Professional Documents
Culture Documents
I.
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the form of carbonates, sulfates, chlorides, and nitrates. Raw water also contains a
certain quantity of gases in solution, such as air, CO 2 , and occasionally, hydrogen
sulfide.
The most widely known evidence of the presence of scale-forming ingredients in feedwater is known as hardness. If the water contains only such ingredients
as the bicarbonates of lime, magnesia, and iron, which may be precipitated as
normal carbonates by boiling at 212F, it is said to have temporary hardness.
Permanent hardness is due to the presence of sulfates, chlorides, and nitrates of
lime, magnesia, and iron that are not completely precipitated at a temperature of
212F.
A.
Scale
Mud or suspended mineral matter, if introduced into the boiler with the feedwater,
will eventually form a deposit on the heating surfaces. Iron, aluminum, and silicon in colloidal solution will also tend to produce scale, but by far the greater
part of the objectionable scale deposit results from the salts of calcium and magnesium. The salts are in solution in the cold raw water and constitute hardness.
Raw water from surface or subsurface sources invariably contains in solution some degree of troublesome scale-forming materials, free oxygen, and sometimes acids. Because good water conditioning is essential in the operation of any
steam cycle, these impurities must be removed.
Dissolved oxygen will attack steel and the rate of attack increases sharply
with a rise in temperature. High chemical concentrations in the boiler water and
feedwater cause furnace tube deposition and allow solids carryover into the superheater and turbine, resulting in tube failures and turbine blade deposition or erosion.
As steam plant operating pressures have increased, the water treatment system has become more critical. This has led to the installation of more complete
and refined water treatment facilities.
The temperature of the feedwater entering an economizer should be high
enough to prevent condensation and acid attack on the gas side of the tubes. Dew
point and rate of corrosion vary with the sulfur content of the fuel and with the
type of firing equipment.
II. OXYGEN IN BOILER FEEDWATER
A.
Oxygen
The presence of oxygen accelerates the combining of iron and water. Oxygen can
react with iron hydroxide to form a hydrated ferric oxide or magnetite. Generally
localized, this reaction forms a pit in the metal. Severe attack can occur if the
pit becomes progressively anodic in operation. Oxygen reacts with hydrogen at
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the cathodic surface and depolarizes the surface locally. This permits more iron
to dissolve, gradually creating a pit.
The most severe corrosion action occurs when a deposit covers a small
area. The creation of a differential aeration cell about the deposit can lead to a
severe local action. The metal beneath the deposit is lower in oxygen than areas
surrounding it, becomes anodic, and is attacked. Pitting is most prevalent in
stressed sections of boiler tubing, such as at welds and cold-worked sections,
and at surface discontinuities in the metal.
Efficient operation of boilers requires the exclusion of oxygen from the
feedwater. The normal guaranteed value of oxygen leaving the deaerating heater
or a deaerating condenser is less than 0.005 ppm. Some problem areas are air
leakage during boiler start-up, the addition of nondeaerated water to the feedwater, the aerated heater drips into the condensate, and feedwater exposure to air
during short outages. During an outage, auxiliary steam should be admitted to the
deaerator to maintain a pressure of 35 psig and prevent oxygen contamination
of the feedwater. During an outage, low-pressure feedwater heaters and related
extraction piping are often under negative pressure, and any leading valves,
pumps, or flanges will provide a path for oxygen introduction into the system.
Acceptable feedwater oxygen levels during steady-state operation do not
necessarily mean that oxygen concentration is within safe limits. And do not be
lulled into a false sense of security if oxygen levels are excessive only for a
short time. Considerable damage can still occur. Thus, use of dissolved-oxygen
monitors is important, particularly during load swings and start-up operations.
B. pH of Boiler Feedwater [1,13]
Of equal importance with oxygen is the control of boiler-water pH. Small deviations from the recommended boiler water limits will result in tube corrosion.
Large deviations can lead to the destruction of all furnace wall tubes in a matter
of minutes.
The primary cause of acidic and caustic boiler-water conditions is raw water leakage into the boiler feedwater system. The water source determines whether
the in-leakage is either acid-producing or caustic-producing. Freshwater from
lakes and rivers, for example, usually provides dissolved solids that hydrolyze
in the boiler water environment to form a caustic, such as sodium hydroxide. By
contrast, seawater and water from recirculation cooling water systems with cooling towers contain dissolved solids that hydrolyze to form acidic compounds.
Strict tolerance levels on leakage should be established for all high-pressure
boilers. Set a limit of 0.5-ppm dissolved solids in the feedwater for normal operation; allow 0.52 ppm for short periods only.
Another potential source of acidic and caustic contaminants is the makeup
demineralizer, where regenerant chemicals such as sulfuric acid and caustic may
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149
prevent the addition of aerated heater drips into the condensate, and to assure
the exclusion of air into the feedwater cycle during short outages of the boiler.
The tray-type deaerator is prevalent. Although it has some tendency to
scale, it will operate at wide load conditions and is practically independent of
water inlet temperature. Trays can be loaded to some 10,000 lb/ft 2 hr1, and the
deaerator seldom exceeds 8 ft in height.
The spray type uses a high-velocity steam jet to atomize and scrub the
preheated water. In industrial plants, the operating pressures must be stable for
this type of deaerator to be applied satisfactorily. It requires a temperature gradient (e.g., 50F minimum) to produce the fine sprays and vacuums with the cold
water required.
A. Estimating Deaerator Steam Requirements
Because the deaerator is a direct-contact heat exchanger, the calculations are the
same.
1.
Assumptions:
2.
3.
4.
Example
Boiler (lb/hr)
Steam pressure (psig)
Steam temperature
Steam enthalpy (Btu/lb)
Blowdown (%)
Total boiler feedwater required (lb/hr)
Water temperature to deaerator (F)
Water entering deaerator; enthalpy (Btu/lb)
Deaerator operating pressure (psig)
100,000
125
Saturated
(h s ) 1,194.0
3
(W2 ) 103,000
70
(h 1 ) 70 32 38
15
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Water temperature leaving deaerator (F)
Water leaving deaerator; enthalpy (Btu/lb)
Deaerating steam required (lb/hr)
(h 2 )
250
250 32 218
B.
A temperature rise of at least 50F (30C) over the temperature of the incoming
water is required to make spray-type deaerators perform effectively at full load.
Furthermore, the effectiveness of deaeration in a spray-type unit seriously decreases as loads decrease, for at operating loads of less than 25% of design rating,
the heating steam requirements are not sufficient to maintain a high steam flow.
Tray-type deaerators, on the other hand, use a different principle for the
release of gases. It is still necessary to provide a large water surface area to give
adequate opportunity for the release of the dissolved gases. This is accomplished
by the water cascading from one tray tier to another, exposing as much surface
as possible to the scrubbing action of the steam.
Tray-type deaerators are designed with as many as 24 tray tiers to permit
an adequate surface exposure. With this design method, the same amount of water
surface is exposed to the steam for gas release, regardless of inlet water temperature. Also, as operating loads decrease under the design maximum, the ratio of
surface to throughput water increases, and thinner films for release of gases are
provided. This ensures effective deaeration under all inlet water temperatures and
flow conditions.
Therefore, when a deaerator is operated under varying load conditions or
inlet water temperature, the tray-type deaerator gives the most satisfactory results
over the entire operating range.
Translating the foregoing points into terms of application, it follows that
industrial plants that may operate under low-load conditions (at night, on weekend, or during the summer) will find that a tray-type deaerator gives better assurance of satisfactory oxygen removal than a spray type. In addition, central station
deaerators serving turbines that also operate over a wide range of load conditions
can get better deaeration with a tray-type unit.
This is not an indictment of spray-type deaerators. They do have definite
places of application, and, when operated within their specified limits, will do
an excellent job of gas removal. In marine service, where it is not possible to
maintain the trays in a level state because of the toss and roll of a ship, spray-type
units are always used. Waters that are seriously scaling will cause less difficulty in
a spray-type than a tray-type unit.
See Tables 5.1 and 5.2 for data on properties of water.
TABLE 5.1
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TABLE 5.2
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153
30
3. The first stage shall consist of a 304 stainless steel water box assembly
containing spring-loaded, variable orifice spray valves mounted to spray into a
stainless steel vent condensing chamber and containing a stainless steel vent pipe
positioned to permit efficient venting to the atmosphere. Spray valves shall be
cast from type 316 stainless steel and shall produce a hollow cone, thin-filmed
spray pattern over the range of 5%200% of rated valve capacity to assure rapid
heating and stable venting. Valves shall operate with the use of Teflon guides to
assure quiet operation.
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4. The second stage shall consist of tray assemblies housed in a tray enclosure constructed of carbon steel (304 stainless steel optional). The tray enclosure shall be closed on five sides to eliminate oxygen coming in contact with the
carbon steel head/shell. A parallel flow is acceptable if the vessel is lined with
stainless steel to protect the shell from traces of oxygen. Counterflow movement
of water and steam shall be provided such that the water leaving the bottom layer
of trays will be stripped by pure steam entering the heater, and such that
corrosive gases do not contact the vessel heads or shell. Trays shall be type 430
stainless steel, not less than 16 gauge, and shall be assembled with stainless steel
rivets, not stamped or welded.
5. The deaerator shall be constructed in accord with the ASME Code,
Section VIII, Division 1, for unfired pressure vessels and designed for 30-psig
design pressure (50 psig optional; full vacuum optional). All steel plate shall be
ASTM grade SA-516-70. A corrosion allowance of at least 1/16 in. (1/8 in.
optional) shall be included over the ASME calculated thicknesses.
6. Access to deaerator internals and storage shall be through an 18-in.
diameter access door, and an adequately sized manhole shall be provided for
storage vessel access.
7. The deaerator shall include heavy-duty saddles that provide continuous
support over a contact arc of not less than 120 degrees of storage vessel circumference.
8. All connections necessary to accommodate piping and specified accessories shall be included so as to comprise a complete, working unit, NPT couplings shall be provided for connections 2 1/2 in. and smaller. Connections above
3-in. connections will be pad flange, flanged pipe, or NPT coupling. All interconnecting piping and bridles will be furnished by purchaser. The deaerator shall be
shipped as complete as possible. Final piping assembly shall be furnished by the
purchaser.
9. The stainless steel vent condensing system shall provide for the efficient release of oxygen and carbon dioxide with minimum loss of steam, and
shall be complete with stainless steel vent pipe.
10. The deaerator shall be guaranteed.
a. To deliver specific capacity at the saturated steam temperature
corresponding to the steam pressure within the heater.
b. To deliver specified capacity with an oxygen content not to exceed 0.005 cc/L as determined by the Winkler test, or equal, and
with a free carbon dioxide content of zero as determined by the
APHA test, one time through without recirculating pumps.
c. To be free from defects in material and workmanship for a period
of 1 year from date of initial operating or 18 months from date
of shipment, whichever occurs first.
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11. Optional: The deaerator shall be in accordance with the Heat Exchange Institute 1992, 5th ed., and shall include the following to assure a safe,
reliable vessel.
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Chapter 5
TEFC). Pumps shall have low NPSH requirements which shall not be
exceeded at any time during operation.
c. Boiler feed pump suction piping is included. The suction piping will
consist of a gate valve, Y strainer, and expansion joint. The piping will
be fit up between the deaerator and the boiler feed pump(s), if shipment
clearances allow. Boiler feed pump recirculation piping is to be supplied with isolation valves and orifice plates.
d. A control panel is to be furnished completely wired, tested, and
mounted on the stand. The enclosure is Nema 4 (Nema 12 optional).
Internals included flange mounted main breaker, fused control power
transformer, motor fuse protection, motor starters with overload heaters, hand-off autoselection switch and on pilot lights. Panel is capable of housing up to four pump starters.
e. Optional: A bridle piping assembly is supplied prefit up to the deaerator
tanks bridle connections. The bridle can be tapped for any customer
usage.
14. Any deviations from, or exceptions to, the above specifications must
be clearly stated in bid; otherwise, bidder will be expected to deliver equipment
exactly as specified.
D.
157
30
25 psig
3. The first stage shall consist of a 304 stainless steel water box assembly
containing spring-loaded, variable orifice spray valves mounted to spray into the
vent condensing chamber and containing a stainless steel vent pipe positioned
to permit efficient venting to the atmosphere. Spray valves shall be cast from
type 316 stainless steel and shall produce a hollow cone, thin-filmed spray pattern
over the range of 5200% of rated valve capacity to assure rapid heating and
stable venting. Valves shall operate with the use of Teflon guides to assure quiet
operation. A heavy-gauge collection basin shall be provided to accumulate preheated water for entry into the scrubber.
4. The second stage shall consist of a deaerating steam scrubber, receiving
preheated water from a collection basin downcomer, and receiving pure steam
from a variable area steam distributor, such that a vigorous scrubbing action
occurs to strip the water of its final traces of oxygen and carbon dioxide. Scrubber
outlet shall be positioned to permit exiting steam to flow into the vent condensing
chamber for stage 1 heating, deaerating, and venting.
5. The deaerator shall be constructed in accord with the ASME Code,
Section VIII, Division 1, for unfired pressure vessels and designed for 30-psig
design pressure (50 psig optional; full vacuum optional). All steel plate shall be
ASTM grade SA-516-70. A corrosion allowance of at least 1/16 in. (1/8 in.
optional) shall be included over the ASME calculated thicknesses.
6. Access to deaerator internals and storage shall be provided through a
12 16 manhole.
7. The deaerator shall include heavy-duty saddles that provide continuous
support over a contact arc of not less than 120 degrees of storage vessel circumference.
8. All connections necessary to accommodate piping and specified accessories shall be included such as to comprise a complete, working unit, NPT couplings shall be provided for connections 2 1/2 in. and smaller. Connections above
3 in. connections will be pad flange, flanged pipe, or NPT coupling. All interconnecting piping and bridles will be furnished by purchaser. The deaerator shall be
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159
13. OPTIONAL: When a Package unit is requested, the following additional components shall be included. The package assemble shall be factory preassembled and shall be broken down for shipment due to clearances.
a. Structural stand build per OSHA. Stand is prefit up to match up
with deaerator. The stand will have proper anchor bolt holes for
attachment to site foundation.
b. Boiler feed pump is sized to accommodate 100% of rated capacity with low NPSH required. The pump will be attached to the
pump skid which is welded to the structural stand. A quantity
of pump(s) is required for a capacity of GPM each
(0.002099 pph GPM). Discharge pressure to boiler is psig. The pump is a centrifugal type and have seals and materials
suitable for continuous operation up to 250F (300F optional).
Each pump is driven by a HP, 3600 RPM, volt, 3-phase
open drip proof (ODP) motor (optional: TEFC). Pumps shall
have low NPSH requirements that shall not be exceeded at any
time during operation.
c. Boiler feed pump suction piping is included. The suction piping
will consist of a gate valve, Y-strainer and expansion joint. The
piping will be fit up between the deaerator and the boiler feed
pump(s), if shipment clearances allow. Boiler feed pump recirculation piping is to be supplied with isolation valves and orifice
plates.
d. A control panel is to be furnished completely wired, tested, and
mounted on the stand. The enclosure is Nema 4 (Nema 12 optional). Internals included flange mounted main breaker, fused
control power transformer, motor fuse protection, motor starters
with overload heaters, hand-off autoselection switch and on
pilot lights. Panel is capable of housing up to four pump starters.
e. Optional: A bridle piping assembly is supplied prefit up to the
deaerator tanks bridle connections. The bridle can be tapped for
any customer usage.
14. Any deviations from, or exceptions to, the above specifications must
be clearly stated in bid; otherwise, bidder will be expected to deliver equipment
exactly as specified.