whole or in part
in the contract. Neither this proposal nor any information contained therein, nor any proprietary information furnished pursu ant thereto, shall
be disclosed to others or used for any purpose other than that set for the above, without the prior written approval of ARUDRA ENGINEERS PVT
LTD.
M/s.Sarda Metals & Alloys Ltd. RFQ Ref: By Telecon Date 22.08.2020
Address: D No 50 96 4 1 Floor II III Offer No: AEPL/SMAL/ST/082022 Date 20.05.2020
Sri Gowri Nilayam Seethammadhara Job: Chemical Cleaning of 1 x 80 MW Units
Project: Jharsuguda 1 x 80 MW Power Plant.
NE. City: Visakhatapnam.
State: Andhra Pradesh.
Kind Attn To :
Mr. Alok Choudhary, E-mail: [email protected]
Head-Commercial

Dear Sir,

With reference to the telecom on the above subject, for Chemical Cleaning of 1 x 80
Unit at M/s.Sharda Metal & Alloy plant in Vishakhapatnam.

We wish to bring to your kind attention that we are leading Chemical Cleaning service
provider on turnkey basis for coal fired boilers and pre boiler system and HRSG to our
valued customers like ANSALDO, GE POWER, BHEL, BABCOCK, L&T-MHPS,
DOOSAN, IHI POWER, BGR-HITACHI, FOSTER WHEELER, TOSHIBA, SHANGHAI
ELECTRIC, DONGFANG ELECTRIC, HARBIN BOILERS, Power plant like NTPC, All
State Electricity Board, Tata Power, Adani Power, Reliance, Vedanta, JSW,
JSPL,CLP,GMR, Essar Power, tc.

We are happy to inform you that we have successfully carried out chemical cleaning for
boilers more than 400 units at various capacities from 30 MW up to 1000 MW in India and
overseas. Please find herewith partial list of projects which we have successfully executed
in India and overseas for your kind reference;

PROJECT Capacity NO OF EPC METHOD

MW UNITS
DOMESTIC PROJETCS
JVPL -NIGREE PROJECT 660 2 L&T MHPS CITRIC ACID
L&T- RAJPURA PROJECT 700 2 L&T MHPS CITRIC ACID
MAHAGENCO- KORADI 660 3 L&T MHPS CITRIC ACID
MAHAGENCO- CHABBRA 660 2 L&T MHPS CITRIC ACID
MPPGCL- MALWA 660 2 L&T MHPS CITRIC ACID
NTPC -KHRGONE 660 2 L&T MHPS CITRIC ACID
NTPC-TANDA 660 2 L&T MHPS CITRIC ACID
NTPC-SIPAT 660 3 DOOSAN FORMIC ACID
ADANI-MUNDRA 660 5 HARBIN CITRIC ACID
ADANI-TIRODA 660 5 DONGFANG CITRIC ACID

Pre-Commissioning Chemical Cleaning of 2 x 0 MW Boilers at CJP Project.

CLP-JHAJAR 660 2 DONGFANG CITRIC ACID
RELIANCE-SASAN 660 6 SHANGHAI CITRIC ACID
ADANI-KAWAI 660 2 DONGFANG CITRIC ACID
TPCIL NELLORE 660 2 BGR -HITACHI CITRIC ACID
TSPL-TALWANDI 660 3 HARBIN CITRIC ACID
SEMBCORP NELLORE 660 2 DONGFANG CITRIC ACID
NTPC-BARH 660 3 DOOSAN CITRIC ACID
NTPC SOLAPUR 660 2 BGR -HITACHI HF ACID
NTPC-MEJA 660 2 BGR -HITACHI HF ACID
GMR-RAIPUR 685 2 DOOSAN FORMIC ACID
NTPC- LARA 800 2 DOOSAN CITRIC ACID
TATA CGPL MUNDRA 800 5 DOOSAN CITRIC ACID
NTPC- KUDIGI 800 3 DOOSAN CITRIC ACID
INTERNATIONAL PROJECTS
MALAYSIA
JIMAH EAST 3B PROJECT 1000 2 IHI-JAPAN CITRIC ACID
PHILIPPAINS
AES-MASINLAC PHASE-1 300 2 MHI-JAPAN CITRIC ACID
MASINLAC POWER PLANT 300 1 BABCOCK CITRIC ACID
SRILANKA
Lakvijaya Power Plant 300 1 Harbin Boiler CITRIC ACID
Based on the experiences, we take pleasure in submitting our best techno-commercial
offer for Post operational chemical cleaning of 1 x 80 MW Boiler in two options (with super
heater and without super heater) on turnkey basis.
We hope our offer is in line with your requirement and looking forward to hearing from
you. If you need further any clarifications please feel free to contact us, we will respond
immediately.

Thanking you and assuring you of our best quality and quick services.

Yours Faithfully,
For ARUDRA ENGINEERS PVT LTD,

Mr. S.THIRUMALAI,
Senior Manager-Projects.
Mob +919840174989/ + 917823950052
E-mail [email protected].

Pre-Commissioning Chemical Cleaning of 2 x 0 MW Boilers at CJP Project.

 ANNEXXURE-I
TECHNICAL PROCEDURE
OPTION-1: CHEMICAL CLEANING OF BOILER WITH SUPER HEATER
INHIBITED CITRIC ACID METHOD
1. INTRODUCTION:

The following will constitute brief technical specifications in connection with post operational
chemical cleaning of 80 Boiler at Visakhapatnam plant during shut down. The cleaning circuit
consists of the following equipment’s of the boiler.

• Economizer
• Steam Drum
• Super heater & main steam line
• Water wall tubes & risers.
• Down Comer/ Bottom header.
Water Volume considered approx.: 150-170 M3

2. BASIC TECHNIQUE:

• The aim of Chemical Cleaning is to remove mill scale, oil, paint, preservatives, rust,
welding slag’s that would have entered during the assembly of new tubes and also to
remove the oxides of iron, copper and silica from the existing tubes.
• After carrying out the process, the internal surfaces of the tubes are passivated by means
of protective layer to prevent further rusting and corrosion.
• Chemical cleaning is to be done adopting circulation technique. The water & steam
touched pressure parts are cleaned using inhibited citric acid and passivation with sodium
nitrite. The cleaning operation comprises of the following major steps.

• WATER FLUSHING
• INHIBITED ACID CLEANING
• CITRIC RINSE & NEUTRALISATION
• PASSIVATION
3. PREPARATION WORKS;

• Temporary chemical cleaning system will be made readily available.

• The whole process will be carried out using our blending tank, circulating pumps, piping
and valves which from a temporary circuit with the main boiler.
• The common header of circulating pumps will be connected to the Economizer inlet at
after feed control station and MSL for SH cleaning.
• All the drum internals no need to be removed before chemical cleaning
• Down comers are suitably fitted with orifice plate to improve more flow through water
wall steam generation tubes.
• The hand hole plates/End caps of the lower ring header will be removed and necessary
temporary piping will be connected to return line. After completion of the chemical
cleaning process, the piping will be cut & hand hole plates are reinstalled as per IBR.

Pre-Commissioning Chemical Cleaning of 2 x 0 MW Boilers at CJP Project.

 • A separate line connecting all the drains from the dissolving tank, main boiler and all
other pipelines will be laid and led to a neutralization pit where neutralization of
effluents after each process will be carried.
• Necessary safety precautions will be taken during cleaning process to prevent any sort
of injury to the operating personnel.
• All permanent instrumentation lines will be either plugged or removed temporarily
during cleaning by the customer to prevent of acid entry.
• Chemical analysis will be carried out during process for the required test results.
• Detailed process report will prepared and submit after completion of the process.
4. COLD & HOT WATER FLUSHING:

• The temporary circuit consisting of tank, circulating pumps, valves and piping is
fabricated as per the site requirement. The complete circuit is tested for any leakage.
• DM Water is filled up and the system is flushed till the drain water is clear. Further to
this flushing, steam is admitted in the entire circuit and the temperature raise to >70 0 C
and flushing continued till the parameter is achieved (turbidity <10 NTU).
5. INHIBITED CITRIC ACID CLEANING:

• After completion of DM water rinse, ensure the system temp >60 Deg C. Then add the
following chemicals one by one.
• Inhibitor CORONIL –92-B - 1% of acid Volume
• Citric Acid - 3.0%
• Ammonium Bi fluoride - 0.20%
• Circulation is continued for 4-6 hours during which time testing for total iron and % of
acid to be tested out at regular intervals.
• Once achieved 3 steady values the whole solution is completely drained by water
displacement method. The drained acid solution is neutralized using lime and then
discharged to the storm water drain.
6. DM WATER RINSING:

• The Boiler is filled up with DM water and flush the system till iron content is achieved
less than 50 ppm.
7. ACID RINSE & PASSIVATION:

• After DM water rinse continue circulation. Add the following chemicals one by one.
• Citric Acid - 0.1 %
• Ammonia - Adjust the pH 3.5 to 4.0
• Keep circulation for 1 hour.
• In continuation of the above process, raise the pH 9.5 to 10.0 by adding ammonia. and
0.5% sodium nitrite. Continue circulation for 4-6 hrs. Check the Ph at regular intervals
and drain the system..
8. INSPECTION

• The drum is opened for visual inspection of uniform gray color passivation gamma ferric
oxide protective layer. All loose debris in the Steam drum is cleaned manually. Remove
all the temporary piping and restore the boiler for restoration.

Pre-Commissioning Chemical Cleaning of 2 x 0 MW Boilers at CJP Project.

 OPTION-2 CHEMICAL CLEANING OF BOILER WITH OUT SUPER HEATER
INHIBITED HYDROCHLORIC ACID METHOD
1. INTRODUCTION:

The following will constitute brief technical specifications in connection with post operational
chemical cleaning of 80 Boiler at Visakhapatnam plant during overhauling. The cleaning circuit
consists of the following equipment’s of the boiler.

• Economizer
• Steam Drum
• Water wall tubes & risers.
• Down Comer/ Bottom header.
• Water Volume considered approx.: 100-110 M3
• Super heater is isolated from the cleaning circuit. It is flushed and filled with
200 ppm Hydrazine and ammonia pH 9.5 to 10.

2. BASIC TECHNIQUE:

• The aim of Chemical Cleaning is to remove mill scale, oil, paint, preservatives, rust,
welding slag’s that would have entered during the assembly of new tubes and also to
remove the oxides of iron, copper and silica from the existing tubes.
• After carrying out the process, the internal surfaces of the tubes are passivated by means
of protective layer to prevent further rusting and corrosion.
• Chemical cleaning is to be done adopting circulation technique. The water & steam
touched pressure parts are cleaned using inhibited Hydrochloric acid and passivation with
sodium nitrite. The cleaning operation comprises of the following major steps.
• WATER FLUSHING
• INHIBITED ACID CLEANING
• CITRIC RINSE & NEUTRALISATION
• PASSIVATION
3. PREPARATION WORKS;

• Temporary chemical cleaning system will be made readily available.

• The whole process will be carried out using our blending tank, circulating pumps, piping
and valves which from a temporary circuit with the main boiler.
• The common header of circulating pumps will be connected to the Economizer inlet at
after feed control station.
• All the drum internals to be removed before chemical cleaning for plugging
SH tubes.
• Down comers are suitably fitted with orifice plate to improve more flow through water
wall steam generation tubes.
• The hand hole plates/End caps of the lower ring header will be removed and necessary
temporary piping will be connected to return line. After completion of the chemical
cleaning process, the piping will be cut & hand hole plates are reinstalled as per IBR.

Pre-Commissioning Chemical Cleaning of 2 x 0 MW Boilers at CJP Project.

 • A separate line connecting all the drains from the dissolving tank, main boiler and all
other pipelines will be laid and led to a neutralization pit where neutralization of
effluents after each process will be carried.
• Necessary safety precautions will be taken during cleaning process to prevent any sort
of injury to the operating personnel.
• All permanent instrumentation lines will be either plugged or removed temporarily
during cleaning by the customer to prevent of acid entry.
• Chemical analysis will be carried out during process for the required test results.
• Detailed process report will prepared and submit after completion of the process.
4. WATER FLUSHING:

• The temporary circuit consisting of tank, circulating pumps, valves and piping is
fabricated as per the site requirement. The complete circuit is tested for any leakage.
• DM Water is filled up and the system is flushed till the drain water is clear. Further to
this flushing, steam is admitted in the entire circuit and the temperature raise to >70 0 C
and flushing continued till the parameter is achieved (turbidity <10 NTU).
5. INHIBITED CITRIC ACID CLEANING:

• After completion of DM water rinse, ensure the system temp >60 Deg C. Then add the
following chemicals one by one.
• Inhibitor CORONIL –213 Spl - 0.3 % of system Volume
• Hydrochloric Acid - 4-5.0%
• Ammonium Bi fluoride - 0.20%
• Circulation is continued for 4-6 hours during which time testing for total iron and % of
acid to be tested out at regular intervals.
• Once achieved 3 steady values the whole solution is completely drained by water
displacement method. The drained acid solution is neutralized using lime and then
discharged to the storm water drain.
6. DM WATER RINSING:

• The Boiler is filled up with DM water and flush the system till iron content is achieved
less than 50 ppm.
7. ACID RINSE & PASSIVATION:

• After DM water rinse continue circulation. Add the following chemicals one by one.
• Citric Acid - 0.1 %
• Ammonia - Adjust the pH 3.5 to 4.0
• Keep circulation for 1 hour.
• In continuation of the above process, raise the pH 9.5 to 10.0 by adding ammonia. and
0.5% sodium nitrite. Continue circulation for 4-6 hrs. Check the Ph at regular intervals
and drain the system..
8. INSPECTION

• The drum is opened for visual inspection of uniform gray color passivation gamma ferric
oxide protective layer. All loose debris in the Steam drum is cleaned manually. Remove
all the temporary piping and restore the boiler for restoration.

Pre-Commissioning Chemical Cleaning of 2 x 0 MW Boilers at CJP Project.

 ANNEXURE-II
SCOPE OF WORKS FOR BOILER ARUDRA AND SMAL

Sr. ARUDRA SMAL REMARKS

DESCRIPTION
No
1 Providing of chemical circulation Pump,
Chemical mixing tank, valves, temporary pipes, √ X
MCC panel, tools & tackles, etc.
2 Transportation charges (To& fro)of chemical
cleaning materials √ X
3 Providing experienced technical staff for
chemical cleaning operation. √ X
4 Supply of chemicals for chemical cleaning √ X Optional
5 Providing Express chemical laboratory along
with reagents for process monitoring. √ X
6 Monitoring chemical cleaning process by
experienced Process engineers and chemist. √ X
7 Accommodation for our crew √ X
8 Temporary erection and dismantling of X √
temporary system under supervision of
ARUDRA EIC.
9 Providing drain line from boiler to
neutralization pit maximum distance of 100 √ X
meters.
10 Workmen compensation Insurance for our √ X
manpower.
11 Preparation and submission of chemical √ X
cleaning method statement & drawing.
12 Insulation works on temporary pipe lines. X √

13 Civil foundation for Motor pumps/tanks X √ If required

14 Providing all PPE for all workmen , safety
shower & First Aid box √ X
15 Temporary/permanent Neutralization Pit. X √

16 Free supply of DM Water, Aux Steam & air If steam is not

within 20 meter distance from the chemical X √ available, we
cleaning tank. can provide
Hot water
Generator

Pre-Commissioning Chemical Cleaning of 2 x 0 MW Boilers at CJP Project.

Sr. ARUDRA SMAL REMARKS
DESCRIPTION
No
17 Free supply of 3 phase 415 V Electrical power
supply for chemical cleaning operation. X √
Normal power supply (200 KW).
Emergency power (200Kw) DG set in case of
power failure.
18 Hydra facilities for loading / unloading of
materials/equipment. X √
19 Necessary removal and refitting of steam drum × √
internals for plugging of SH under our
supervision.
20 Necessary cutting and welding of header stubs, × √
pipes as per IBR norms.
21 Insulation completion in boiler during chemical X √
cleaning
22 Providing of neutralization pit (capacity 200 X √
M3) for collecting of waste water from boiler.
23 Free Supply of fuel/Diesel for Hot water X √
Generator. (Approx. 10 KL).
For ARUDRA ENGINEERS PVT LTD,

S.THIRUMALAI,
Senior Manager-Projects.
Mob.098401 74989.

Pre-Commissioning Chemical Cleaning of 2 x 0 MW Boilers at CJP Project.