DOCUMENT TITLE
SODA BOILING PROCEDURE FOR
BOILER SHP W-803 & 804
At
PT. MAGNA PT. LOTTE CHEMICAL INDONESIA
INDONESIA
REVISION NO :00
UNIT ISSUING APPROVED BY : DATE : PAGE :
04 - 04 – 2024 1 OF 8
SODA BOILING PROCEDURE
PROJECT : LINE PROJECT
JOB NO. : AAID2102
LOCATION : CILEGON, INDONESIA
OWNER : PT. LOTTE CHEMICAL INDONESIA
NO : XXX
Page 1 of 8
INDEX
Page
1. OBJECTIVES........................................................................................................................ 3
2. PREPARATION.................................................................................................................... 3
3. TEST EQUIPMENT AND TOOL........................................................................................ 4
4. UTILITIES FOR SODA BOILING.......................................................................................5
5. PROCEDURE....................................................................................................................... 5
6. ACCEPTANCE CRITERIA..................................................................................................5
7. CAUTION AND SAFETY.....................................................................................................6
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1. OBJECTIVES
Soda boiling should be performed for the new installed boiler system to remove
oily material and surface deposits. Oily materials could cause priming and foaming as well
as interfere with heat transfer. Surface deposits could cause circulation restrictions and
blowdown blockages. Therefore soda boiling should be done prior to the operation of
boiler.
2. PREPARATION
1) Water shall be treated Suitably.
Feed Water Quality
Parameter Units Specification
Dissolved Oxygen, as O2 ppm ≤ 0.005
Total iron, as Fe ppm ≤ 0.02
Total Copper, as Cu ppm ≤ 0.003
Total hardness ppm ND
pH @25℃ - 8.8 – 9.6
Nonvolatile TOC ppm < 0.2
Oily matter ppm < 0.2
Silica, as Si O2 ppm ≤ 0.02
El. Conductivity μs/cm < 0.2
2) All Safety valves (PSV-8801/8802/8803/8804A/8804B) Shall be installed and all
test gags Shall be removed.
3) Steam drum internal (Mist eliminator) Should be removed. It was delivered
Separately and will be installed after Soda boiling Completion.
4) Draft line, fuel line, feed water line have to be Commissioned and in operation
5) Air ducts, Combustion Chamber, flue gas passes, flue gas ducts and boiler drum
internals for Cleanliness and operation ability Should be checked.
6) All temperature, pressure and level measurements have to be Commissioned
and in operation. However, the block valve to drum level transmitter (LT-
8802A/8802B/8802C) Should be Closed to prevent the damage of transmitter.
In Case of the level gauges and transmitters (LG-8803/8804 LT-
8802A/8802B/8802C), primary block valve Shall be Closed and Chemicals Such
as Soda Shall not be Contacted to gauges and transmitters
One level transmitter (LT-8801) is used for drum level monitoring at CCR, refer to
the following Steps and it Shall be normalized.
a) Flush impurities in the impulse tube Several times.
b) Finish the Calibration of transmitter.
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c) Before Soda boiling, fill the demi-water enough in Condensing pot of drum
level transmitter impulse tube. Soda boiling water Shall not be Contacted
directly to transmitters.
d) After that, drum level transmitter Can be used.
e) Flush Chemicals in the impulse tube and liquid-Contact point Several times
enough after Soda boiling.
7) Confirm all piping Condition and Correct installation Connected to Steam drum,
level gauge, Saturated Steam piping, main Steam piping and main Steam Start-
up vent (PV-8809) must be in proper operating Condition including Supports for
any possible Clash, when Steam drum expands due to thermal effects during
operation.
8) Check feed water and fuel Control valve Controls and operation ability. Action
test for each motorized, Control and fuel Shut off valve Should be Completed.
9) Check for electrical Supply, voltage, fuse and overloads.
10) Check air ducts, flue gas passes and flue gas ducts for Cleanliness and
operation ability. All manholes Should be Closed.
11) Burner ignition test Should be Completed. This is to Confirm and verify the firing
equipment’s reliability and function ability during Start-up and normal operation.
12) Boiler interlock Should be in reliable operating Condition.
13) Any overlapping parts by expansion has to be Checked.
14) FD fan is ready for Service
15) DCS/ESD are ready for burner light up
3. TEST EQUIPMENT AND TOOL
No. Item Qty UOM
1. Centrifugal Pump Circulation 11 KW 1 Lot
2. Accessories circulation centrifugal pump & Hose circulation 1 Lot
3. Tank circulation 1 Lot
4. Verganio Pump Circulation 30 KW 2 Lot
5. Accessories circulation verganio pump & Hose circulation 1 Lot
6. Tank circulation 30 ton 1 Lot
7. Onga KNA 20 2 Unit
8. Boiler 5 ton 1 Lot
9. Genset generator 250 KVA 1 Lot
10. Distribution panel 2 Lot
Page 4 of 8
No. Item Qty UOM
11. Wilden pump 2 Unit
12. Test kit onsite analysis 1 Lot
13. Personal protective Equipment 1 Unit
14. Tool Kits 1 Lot
15. Consumable 1 Lot
16. Accessories cleaning 1 Lot
17. Safety Equipment 1 Lot
4. UTILITIES FOR SODA BOILING
Below are utilities needed for soda boiling works Boiler SHP W-803 dan W-804:
Demin Water
No. Activity Remarks
Quantity, m3
Boiler SHP W-803
1 Flushing 74 2 times holding volume
2 Soda Boiling 37
3 Rinsing 111 3 times rinsing (estimated)
Total Demin Water 222
Boiler SHP W-804
1 Flushing 74 2 times holding volume
2 Soda Boiling 37
3 Rinsing 111 3 times rinsing (estimated)
Total Demin Water 222
* Demin Water (by client)
Chemical List
Solution
No. Chemicals Qty (kg)
Concentration (% weight)
Soda Boiling for SHP W-803
A Caustic Soda Flake 98% 95 kg NaOH 0.25 %
B TSP Flake 98% 95 kg TSP 0.25 %
Soda Boiling for SHP W-804
A Caustic Soda Flake 98% 95 kg NaOH 0.25 %
B TSP Flake 98% 95 kg TSP 0.25 %
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5. PROCEDURE
1) Flushing
a. Fill the boiler system until fully filled, and then drain the water from the system until
water level is empty.
b. Remove and check the filter in the strainer, remove any debris that is caught on the
filter before reinstalling the filter.
c. Check turbidity periodically and continue flushing until turbidity has reached 10
NTU.
d. Repeat the flushing procedure at least twice. Stop flushing if turbidity has reached
the target value.
2) Soda Boiling
a. Mix the chemicals in the mixing tank and then transfer to boiler drum using transfer
pump through nozzle connection on the steam drum.
b. Fill boiler with chemical until normal water level.
c. Take sample of boiler drum water and do the analysis after chemical has been
transferred into the boiler. The target parameters are:
pH : 10-13
Alkalinity Content : 0.4-0.5 as NaOH
d. Start burner at minimum firing rate until steam vapor is flowing from the open valve
(by commissioning team/client).
e. Use manual boiler feed water control to maintain boiler water at normal water level.
f. Increase burner firing rate (steam pressure) until the boil-out pressure is reached. If
the steam flow at boil out pressure is excessive, the boiler steam vent valve may be
partially closed to maintain pressure while the boiler firing rate is reduced (by
commissioning team/client).
g. Hold pressure in the boiler for 8-12 hours, use no blow down.
h. Take sample and analyze the total iron and oil content per 2 hours until equilibrium
state has been reached (at least 3 constant data
i. After total iron and oil content has reached equilibrium state, drain the system.
j. After boil-out has been completed,
Open the mud drain valve
Keep the steam drum vent open
Drain the steam generator
k. Allow unit to cool to less than 150 oF before refilling to avoid thermal shock.
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3) Rinsing
a. Using boiler feed water, refill, and drain the boiler to remove any remaining caustic
on the internal surface.
b. Rinse the system with boiler feed water until pH rinsing equals pH of boiler feed
water.
c. After acceptance criteria has been reached, stop rinsing, drain the system, then
remove the boiler manhole cover.
d. Wash tube and drum surfaces with fresh water and high-pressure hose.
e. Inspect drum internals for cleanliness.
6. ACCEPTANCE CRITERIA
Progress of Work Parameter End Point
Flushing Turbidity < 10 NTU
Mixing Chemical pH 10-13
Alkalinity 0.4-0.5 as NaOH
During Soda Boiling Total Iron Reach Equilibrium
Oil Content Reach Equilibrium
Rinsing pH pH Boiler Feed Water ± 2
7. CAUTION AND SAFETY
1) Safety requirement for this procedure will be covered by the permit to work and the
JSA specifically written for this procedure.
2) Chemical handling storage shall be installed chemical shelter with scaffolding and
terpauline for covering chemical from the weather.
3) The chemical shelter needed to safe and keep humidity and temperature the
chemical.
4) The chemical cleaning operator who is mixing chemical to the mix tank will use the
special personal protective equipment such as, safety google, chemical clothes,
rubber gloves, safety rubber shoes, and full masker respiratory.
5) In the chemical shelter will be attached MSDS for every chemical that will be used
for chemical cleaning activitys.
6) Shower and eyewash will be installed in the near area of soda boiling.
7) To avoid the damage of equipment during soda boiling activity. We will take the
following action where necessary :
8) Motors, insulation, and the instruments near the flow outlet shall be protected or
covered by terpauline.
9) The mixing tank will be protected with sign board, such as “hot water”, “chemical
solution”.
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10) In the connection between hose and system or hose to hose will be installed spill kit
or second containment and all flange joint have to be wrapped up with wrapping
plastic.
11) Clear communication between skid pump operator and valve operator shall be
taken care necessary and carefully in order to avoid the faulty of operation
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