Home > The detailed and practical HRSG cleaning process for the factory

The detailed and practical HRSG cleaning process for the factory

Cleaning the cooling tower is essential to ensure the system works stably and sustainably for a long time. In this article, we will explore the role of HRSG cleaning. At the same time, we will also present the basic steps in the cleaning process that industrial plants have been applying.

The importance of HRSG cleaning and water treatment in the tower

After a period of operation, the cooling tower will become an ideal environment for the growth of microorganisms and algae. This causes many problems for the entire tower system. Therefore, we need to carry on hygiene. In machine parts, biofilms can appear filled with microorganisms, bacteria harmful to equipment and health, such as Legionella. This film is also capable of causing corrosion. To remove the biofilm, we can use dispersants. In addition, industrial cleaning for the cooling tower also works to prevent the accumulation of harmful bacteria.

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The Occupational Safety and Health Administration (OSHA) recommends that factories clean cooling towers at least twice a year to minimize the accumulation and growth of dangerous bacteria, such as Legionella. If this HRSG cleaning schedule is not followed, workers near the cooling tower can breathe in Legionella bacteria, which can pose a risk of illness and death. And yet, when corroded too severely, the mechanical parts will be challenging to repair. Some businesses had to buy new cooling towers because the machine parts were severely damaged.

Not cleaning the cooling tower regularly will cost even more in the future, and this will cost businesses a lot of time and money to maintain and repair. Improper and timely tower cleaning also affects the operation. If you still have doubts about the importance of cleaning a cooling tower, please refer to the article “Why you need to do the HRSG cleaning and five steps to do it methodically.”

5-step process of properly and effectively HRSG cleaning that you should know

The following content will present five steps to effective and time-saving cooling tower cleaning:

  1. Disinfecting with chlorine
  2. Hot floor cleaning
  3. Disinfection of tower and fan basin
  4. Cleaning distribution pans, surface, and tower basin
  5. Vacuuming the septic tank and cleaning the debris

1. HRSG Cleaning – Step 1: Disinfecting the whole system with chlorine

Chemical disinfection can prevent the growth and attachment of Legionella bacteria and other harmful bacteria. The Centers for Disease Control (CDC) recommends creating chlorine sanitizers to avoid bacteria. Each type of chlorine concentration will have its way of preparing the solution. You can refer to the following methods to do HRSG cleaning:

  • NaOCl Chlorine 13% – 15%: Use 3 lbs mixed with 1,000 gallons of water.
  • 3% – 5% Chlorine NaOCl: Use 10.5 lbs per 1,000 gallons of water.
  • Ca(ClO)2: Use 0.6 lbs per 1,000 gallons of water.

Add 10 to 25 pounds of dishwashing liquid per 1,000 gallons of water within 15 minutes of adding the disinfectant. Dishwashing liquid will help disperse the detergent better. Pour the chemical solution into the tower, then open the valves and pipes. Next, turn on the water pump, so the cleaning chemicals circulate, pushing all the dirt out of the system.

2. HRSG cleaning – Step 2: Cleaning floors with heat to remove built-up deposits

Hot floor cleaning removes deposits, bacteria, fungi, and algae from any floor, holes, and nozzles. Cleaning the cooling tower but ignoring this area will cause contaminated water to return after it has been treated. Therefore, in this process, cleaning is essential. Hot floors can be cleaned with low-pressure water from a hose or brush, and these items clean well without damaging the device.

During the HRSG cleaning process, if any injector is found to be damaged or missing, it should be replaced immediately. The lack of nozzles will reduce the tower’s heat exchange efficiency by reducing water flow to the hot floor and the cooling system, significantly affecting the tower’s performance.

3. HRSG cleaning – Step 3: Disinfecting the tower and fan basin area

The indispensable industrial cleaning step is disinfecting the tower area and the fan casing. This cleaning step eliminates the bacteria distributed on the water surface using aeration. This step is essential because it can prevent Legionella bacteria from growing and spreading to people nearby.

This type of bacteria causes several diseases such as pneumonia, bronchitis, infections… Proper disinfection of towers helps improve workers’ health, limit many risks and increase equipment performance.

4. HRSG cleaning – Step 4: Cleaning the distribution pans, surfaces, and tower basins.

Inspect all dispenser pans and other components for complete cleaning of sludge, scale, bacteria, sediment, algae, or biofilm. In addition, all other parts need to be checked. Repair and replacement work should be done if a damaged or missing component is found, which helps ensure the tower can function correctly.

In addition, when doing HRSG cleaning, we also need to pay attention to the tower’s surfaces. This is an area that can harbor bacteria. Cleaning all surfaces and basins and disinfecting any surfaces that come in contact with water will increase the effectiveness of the cleaning work.

In addition, we would like to introduce a popular material in the field of industrial hygiene, which is CO2 dry ice, which is mentioned in more detail in the article “Cleaning with CO2 dry ice.”

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5. HRSG cleaning – Step 5: Vacuuming sump and cleaning debris

Vacuum up the details in the sump to remove unresolved dirt, mud, or debris. If this step is skipped, the industrial cleaning process may not be complete. After aspirating debris, it should be handled with care. Treating wastewater during tower cleaning is also essential to ensure that the discharge process complies with laws and regulations.

Effective cooling tower cleaning requires the help of an experienced team and is performed by skilled professionals. VIVABLAST is an ideal HRSG cleaning solution provider with modern machines and processes that save time and costs. The technicians at VIVABLAST are professionally trained, ensuring high efficiency.

You can contact VIVABLAST:

  • Tel: (+84-28)38 965 006/7/8
  • Fax: (+84-28)38 965 004
  • Email: vivablast@vivablast.com

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