PART II

PART-II
A presentation by,
B.K.Patnaik
Indian Institute for Production Management

H2O
1

Water
z
z
z
z

Water is a chemical mixture of Hydrogen and

Oxygen.
yg
It is p
plentifully
y available on our earth.
Water is the main requirement of a boiler.
It is converted into steam by application of heat.
Water as such is not suitable to be used in a
boiler as it contains lot of impurities, which are
harmful
harmful.
Water has to be treated properly in a water
treatment plant before it is fed to a boiler.
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Water
z

Impure water may have either

a)
z b)
z

Suspended Impurities
Dissolved Impurities

Suspended impurities can be separated

out by Coagulation,
Coagulation Filtration etc.
etc
z Dissolved Impurities can only be removed
by Heating or by Chemical Treatment.
z

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Impurities of Water

Impurities in water can be classified into :

1) SCALE FORMING SUBSTANCES :
z Carbonates and Sulphates of Calcium and
M
Magnesium.
i
2) SCUM FORMING SUBSTANCES :
z a) Minerals i.e. Soda in form of
z
Carbonates, Chlorides, Sulphates.
z b) Organic i.e. Water containing sewerages.
z 3) SLUDGE FORMING SUBSTANCES :
z Usually Solid Minerals carried in suspension.
4) CORROSION FORMING SUBSTANCES :
z Free
Acids, Oxygen,
CO2, Chioride of
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Management
Magnesium etc.

Common Impurities in Water and their effects

Sl.
No

Chemical name

Symbol

Calcium Carbonate

CaCo3

Calcium Bicarbonates

Ca(Hco3)2

Calcium Sulphate.

CaSo4

Calcium Chloride

CaCl2

Magnesium Carbonate

MgCo3

Magnesium Bicarbonates Mg (Hco3)2

Magnesium Sulphate.

MgSo4

Magnesium Chloride

MgCl2

Common
name
Chalk

Effect
Soft scale
Soft scale

Gypsum

Hard scale
Corrosion

Magnesite Soft scale

Corrosion
Epson salt Corrosion
Corrosion
(Continued)

Common Impurities in Water and their effects

Sl.N
o.

Chemical name

Symbol

Sodium Carbonate

Na2Co3

10
11

Common name

Effect

Washing Soda

Alkalinity

Sodium Bicarbonates NaHco3

Baking Soda

Priming

Sodium Sulphate.

Na2So4

Glauber Salt

Alkalinity

12

Sodium Chloride

NaCl

Common Salt

Electrolysis

13

Sodium Hydroxide

NaOH

Caustic Soda

Embrittlemen

14

Silicon Oxide

Sio2

Silica

Hard scale

Boiler Water Treatment

As we know that Water available from Rivers,

Ponds or Wells or even Drinking water
mains, are not suitable to be used as Boiler
Feed, it is essential that it has to be treated
mechanically or chemically, before it is
allowed to enter into the Boiler.
Boiler water treatment can be either EXTERNAL
or INTERNAL.

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External Treatment

In the External treatment, water is made free from

suspended as well as solube impurities.
The RAW water is first passed through GRAVEL
FILTERS containing different sizes of Gravels which
retain almost all the Suspended impurities. These
Gravel Filters are reactivated or cleaned by back
washing with water and Compressed Air under
pressure.
Clean water from the Gravel filters are then passed
through the Base Exchangers where Hardness is
removed.
S ft water
Soft
t
i kept
is
k t in
i the
th Storage
St
t k called
tank
ll d FEED
TANK where it is heated to almost Boiling point to
drive out the Dissolved Oxygen.
In High Pressure Boilers, water is Softened as well as
Demineralised
by
passing
through
CATION
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FILTERS, DEGASIFIERS
ANION
FILTERS.
9
Management

Water Softning
SOFT WATER
z Water is called SOFT when it produce
enough lather with soap. It contains
little or no Scale forming impurities.
impurities
Soft water is suitable to be used as
Boiler feed.
z

HARD WATER
z Water is said to be HARD when it does
not produce lather with soap solution
easily. It contains excessive scale
forming impurities such as Carbonates
of Calcium and Magnesium.
z

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Water Softning
z

HARDNESS is expressed in Parts

per Million (ppm) or in Grains Per
Gallon.

1
z1
z

ppm = 0.058 Gr/Gallon

Gr/Gln. = 17.1 ppm.

Hardness can be of two types.

types
z1
TEMPORARY HARDNESS.
z2
PERMANENT HARDNESS
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Water Softning

TEMPORARY HARDNESS
z Water containing Bicarbonate hardness
is said to have Temporary hardness, as
this can be removed by heating. When
water is heated to its boiling point,
Bicarbonate hardness is separated out
and is precipitated.
PERMANENT HARDNESS
z Water
containing soluble salts of
Calcium and Magnesium (Other than
Bicarbonates)
is
said
to
have
permanent hardness. These impurities
cannot be removed just by heating. But
they form scale deposits when heated
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to more than Indian
300F
in the Boiler.
12
Management

Removal of Permanent
Hardness
1) CLARKS METHOD : By adding Washing Soda

when Calcium and Magnesium salts are

precipitated as insoluble carbonates.
2) BASE EXCHANGER PROCESS : In this process
Hard water is passed through a bed containing a
Chemical Compound like ZEOLITE which
consists of a compound (SODIUM ALLUMINIUM
ORTHOSILICATE) or Synthetic Ion Exchange
Resins.
While passing through the resins the Ca & Mg
ions of water are replaced by harmless Sodium
ions which DONOT cause any scales in the
ions,
Boiler.
Calcium Carbonate + Sodium Zeolite
Calcium Zeolite & sodium carbonate similarly,
Magnesium Carbonate + Sodium Zeolite
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Magnesium Zeolite & Sodium
Carbonate.

Base Exchanger Method

Thus it is seen that the Ca & Mg
Carbonates are changed into harmless
Sodium Carbonates.
Carbonates
When all the Sodium ions of these resins
are exchanged, it does not have any
more capacity to remove hardness. At
this stage, it is said to be EXHAUSTED.
CaCo3 + 2Naz CaZ2 + Na2Co3
MgCo3 + 2Naz MgZ2 + Na2Co3

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Low Pressure boiler

Water treatment
z

Base Exchanger system is employed for

l
low
pressure b
boiler
il water
t ttreatment.
t
t

Gravel

Gravel

filter

filter

BASE
Exchan
ger

BASE
Exchan
ger

SOFT
WATER
TANK

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BASE EXCHANGER
CHEMICAL REACTIONS
z

Base exchanger Resins are Sodium

Zeolite resins. (NaZ)
Co3
Ca Co3
Mg So4 + NaZ = Ca/ Mg Z+Na So4
Cl2

Cl2

Regeneration with common salt.

Ca/ Mg Z + NaCl = NaZ +Ca/Mg Cl2
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Layout of D M Water treatment plant.

Raw
water
ater
ALUM
pump Reaction

tank

DM
WATER
TANK

Gravel

Gravel

filter

filter

Mixed

Mixed

bed

bed

filter

filter

Cat ion
Cat-ion

Cat ion
Cat-ion

filter

filter

Degasifier

Anion

Anion

filter

filter

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DM WATER ION EXCHANGE PROCESS

Cat-ion and Anion exchangers enable to

remove all soluble mineral salts from water.

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CATION EXCHANGE PROCESS

CAT-ION resins are synthetic polymers containing Hydrogen
Ions.
Ions
Ca/Mg/Na (HCO3)2
Ca
CO3
Ca/Mg/Na So4
+ 2HR = Mg R2+H2 SO4
Ca/Mg/Na Cl2
Na
Cl2
Regeneration with HCl or H2SO4
Ca
Ca
Mg R2+ H2So4 = 2HR + Mg So4
Na
Na

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ANION EXCHANGE PROCESS

ANION resins are synthetic polymers containing Hydroxyl
Ions.
Ions
CO3
CO3
H2 SO4 + 2R(OH) = R2 SO4 + 2H2O
Cl2
CFl2
Regeneration with NaOH
CO3
CO3
R2 SO4 + 2NaOH = 2R(OH) + Na2 So4
Cl2
Cl2

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10

De Mineralized water

High pressure boilers, require feed water of highest

purity which can only be achieved by the
production of Demineralized
water instead of
ordinary soft water available from Conventional
Base exchangers.
g
In this process, Raw water after filtering through
pressure filters, is passed through CATION
FILTERS, DEGASIFIERS, ANION FILTERS and
MIXED BED FILTERS to get Dematerialized water
(DM water).
Cation filters are regenerated with Hydrochloric
acid/Sulphuric acid.
acid
Similarly, Anion filters are reactivated by Alkalies.
Degasifiers help to remove dissolved gases like Co2 and
free Oxygen.
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Internal Treatment

Since, even small amount of Dissolved or Suspended

Impurities can create problems in the Boiler,
Internal
Chemical
Treatment
is
necessary
regardless of how best the Feed Water is treated
y,
Externally,
Complete Boiler Water Treatment Programme includes
1) Chemicals to react with feed water hardness.
2) Natural or Synthetic Sludge Conditioners to prevent
suspended solids from sticking to the boiler metal.
3) Oxygen Scavengers to prevent Corrosion.
4) Chemical Anti Foams to prevent Carryover.
5) Chemicals to maintain enough Alkalinity in the
boiler water to prevent corrosion.
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11

Internal Treatment

The following Chemicals take care of the

above mentioned impurities.
i) PHOSPHATES
ii) SYNTHETIC CHEMICALS
iii) SODIUM SULPHITES or HYDRAZINE

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Internal Treatment for Hardness

Bi Carbonates of Calcium and Magnesium break into
Carbonates at the boiler temperature. Since the
Carbonates
are
relatively
Insoluble,
they
precipitate.
PHOSPHATES in the form of Hexa Meta phosphate,
TriSodium Phosphate, Poly Phosphates or Chelate
are added to take care of Hardness.
The Sodium Phosphates react with Calcium Carbonates
to
form
Calcium
Phosphates
and
Sodium
Carbonates. In presence of sufficient Hydroxide
Alkalinity Magnesium Carbonate will precipitate as
Alkalinity,
Magnesium Hydroxide. Magnesium carbonate also
reacts with any Silica present to form Magnesium
Silicate. These precipitated minerals like Calcium
Phosphate, Magnesium Hydroxide and Magnesium
Silicate form SLUDGE,
which are removed by Blow
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Management
down.

12

Internal Treatment for Sludge

SLUDGE CONDITIONERS
Sludge
Sl
d
f
formed
d by
b Chemical
Ch
i l reaction
i
should
h ld not
be allowed to stick to the metal surface and
hence Natural Organic or Synthetic Polymer
Sludge Conditioners are dosed in the boiler
water. They help in forming these sludge
into Anti Sticking compounds and are
removed out by Blow down.

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Internal Treatment for Corrosion

z

Oxygen and Carbon Dioxide present in the boiler

water cause corrosion. Carbon Dioxide with Oxygen
and Water form Carbonic Acid and is highly
corrosive It causes localized pitting on the metal
corrosive.
surface.
Feed water heating in the Feed Tank removes
almost all the dissolved Oxygen. But very small
amount of Oxygen still pass into the boiler.
Oxygen Scavengers like Sodium Sulphite or
Hydrazine are the common chemicals used to
prevent corrosion.
As it is necessary to remove the Oxygen from the
feed water before it enters the boiler drum, the
Oxygen Scavengers are dosed in the Feed Tank
itself.
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13

Internal Treatment for Corrosion

CHEMICALS TO PREVENT FOAMING
z Certain Synthetic Organic Chemical is often used to
prevent Anti Foaming activities of the Boiler Water.
z

C
z

CHEMICALS TO MAINTAIN ALKALINITY

Alkalinity is the presence of Alkaline (Acid
Neutralising)
Minerals
in
water.
Normality
Phosphates added to water help in maintaining the
Alkalinity level in the Boiler water.

z
z

P alkalinity is that which is produced above

PHENOL HTHALEIN end point range to PH 8.2 8.4

z
z

m is the Total alkalinity which is produced above

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end point of PH 4.2-4.4
27
Management

Internal Treatment for Corrosion

CHEMICALS
TO
PREVENT
CAUSTIC
EMBRITTLEMENT:
z Concentrated Caustics present in the Boiler
water, attack the stressed metal and result
in
Caustic
cracking
or
Caustic
Embrittlement.
z
z

To avoid Caustic Embrittlement,

Embrittlement
some
Chemical Inhibitors like Sodium Nitrate are
used.
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14

Boiler operation
z
z
z
z
z
z
z
z
z
z
z
z

Parts
Pre start checks
Preparation for starting
Firing
Pressure build up
Circulation
Charging
Running
Emergency handling
Shutdown
Cooling
Preservation
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15

STEAM STOP
VALVE

SPH 3

SPH 1

APH

SPH 2

FUEL

ESP

AIR
THROUGH
APH
FD

BOILER WITH WATER WALLS AND

SUPER HEATERS

ID

Boiler operation - Parts

z
z
z
z
z
z
z
z
z
z

Drum and mountings

Downcomer tubes
M dd
Mud
drum
Riser tubes with headers
Furnace
Firing equipment
Super heater
Economiser
Accessories
Chimney
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16

Boiler operation Pre start checks

z
z
z
z
z
z
z
z
z

Check furnace
Clear furnace of all unwanted substances, Close
drums
Check all drives
Close drain valves
Open all vents
Fill Feed tank with D M water
Start feed pump and fill boiler upto minimum level.
Ch
Charge
gauge glass
l
Start I D Fan and then F D Fan
Make control panel ready
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17

Boiler operation Start up

z
z
z
z
z
z
z
z
z
z
z
z
z

Light up with Pilot burner

Start Diesel burner
Adjust flame, furnace pressure
Rate of firing is to be slow.
Temperature of water is to be raised @ 38 deg. C per hour.
When pressure is 2 Kg/Cm2, close vents
Pressure increase further should be gradual
At 25% pressure brating, open Blow Down valves.
Oil firing can be introduced after reaching about 50% of the full
working pressure. ( or as per the instruction manual)
After achieving about 75% pressure range, Test safety valves
manually.
At full working pressure start charging the stop valve slowly to
prevent water hammer
If Foaming is experienced, reduce firing rate.
Severe water level fluctuation indicates high alkalinity.
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Boiler operation Circulation

Lay out of the Water Steam cycle.
z Lay out of Air flue gas cycle
z

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18

Boiler Drum

Turbo Generator

Feed Tank
Super Heater
E
Economiser
i

Boiler Furnace
Condensor
Fuel+Air

Feed Pump
Flue gas
Condensate Pump

WATER - STEAM CYCLE

FUEL- FLUE GAS CYCLE

Boiler Drum

Boiler Furnace
E
i
Economiser

FUEL

Burner

Flue Gas

ESP

CHIMNEY

Air Preheater
F D FAN
I D FAN

19

Boiler operation Circulation

Natural circulation.
z Forced circulation
circulation.
z

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Boiler operation Circulation

z

Natural circulation.
Natural circulation of water inside the boiler is
the circulation due to the density differences of
steam and water.
Inside the furnace, when water is heated and is
converted to partly steam, it moves up and
comparatively cold water from the drum moves
down to fill the space and thus water circulates
from top drum to mud drum and back to the
top drum. This process is termed as Natural
circulation.

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20

WATER &
STEAM

WATER

NATURAL CIRCULATION

Boiler Natural Circulation

Graph of steam and water density

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PRESSURE

42

21

Boiler Forced Circulation

z

The density difference between the steam and

water narrows as the pressure increases, at
high pressures
pressures, natural circulation is not
effective. Hence a separate pump is used
which draws water from the mud drum and
distributes to the riser tubes under pressure.
This is termed as Forced circulation.
z Boilers with pressures of 150 bar and above,
circulation is effected by forced circulation.
z Sub critical and super critical pressure boilers
work under this principle.

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FORCED CIRCULATION

WATER &
STEAM

Pump

WATER

MUD
DRUM

22

210 MW Boiler: Water and Steam Circuit

LTSH

Final SH.
Platen SH.

330-375C

500-540C
375C-425C

Economizer
Water Wall
240-310C
310C

A HIGH PRESSURE BOILER FORCED CIRCULATION

SUPERHEATED STEAM OUTLET
WATER TO DRUM

STEAM OUT FROM DRUM

DRUM
SUPERHEATER-1
SUPERHEATER
1
SUPERHEATER-3

SUPERHEATER-2
DOWNCOMER
RISER TUBES

BURNERS

ECONOMIZER

FORCE
CIRCULATIO
N PUMP

23

Boiler operation Charging

z

Charging of stop valve

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Boiler operation Running

Log sheet
z Controls
z Auto controls
Steam pressure
Water level
Steam temperature
combustion control
Flame scanner
z

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24

Automatic Combustion Control

STEAM LOAD
DRUM LEVEL

Drum level setting

STEAM PRESSURE

Air Fuel Ratio

F.D.FAN

FEED WATER

Chamber Press. Setting

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I.D.FAN

49

Boiler operation Emergency handling

Interlocks
z Power failure
z Flame failure
z Leakage
z

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25

Boiler operation Automatic controls

Steam pressure.
z Steam temperature
temperature.
z Furnace chamber pressure.
z Combustion .
z Water level.
z

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Boiler operation FSSS

FURNACE SAFEGAURD SUPERVISING
SYSTEM:
z Furnace purging.
z Ignition interlocks.
z Firing sequence.
z Flame supervision.
z Explosion and Implosion
Implosion.
z Explosion and Implosion flaps.
All these are linked with boiler trip.
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26

Boiler Flue gas explosion

z
z
z

Instantaneous combustion of inflammable or explosive

gases, vopour is termed as flue gas explosion.
Minor explosions are termed as PUFFS or
BLOWBACKS.
Main reasons of flue gas explosion:
z
z

z
z
z
z
z

Sudden firing after is banked or stopped for a short time.

If a forced draft is suddenly started after when a boiler is on
chimney draft.
Ad itti gas/oil/pf
Admitting
/ il/ f ffuell without
ith t lilighting
hti a pilot
il t b
burner.
When such burners are ignited by hot refractory.
Fuel shut off valve leakage.
Explosions are more at 538OC furnace temperature.
Explosions are rare at 760OC furnace temperature.
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Boiler operation Shutdown

z
z
z
z
z

Shutdown of Boiler may be classified as:

Normal to Cold.
N
Normal
l tto H
Hott standby.
t db
Emergency.
Shutting down for maintenance.
z If the unit is shut down to Cold, drum vent to be
opened at 2Kg/Cm2.
z For Hot standby, fire to be Banked or Cut off
shutting down FD & ID. Steam outlet and water in
to be
b stopped.
d
z For all types of shut down, cooling rate should be
@50OC.
z For shut down for maintenance, water temperature
should be 90OC.before draining.
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27

Causes of water level fluctuation:

Excessive salt content in boiler water.
z Feed line pressure variations
z Cutting in and out additional burners
z Lifting of boiler safety valve.Sudden
feeding of cold water causing shrinkage.
z Sudden demand of steam.
z Collapse of baffles in gas path.
z Heavy blow down.
z

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Causes of water hammer:

z

When cold water comes in contact with

steam. there is condensation and
vacuum is created. This action rushes
water in side the pipe at a very high
velocity and fine particles of water hit the
steel pipe like a hammer hit and causes
water hammer
hammer.

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28

A HIGH PRESSURE BOILER SKETCH

SUPERHEATED STEAM OUTLET
WATER TO DRUM

STEAM OUT FROM DRUM

DRUM
SUPERHEATER-1
SUPERHEATER
1
SUPERHEATER-3

SUPERHEATER-2
DOWNCOMER
RISER TUBES

BURNERS

ECONOMIZER

FLUE GAS PATH

29

Heat Balance
Heat input to boiler
Energy in fuel
w*C
Heat in air
Ta*Sp.heat

Heat in feed water

Tfw

Heat out of Boiler

Total heat of steam
W(Hs-Hfw)
Heat in flue gas
a) Mass of flue gas *
Sp.ht* (Tg-Ta)
b) Heat in water
vapour
m*[(Ts-Ta)+l+cp(Tf-Ts)]
Radiation loss
(heat supplied-(heat
used+Heat in flue gas)

Boiler efficiency
Boiler Eff. = Heat output/ Heat input
[(
)
cp(T2-T1)]
p(
)]
W[(h-h1)+L+
w*C
W= weight of steam generated in a given period
h = Sensible heat.
h1 = heat in feed water.
L = Latent heat of steam.
cp = Specific heat of steam.
T2 = absolute temperature of superheated steam.
T1 =absolute temperature of saturated steam.
w = weight of fuel burnt in the same period.
C = calorific value of fuel.
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30

Boiler efficiency Example:Boiler evaporates 8 lbs of water/lb of fuel. Feed water

inlet temp is 38OC, pressure 150 psia. Find the
equivalent evaporotion from and at 14.7 psia and at
100OC,, x=0.95,, CV = 7000 chu/lb. L=539.2 chu. Find
the eff.
From steam table
h-183.7 chu/lb; L-480.3 chu/lb; x-0.95; W-8lbs;
h1-38 chu.
Eq Eva = 8[(183.7-38)+(0.95
Eq.Eva
8[(183 7-38)+(0 95*480
480.3)]/
3)]/ 539
539.2
2
=4816/539.2=8.93
Eff. = 4816/(1*7000) =68.8%

Boiler Trial
v

31

Boiler Availability
Boiler availability depends upon:
z
z
z
z
z
z
z
z
z
z
z
z
z
z

Proper care in operation.

Proper cleaning of heating surface.
surface
Proper flue gas passage.
Condition of water.
Water blow down schedule.
Soot blower schedule.
Variation of load.
Proper heat transfer.
Excessive outages.
g
Efficient boiler management.
Proper annual overhauling.
Proper water circulation.
Proper function of accessories.
Proper maintenance.
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Fouling of gas passages

Can be judged by:
z Increased draft losses.
Gas exit temperature rise.
z Excess air.
z Slagging can be observed through windows.
z Hard
H d scale
l on external
t
l surface
f
can b
be d
due tto
moisture in flue gas.
z Corrosion due to low temperature flue gas.
z

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32

MAINTENANCE is a system
y
by
y
which the Machinery Assets are
kept in GOOD working condition
and maintain in the same
condition by preventing from
deterioration.

33

WHY MAINTENANCE ?

RELATIVE MOTION

Motion

One
Stationary &
other Moving

Both moving
but in
opposite
direction

Both moving in
same direction
But at diff. speeds

34

Friction : Why not desired?

Primary Damage
Causes Heat generation
C
Causes
W
Wear & early
l failures
f il
Causes more Energy consumption
Secondary Damage
Cascading Wear by Worn particles
Modes of Friction
Sliding
Rolling
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Case -1

Case -2

Surface contact

Point contact

SLIDING FRICTION

ROLLING FRICTION

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TO PREVENT FRICTION

zLUBRICATION

36

OIL

FILM

Normal Wear And Tear

And hence
MAINTENANCE

37

MACHINE
A LWAYS
IN
N EW
T OPCLASS
E FFICIENT
N EAT
A ND
N ICE
C ONDITION
E VERYWHERE

MAINTENANCE
STRATEGIES

38

Boiler Maintenance
MAINTENANCE STRATERGIES:

ON FAILURE MAINTENANCE.
2 FIXED TIME MAINTENANCE
2.
1.

z
z
z

3.

PREDICTIVE MAINTENANCE
z
z
z

4.

ONLINE
SHUTDOWN
OVERHAULING
Vibration
Thermography
Wear Debris Analysis

DESIGN OUT MAINTENANCE

77

BOILER VIDEO

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