Boiler Water Training.pdf

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Boiler Technical Training
At
Reliance Industries Limited
Hazira Manufacturing Division
February 26, 2008
K S Rajan

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BOILER WATER TREATMENT
• BASIC WATER CHEMISTRY
• BOILER DESCRIPTION
• OXYGEN PITTING & CONTROL
• CONDENSATE TREATMENT
• INTERNAL TREATMENT, COORDINATED
pH/PO4
• STEAM PURITY
• BOILER STORAGE
• DISCUSSION, Q&A

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Basics & Interpretation of Water Analysis

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“The Basics”
• Hydrologic Cycle
• Properties of Water
• pH and Alkalinity
• Langelier Saturation Index
• Analytical Expressions
• Water Analysis/Deposit Analysis
• Corrosion and Deposition & Monitoring
• Chemical Feed

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Properties of Water
•Density - 1 kg/l @ 4 oC ; 0.998 kg/l @ ambient temperature and
varies inversely with temperature
•Boiling point = 100 oC and freezing point @ 0 oC
•Viscosity ~ 1 cps at ambient temperature and varies inversely
with temperature
•Specific heat - 1 BTU/lb-deg F or 1 kcal/kg-deg C or 4.2 kJ/kg-
deg C
•Universal solvent - dissolves most substances to some extent

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Impurities found in Water
• 3 Categories
• SUSPENDED SOLIDS (Silt)
• DISSOLVED SOLIDS (Minerals)
• DISSOLVED GASES
• Where do these things come from?

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Hydrologic Cycle

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Impurities found in Water
• Dissolved solids present as ions
• Cations - Ions that carry net positive charges e.g. Calcium (Ca2+), Magnesium
(Mg2+), Sodium (Na+), Iron (Fe2+), Aluminium (Al3+)
• Anions - Ions that carry net negative charges e.g. Bicarbonates (HCO3
-),
Carbonates (CO3
2-), Sulfate (SO4
2-), Chlorides (Cl-), Oxides (O2-), Hydroxides (OH-)

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Water Impurities
Impurity Concern Removal
Suspended Solids
Silt, Iron,
Microbiogical
Fouling
Erosion
Underdeposit corrosion
Clarification
Filtration
Dissolved Solids
Minerals,
Organics
Scaling
Corrosion
Ion Exchange
Reverse Osmosis
Evaporation
Dissolved Gases
O2, CO2, NH3
Pitting
General Corrosion
Corrosion products
Deaeration
Steam Stripping

13. Dissolved Solids
Cations Anions
Na+
K+
NH4+
Organic acids
SiO2, possibly free CO2
HCO3-
possibly OH- & CO3--
Cl- F-
SO4--
Ca++ Mg++
NO3- PO4 ---
Total
Alkalinity
Mineral
Acidity
Temporary
Hardness
Permanent
Hardness

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Dissolved Solids Commonly Found in Water
Calcium
Magnesium
Sodium
Silica
Iron
Bicarbonate
Sulfate
Bicarbonate
Sulfate
Bicarbonate
Sulfate
Chloride
Oxide
Bicarbonate
Hydroxide
Sulfate
Ca(HCO3)2
CaSO4
Mg(HCO3)2
MgSO4
NaHCO3
Na2SO4
NaCl
SiO2
Fe(HCO3)2
Fe(OH)3
FeSO4
Chemical Name
Anion
Cation

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Factors Affecting Solubility
•Temperature - Most salts increases except for Ca and Mg Salts
with increasing temperature
•Alkalinity - Most salt solubility increases with decreasing
alkalinity with the exception of Silica
•pH - most salts solubility increases as the pH drops
•Oxidation state - Fe and Mn salt solubility increases with
decreasing oxidation state

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Impurities found in
Water
• Turbidity - suspended solids
– silt, organic matters, precipitated
salts
• Color - suspended solids and
dissolved solids
• Dissolved gases e.g. CO2, O2, NH3,
H2S
• Organics - humus, vegetation, micro-
organisms

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Typical Water Analysis
pH
Conductivity μS/cm
Alkalinity “P” as CaCO3, ppm
Alkalinity “M” as CaCO3, ppm
Sulfate as SO4, ppm
Chloride as Cl, ppm
Hardness, Total, as CaCO3, ppm
Calcium Hardness, as CaCO3, ppm
Magnesium Hardness, as CaCO3 ppm
Copper, Total as Cu, ppm
Iron, Total as Fe, ppm
Sodium, as Na, ppm
Phosphate, Total, as PO4, ppm
Silica (reactive), as SiO2, ppm
Turbidity, NTU
TSS, ppm
Color, Hazen
TOC, as C, ppm
Value
Parameter
7.3
150
0
20
15
10
20
15
5
0.05
1.5
12
<0.05
4
50
20
3
1

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Special Ions
• pH
• Hydrogen, H+
• Hydroxide, OH-
• Alkalinity
• Bicarbonate, HCO3
-
• Carbonate, CO3
--
• Hydroxide, OH-

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pH
• Hydrogen Ion Concentration
• Logarithmic Scale
• pH = -log [H+]
• Unit change in log scale

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How Does pH Apply
to Us?
• pH < 7: Acidic (corrosion)
• pH > 7: Alkaline (deposition)

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Alkalinity
Relationships •M-Alkalinity = Total
– Titration to pH = 4.3
– Sum of: HCO3
-
+ CO3
-
+ OH-
•P-Alkalinity = OH-
+ 1/2 CO3
-
– Titration to pH 8.3
•OH-Alkalinity = 2P - M or titration
– Neutral barium chloride precipitates CO3
-

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Conductivity
• Inverse of Resistance [mho]
• Measure of concentration of ions in solution

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Types of Solubility
Normal: Increases with Temperature
• Table Salt (NaCl)
• Sugar
Retrograde: Decreases with
Temperature
• Calcium Carbonate
• Calcium Phosphate

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How Do We Quantify What Is in the Water?

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Analytical Expressions
• “Concentration”
• units of solute per unit of solvent:
• PPM (parts per million)
– parts of solute per million parts of
solvent
• mg/l (milligrams per liter)
– 1 gram solute/1,000,000 grams
solvent
• PPB (Parts Per Billion)
parts of solute per Billion parts of solvent

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Analytical Expressions
•“Mg as CaCO3”
Magnesium expressed as its Equivalent weight
in Calcium Carbonate
100 (MW CaCO3) = 4.1
24 (MW Mg)

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Analytical
Expressions
• Different Conventions
• We use “ppm as CaCO3”
• ppm ppm
• as substance factors as CaCO3
• Ca 50 2.5 125
• Mg 20 4.1 82
•

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Boiler Descriptions
Boiler Descriptions

29. FIRETUBE BOILERS
ADVANTAGES DISADVANTAGES
High load swing capacity Low pressure
Ease of repair Capacity limit
Low space requirement Usually no superheater
Self contained package Usually no economizer
Relatively low cost Usually low efficiency
Ease of installation One fuel at a time
FOUR-PASS FIRETUBE BOILER

30. – Economizer
– Steam drum
– Mud Drum
– Headers
– Boiler Bank
• Downcomers - Risers
• Waterwalls
• Screen tubes
• Arches
• Floor tubes
• Roof tubes
– Superheater
– Air Heater
WATERTUBE BOILERS
Typical Parts of a
Water Tube
Boiler Includes:

31. WATERTUBE BOILERS
BOILER DESIGN
WATER WALLS
SUPERHEATER
SCREEN TUBES
STEAM
DRUM
MUD
DRUM
ECONOMIZER
AIR HEATER
RISERS
DOWNCOMERS
140-150 C
To stack
Coal
Lower Water
Walls Header

32. Fire Tube
Water Flue
Gases
Water Tube
Steam
Steam
Drum
Feedwater CBD
Mud
Drum
IBD
Flue
Gases
Risers
Downcomers
Comparison - Watertube vs. Firetube:

33. WATERTUBE BOILERS
ADVANTAGES
Low to super critical
pressure
z Virtually unlimited capacity
z Typically high efficiency
z Superheaters
zEconomizers
z Multiple fuels
z Drum or once-through
z Package or field-erected
DISADVANTAGES
z High Cost
z Require Large Space
z Usually require higher quality
feedwater
z Sensitive to low load operation
WATERTUBE BOILER: A-TYPE

34. BFW
Steam Exit Drum
Flue
Gas
Path
Sidewall Problem
Area
Downcomers
Risers
Burner

35. Furnace Wall
Tubes
Steam Drum
Downcomers
Risers
D-Frame
Package Boiler

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Babcock & Wilcox
Coal Fired Boiler

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Power Utility Boiler
Simplified Flow Diagram
B&W Boiler
BD
Sat Steam
HP SH Steam
HP Turbine
Cold Reheat
BFW
LP Heaters
HP Heaters
Cond Polisher
IP Turbine LP Turbine
Condenser
Deaerator
MB MU
Hot Reheat

38. CAUSE AND EFFECT DIAGRAM FOR BOILER PROBLEMS
BOILER
CORROSION
OXYGEN PITTING
STRESS CORROSION CRACKING
DOWNTIME
CORROSION
MECHANICAL
DEAERATOR
PERFORMANCE
SCAVENGER
UNDERFEED
OXYGEN
IN-LEAKAGE
STRESSED
AREA
EMBRITTLING WATER
CHARACTERISTICS
CONCENTRATING
MECHANISM
POOR pH CONTROL
DEPOSITION
POOR CHEMICAL
FEED CONTROL
DOWNTIME
CORROSION
INADEQUATE
BLOWDOWN
CONTROL
POOR BOILER
FEEDWATER
QUALITY
CONDENSATE
CONTAMINATION
POOR
EXTERNAL
TREATMENT
CONDENSATE
CONTAMINATION
POOR EXTERNAL
TREATMENT
INADEQUATE
BLOWDOWN
CONTROL
POOR CHEMICAL
FEED CONTROL
POOR BOILER
FEEDWATER
QUALITY

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Boiler Calculations
FeedWater = Steam + Blowdown
% Blowdown = 1 X 100
Cycles
FeedWater (kg/hr) = Steam Generation (kg/hr)
1 – (%blowdown)
100
FW= STM ( C )
C-1

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Determining Cycles of Concentration
•Feedwater vs. Boiler Water analysis
•BFW Cycles = [Boiler Conc.] / [FW Conc.]
• Cycles = Neutralized Boiler Water Cond. (umhos at 25C)
___________________________________________
Feedwater Cond. (umhos at 25C)
• Check via Chlorides, Silica
• Do not use compounds that routinely precipitate (phosphate,
hardness) or that are part of treatment (sulfite/sulfate)
•Demineralized or RO make-up – Tracer methods
• Molybdate

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Steam, Feed Water & Blowdown Relationships
ƒ % Blowdown = 100 / FW Cycles
• % BD at 20 FW cycles = 100/20 = 5%
ƒ Feedwater = Steam X [Cycles / (Cycles –1)]
• FW = 100 MM ppy steam X [20 / (20 – 1)] = 105.3
ƒ Feedwater = Steam + Blowdown
• BD = FW – ST = (105.3 – 100) MM ppy = 5.3 MM
ppy
ƒ Feedwater = Make-up + Condensate

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Oxygen Control
• Deaeration
• Chemical treatment

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Corrosion of Iron by Oxygen
WATER
Fe(OH)3
O2
Fe2+
OH- O2
ANODE CATHODE
ANODE REACTION
Fe. = Fe++ 2e-
CATHODE REACTION
1/2 O2 + H2O + 2e- = 20H-
• Iron Is Oxidized on the Surface (Anode) - Metal Loss
• Oxygen Is Reduced (Cathode)
MECHANISM
ELECTRON FLOW

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Oxygen Corrosion
• Corrosion Rate Doubles With Every
10 C Increase in Water Temperature
• Metal Loss is low
• Localized attack
• Pit Formation
• Rapid Failure

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Rapid Perforation ~ Equipment Failure

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Oxygen Guidelines
Organization Dissolved O2 Level, ppb
ASME
TAPPI
ABMA
EPRI
DEAERATOR
GUARANTEE
TYPICAL DEAERATOR
O2 LEVELS
< 7
< 7
NO RECOMMENDATION
< 5
7
15 - 40

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Types of Oxygen Scavengers
• Solid
– Sodium Bisulfite
– Sodium Sulfite
• Non-Solids
– Hydrazine
– Hydroquinone
– Diethylhydroxlamine (DEHA)
– CARBOHYDRAZIDE
– ASCORBIC ACID

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Residual (ppm SO3
-) Pressure
30 - 60 < 40 bar
10 - 20 40 - 60 bar
ATTEMPERATION / DESUPERHEATING: NO
RECOMMENDED
SULFITE CONTROL LIMITS

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Hydrazine
Reaction:
N2H4 + O2 N2 + 2H2O
Decomposition Reaction:
2N2H4 + HEAT + 2H2O 4NH3 + O2
Feedrates:
3 x (ppm O2 + Residual)
Control Limits:
0.1 ppm Residual N2H4 at Economizer Inlet
Attemperation / Desuperheating:
Yes

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Hydrazine
• Advantages:
– Doesn’t contribute to TDS
– True residual test
• Disadvantages:
– Poor reactivity with low temperature
– Expensive compared to Sulfite
– Suspect carcinogen
– Requires special handling / feed
equipment
– Decomposes to NH3, which can lead to
copper corrosion
Hydrazine

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Organic O2 Scavengers
• Pressure > 900 psig (60 bar)
• BFW used for superheat attemperation
• Condensing turbine present
• High-Purity Makeup (Demin./RO)
• Coordinated PO4 / pH control

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HYDROQUINONE
REACTION:
C6H6O2 + 1/2O2 H2O + C6H4O2
CONTROL LIMITS:
DISSOLVED OXYGEN TEST
IRON REDUCTION TEST
OH
OH

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OH
OH
OH
OH
+
+ O
O2
2 =
=
O
O
O
O
• DOES NOT CONTRIBUTE TO TDS
• FASTEST ORGANIC OXYGEN SCAVENGER
• REQUIRES NO SPECIAL HANDLING
• EXCELLENT FOR WET LAY-UP
• AVOIDS SULFUR CATALYST POISON
• NOT A LISTED CARCINOGENIC
HYDROQUINONE
ADVANTAGES

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Carbohydrazide
REACTION:
DECOMPOSITION REACTION:
CORTROL-OS-5613
RESIDUAL(0.3-0.5 ppm product)
N4H6CO + O2 2 N2 + 3H2O + CO2
N4H6CO + H2O + HEAT 2N2H4 + CO2
2N2H4 + HEAT + 2H2O 4NH3 + O2
H
H 3
3
N
N 2
2
-
- C
C
-
- N
N 2
2
H
H 3
3
O
O

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Carbohydrazide
Advantages
• Low/no cation conductivity
contribution
– Does not form LMW organic
acids
– CO2 contribute to non degassed
cationic conductivity
• Well-accepted in Industry
• Much safer than hydrazine

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Variables Influencing
Scavenger Reaction
• Time
• Temperature
• pH
• Catalyst

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pH and Temperature Recommendations
OXYGEN SCAVENGER
SULFITES
HYDRAZINE
HYDROQUINONE (HQ)
HYDROXYLAMINES (HA)
ASCORBIC ACID
CARBOHYDRAZIDE
*FOR EFFICIENT OXYGEN SCAVENGING
PERFORMANCE
MINIMUM TEMP*
80 OF (27 C)
190 OF (88 C)
80 OF (27 C)
>200 OF (> 93 C)
180 OF (82 C)
>200 oF(> 93 C)
MINIMUM pH*
>8.5
>8.5
>8.5
>8.5
>8.5
>8.5

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Monitoring
1) Primary sample point for oxygen testing
2) Sample point necessary for deaerator studies and for
troubleshooting oxygen intrusion through the pump
ECONOMIZER
1
2
Ideal
Point

59. MONITORING • pH
• Conductivity
• Hardness, silica
• Oxygen
• Corrosion
– metals analysis
– corrosion coupons

60. Millipore Iron Testing

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Feed Water and Condensate
System Treatment
• Ammonia
• Amines
• Condensate polishing

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Condensate Treatment
In The Condensate:
• Carbon Dioxide
H2CO3 H+ + HCO3-
CO2 + H2O H2CO3
pH DECREASES

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Feedwater Alkalinity
Is a Source of CO2 in Condensate
IN THE BOILER:
2HCO3
- CO3
= + H20 + CO2
CO3
= CO2 + 2OH-
STEAM
CO2
FEEDWATER
HCO3
-
CO3
=
OH-
BLOWDOWN

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Relative Corrosion Rate of
Copper Alloys and Carbon Steel vs pH
7 8 9 10
CORROSION
RATE
COPPER
CARBON
STEEL
pH

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Fundamental Amine
Characteristics
• Distribution Ratio
• Neutralizing Capacity
• Basicity
• Thermal Stability

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NEUTRALIZING AMINES
10
9
8
7
6
5 0 2 4 6 8 10 12 14 16
AMINE FEED (ppm)
CONDENSATE,
pH
R - NH2 + H2CO3 R - NH3
+ + HCO3
-
R - NH2 + H2O R - NH3
+ + OH-

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BASICITY
Morpholine
Ammonia
Ethanolamine
DEAE
MOPA
Cyclohexylamine
2
18
32
66
126
440
Neutralizing Basicity Constant

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Concentration in steam
Concentration in liquid
DR =
VAPOR
LIQUID
HIGH DISTRIBUTION
RATIO
LOW DISTRIBUTION
RATIO
DISTRIBUTION RATIOS

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DISTRIBUTION RATIOS
DR
AMINE 0 PSIG 200 PSIG 1000 PSIG
AMMONIA 10 7.1 3.6
CYCLOHEXYLAMINE 4.0 16.0 9.3
DEAE 1.7 4.5 3.4
MOPA 1.0 2.4 2.5
MORPHOLINE 0.4 1.6 1.0
ETHANOLAMINE 0.07 0.15 0.29
DIAMINE 0.45 1.9 2.7
CONTAMINANTS
CO2 5400 500 100

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Boiler Internal Treatment
& Steam Purity
• Coordinated PO4 /pH
• Steam purity

71. Deposit Formation
• Deposition rate increases with heat flux (Btu/Ft2)
• Reduces Heat Transfer
• Increases tube wall temperature
• Induces corrosion
• Ultimately - Tube failure

72. Effect of Deposition on Heat Transfer
500°F
500°F
Waterside
Waterside
600°F
600°F
Fireside
Fireside
800°F
800°F
Fireside
Fireside
500°F
500°F
Waterside
Waterside
Combustion
Combustion
Gases
Gases
Tube Metal
Tube Metal
Insulating
Insulating
Scale
Scale
Scaled Tube
Scaled Tube
Surface
Surface
Clean Tube
Clean Tube
Surface
Surface

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Cause and Effect Diagram for Boiler Deposition
Intermittent
Contamination
Deposition
Fouling
Condensate Hardness
Contamination
Chemical Underfeed
Poor NaZ Performance
Condensate Hydrocarbon
Contamination
Poor Blowdown Control
Intermittent
Contamination
Condensate Corrosion
Poor Blowdown Control
Chemical Underfeed
Poor Chemical Feed Control
Poor Storage Practices
Hardness Salts Iron
High Boiler Silica
Poor Separation
Equipment Performance
Hydrocarbon Contamination
Poor Blowdown Control
Rapid Load Swings
Header Pressure Swings
Hydrocarbon Superheater/Turbine Fouling
Monitoring Tools
1. On-Line Total Analyzer
2. Boiler Feedwater Inspection
3. Equipment Inspections
Monitoring Tools
1. Steam Purity Monitoring
2. Routine Boiler Testing
3. On-Line Sodium Analyzer
4. Equipment Inspections
5. Data Tracking
Monitoring Tools
1. Boiler Feedwater/ Condensate
Iron Monitoring
2. Turbidity Monitoring
3. Equipment Inspections
Monitoring Tools
1. Monitor NaZ Performance:
2. Monitoring Boiler Feedwater/
Condensate Hardness
3. On-Line Hardness Analyzers
4. Equipment Inspections
5. Routine Blowdown Testing
6. Data Tracking

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Coordinated Phosphate/pH Programs
z Used Primarily in high pressure boilers to
protect against caustic gouging
z Applicable for lower pressure boiler
systems on demin quality makeup
z Sodium (caustic) is primary feedwater
contaminant
z Iron may also be a problem polymers used
for iron control

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Coordinated PO4/pH Boiler Treatment
• To control boiler water pH......
• ......Create a buffer system
between PO4 and NaOH

76. Under-Deposit Corrosion

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High or Low Boiler Water pH
Corrodes Boiler Steel
1 2 3 4 5 6 7 8 9 10 11 12 13 14
RELATIVE
CORROSIVE
ATTACK
pH
8.5 pH 12.7 pH
SAFE RANGE

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Na: PO4 RATIO OUT OF CONTROL
EXCESS “SODIUM LEAKAGE”
Na2 HPO4 + 2NaOH Na3PO4 + NaOH + H2O
4Na + 1PO4
Na:PO4 = 4:1
Low DSP Fed “Free Caustic”

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PREVENTING CAUSTIC
CONCENTRATION
NaOH + Na2HPO4 Na3PO4 + H2O
Caustic Disodium
Phosphate
Trisodium
Phosphate Water

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2Na2 HPO4 + 2NaOH 2Na3PO4 + 2H2O
6Na + 2PO4
Na:PO4 = 3:1
“Exact” DSP Fed
Coordinated Phosphate/pH Control

81. Under-Deposit Neutralization

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C O O R D IN AT E D pH /P H O S P H ATE C O N TR O L
10.8
10.6
10.4
10.2
10.0
9.8
9.6
9.4
9.2
9.0
8.8
8.6
8.4
8.2
1.0 2 3 4 5 6 7 8 10 15 20 30 40 50 60
ppm O rthophosphate, as P O 4
``Free'' C austic
R egion
``C aptive''
Alkalinity
R egion
V ector
C ontrol
D iagram
C o ntrol Area
>2600 psi
C ontrol Area
2001-2500 psi
C o ntrol Area
1501-2000 psi
C o ntrol Area
901-1500 psi
C o ntrol Area
<900 psi
C O N T R O L AR E A
2501-2600 psi
M AX IM U M B O U N D AR Y 3.0:1 M O LA R R A T IO
2.6:1 N a/P O 4
2.7:1 N a/P O 4
2.8:1 N a/P O 4
C O N T R O L B O U N D AR Y
2.2:1 N a/P O 4
M O LAR R AT IO
B LO W D O W N M O N O -S O D IU M
P H O S P H ATE
D I-S O D IU M
P H O S P H ATE
T R I-S O D IU M
P H O S P H ATE
C A U S T IC
pH AT
25C

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Di-sodium PO4
Caustic
Blowdown
Tri-sodium PO4
Mono-sodium PO4
Caustic-Phosphate Equilibrium

84. Reality Check
Your 90 bar boiler has a pH 9.5 and PO4 of 30 ppm.
Boiler PO4 control range is 10 - 20 ppm
How should we respond?
[A]

85. Reality Check
Your readings for this 100 bar boiler are pH 10.2 and PO4 of 6. PO4
control range is 4 - 8 ppm.
What actions will put you back into control?
[A]

86. Acid Phosphate Corrosion
zAcid PO4 corrosion potential exists when
boiler water Na/PO4 ratio is less than 2.3
zSodium PO4 (Di or Mono) can react with
Magnetite or Iron to form Maricite (NaFePO4)
under high temperature (>300 C)

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Steam Purity
Importance of Steam Purity
z Protect Capital Investments, such
as:
– Superheaters
– Turbines
– Steam lines and valves
z Maintain Production
z Prevent Process Contamination

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Definitions • Steam Purity
Solid, liquid or vaporous
contamination in the steam
• Steam Quality
A measure of the moisture in
the steam

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Steam Purity
Guidelines • Turbine manufacturer (ppb
levels)
• Boiler manufacturer (ppm
levels)
• Industry professional
organizations
• Operations

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Turbine Manufacturers’ Steam Purity Limits
General
Electric
Westing
house
Allis
Chalmers
PARAMETER NORMAL 100 HR. 24 HR. NORMAL 2 WEEK 24 HR. NORMAL
Cation Cond.
uS/cm
0.2 0.5 1 0.3 0.3-0.5 0.5-1.1 0.1
Sodium, ppb 3 6 10 5 5-10 10-20 10
Chloride, ppb A A A 5 5-10 10-20 10
Silica, ppb A A A 10 10-20 20-50 10
Iron, ppb A A A 20 5
Copper, ppb A A A 2 1
Oxygen, ppb A A A 10 10-30 30-100 5
A - Governed by requirements of the steam-generator manufactureer

91. Steam Turbine - Problems
• Deposition
– Deposit thickness 0.1 mm reduces stage efficiency by
3%
• Surface Roughness
– Affects flow passage width
– Reduce stage efficiency
• LP Blade corrosion
– Stress corrosion cracking (NaOH, Cl)
– Pitting
– Erosion

92. Industrial Steam Turbines
Typical Sources of Impurities
Makeup Water
Demineralizers
Water Treatment
Chemicals
Process Chemicals
Corrosion Products
Condenser Leaks
Air In-Leakage
Chemical Cleaning
Water
and
Steam

93. STEAM PURITY
Steam Purity vs Steam Quality
• Steam purity is the solid, liquid, or vaporous contamination
in the steam
• Steam quality is the measurement of moisture in steam
Steam Purity Guidelines
• Turbine & Boiler Manufacturers
• Industry Professional Organizations
– (ASME, ABMA, EPRI, VGB, BS )
• Boiler Manufacturers
• Operations

94. Steam Purity
Guidelines
Normal Operation
Parameter ABB GE Westinghouse Mitsubishi
Na, ppb <10 <20 <10 <10
SiO2, ppb <20 <20 <20 <15
TotalFe, ppb <20 <20 <5
Cu, ppb <3 <2
Cl, ppb <15 <2
Cationic
Cond. us/cm <0.2 <0.2 <0.3 <0.2

95. Steam Purity Guidelines
Abnormal Operation (Westinghouse)
* Time refers to continuous time in the range and also to total time in a 12-month period in the
range
Parameter 2-week * 24-Hour * Immediate
Shut Down
Cation Cond.
us/cm
0.3 - 0.5 0.5 - 1.0 > 1.0
Na, ppb 10 - 20 20 - 35 > 35
SiO2, ppb 20 - 40 40 - 80 > 80
Cl, ppb 15 -30 30 - 50 > 50
SO4, ppb 15 -30 30 - 50 > 50

96. CARRYOVER: MECHANICAL CAUSES
• STEAM SEPARATION EQUIPMENT
• STEAM DRUM LEVEL
• STEAM LOAD
• OVERFIRING

97. CARRYOVER:
CHEMICAL CAUSES
• FOAMING
–TDS
–Alkalinity
–Organics/ Polymer Overfeeding
–Antifoam
• SELECTIVE VAPOROUS CARRYOVER (GOVERNED BY DRUM
pH, PRESSURE AND TEMPERATURE
–Silica
–Others - Cl, SO4, Fe

98. ATTEMPERATION
WATER
• FEEDWATER
–Quality of Feed water
–Chemical Treatment
• SWEET WATER CONDENSER
–Source of Coolant
–Purity of Steam Source
• CONDENSATE

99. MONITORING STEAM PURITY
SODIUM
• On Line Analyzer
• Isokinetic Sampling
• Bottle Study (Na free
bottles)
• Saturated Steam

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Boiler Storage
• Most oxygen corrosion occurs or is
initiated when boiler is off-line (wet
storage)
• Key to Success - Alkaline & oxygen-free
during wet storage

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• Dry Storage with a desiccant is
recommended for long-term storage
• What constitutes ‘long-term’?
– Off-season storage
– Rule-of-thumb: Normally recommend
dry storage if lay-up will be >1 month
and boiler will not be needed on short
notice
Boiler Storage

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• Wet storage is recommended when:
– Boiler is required for emergency
stand-by or on short notice
– Capacity required to meet peak
demand
– Unit will be out-of-service for
< 1 month
Boiler Storage

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Wet Storage Methods
1. Volatile Chemicals
2. Sulfite & Caustic
3. Cascade lay-up / Hot standby
4. Dry lay-up with desiccant

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• Add chemicals to fill water as it is pumped
into boiler
• Fire boiler moderately after chemical
addition to circulate & distribute or utilize
external circulation pump
– Always follow boiler manufacturers
recommendations for firing the boiler
• Adjust pH/alkalinity with amine or caustic
consistent with the lay-up chemical being
used.
General guidelines for wet
storage with chemicals

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• Weekly testing during wet storage
– Measure pH/Alkalinity
– Test dissolved oxygen and/or
scavenger residual
– Maintain dissolved oxygen level below
10 ppb
– Supplement scavenger/amine as
required
• Preventing oxygen ingress during storage:
– Connect surge tank (drum) filled with
lay-up solution to upper vent
– Alternative - 5 psig (0.34 bar) nitrogen
‘cap’
General guidelines for wet storage of high-pressure
boilers with chemicals

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Volatile Chemicals
• Required when:
– Above 900 psig (60 bar)
– Non-drainable superheaters
– Turbines
– High-purity make-up
• Sulfite is NOT suitable

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• Acceptable water for preparation of high-
pressure boiler lay-up solutions:
– Good-quality demineralized H2O
– Good quality condensate (no solids)
– No softened-quality, RO or raw water
with appreciable TDS
• Add chemicals to fill water as it is pumped
into boiler
Volatile Chemicals

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Suitable volatile
oxygen scavengers
• Hydroquinone
– Fastest reaction with oxygen at
ambient temp
– Must use neutralizing amine with HQ
– Important - Amine MUST be
compatible
with HQ (or will develop sludge):
• Hydroxylamines
– Most volatile & compatible with
amines

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Suitable volatile
oxygen scavengers
• Hydrazine - 200 ppm as N2H4
– Excellent passivator at > 200 ppm as
N2H4, BUT:
– Not recommended - Safety hazard!
– Amine is not typically required
• Ascorbic acid - Not recommended:
– Poor thermal stability
– Acidic decomposition products
– Non-volatile

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• Special lay-up product - CorTrol OS7700
• HQ plus special low-volatility amine
package
• Avoids low pH excursions on re-start
• Feedrate: 2000 ppm product
– 4000 ppm in new systems (non-
passivated)
– Maintain pH above 10.5 throughout
Volatile Chemicals

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• Drain boiler
• Hot air/heat to remove all moisture
• Use desiccant (with color indicator)
– Silica gel
– Quick lime
– Activated alumina
Dry Lay
Dry Lay-
-up with Desiccant
up with Desiccant (Long
(Long-
-term
term
storage)
storage)

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PRESENT TREATMENT PROGRAM AT HAZIRA
• CORTROL-5613-OXYGEN SCAVENGER
– FEED RATE 0.5-1.0 PPM
– RESIDUAL MONITORING.
• STEAMATE-NA8590
– CONDENSATE TREATMENT
– LOW DR AMINE
• TRI SODIUM PHOSPHATE
– FOR pH/PO4 coordination
• AMMONIA
– FEED WATER & STEAM pH CONTROL

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Thank You