Cb gf web in sep 2016, feeding chemicals to boilers.
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El mejor tratamiento quimico para una caldera. Podras elegir el que mas se ajuste a tu generaciion de Vapor.
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Cb gf web in sep 2016, feeding chemicals to boilers.
- 1. THE IMPORTANCE OF BOILER FEED WATER TREATMENT Presented by Cleaver Brooks’ Steve Connor & Jared Gabel September 21.2016
- 2. TODAY’S TOPICS • What a sound water treatment program involves • The mechanical elements • Keeping the boiler and connected system safe, efficient & reliable • The major chemical elements • The chemical dosing systems and their applications • Boiler dosing and expert coordination • Dosing pump details • Key points to be aware of • The system options 2
- 3. BOILER WATER TREATMENT 3 Water is an excellent heat transfer medium, but it must be properly treated in both steam and hot water systems or serious problems will ensue, robbing energy and reducing the life of the asset.
- 4. 4 T T T T T Legend Steam Cond Vapor H P Cond Return Vent D A TankD A Tank Feed PumpBoiler TT TT DA Tank TT TT TTT Legend HP Steam LP Condensate Return Cond Rcvr & Pump Motive Force Flash TYPICAL STEAM SYSTEM
- 5. PROPER BOILER WATER DOSING Steam Systems 5
- 6. THE PROBLEMS CHEMICAL DOSING ADDRESSES 6 • Scaling • Porous Deposition • Corrosion • Efficiency Loss • Life of the Asset • Steam Quality • % moisture • Steam Purity • Silica • Sodium ion
- 7. WHAT NEEDS TO BE REMOVED 7 • Dissolved Minerals • Hard Scale Formers • Calcium • Magnesium • TDS • Calcium (Scale) • Magnesium (Scale) • Sulfate (Instability) • Iron (Scale) • Silica (Deposition) • Chloride (Instability) • Alkalinity (Foaming) • Dissolved Gas • Free Oxygen (Corrosion) • Free Carbon Dioxide (Corrosion) Waterside Scale Waterside Corrosion
- 8. MOST ECONOMICAL LONG-TERM APPROACH 8 Mechanical Chemical
- 9. 9 WHAT NEEDS TO BE REMOVED Waterside Scale Waterside Corrosion • Dissolved Minerals • Hard Scale Formers • Calcium • Magnesium • TDS • Calcium (scale) • Magnesium (scale) • Sulfate (corrosion) • Sodium (deposition) • Silica (scale) • Chloride (instability) • Alkalinity (foaming) • Dissolved Gas • Free Oxygen (corrosion) • Free Carbon Dioxide (corrosion)
- 10. SCALE AND DEPOSITS FORM IN HIGH HEAT FLUX AREAS 10 • Effect of Scale & Deposits: • Calcium, magnesium inhibit heat transfer • Raise tube metal temperature • Efficiency loss • Vessel failure • Downtime
- 11. 11 MECHANICAL REMOVAL 11 Removes • Calcium • Magnesium Brine Tank Twin Water Softener (Resin Tanks)
- 12. 12 WHAT NEEDS TO BE REMOVED Waterside Scale Waterside Corrosion • Dissolved Minerals • Hard Scale Formers • Calcium • Magnesium • TDS • Calcium • Magnesium • Sulfate • Sodium • Silica • Chloride • Alkalinity • Dissolved Gas • Free Oxygen • Free Carbon Dioxide
- 13. BOILER WATER FOAMING & CARRYOVER 13
- 14. MECHANICAL REMOVAL PROCESS 14 Removes • Bicarbonate & Carbonate Alkalinity • Sulfate • Silica Dealkalizer
- 15. 15 WHAT NEEDS TO BE REMOVED Waterside Scale Waterside Corrosion • Dissolved Minerals • Hard Scale Formers • Calcium • Magnesium • TDS • Calcium • Magnesium • Sulfate • Sodium • Silica • Chloride • Alkalinity • Dissolved Gas • Free Oxygen • Free Carbon Dioxide
- 17. 17 HOT CONDENSATE RETURNED DeaeratorBoiler Feed System Pressurized receiver. Steam diffusing tube Vented receiver
- 18. 18 Chemicals are required too!
- 19. 19 TOLERANCES ARE BASED ON PRESSURE & TEMPERATURE Feed Water Boiler Water Oxygen Silica Iron & copper Total Alkalinity Total Hardness Free OH Alkalinity pH Specific Conductance Non-Volatile TOC (Total Organic Carbon) Oily Matter Water Constituent Tolerance: 0-300 operating psig ASME Guidelines: Broken down by feed water and boiler water, and then by firetube and watertube boilers.
- 20. 20 SUGGESTED WATER CHEMISTRY LIMITS Drum Operating Pressure psig 0 - 300 Dissolved Oxygen ppm (mg/L) O2 – measured before chemical scavenger addition <0.007 Total iron ppm (mg/L) Fe ≤0.1 Total copper ppm (mg/L) Cu ≤0.05 Total hardness ppm (mg/L) as CaCO3 ≤0.5 pH @ approx. 80 degrees F 8.3 -10.5 Feedwater
- 21. 21 SUGGESTED WATER CHEMISTRY LIMITS Boiler Water Drum Operating Pressure psig 0 - 300 Silica ppm (mg/L) SiO2 ≤150 Total Alkalinity ppm (mg/L) as CaCO3 <1000
- 23. PRECIPITATING PROGRAMS 23 • Phosphate based • Scale inhibitor • Dosed based on hardness after softening
- 24. THERSHOLD SCALE/ DEPOSITION INHIBITOR 24 • Combines phosphonate and polymer for dosing • Distorts crystal structure
- 25. SOLUBILIZING PROGRAM 25 • All-polymer dosing • Dosed based on hardness • Conditions sludge and solubilizes hardness
- 27. MECHANICAL REMOVAL 27 • Automatic blowdown system senses anything that adds conductivity: • Calcium • Magnesium • Sodium • Silica • Sulfate • Chloride • Iron Conductivity Sensor Auto BD System
- 28. TDS CONTROL WITH BLOWDOWN HEAT RECOVERY 28 Water inletTo drain To drain Separator Heat exchanger ?
- 29. BLOWDOWN HEAT RECOVERY TYPES: BLOWDOWN HEAT RECOVERY UNIT 29 • Proportional blowdown heat recovery system • Send to Atmospheric feed or deaerator tank • Automatically controls TDS • Single or multiple boilers • Blowdown is cooled before discharge (code compliance)
- 30. TYPICAL STEAM SYSTEM 30 T T T T T Legend Steam Cond Vapor H P Cond Return Vent D A TankD A Tank Feed PumpBoiler Strainer Trap Trap Trap Trap TT TT DA Tank TT TT TTT Legend HP Steam PRV LP Steam Trap LP Condensate Return Cond Rcvr & Pump Motive Force Flash
- 32. CONDENSATE LINE TREATMENT 32 Neutralizing & Filming Amines
- 34. LEARNING OBJECTIVES Bytheendofthiscourseyouwillbeableto: 34 1. Provide a brief overview of dosing pumps and systems 2. Explain the mechanics of dosing pumps and system components 3. Describe typical control panels 4. Identify good installation practices.
- 35. 35 Hydraulic Institute Definition: A Metering Pump is a reciprocating pump used to accurately displace a volume of liquid in a specified time period. www.pumps.org • High flow accuracy and improved process control • Effective handling of hazardous and/or expensive chemicals
- 36. A VARIETY OF STYLES AND CONFIGURATIONS 36 Mechanical Diaphragm Solenoid Driven Motor Driven Stepper Motor Driven Hydraulic Diaphragm
- 37. STEAM BOILER - SUPPORT SYSTEMS 37 Surge tank Condensate tank Treatment system Deaerator tank Boiler
- 39. CONSIDERATIONS FOR HANDLING AMINES 39 • Feed point for amine is directly in to the steam header • Ensures good volatilization and minimizes any potential losses from feeding to the DA or the boiler • Injection nozzle shown is stainless steel and is good to 1000 psi, and 500 degrees F.
- 40. LIQUID PROPERTIES 1. Corrosive 2. Abrasive 3. Temperature 4. Viscosity 5. Specific Gravity 6. Entrained gas 7. Vapor Pressure 8. Concentration 40
- 41. METERING PUMP BASIC COMPONENTS 41 Control Flow rate is adjustable by varying the stroke length, stroke frequency or motor speed. Motor Can be constant speed, variable speed or it may be a solenoid. Drive Converts rotary motion into reciprocating motion. Liquid End Type of liquid end and materials of construction determined by application.
- 42. CONTROLLING VOLUME METERING PUMPS: Two Basic Types 42 • Mechanically • Actuated • Diaphragm • Hydraulically • Actuated • Diaphragm
- 43. What types of Drivers are available? 43 Conventional motor Stepper motor Solenoid
- 44. SETTING DOSE RATE 44 Stroke Frequency Control Stroke Length Control Motor speed control VFD Stepper Motor
- 45. TYPICAL DOSING PUMP PERFORMANCE CHART 45
- 46. Definition of “Turndown” 46 A statement of relationship between the maximum flow indicated on a pump’s chart and the minimum flow that the same unit can dose with accuracy
- 47. 47 Flow Range: .00066 gph to 9000 gph or 1/100 of a teaspoon per minute to 150 gpm
- 48. 48 How is injection flow rate determined? • Flow rate in process water. • Nature and concentration of the treatment liquid • Desired concentration in liquid to be treated
- 49. PUMP MATERIALS AND LIQUIDS 49 Start with chemical compatibility guides • Cole-Parmer • Manufacturers pumped liquid guides
- 50. HANDOUT- SELECTION QUESTIONS 50 Dosing Pump Sizing and Selection Questions September 15, 2016 New application or replacement pump? If new, do you need just a pump or a complete injection system? If just a pump: Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Whatfluid are you injecting Can you provide an MSDS Is the liquid expensive Whatwill be used to monitorthe needed injection rate How will feedback on this be provided to the pump Will the pump controls be manual orautomatic Is itconstantcontrol, or Atwhatintervals mustthe liquid be injected Maximum liquid temperature Question Whattype of treatmentsystem are we dealingwith Whatare we pumpinginto How importantis accuracy Is flow pulsation an issue Whato-ringmaterial is required Minimum liquid temperature Any abrasives Any entrained gases Any pipingsystem pressure limits Whatis the viscosity of the liquid Whatis the specificgravity of the liquid Is itbatch control, or Is itfeed forward control, or Is itfeed back control, or Is itcombined control Whatpump materials are dictated by the fluid Whatball seatmaterial is required Whatvalve ball material is required Are there any applicable specifications Are any national orlocal Standards orCodes referenced Item 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Item From the above you must determine: a b c d e f g h i Itis agoodideatoknow: Is the liquid toxic Whatpsi is required atthe injection point How farfrom the pointof injection will the pump be located Mightthe psi requirementchange in the future Whatis the suction liftin feet Whatenvironment-is ithazardous Whatmotorenclosure Whatis the injection rate required Is aflow safety factorrequired (forprimingissues) Mightthe flow rate change in the future Question Is ULlistingorrecognition required Whatphase Whatis the suction pipingspecification Is the suction vessel vented to atmosphere, or Whatis pressure of atmosphere in vessel if itis notvented Whatvoltage WhatHertz Whatpsi will the pump be exposed to Will turndown impactpump flow rate Who will do installation and startup Is itcorrosive Is ithazardous Is itexpensive Whatis the vaporpressure of the fluid Is there adequate NPSHa Do we need anti-cavitation provisions
- 51. BENEFITS OF PACKAGED DOSING SYSTEMS 51 • Easy plug and play solutions to chemical feed • Pre-engineered to specific needs • Factory tested as one unit • One phone call for support
- 55. PANEL OPTIONS 55 HOAJBox Power Receptacle• Lock out (on/off) • Terminal Block • Power supply • Emergency Stop • HOA switches for each pump • Run Lights • Alarm Lights • Lock out • Terminal Block • Power supply
- 56. GOOD INSTALLATION PRACTICES: Avoid long or complex suction lines 56
- 57. MORE INSTALLATION TIPS: 57 Avoid long or complex suction lines Avoid gas traps in suction lines
- 58. MORE INSTALLATION TIPS: 58 Flexible suction line Rigid suction line Keep foot valve 3” to 6” off bottom of tank to keep debris out.
- 59. 6 1 GRUNDFOS TECHNICAL INSTITUTE www.grundfos.us/training • Virtual Classroom - Self-Paced - Over 40 courses - Certificates of Completion • Webinars - Live and Recorded • Face-to-Face Training 59
- 60. TODAY’S TAKE-A-WAYS • Proper water treatment is a combination of mechanical and chemical remediation • Has significant impact on efficiency and reliability attainment • Increasing cycles of concentration saves fuel dollars • Heat from continuous blow down for TDS control can be recouped • Proper and reliable chemical dosing is paramount for assuring steam boiler system reliability and life. • A chemical metering pump is a reciprocating pump used to accurately dispense a specific volume of liquid in a specific amount of time. • Amine injection is in the steam line to assure proper volatilization and dispensing throughout the piping system especially the condensate line(s). • All metering pumps have a motor, drive assembly, liquid end, and a control adjustment. • Liquid properties in the chemical to be dispensed need to be evaluated for proper pump type selection and its materials of construction. • Normally mechanically actuated pumps are used for steam boiler applications because they have adequate pressure tolerance and provide the suction lift often required. • When selecting a chemical dosing pump what is important is the maximum and minimum pumping limits. • Packaged dosing systems offer a high degree of assurance the chemicals are being properly dispensed while including ongoing monitoring and alarms. 60
- 61. Steve Connor Consultant: Marketing & Technical Services sconnor@cleaverbrooks.com 262- 377- 6347 QUESTIONS? Jared Gabel Senior Product Specialist jgabel@grundfos.com 913- 227- 3553