Boiler Water Training

Infrastructure Water & Process Technologies
More Proof. More Proof. More Power. More Power.
Boiler Technical Training At Reliance Industries Limited Hazira Manufacturing Division

K S Rajan
February 26, 2008
RIL-Hazira/BWT-Technical Training GEWPT- Confidential Material
More Proof. More Power.
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
Basics & Interpretation of Water Analysis
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
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/kgdeg C Universal solvent - dissolves most substances to some extent
Impurities found in Water
3 Categories
SUSPENDED SOLIDS (Silt)
DISSOLVED SOLIDS (Minerals) DISSOLVED GASES
Where do these things come from?

Infrastructure Hydrologic&Cycle Technologies Water Process

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 (CO32-), Sulfate (SO42-), Chlorides (Cl-), Oxides (O2-), Hydroxides (OH-)
Water Impurities
Impurity
Suspended Solids Silt, Iron, Microbiogical Dissolved Solids Minerals, Organics Dissolved Gases O2, CO2, NH3
Concern
Fouling Erosion Underdeposit corrosion Scaling Corrosion Pitting General Corrosion Corrosion products
Removal
Clarification Filtration Ion Exchange Reverse Osmosis Evaporation Deaeration Steam Stripping
Dissolved Solids
Cations
Temporary Hardness Permanent Hardness
Anions
HCO3possibly OH- & CO3-ClF-
Ca++
Mg++
Total Alkalinity
Na+ K+ NH4+
NO3- PO4 --SO4--
Mineral Acidity
SiO2, possibly free CO2 Organic acids
Dissolved Solids Commonly Found in Water
Cation
Calcium
Anion
Bicarbonate Sulfate Bicarbonate Sulfate Bicarbonate Sulfate Chloride Oxide Bicarbonate Hydroxide Sulfate
Chemical Name
Ca(HCO3)2 CaSO4 Mg(HCO3)2 MgSO4 NaHCO3 Na2SO4 NaCl SiO2 Fe(HCO3)2 Fe(OH)3 FeSO4
Magnesium
Sodium
Silica Iron
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
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, microorganisms
Typical Water Analysis
Infrastructure Water & Process Technologies Value

7.3 150 0 20 15 10 20 15 5 0.05 1.5 12 <0.05 4 50 20 3 1
Parameter
Conductivity S/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 RIL-Hazira/BWT-Technical Training TOC, as C, ppm
GEWPT- Confidential Material
pH
Special Ions
pH
Hydrogen, H+ Hydroxide, OH-
Alkalinity Bicarbonate, HCO3 Carbonate, CO3- Hydroxide, OH-
pH
Hydrogen Ion Concentration Logarithmic Scale pH = -log [H+] Unit change in log scale
How Does pH Apply to Us?
pH < 7: Acidic (corrosion) pH > 7: Alkaline (deposition)
Alkalinity Relationships
M-Alkalinity = Total Titration to pH = 4.3 Sum of: HCO3- + CO3- + OHP-Alkalinity = OH- + 1/2 CO3 Titration to pH 8.3 OH-Alkalinity = 2P - M or titration Neutral barium chloride precipitates CO3-
Conductivity
Inverse of Resistance [mho] Measure of concentration of ions in solution
Types of Solubility
Normal: Increases with Temperature

Table Salt (NaCl) Sugar
Retrograde: Decreases with Temperature

Calcium Carbonate Calcium Phosphate
How Do We Quantify What Is in the Water?
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
Mg as CaCO3
Magnesium expressed as its Equivalent weight in Calcium Carbonate

100 (MW CaCO3) = 4.1 24 (MW Mg)
Different Conventions We use ppm as CaCO3 ppm as substance factors Ca 50 2.5 Mg 20 4.1
ppm as CaCO3
125 82
Boiler Descriptions Boiler Descriptions
FIRETUBE BOILERS
ADVANTAGES
High load swing capacity Ease of repair Low space requirement Self contained package Relatively low cost Ease of installation
DISADVANTAGES
Low pressure Capacity limit Usually no superheater Usually no economizer Usually low efficiency One fuel at a time FOUR-PASS FIRETUBE BOILER
WATERTUBE BOILERS
Economizer Steam drum Mud Drum Headers Boiler Bank Downcomers - Risers Waterwalls Screen tubes Arches Floor tubes Roof tubes Superheater Air Heater
Typical Parts of a Water Tube Boiler Includes:
WATERTUBE BOILERS
RISERS DOWNCOMERS
STEAM DRUM
SUPERHEATER SCREEN TUBES
ECONOMIZER WATER WALLS
AIR HEATER
MUD DRUM
Coal
140-150 C
To stack Lower Water Walls Header
BOILER DESIGN
Comparison - Watertube vs. Firetube:

Water Tube
Steam
Feedwater
Steam Drum
Fire Tube
CBD
Water
Risers
Flue Gases
Flue Gases
Mud Drum
Downcomers IBD
WATERTUBE BOILERS
Low to super critical pressure Virtually unlimited capacity Typically high efficiency Superheaters Economizers Multiple fuels Drum or once-through Package or field-erected
ADVANTAGES
WATERTUBE BOILER: A-TYPE
DISADVANTAGES
High Cost Require Large Space Usually require higher quality feedwater Sensitive to low load operation
Risers
Steam Exit Drum
W BF
Downcomers
Burner
Flue Gas Path
Sidewall Problem Area
Steam Drum
D-Frame Package Boiler
Downcomers
Furnace Wall Tubes

Risers
Infrastructure Water & Process Technologies Babcock & Wilcox

Coal FiredMore Power. Boiler
More Proof.
Hot Reheat HP Turbine HP SH Steam Sat Steam
Infrastructure Power Utility Boiler Simplified Flow Diagram Water & Process Technologies
Condenser IP Turbine B&W Boiler BD Cold Reheat LP Heaters Cond Polisher LP Turbine
MB MU
HP Heaters Deaerator BFW
CAUSE AND EFFECT DIAGRAM FOR BOILER PROBLEMS

POOR pH CONTROL POOR CHEMICAL FEED CONTROL INADEQUATE BLOWDOWN CONTROL OXYGEN IN-LEAKAGE DOWNTIME CORROSION SCAVENGER UNDERFEED POOR EXTERNAL TREATMENT OXYGEN PITTING
MECHANICAL DEAERATOR PERFORMANCE
POOR BOILER FEEDWATER QUALITY CONDENSATE CONTAMINATION
DOWNTIME CORROSION
POOR BOILER FEEDWATER QUALITY CONDENSATE CONTAMINATION POOR EXTERNAL TREATMENT INADEQUATE BLOWDOWN CONTROL DEPOSITION CONCENTRATING MECHANISM STRESSED AREA
BOILER CORROSION
POOR CHEMICAL FEED CONTROL EMBRITTLING WATER CHARACTERISTICS
STRESS CORROSION CRACKING
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
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
Steam, Feed Water & Blowdown Relationships
% Blowdown = 100 / FW Cycles

% BD at 20 FW cycles = 100/20 = 5%
Feedwater = Steam X [Cycles / (Cycles 1)]

FW = 100 MM ppy steam X [20 / (20 1)] = 105.3
Feedwater = Steam + Blowdown BD = FW ST = (105.3 100) MM ppy = 5.3 MM ppy Feedwater = Make-up + Condensate
Oxygen Control
Deaeration Chemical treatment
Corrosion of Iron by Oxygen
O2 Fe(OH)3 Fe2+
OHWATER
O2
ELECTRON FLOW
ANODE
ANODE REACTION Fe. = Fe++ 2eMECHANISM

CATHODE
CATHODE REACTION 1/2 O2 + H2O + 2e- = 20H-
Iron Is Oxidized on the Surface (Anode) - Metal Loss Oxygen Is Reduced (Cathode)
Oxygen Corrosion
Corrosion Rate Doubles With Every 10 C Increase in Water Temperature Metal Loss is low Localized attack Pit Formation Rapid Failure
Rapid Perforation ~ Equipment Failure
Oxygen Guidelines

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

Solid
Sodium Bisulfite Sodium Sulfite Non-Solids Hydrazine Hydroquinone Diethylhydroxlamine (DEHA) CARBOHYDRAZIDE ASCORBIC ACID
RECOMMENDED SULFITE CONTROL LIMITS
Residual (ppm SO3-) 30 - 60 10 - 20
Pressure < 40 bar 40 - 60 bar
ATTEMPERATION / DESUPERHEATING: NO
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
Infrastructure Hydrazine Water & Process Technologies
Hydrazine
Advantages: Doesnt 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
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

HYDROQUINONE REACTION: C6H6O2 + 1/2O2
OH
H2O + C6H4O2
CONTROL LIMITS:
DISSOLVED OXYGEN TEST IRON REDUCTION TEST
OH
HYDROQUINONE
ADVANTAGES
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
OH
+ O2 =
OH
Carbohydrazide
REACTION:
N4H6CO + O2

O N2 3 -C
-N
H3 2
2 N2
+ 3H2O + CO2
DECOMPOSITION REACTION:
N4H6CO + H2O + HEAT 2N2H4 + HEAT + 2H2O 2N2H4 + CO2 4NH3 + O2
CORTROL-OS-5613 RESIDUAL(0.3-0.5 ppm product)
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
Variables Influencing Scavenger Reaction

Time Temperature pH Catalyst
pH and Temperature Recommendations

OXYGEN SCAVENGER SULFITES HYDRAZINE HYDROQUINONE (HQ) HYDROXYLAMINES (HA) ASCORBIC ACID CARBOHYDRAZIDE
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
*FOR EFFICIENT OXYGEN SCAVENGING PERFORMANCE

Monitoring
1 ECONOMIZER 2
Ideal Point
1) 2)
Primary sample point for oxygen testing Sample point necessary for deaerator studies and for troubleshooting oxygen intrusion through the pump
MONITORING
pH Conductivity Hardness, silica Oxygen Corrosion metals analysis corrosion coupons
Millipore Iron Testing
Feed Water and Condensate System Treatment

Ammonia Amines Condensate polishing
Condensate Treatment
In The Condensate: Carbon Dioxide
CO2 + H2O H2CO3 H2CO3 H+ + HCO3-
pH DECREASES
Feedwater Alkalinity Is a Source of CO2 in Condensate

IN THE BOILER:
2HCO3CO3=
CO3= + H20 + CO2 CO2 + 2OHSTEAM CO2
FEEDWATER HCO3CO3=
OH-
BLOWDOWN
Relative Corrosion Rate of Copper Alloys and Carbon Steel vs pH
CARBON STEEL CORROSION RATE COPPER
7
8 pH
10
Fundamental Amine Characteristics

Distribution Ratio Neutralizing Capacity Basicity Thermal Stability
NEUTRALIZING AMINES
R - NH2 + H2CO3 R - NH2 + H2O
R - NH3+ + HCO3R - NH3+ + OH-
10
CONDENSATE, pH
6 0 2 4 6 8 10 AMINE FEED (ppm) 12 14 16
BASICITY
Neutralizing Basicity Constant Morpholine Ammonia Ethanolamine DEAE MOPA Cyclohexylamine 2 18 32 66 126 440
DISTRIBUTION RATIOS
DR = Concentration in steam Concentration in liquid
VAPOR LIQUID HIGH DISTRIBUTION RATIO

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

Coordinated PO4 /pH Steam purity
Deposit Formation
Deposition rate increases with heat flux (Btu/Ft2) Reduces Heat Transfer Increases tube wall temperature Induces corrosion Ultimately - Tube failure
Effect of Deposition on Heat Transfer

Tube Metal
800F Fireside Combustion Gases
Insulating Scale
600F Fireside 500F Waterside 500F Waterside
Scaled Tube Surface
Clean Tube Surface
Cause and Effect Diagram for Boiler Deposition Infrastructure

Water & Process Technologies
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
Monitoring Tools 1. Boiler Feedwater/ Condensate Iron Monitoring 2. Turbidity Monitoring 3. Equipment Inspections
Hardness Salts Intermittent Contamination Condensate Hardness Contamination Poor NaZ Performance Chemical Underfeed Poor Blowdown Control Intermittent Contamination Condensate Corrosion
Iron
Chemical Underfeed Poor Blowdown Control Poor Storage Practices

Deposition Fouling
Poor Chemical Feed Control Condensate Hydrocarbon Contamination High Boiler Silica Poor Separation Equipment Performance Rapid Load Swings Hydrocarbon Contamination Poor Blowdown Control Hydrocarbon
Monitoring Tools 1. On-Line Total Analyzer 2. Boiler Feedwater Inspection 3. Equipment Inspections
Header Pressure Swings
Superheater/Turbine Fouling
Monitoring Tools 1. Steam Purity Monitoring 2. Routine Boiler Testing 3. On-Line Sodium Analyzer 4. Equipment Inspections 5. Data Tracking
Coordinated Phosphate/pH Programs
Used Primarily in high pressure boilers to protect against caustic gouging Applicable for lower pressure boiler systems on demin quality makeup Sodium (caustic) is primary feedwater contaminant Iron may also be a problem polymers used for iron control
Coordinated PO4/pH Boiler Treatment

To control boiler water pH...... ......Create a buffer system between PO4 and NaOH
Under-Deposit Corrosion
High or Low Boiler Water pH Corrodes Boiler Steel
RELATIVE CORROSIVE ATTACK
8.5 pH
12.7 pH SAFE RANGE
10 11 12 13 14
pH
Na: PO4 RATIO OUT OF CONTROL EXCESS SODIUM LEAKAGE
Na2 HPO4 + 2NaOH Low DSP Fed
Na3PO4 + NaOH + H2O Free Caustic
4Na + 1PO4 Na:PO4 = 4:1
PREVENTING CAUSTIC CONCENTRATION
NaOH + Na2HPO4
Caustic Disodium Phosphate
Na3PO4 + H2O
Trisodium Phosphate Water
Coordinated Phosphate/pH Control
2Na2 HPO4 + 2NaOH Exact DSP Fed 6Na + 2PO4 Na:PO4 = 3:1
2Na3PO4 + 2H2O
Under-Deposit Neutralization

C O O R D IN A T E D p H /P H O S P H A T E C O N T R O L
1 0 .8 1 0 .6 1 0 .4 1 0 .2 1 0 .0 9 .8 2 .7 :1 N a /P O 4
C o n tr o l A r e a
M A X IM U M B O U N D A R Y 3 .0 :1 M O L A R R A T IO
``F re e '' C a u s tic R e g io n 2 .8 :1 N a /P O 4
<900 psi
9 0 1 -1 5 0 0 p s i
`` C a p tiv e ''
A lk a lin ity R e g io n
pH AT 25C
9 .6 9 .4 9 .2 9 .0 8 .8 8 .6 8 .4 8 .2 1 .0 2 .6 :1 N a /P O 4
1 5 0 1 -2 0 0 0 p s i
C A U S T IC
T R I-S O D IU M PHO SPHATE D I-S O D IU M PHO SPHATE M O N O -S O D IU M PHO SPHATE
C o n tr o l A r e a V e c to r 2 0 0 1 -2 5 0 0 p s i C O N T R O L B O U N D A R Y C o n tro l
C o n tr o l A r e a >2600 psi
2 .2 :1 N a /P O 4 M O L A R R A T IO
D ia g ra m
BLOW DOW N
CO NTRO L AR EA 2 5 0 1 -2 6 0 0 p s i 2 3 4 5 6 7 8 10 15 20 30
40
50
60
p p m O rth o p h o s p h a te , a s P O 4
Caustic-Phosphate Equilibrium
Caustic
Tri-sodium PO4
Di-sodium PO4 Blowdown Mono-sodium PO4

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]
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]
Acid Phosphate Corrosion
Acid PO4 corrosion potential exists when boiler water Na/PO4 ratio is less than 2.3
Sodium PO4 (Di or Mono) can react with Magnetite or Iron to form Maricite (NaFePO4) under high temperature (>300 C)
Steam Purity
Importance of Steam Purity
Protect Capital Investments, such as: Superheaters Turbines Steam lines and valves Maintain Production Prevent Process Contamination
Definitions
Steam Purity Solid, liquid or vaporous contamination in the steam Steam Quality A measure of the moisture in the steam
Steam Purity Guidelines
Turbine manufacturer (ppb levels) Boiler manufacturer (ppm levels) Industry professional organizations Operations

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

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

Turbine & Boiler Manufacturers Industry Professional Organizations
(ASME, ABMA, EPRI, VGB, BS )

Boiler Manufacturers Operations

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

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 Cation Cond. us/cm Na, ppb SiO 2, ppb Cl, ppb SO 4, ppb
2-week *
24-Hour *
Immediate Shut Down
0.3 - 0.5 10 - 20 20 - 40 15 -30 15 -30
0.5 - 1.0 20 - 35 40 - 80 30 - 50 30 - 50
> 1.0 > 35 > 80 > 50 > 50
CARRYOVER: MECHANICAL CAUSES
STEAM SEPARATION EQUIPMENT STEAM DRUM LEVEL STEAM LOAD OVERFIRING
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
ATTEMPERATION WATER
FEEDWATER
Quality of Feed water Chemical Treatment

SWEET WATER CONDENSER
Source of Coolant Purity of Steam Source

CONDENSATE
MONITORING STEAM PURITY
SODIUM
On Line Analyzer Isokinetic Sampling Bottle Study (Na free
bottles)
Saturated Steam
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
Boiler Storage
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
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
Wet Storage Methods

1. Volatile Chemicals 2. Sulfite & Caustic 3. Cascade lay-up / Hot standby 4. Dry lay-up with desiccant
General guidelines for wet storage with chemicals
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 of high-pressure boilers with chemicals
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
Volatile Chemicals
Required when: Above 900 psig (60 bar) Non-drainable superheaters Turbines High-purity make-up Sulfite is NOT suitable
Volatile Chemicals
Acceptable water for preparation of highpressure 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
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
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
Volatile Chemicals
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 (nonpassivated) Maintain pH above 10.5 throughout
Dry Lay-up with Desiccant (Long-term storage)

Drain boiler
Hot air/heat to remove all moisture Use desiccant (with color indicator) Silica gel Quick lime Activated alumina
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
Thank You

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Infrastructure Water & Process Technologies

More Proof. More Proof. More Power. More Power.

Boiler Technical Training At Reliance Industries Limited Hazira Manufacturing Division

February 26, 2008

RIL-Hazira/BWT-Technical Training GEWPT- Confidential Material

Infrastructure Water & Process Technologies

More Proof. More Power.

BOILER WATER TREATMENT

Infrastructure Water & Process Technologies

More Proof. More Power.

Basics & Interpretation of Water Analysis

RIL-Hazira/BWT-Technical Training GEWPT- Confidential Material

Infrastructure Water & Process Technologies

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RIL-Hazira/BWT-Technical Training GEWPT- Confidential Material

Infrastructure Water & Process Technologies

More Proof. More Power.

RIL-Hazira/BWT-Technical Training GEWPT- Confidential Material

Infrastructure Water & Process Technologies

More Proof. More Power.

Impurities found in Water

SUSPENDED SOLIDS (Silt)

DISSOLVED SOLIDS (Minerals) DISSOLVED GASES

Where do these things come from?

Infrastructure Water & Process Technologies

More Proof. More Power.

RIL-Hazira/BWT-Technical Training GEWPT- Confidential Material

Infrastructure Hydrologic&Cycle Technologies Water Process

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RIL-Hazira/BWT-Technical Training GEWPT- Confidential Material

Infrastructure Water & Process Technologies

More Proof. More Power.

RIL-Hazira/BWT-Technical Training GEWPT- Confidential Material

Infrastructure Water & Process Technologies

More Proof. More Power.

RIL-Hazira/BWT-Technical Training GEWPT- Confidential Material

Infrastructure Water & Process Technologies

Impurities found in Water

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RIL-Hazira/BWT-Technical Training GEWPT- Confidential Material

Infrastructure Water & Process Technologies

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RIL-Hazira/BWT-Technical Training GEWPT- Confidential Material

NO3- PO4 --SO4--

SiO2, possibly free CO2 Organic acids

Dissolved Solids Commonly Found in Water

Infrastructure Water & Process Technologies

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Factors Affecting Solubility

Infrastructure Water & Process Technologies

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RIL-Hazira/BWT-Technical Training GEWPT- Confidential Material

Infrastructure Water & Process Technologies

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Impurities found in Water

RIL-Hazira/BWT-Technical Training GEWPT- Confidential Material

Typical Water Analysis

Infrastructure Water & Process Technologies Value

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Infrastructure Water & Process Technologies

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Hydrogen, H+ Hydroxide, OH-

Alkalinity Bicarbonate, HCO3 Carbonate, CO3- Hydroxide, OH-