Section 2.

DEAERATORS AND FEEDWATER TANKS

Deaerators and feedwater tanks provide the most common means of deoxygenation in the plants/systems we service. Mechanical removal of oxygen should be the primary means of deoxygenation, with removal by oxygen scavenging secondary. It is, therefore, necessary to be able to survey and troubleshoot deaerators and feedwater tanks, determine whether performance is appropriate, and make recommendations if improvements are needed.

DEAERATORS
THE SURVEY The first step in servicing or troubleshooting a deaerator is to complete a Mechanical-Operational-Chemical (MOC) survey. The survey form should include questions in each of the MOC areas. Answers to these questions will help establish expected versus existing performance of the deaerator, as well as identify potential problem areas. Mechanical questions: For what boiler(s) or system does this specific deaerator provide feedwater? How many deaerators are present in this system? What is the type of deaerator (spray, tray, atomizing, co-current, counter-current, etc.)? What is the metallurgy of the main deaerator components (shell, sprays, and trays)? Is there an external vent condenser? What is the design flow rate? What are the design temperatures and flows for all makeup and condensate streams? Do condensate and makeup mix before the deaerator or enter separately? What is the return (entry) point for hightemperature condensate streams? What is the design pressure? Where is the dome pressure sensor located? Where are the sample points located, and what are their estimated lag times based on line length and diameter? What is the sample line metallurgy? What dissolved oxygen concentration is the deaerator designed to supply? Operational questions: What is the actual water flow through the deaerator? What is the condition of the vent (steady, sputtering, an invisible space between the top of the vent and the plume, etc.)? What are the source, pressure, and temperature of the steam to the deaerator? What is the actual operating pressure? Does the temperature fluctuate, if so by how much? Does the pressure fluctuate, if so by how much? What are the dome temperature and pressure? What is the storage tank temperature? What is the temperature and flow rate of all high-temperature condensate streams? What is the temperature and flow rate of all makeup and low-temperature condensate streams? Do sample lines flow continuously or only as needed? If only as needed, how much flush time is provided before sampling? Is there an oxygen meter present, and how often is it calibrated?

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

221

Section 2.7

DEAERATORS AND FEEDWATER TANKS

What are the date and findings of the most recent oxygen testing done without scavenger? What are the date and findings of the last internal inspection, e.g., condition of the spray nozzles, trays, storage tank, welds, etc.? What are the date and findings of the last weld integrity testing? Chemical questions: What products/chemicals are fed to the deaerator or in the deaerator recirculation line? What is the dosage of these products? Are the products fed neat or diluted? Are multiple products mixed together before or at the injection point? What are the point(s) of injection for all products fed into the deaerator, e.g., to deaerator neck, storage, dropleg (after deaerator storage), recirculation line, etc.? Is a quill or extended feed header used, and how far does it extend into the feed point? What is the metallurgy of the feed system? What is the measured dissolved oxygen concentration in the deaerator effluent with oxygen scavenger? What is the feedwater pH out of the storage tank after scavenger injection? Evaluate Original Design and Installation Obtain original design parameters and deaerator specifications A deaerator is a relatively simple mechanical device, which is designed to remove dissolved oxygen (DO) from boiler feedwater down to maximum concentrations of 7-40 ppb. The level of removal depends on deaerator design. When a deaerator does not function properly, it is due to one of two causes: 1. Deviations from original design specifications 2. Mechanical failure Deviations from specifications can be caused by changed plant operating conditions, design retrofits, or engineering changes that have occurred since design. Start your survey at the original deaerator operating manual. Record all manufacturers design criteria and specifications. (Refer to mechanical questions previously listed.) Obtain an original drawing of the vessel. Carefully note the positions of all inlets, outlets, baffles, gauges, and sensors. Obtain current system diagram and determine current operating parameters Go to the deaerator, and prepare a drawing of the unit, as it currently exists. Carefully note the position of all inlets, outlets, gauges, thermocouples, and other sensors. Obtain accurate flow and temperature data for all influent streams and for the steam supply. Note flow swings. Do not average flow information, but record the flow ranges. Diagnostic TRASAR can be used for calibration of flow meters and verification of estimated flow rates. Evaluate Current On-Line Performance Check pressure of deaerator dome The operating pressure should be well regulated and not vary more than 0.5 psig (3.4 kPag). Pressure fluctuations can be caused by any of the following: Rapid flow changes in inlet water

TROUBLESHOOTING POOR PERFORMANCE In troubleshooting a deaerator, an open mind and a systematic plan of attack are necessary. Working your way through the following actions should reveal whether or not the deaerator you are working with is operating properly. If it is not, these procedures should pinpoint the problems. When you conclude your survey, make sure your observations and recommendations fit the facts that you observed.

222

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

Section 2.7

DEAERATORS AND FEEDWATER TANKS

Rapid changes in condensate return flow or temperature, especially of high-temperature return streams Insufficient or fluctuating steam supply Improper instrument tuning of the pressure reducing valve (PRV) Improper size or design or excess pressure drop across the PRV Improper location of pressure sensing devices for PRV In general, the pressure sensor for a PRV should be located on the deaerator proper, not on the steam piping coming to the deaerator. Locations other than the deaerator result in a lag in response time to pressure changes in the dome, resulting from changes in load or inlet temperatures. This lag allows continuous rapid pressure and temperature changes in the unit and continuous changes in the stress level applied to the tank. Check temperature of deaerator dome The temperature of the deaerator dome section should be within 1-2F (0.6-1.1C) of the theoretical saturated steam temperature at the operating pressure. Atmospheric pressure (14.7 psia; 101.3 kPaa in most locations) must be added to the gauge pressure before referring to most steam tables for the temperature value. EXAMPLE 1 Gauge pressure on deaerator dome = 10.0 psig (68.9 kPag) Atmospheric pressure = 14.7 psia (101.3 kPag) Absolute pressure for steam table = 24.7 psia (170.2 kPaa) Therefore, the dome temperature should be 238.5F 2F [114.7 1.1C] based on steam table in Appendix A. Too low a temperature will indicate an internal malfunction, insufficient venting, too little steam flow, too much feedwater flow, or too low an inlet water temperature. It is important to note that a fluctuating dome pressure will result in fluctuating temperatures. This will increase the probability that the temperature is below saturation for a portion of the cycle. Oxygen solubility increases significantly, whenever the temperature drops below saturation. The result is typically high oxygen content in the effluent (feedwater). The effect of fluctuating pressure and temperature is more pronounced in a spray type deaerator because there is less water volume within the dome. Location of the deaerator thermometer (if present) is just as important as location of the pressure sensor. It is not uncommon for the thermometer to be located very close to the steam inlet. When this is the case, the thermometer is actually measuring the temperature of the inlet steam and not the temperature of the dome. This is of particular importance when the steam used is superheated. The difference between theoretical (from steam tables) versus measured will then be very large, with measured being the larger number. Check temperature of deaerator storage section The temperature of the deaerator storage section should be within 1-4F (0.6-2.2C) of the deaerator dome temperature. A temperature difference greater than this indicates that there was insufficient contact between the water and steam as the water made its way through the dome. The storage section temperature will be the lower of the two temperatures. The temperature difference between dome and storage may be very large if the dome temperature is actually the temperature of superheated steam because of an improperly positioned probe. Under these circumstances, you will need to estimate the dome temperature from the steam tables using the dome pressure and compare that temperature to the storage temperature.

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

223

Section 2.7

DEAERATORS AND FEEDWATER TANKS

reference. The plume should be visible (even with a vent condenser), strong, steady (not puffing), and without entrained water. Common causes for insufficient venting are choked flow, plugged orifices, intentional reduction for conservation of energy, convoluted or excessively long vent piping, and rapid variations of feedwater flow or temperature, which results in a temporary upset condition. Energy conservation measures may also result in the installation of heat exchangers, cooling jackets, or other devices to reclaim the heat content of the vent steam containing the noncondensables. Many of these devices cause a backpressure on the vent line and thus restrict flow. The result is higher noncondensable gases in the deaerator effluent (feedwater). Irregular spitting of water with the vent discharge can indicate condensation, internal leaks, water entrainment from broken or damaged spray nozzles, erratic spray valve action, insufficient vent opening, or incorrect vent piping. This condition, whatever the cause, can choke the vent gas flow. Cooling water leaks in an external vent condenser can cause excess water accumulation in the shell. If the drainpipe cannot discharge the excess liquid or is plugged, gas flow through the vent will be restricted. Typically, the maximum quantity of steam required for venting a properly operating deaerator is less than 0.2% of the feedwater flow. (See Figures 2.7.1 and 2.7.2.) This value varies relative to the percentage of fresh makeup used, but is less than 0.2% for tray or spray type deaerators operating with 100% makeup. Some deaerator manufacturers might conservatively recommend 0.5% to assure sufficient venting.

Typically, anything that results in uneven distribution of water through the sprays or across the trays will result in insufficient contact. This can include broken spray nozzles and cracked, plugged, broken, or shifted trays. Separate introduction of return condensate and cold makeup into the deaerator water box or preheater sprays can result in a slightly different distribution problem. The amount of mixing that actually occurs in the water box is minimal so that the water spraying out of the water box tends to divide the preheater and tray sections into hot and cold zones. This creates an imbalance of steam flow through the tray stack, with the steam gravitating to the cold side. The performance impact of this condition will depend on the temperature difference between zones. Check deaerator vent and vent line Insufficient venting is one of the most common causes of poor deaerator performance. Noncondensable gases not vented from the deaerator will concentrate in the vapor phase, increasing their partial pressure. This in turn, increases their concentration in the liquid phase or deaerator effluent (feedwater). Proper venting of a deaerator will result in an invisible or clear area between the vent pipe discharge to the atmosphere and the plume. There are numerous opinions on how long this clear space should be. There are also numerous opinions on plume height, ranging from 6-36 inches (152-914 mm). Acceptable plume height is actually deaerator specific and is affected by existing weather, such as temperature and wind speed. It is better to adjust the vent rate to achieve an acceptable oxygen concentration (verified by measurement) and then note general plume appearance for future

224

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

Section 2.7

DEAERATORS AND FEEDWATER TANKS

Figure 2.7.1 Vent rate for a tray type deaerator (U.S.)

Figure 2.7.1 Vent rate for a tray type deaerator (Metric)

Figure 2.7.2 Vent rate for a spray type deaerator (U.S.)

Figure 2.7.2 Vent rate for a spray type deaerator (Metric)

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

225

Section 2.7

DEAERATORS AND FEEDWATER TANKS

The vent valve may have a 1/8 inch (3.2 mm) hole drilled in the seat to prevent the valve from being tightly closed during operation. For very light loads or small noncondensable loading, this 1/8 inch (3.2 mm) hole is sometimes large enough to act as a throttling orifice, but this is an unusual situation. The vent valve should not be operated in this closed position (with only the 1/8 inch [3.2 mm] hole as vent), unless adequate venting is indicated by temperature and oxygen checks. To determine the correct amount of opening required, the vent valve should be opened approximately one or two turns and the effect on the operating temperature noted. If no appreciable effect on the temperature is noted after one hour, oxygen tests should be done to determine the effectiveness of venting, i.e., is the appropriate oxygen removal achieved. The vent rate can be reduced by tightening (closing) the vent valve. If after reducing the opening, the deaerator operating temperature drops or the difference between dome and storage temperatures increases, venting is not adequate, and the vent valve must be opened further. When loads are small or where uniform operation (flow and pressure) is expected, a fixed orifice can be used. This usually consists of a drilled pipe cap or orifice plate mounted above a vent valve. The vent valve should be fully open and not drilled with the 1/8 inch (3.2 mm) hole. The optimum size of the orifice can be found by checking dissolved oxygen in the effluent and verifying that the deaerator temperature matches the theoretical saturation temperature for the operating pressure. If the oxygen is high or the temperature is low, the hole size in the orifice needs to be increased. Orifice hole size can also be estimated based on feedwater flow and pressure. (See Figure 2.7.3 and Table 2.7.1.)

1800

13/16

1600
3/4 in

1400
11/16 in

1200

Flow (lb/hr)

1000

5/8 in

800

9/16 in

600

1/2 in 7/16 in

400

3/8 in 5/16 in

200

0 0.0 10.0 20.0

1/4 in 3/16 in 1/8 in

Pressure (psig)

30.0

40.0

50.0

60.0

Figure 2.7.3 Estimated steam flow vs. orifice size (U.S.)

120 8 mm

7.5 mm 100 7 mm

80

6.5 mm 6 mm

Flow (kg/hr)

60

5.5 5 mm

40

4.5 4 mm

20

3.5 3 mm 2.5 mm 2 mm

0 0 100

Pressure (kPag)

200

300

400

Figure 2.7.3 Estimated steam flow vs. orifice size (Metric)

226

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

Table 2.7.1 Steam flow through nozzles (U.S.)1

NOZZLE DIAMETER (in)
1/4 5/16 3/8 7/16 1/2 9/16 5/8 11/16 3/4 13/16 7/8 15/16

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)
1.0 652.0 681.3 710.6 739.8 769.1 798.4 827.7 857.0 886.2 944.8 1003.3 1061.9 1120.4 1179.0 1296.1 1413.2 1530.3 1647.4 1764.5 2057.3 2350.1 2642.8 40.8 42.6 44.4 46.2 48.1 49.9 51.7 53.6 55.4 59.0 62.7 66.4 70.0 73.7 81.0 88.3 95.6 103.0 110.3 128.6 146.9 165.2 63.7 66.5 69.4 72.3 75.1 78.0 80.8 83.7 86.5 92.3 98.0 103.7 109.4 115.1 126.6 138.0 149.4 160.9 172.3 200.9 229.5 258.1 91.7 95.8 99.9 104.0 108.2 112.3 116.4 120.5 124.6 132.9 141.1 149.3 157.6 165.8 182.3 198.7 215.2 231.7 248.1 289.3 330.5 371.6 124.8 130.4 136.0 141.6 147.2 152.8 158.4 164.0 169.6 180.8 192.0 203.3 214.5 225.7 248.1 270.5 292.9 315.3 337.7 393.8 449.8 505.9 FLOW RATE (lb/h)1 163.0 206.3 254.7 170.3 215.6 266.1 177.6 224.8 277.6 185.0 234.1 289.0 192.3 243.4 300.4 199.6 252.6 311.9 206.9 261.9 323.3 214.2 271.1 334.7 221.6 280.4 346.2 236.2 298.9 369.1 250.8 317.5 391.9 265.5 336.0 414.8 280.1 354.5 437.7 294.7 373.0 460.5 324.0 410.1 506.3 353.3 447.1 552.0 382.6 484.2 597.8 411.9 521.3 643.5 441.1 558.3 689.3 514.3 650.9 803.6 587.5 743.6 918.0 660.7 836.2 1032.4 308.2 322.0 335.9 349.7 363.5 377.4 391.2 405.0 418.9 446.6 474.2 501.9 529.6 557.3 612.6 668.0 723.3 778.7 834.0 972.4 1110.8 1249.2 366.8 383.2 399.7 416.2 432.6 449.1 465.6 482.0 498.5 531.4 564.4 597.3 630.2 663.2 729.1 794.9 860.8 926.7 992.6 1157.2 1321.9 1486.6 430.4 449.8 469.1 488.4 507.7 527.1 546.4 565.7 585.0 623.7 662.4 701.0 739.7 778.3 855.6 932.9 1010.3 1087.6 1164.9 1358.1 1551.4 1744.7 499.2 521.6 544.0 566.4 588.9 611.3 633.7 656.1 678.5 723.3 768.2 813.0 857.8 902.7 992.3 1082.0 1171.7 1261.3 1351.0 1575.1 1799.3 2023.4 573.1 598.8 624.5 650.3 676.0 701.7 727.4 753.2 778.9 830.4 881.8 933.3 984.8 1036.2 1139.2 1242.1 1345.0 1447.9 1550.9 1808.2 2065.5 2322.8

Gauge Pressure 1/8 psig 1.5 10.2 2.2 10.6 2.9 11.1 3.6 11.6 4.4 12.0 5.1 12.5 5.8 12.9 6.5 13.4 7.3 13.8 8.7 14.8 10.2 15.7 11.6 16.6 13.1 17.5 14.5 18.4 17.4 20.3 20.3 22.1 23.2 23.9 26.1 25.7 29.0 27.6 36.3 32.1 43.5 36.7 50.8 41.3

3/16

22.9 24.0 25.0 26.0 27.0 28.1 29.1 30.1 31.2 33.2 35.3 37.3 39.4 41.4 45.6 49.7 53.8 57.9 62.0 72.3 82.6 92.9

1. Based on Napier's formula

Section 2.7

DEAERATORS AND FEEDWATER TANKS

227

228
2.5 2.84 2.97 3.10 3.23 3.36 3.49 3.62 3.74 3.87 4.13 4.39 4.65 4.90 5.16 5.68 6.19 6.71 7.22 7.74 9.03 10.32 11.60 4.09 4.28 4.46 4.65 4.84 5.02 5.21 5.39 5.58 5.95 6.32 6.69 7.06 7.43 8.18 8.92 9.66 10.40 11.14 13.00 14.85 16.71 5.57 5.82 6.08 6.33 6.58 6.83 7.09 7.34 7.59 8.10 8.60 9.11 9.61 10.12 11.13 12.14 13.15 14.16 15.17 17.69 20.22 22.74 7.28 7.61 7.94 8.27 8.60 8.93 9.26 9.59 9.92 10.58 11.24 11.90 12.55 13.21 14.53 15.85 17.17 18.49 19.81 23.11 26.41 29.71 19.22 20.09 20.96 21.83 22.70 23.57 24.44 25.31 26.18 27.93 29.67 31.41 33.15 34.89 38.38 41.86 45.35 48.83 52.31 61.02 69.73 78.44 22.29 23.30 24.31 25.32 26.33 27.34 28.35 29.36 30.37 32.39 34.41 36.43 38.45 40.47 44.51 48.55 52.59 56.63 60.67 70.77 80.87 90.97 25.58 29.11 36.84 26.74 30.43 38.51 27.90 31.75 40.18 29.06 33.07 41.85 30.22 34.39 43.52 31.38 35.71 45.19 32.54 37.03 46.86 33.70 38.34 48.53 34.86 39.66 50.20 37.18 42.30 53.54 39.50 44.94 56.88 41.82 47.58 60.22 44.14 50.22 63.56 46.46 52.86 66.90 51.10 58.13 73.58 55.73 63.41 80.26 60.37 68.69 86.94 65.01 73.97 93.61 69.65 79.24 100.29 81.24 92.44 116.99 92.84 105.63 133.69 104.44 118.82 150.39 3.0 3.5 4.0 4.5 6.5 7.0 7.5 8.0 9.0 10.0 45.48 47.55 49.61 51.67 53.73 55.79 57.85 59.91 61.98 66.10 70.22 74.34 78.47 82.59 90.84 99.08 107.33 115.57 123.82 144.43 165.05 185.66 NOZZLE DIAMETER (mm) 5.0 5.5 6.0 FLOW RATE (kg/h)1 9.21 11.37 13.76 16.37 9.63 11.89 14.38 17.12 10.05 12.40 15.01 17.86 10.46 12.92 15.63 18.60 10.88 13.43 16.25 19.34 11.30 13.95 16.88 20.08 11.72 14.46 17.50 20.83 12.13 14.98 18.12 21.57 12.55 15.49 18.75 22.31 13.38 16.52 19.99 23.80 14.22 17.56 21.24 25.28 15.05 18.59 22.49 26.76 15.89 19.62 23.74 28.25 16.72 20.65 24.98 29.73 18.39 22.71 27.48 32.70 20.06 24.77 29.97 35.67 21.73 26.83 32.47 38.64 23.40 28.89 34.96 41.61 25.07 30.95 37.46 44.57 29.25 36.11 43.69 52.00 33.42 41.26 49.93 59.42 37.60 46.42 56.16 66.84

Section 2.7

Table 2.7.1 Steam flow through nozzles (Metric)1

DEAERATORS AND FEEDWATER TANKS

Gauge Pressure (kPag) 10 15 20 25 30 35 40 45 50 60 70 80 90 100 120 140 160 180 200 250 300 350

2.0

1.82 1.90 1.98 2.07 2.15 2.23 2.31 2.40 2.48 2.64 2.81 2.97 3.14 3.30 3.63 3.96 4.29 4.62 4.95 5.78 6.60 7.43

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

1. Based on Napier's formula

Section 2.7

DEAERATORS AND FEEDWATER TANKS

The presence of a 1/8 inch (3.2 mm) hole in the seat of the vent valve will always prevent oxygen free deaerator lay-up. Check temperature of water entering deaerator Deaerators are designed to operate within specific water temperature ranges. They are designed for a certain amount of makeup within a specific temperature range and a certain amount of condensate within a specific temperature range. Operating outside of these design parameters (flow or temperature) can result in poor deaerator performance. Changes in any one of the flows or corresponding temperatures will affect the mass and energy balance of the entire system. Gradual changes can be expected and, as long as they are within specifications, should cause no decrease in performance. Abrupt flow or temperature changes can also adversely affect performance and even cause internal deaerator damage. The cause of these abrupt changes should be determined and corrected or eliminated. Abrupt flow changes can be mollified by adding surge capacity. Heat recovery projects are sometimes added as system upgrades after the deaerator has been designed and installed. This can cause deaerator performance issues. If steam demand and consumption are lessened by a retrofit heat recovery system, which now delivers feedwater at a significantly higher temperature, steam demand may decrease to a point where an adequate steam flow for stripping oxygen and other noncondensables is not maintained. A temperature differential of 30-50F (17-28C) is typically required between the incoming water (makeup plus condensate) and the operating temperature for spray type deaerators. This differential is typically 10-20F (6-11C) for tray type deaerators. Check the original equipment specifications for the actual differential required. If the feedwater temperature is too cold, steam demand increases. This can create excessive steam flow demand to maintain operating pressure/temperature. The excessive steam flow can damage vessel internals and cause feedwater spray carried through the vent. It can also cause flooding of tray type deaerators. When superheated steam is used instead of saturated steam, the significantly higher heat content of the steam results in a lower steam flow to heat the water to saturation temperature. The lower steam flow means that there is a lower volume of steam available for scrubbing the incoming water and for removing the noncondensable gases through the vent. This may result in a higher dissolved oxygen concentration in the effluent. In order to overcome this situation, the vent rate should be increased so that oxygen can be removed. In such cases, desuperheating the steam should be considered. Heating cold, air-saturated makeup water may generate free air in the line due to its decreased solubility at elevated temperatures. This free air must be removed from the makeup water before it reaches the deaerator, or free air will be released into the deaerator. This can cause air blanketing, which can impair heating and deaeration. A vented atmospheric receiver will eliminate this problem, if located after all heat recovery equipment and any condensate return that will be blended with the makeup. Check flows of water entering deaerator A modulating control valve should be used to maintain water level in the deaerator. Modulating control will give stable operating conditions versus on/off valves, which will provide a sudden rush of colder water and may profoundly affect pressure control. All water supplies entering the deaerator must have sufficient pressure to overcome any loss of head caused by pipe friction, control valves, vent condenser, and spray valves. If the pressure is too low, sufficient water will not enter the

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

229

Section 2.7

DEAERATORS AND FEEDWATER TANKS

deaerator, and distribution through the spray nozzles will be poor. If the pressure is too high, difficulty may be experienced with the inlet control valve due to an excessive pressure drop. Many plants are currently operating under reduced loads. Feedwater flow rates significantly below design specifications will not atomize properly through the spray nozzles, causing poor deaerator performance. Inverting selectively chosen nozzles or retrofitting the deaerator with smaller nozzles (contact the equipment manufacturer for proper sizing) may be required if a spray deaerator is operated consistently below 25% of design capacity. Tray type deaerators can typically operate effectively down to 10% of design capacity. The feedwater flow through the deaerator should not be higher than the design water flow. At flow rates in excess of design, there is too much water flowing through each spray nozzle to obtain the fine mist/film required for good steam/water contact, and effluent oxygen rises. Check location of condensate return lines Condensate return and makeup water should be introduced into the deaerator in such a manner as to avoid extreme temperature interfaces. The separate introduction of condensate return and cold makeup streams into the deaerator water box MUST be avoided. The amount of mixing that actually occurs in a water box is minimal; thus, the water spraying out of the water box into the heater area tends to divide the heater into a cold zone and a hot zone. This affects tray deaerators severely, creating an imbalance of steam flow through the tray stack, with the steam gravitating to the cold side. Performance loss will vary directly with the temperature difference. Condensate returns that are hotter than the operating temperature in the deaerator dome can be expected to generate flash steam. This can create water hammer at the interface between the flashed steam and lower temperature water, if this condensate is returned to the water box. A vented atmospheric receiver for all returns and makeup can go a long way towards the attainment of system stability. An atmospheric receiver should be located downstream of all heat recovery equipment. If condensate at flashing temperatures is returned to the deaerator, it should be introduced into the heater section outside the water box through a T baffle or other energy absorbing device. Larger volumes may be returned to the deaerator dome at a location approximately equivalent to the steam inlet. The hot condensate will flash, adding to the stripping steam present. Problems can arise if the supply of this flash steam varies significantly. In such cases, the steam supply valve must be capable of handling the fluctuations quickly so that dome pressure does not fluctuate by more than 0.5 psig (3.4 kPag). Check steam pressure and flow rate A modulating control valve is typically used to regulate the steam supply to the deaerator. This valve is modulated by means of a pressure controller. A fast acting, pneumatically actuated control is used in most systems, although a pilot operated pressure control valve may be suitable in smaller applications and a self-acting, diaphragm actuated control valve may be used in systems where the load is constant. Remember, deaerator temperature is actually the result of how well the pressure is controlled, so it is very important that the valve be able to maintain a constant pressure. Instruments should be tuned with a relatively narrow proportional band and a very slow reset to minimize pressure and temperature variations. When flash steam from hot condensate return is used as part of the steam supply, a pressure sensor at the supply source should be installed to signal the pressure reducing valve if supply is lost.

230

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

Section 2.7

DEAERATORS AND FEEDWATER TANKS

The amount of steam required by any deaerator is a combination of the amount consumed to heat all the incoming water to the saturated steam temperature within the unit, plus a small amount that is vented with the noncondensable gases, less any flashed steam generated from hot condensate or trap returns. This can be estimated with a heat balance of all incoming and outgoing streams. (See Examples 2.7.1 and 2.7.2.) A general rule of thumb for a typical plant is that 15% of the boiler feedwater is condensed steam from the deaerator. In a utility or where makeup water is hot process softener effluent, this number will be lower due to the higher temperature of the makeup water. If superheat exists in the heating steam, flow is decreased approximately 1% for every 20F (11C) superheat present. The steam requirement will be higher where there is a high percentage of cold makeup water used. Approximately 0.05-0.5% of the total steam requirement is needed for venting. Check dissolved oxygen Dissolved oxygen monitoring at the ppb concentration requires exacting sampling and analytical techniques to achieve accurate results. Dissolved oxygen monitors require regular maintenance and should be checked by wet chemical methods on a regular basis. Acceptable wet chemical methods are the CHEMetrics ampoules and the Hach Indigo Carmen dissolved oxygen tests. The frequency of the wet chemical testing should be based on operating experience, but should not be less frequent than once per month, ideally once per week. Sampling and operator testing techniques are very important for accurate, precise oxygen values. All operators running dissolved oxygen tests should be well trained. Dissolved oxygen should be determined with and without oxygen scavenger present. In the absence of scavenger, the oxygen study is referred to as a deaerator efficiency test, since it focuses only on equipment performance or efficiency. It will typically take 2-3 hours to

Figure 2.7.4 By-pass oxygen scavenger feedpoint

dilute the oxygen scavenger totally out of the storage section, even if the holding time in the storage section is relatively short. This is because mixing is usually very limited in the deaerator storage section. Figure 2.7.4 illustrates an oxygen scavenger bypass feedpoint, which should ideally be installed so deaerator oxygen testing can be performed without shutting off the oxygen scavenger feed. Testing should still be done even if a bypass is not present. Dissolved oxygen samples should be taken from the storage section dropleg. If two deaerators feed into a common storage section, sample lines from each deaerator dropleg or neck to the storage section should be installed, in addition to the storage section dropleg sample. A dissolved oxygen sample should also be available after the boiler feedwater pump, because this is a common contamination point. Section 2.21 discusses proper sampling in detail. In general, all sample lines must be cooled to below 100F (38C) ideally below 90F (32C), they should be stainless steel construction, and they should flow continuously for at least 2-3 hours before taking a sample. Copper connections and lines should never be used, because copper is catalytic to most scavenger/ oxygen reactions. Any non-metal connection

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

231

Section 2.7

DEAERATORS AND FEEDWATER TANKS

EXAMPLE 2.7.1 DEAERATOR ENERGY BALANCE U.S. UNITS

System Boiler Steam load Deaerator Condensate Makeup water

Given 145 psig 21164 lb/hr 4.4 psig, 225F 194F, 75% returned 77F

From Steam Tables hg = 1195 Btu/lb hf = 193.7 Btu/lb, hg = 1155.4 Btu/lb hf = 162 Btu/lb hf = 45 Btu/lb

At 25 cycles of concentration (COC), the boiler will need 22046 lb/hr of water supplied by the deaerator. Feedwater = (Steam)(COC)/(COC - 1) = (21164 lb/hr)(25)/(25 - 1) = 22046 lb/hr The enthalpy of the makeup water and condensate are found in the steam tables and are shown above. These streams must have their enthalpy raised to 193.7 Btu/lb, which is the operating condition of the deaerator. Heat needed by makeup = mmu(hf da - hf mu) = (25%)(22046 lb/hr)(193.7 - 45) Btu/lb = 820000 Btu/hr Heat needed by condensate = mcond(hf da - hf cond) = (75%)(22046 lb/hr)(193.7 - 162) Btu/lb = 520000 Btu/hr Total heat needed = 820000 + 520000 = 1340000 Btu/hr The heat is supplied by condensing steam at 145 psig to water at 4.4 psig and 225F. Heat supplied by the steam = (hg stm - hf da) = (1195 - 193.7) Btu/lb = 1001.3 Btu/lb Therefore, the steam flow required to the deaerator for heat = 1340000 Btu/hr/1001.3 Btu/lb = 1338 lb/hr. A small portion of the steam is also vented. This is typically less than 0.2% of the feedwater flow, or 44 lb/hr for this example. Since it is vented as steam, we use hg instead of hf. This number is small compared to the amount required for heat and can be omitted in most circumstances. Steam vented = (mvented)(hg da)/hg stm = (44 lb/hr)(1155.4 Btu/lb)/1195 Btu/lb = 43 lb/hr The total steam flow to the deaerator is then a combination of the steam required to heat the makeup and condensate plus the amount lost to venting. Total steam flow = 1338 + 43 = 1371 lb/hr

232

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

Section 2.7

DEAERATORS AND FEEDWATER TANKS

EXAMPLE 2.7.2 DEAERATOR ENERGY BALANCE METRIC UNITS System Boiler Steam load Deaerator Condensate Makeup water Given 1000 kPag 9600 kg/hr 30 kPag, 107C 90C, 75% returned 25C From Steam Tables hg = 2780 kJ/kg hf = 450 kJ/kg, hg = 2687 kJ/kg hf = 377 kJ/kg hf = 105 kJ/kg

At 25 cycles of concentration (COC), the boiler will need 10000 kg/hr of water supplied by the deaerator. Feedwater = (Steam)(COC)/(COC - 1) = (9600 kg/hr)(25)/(25 - 1) = 10000 kg/hr The enthalpy of the makeup water and condensate are found in the steam tables and are shown above. These streams must have their enthalpy raised to 450 kJ/kg, which is the operating condition of the deaerator. Heat needed by makeup = mmu(hf da - hf mu) = (25%)(10000 kg/hr)(450 - 105) kJ/kg = 860000 kJ/hr Heat needed by condensate = mcond(hf da - hf cond) = (75%)(10000 kg/hr)(450 - 377) kJ/kg = 550000 kJ/hr Total heat needed = 860000 + 550000 = 1410000 kJ/hr The heat is supplied by condensing steam at 1000 kPag to water at 30 kPag and 107C. Heat supplied by the steam = (hg stm - hf da) = (2780 - 450) kJ/kg = 2330 kJ/kg Therefore, the steam flow required to the deaerator for heat = 1410000 kJ/hr/2330 kJ/kg = 605 kg/hr. A small portion of the steam is also vented. This is typically less than 0.2% of the feedwater flow, or 20 kg/hr for this example. Since it is vented as steam, we use hg instead of hf. This number is small compared to the amount required for heat and can be omitted in most circumstances. Steam vented = (mvented)(hg da)/hg stm = (20 kg/hr)(2687 kJ/kg)/2780 kJ/kg = 19 kg/hr The total steam flow to the deaerator is then a combination of the steam required to heat the makeup and condensate plus the amount lost to venting. Total steam flow = 605 + 19 = 624 kg/hr

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

233

Section 2.7

DEAERATORS AND FEEDWATER TANKS

should have low oxygen permeability. (See Table 2.7.2.) Testing should continue until three samples provide approximately equivalent values over a period of 30 minutes. If high oxygen is noted and confirmed by testing, the troubleshooting process should begin. Vent rates, dome temperature versus pressure, and dome temperature versus storage temperature are usually the first items checked. A number of other potential causes have also been discussed. Two items that have not yet been mentioned are a leaking sample line and a leaking deaerator bypass valve. The sample line might leak air into the sample, or it might draw cooling water (with oxygen) into the sample. The sample line should be throttled only at the outlet to maintain pressure throughout its entire length. A leaking deaerator bypass valve will allow undeaerated makeup water to short circuit the deaerator into the feedwater line. Many new systems no longer have the ability to bypass the deaerator, so this problem is typically (but not always) noted on older construction. Evaluate Chemical Feed and Control Procedures Use proper chemical program Consider the needs of the system, and then fit the best product for the application. Sulfite should typically be used for most systems operating below 250 psig (1.7 MPag). These systems usually place little value on differentiating benefits such as passivation or low product solids contribution provided by carbohydrazide, diethylhydroxylamine (DEHA), erythorbic acid, or hydroquinone (HQ). Sulfite should not be used at pressures above 900 psig (6.2 MPag), because break down to the corrosive gases hydrogen sulfide (H2S) and sulfur dioxide (SO2) can be appreciable. Sulfite cannot be used in feedwater that is used for attemperation or desuperheating, because the sulfite solids will form deposits.

Check corrosion products in feedwater Corrosion product concentrations in the feedwater should be determined regularly using Nalco AP-088, the extended low-level total iron procedure, and AP-022, the low-level Fe (II) procedure. The Fe (II) test measures the fresh products of corrosion reactions in low oxygen environments. The Fe (II) test does not react with iron in the Fe (III) oxidation state or iron in the form of oxide particles. Fe (II) reacts with oxygen to form Fe (III), so this test has limited use during deaerator upsets. Sampling technique is critical. Sample lines must be stainless steel, and samples must be cooled and must flow continuously for many hours before the sample is taken. Additional details on sampling procedures are discussed in Section 2.21 of this manual. Sample points should be located at the inlet and outlet of all feedwater heaters and economizers. The goal of any oxygen scavenger program is to minimize corrosion. Without measuring corrosion products, you will not know if you are achieving this goal or not. Check chemical dosage Calculate the theoretical oxygen scavenger dosage based on dissolved oxygen versus the actual amount being fed. The actual amount fed is best measured by a pump drawdown cylinder mounted on the suction line of the chemical feed pump. Calculations for the theoretical dosage of a given product are found in the Confidential Product Profile (CPP). Deviations from theoretical can be caused by decreased deaerator performance (higher oxygen), oxygen inleakage at the feedwater pump or minimum flow line, and higher feedwater flows. Check chemical feed point Feed all oxygen scavengers to the neck between the dome and storage section of the deaerator using a NALQUILL injector. This provides optimum mixing and retention time for the scavenger. Injection into the neck, however, requires the injection quill shown in Figure 2.7.5

234

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

Section 2.7

DEAERATORS AND FEEDWATER TANKS

Table 2.7.2 Leakage of oxygen through plastic tubing Common plastic materials used for sample tubing show leakage of oxygen into water flowing inside the tubing due to the permeability of the material. The following list shows least permeable to most: O2 pickup in water; ppb/meter 0.02 0.03 0.05 0.05 0.1 0.12 0.14 0.2 0.43 1.7 2.04 3.2 3.9 5.1 5.3 8.5 13 19 60 1700 O2 pickup in water; ppb/lineal foot 0.006 0.009 0.015 0.015 0.030 0.037 0.043 0.061 0.13 0.52 0.62 0.98 1.2 1.6 1.6 2.6 4.0 5.8 18 518

Material Polyvinylidene chloride (Saran) Nylon Polychloro trifluoroethylene (Kel-F) Polyvinyl fluoride (Tedlar) Polyvinylidene fluoride (Kynar) Polyethylene Terephthalate (Mylar) Polyvinyl chloride (Non-plasticized) Polyacetal (Delrin) Ethylene/Monochlorotrifluoroethylene copolymer (Halar) Ethylene/Tetrafluoroethylene copolymer (Tefzel) High density polyethylene (opaque) Polypropylene High density polyethylene (clear) Polycarbonate (Lexan) Polystyrene Low density polyethylene Fluorinated ethylene/propylene (FEP) Tetrafluoroethylene (PTFE) Natural rubber (Latex) Silicone rubber (Silastic)

Data reported in Application Note 1.06, Orbisphere Laboratories

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

235

Section 2.7

DEAERATORS AND FEEDWATER TANKS

sample point so oxygen sampling can occur without shutting off the scavenger feed. (See Figure 2.7.4.) Check chemical preparation and feeding All liquid products should be fed neat. Dry products must be prepared properly to minimize activity loss. Turn the agitator off as soon as mixing is complete. Use a floating cover on the solution tank. Use high quality condensate or demineralized makeup as the water source whenever possible. Never mix other products in with an oxygen scavenger. This is especially important for catalyzed sodium sulfite/bisulfite products since polymers, chelants, phosphates, and alkalizing agents (e.g., caustic or amines) will consume or precipitate the sulfite catalyst. Failure to follow these recommendations will cause a loss in product activity. Check feedwater pH after scavenger injection Most chemical scavengers require a minimum pH of 8.5 for optimum oxygen removal. Acid regenerant breakthrough, demineralized or reverse osmosis quality makeup, raw makeup changes, condensate problems, untreated condensate, removal of amines from condensate treatment program, and high oxygen scavenger dosages can reduce the feedwater pH to unacceptable levels.

Deflection guard Drip guard (6.4 cm) 2 1/2 Ref. (30.5 cm) 12 Ref.

3/16 (0.5 cm) Reference mark to indicate downstream side of quill 5/8 (1.5 cm) 60

Figure 2.7.5 NALQUILL with no-drip shield (231-P4615.88)

Deaerator

stainless steel pipe or tubing capped at the ends with hole in end caps

Water line

Supports Oxygen scavenger supply Drop leg

Figure 2.7.6 Alternate oxygen scavenger feedpoint. 1/2 inch (13 mm) pipe with 1/8 inch (6.4 mm) hole in end caps

(231-P4615.88). A retractable version is also available (231-P4635.88). If the particular deaerator design does not have an external drop leg (neck) between the dome and the storage section or if there is any question whether the drop leg is commonly full of water, scavenger can be fed into the deaerator storage section. Multiple feedpoints may be necessary when feeding to the storage section in order to adequately distribute the product. This is accomplished by feeding to both ends of the deaerator or by means of an internal header that distributes chemical to both ends. (See Figure 2.7.6.) All products must be fed continuously. A bypass should be installed around the oxygen

DAILY OPERATION CHECKS The following items should be checked daily to ensure that the deaerator is functioning properly. Temperature of the water The temperature of the dome should be within 1-2F (0.6-1.1C) of the theoretical saturation temperature for the operating pressure of the deaerator. The temperature of the dome should be within 4F (2.2C) of the storage temperature. Deaerator venting The plume should be visible, strong, steady (not puffing), and without entrained water.

236

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

Section 2.7

DEAERATORS AND FEEDWATER TANKS

Water level gauge glasses These should be checked to ensure that an adequate storage level is being maintained by the makeup regulating valve. Overflow valve The overflow valve should be closed and not bleeding off steam. If the unit has a loop seal, check that this has not blown and that steam is not being lost for lack of a water seal. Oxygen scavenger level Correlate scavenger residuals/demand to normal deaerator operation. A severe change in treatment demand may signify a deaerator problem. Feedwater oxygen Feedwater oxygen should ideally be checked once/day minimum with oxygen scavenger on. Deaerator pH Deaerator (feedwater) pH should be checked once/day minimum and maintained at 8.5 or above. Usually, these simple checks will verify that the deaerator is operating correctly. Usually, the deaerator turnaround is kept as short as possible; however, a temporary deaerator or deoxygenation equipment can be brought into the plant for longer outages or repairs. During the inspection, be sure to check the following. Confirm all safety precautions before entering Inspection of a deaerator requires entry into a confined space and all appropriate safety procedures, such as lock out, tag out must be followed. Check all valves to make sure that they are tightly closed and tagged properly. Check for safe oxygen levels before entering deaerator storage or dome sections. Follow all applicable safety procedures. Determine deaerator type There are three main types of deaerators spray, tray, and atomizing. (See Figures 2.7.7-2.7.9.) These are covered in detail in the PAC-2 Boiler Water Technology Manual. The spray type uses spring loaded spray valves to break the water into a thin film for primary deaeration. This water then falls to a secondary stage, where the pressure is dropped to cause the water to boil and remove the remaining gases. In a tray type unit, the water enters the same as in the spray type for primary deaeration. The water then falls over a series of trays to break it into a thin film so that steam can remove final traces of gases. The atomizer type sprays the water as tiny particles into an atmosphere of steam. From there, it falls to the atomizer where a very high velocity steam jet turns the water to a mist, providing final deaeration. Check trays for proper positioning and cleanliness The trays in a tray type deaerator can fill with corrosion products or can be torn from their proper positions by water hammer or

INSPECT DEAERATOR DURING OUTAGES In many plants, a single deaerator serves multiple boilers. The boilers are dropped off-line individually for inspection or maintenance, but the deaerator stays in service. Sometimes, years go by without a single deaerator inspection. Deaerators are vital pieces of plant equipment and should be inspected annually. In fact, some insurance companies are now requiring yearly inspection of the deaerator as well as the boilers. Although it may require some temporary plumbing, provision can usually be made to bypass the deaerator if it is necessary to keep the boilers running. Higher concentrations of oxygen scavenger are typically fed during this time.

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

237

Section 2.7

DEAERATORS AND FEEDWATER TANKS

Figure 2.7.7 Spray type deaerator

238

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

Section 2.7

DEAERATORS AND FEEDWATER TANKS

Figure 2.7.8 Tray type deaerator

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

239

Section 2.7

DEAERATORS AND FEEDWATER TANKS

Figure 2.7.9 Atomizing type deaerator

240

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

Section 2.7

DEAERATORS AND FEEDWATER TANKS

rapid flow changes. Check all trays to make sure that they are secure in their positions and level (unless otherwise specified). Make sure all trays are clean and not clogged with corrosion products. Check each spray nozzle Spray nozzles have three parts mounting, gasket, and nozzle (Figure 2.7.10). All nozzles should close tightly. A hanging nozzle indicates a broken or weak spring. The nozzle area should be free of deposits. Spring pressure should be checked on each nozzle to insure proper operation. All nozzles should have an equal spring pressure. If not, the water will channel through the loose nozzles, and optimal water distribution will not be achieved. Spring calibration weights are normally provided by the manufacturer when the deaerator is installed. When the weight is hung from the nozzle, it should just begin to open. Spring tension should be adjusted accordingly on any nozzle, which either does not open or opens too much. All gaskets should be inspected. They should be in place and secure. There should be no cracked gaskets. A dark or shiny area on a wall or around a nozzle can indicate a problem with the spray pattern. This can be caused by overloading the deaerator or by a malfunctioning spray nozzle. Record the number of nozzles repaired. Inspect for corrosion and deposits The amount and location of all corrosion and deposits should be recorded. Inspect vessel welds for cracking All welds must be visually inspected for cracking. In addition to the visual inspection, the welds should be inspected by the non-destructive Wet Fluorescent Magnetic Particle technique on a regular basis. Inspection data accumulated by the NACE International have shown that more than 35% of the vessels, which had proper internal inspection, have been cracked severely enough to require weld repairs. Inspect injection and recirculating ports These ports should be free from obstructions. A dark spot across from the port may indicate excessive velocity of the flow. Check vent Make sure the vent is straight up from the deaerator and is free from restrictions. Make sure any vent condensers are free of leaks. Check waterline position Insure that the waterline in the deaerator storage section is at its proper level.

Figure 2.7.10 Typical deaerator spray nozzle assembly

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

241

Section 2.7

DEAERATORS AND FEEDWATER TANKS

EVALUATE LAY-UP PROCEDURES Lay-up procedures for deaerators are covered in the American Society of Mechanical Engineers (ASME) document CRTD Volume 66, Consensus for the Lay-Up of Boilers, Turbines, Turbine Condensers, and Auxiliary Equipment. This document is posted in the Knowledge Management (KM) database. The following paragraphs are from this consensus document. They are copyrighted by ASME and reprinted here with their permission. 12.2 Lay-up of Deaerator and Storage Tank A number of methods may be used to properly lay-up the deaerator and deaerator storage tank. It is preferred to maintain a steam blanket on the equipment, as this ensures some hot deaerated water for the subsequent startup. If steam is not available then the deaerator and storage tank may be: (1) Blanketed with a small continuous flow (30 scfh; 0.85 m3/h) of nitrogen (2) Drained while hot and maintained dry with dehumidified air or desiccant (3) Filled to the vent with water containing volatile oxygen scavenger and either ammonia or amine, as previously described for feedwater heaters 12.1 Lay-up of Feedwater Heaters The tubeside of feedwater heaters should be treated the same as the boiler during lay-up periods. The shellside normally is steam blanketed or dried and pressurized with nitrogen during lay-up. However, the shellside may be flooded with treated condensate or condensate-quality water. All-steel systems should be laid up with condensate containing 200 mg/L (ppm) volatile oxygen scavenger or equivalent, and ammonia or suitable amine such as cyclohexylamine as needed to maintain the pH at 10.0 minimum. For copper or copper alloy systems, use 50-100 mg/L (ppm) of volatile oxygen scavenger, and adjust the pH to 9.5.
Figure 2.7.11 Deaerator water box purge loop

EVALUATE START-UP PROCEDURES Start-up procedures introduce an upset condition regardless of how the start-up is accomplished. The method used should minimize the upset as much as possible. Improper, rapid start-ups after cold or hot lay-ups can produce conditions favoring corrosion fatigue cracking at the welds and can damage vessel internals, which will prevent good deaeration right from the start. The following comments are not meant to replace the equipment manufacturers recommendations for equipment start-up procedures. Provide initial feedwater near saturation temperature An auxiliary recirculation loop from deaerator storage to the main inlet waterline, as shown in Figure 2.7.11, will purge steam from the water box, which is created during a hot stand-by condition. Recirculation will eliminate those problems caused by sudden steam pressure collapse from cold feedwater entering the water box. Start the feedwater flow slowly (10-15% of normal flow). Increase the flow of cold feedwater gradually, watching the dome temperature and pressure and not allowing the pressure to vary more than 0.5 psig

242

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

Section 2.7

DEAERATORS AND FEEDWATER TANKS

(3.4 kPag) from normal. The purging loop is gradually shutdown as the feedwater flow increases and its temperature approaches the saturated steam temperature. Introduce steam first Start the flow of inlet water and slowly increase from 50-60% of design rate. Place the deaerator steam control valve on manual, and heat the unit gradually. Care must be taken as the water temperature passes atmospheric boiling and pressure is

established in the deaerator. Flashing in the boiler feedwater suction line may result in severe upsets if boiler feed pump net positive suction head is marginal. Once pressure is established in the deaerator, it should be increased at a slow rate so the deaerator storage tank water temperature is maintained within 9F (5C) of the saturation water temperature at the pressure in the deaerator.

DEAERATOR PERFORMANCE OPTIMIZATION

Deaerator optimization using data logging oxygen analyzers such as the Orbisphere PowerLogger can provide significant customer value. Optimization of the deaerator is usually limited to operational parameters such as vent rate, steam flow, feedwater flow, deaerator pressure, and feedwater pump(s) in use. Chemical parameters such as scavenger, scavenger feed rate, and feedwater pH can be optimized. Mechanical parameters such as vent size, internal nozzle type and condition, and tray type and condition cannot be changed during plant operation and are not candidates for performance optimization. The actual process consists of connecting the analyzer with logger to a cooled sample point in the feedwater. Scavenger feed should be discontinued approximately 2-3 hours before the start of the study. This allows baseline data on current deaerator performance to be collected. The operational and chemical parameters of interest are then changed one at a time and the effect on feedwater oxygen monitored. Oxygen scavenger may be restarted sometime during this portion of the study, if the intent is to note the effect of these parameters on scavenger performance. (See Figure 2.7.12.) Oxygen must be logged over a period long enough to produce a well-defined correlation to the parameter that was changed. The optimum conditions will produce feedwater with 7-10 ppb dissolved oxygen, which is the commonly accepted performance standard for a pressure deaerator. Dissolved oxygen greater than 10 ppb increases the chance of system corrosion, especially if the feedwater system includes an economizer, and increases the cost of scavenging. Dissolved oxygen less than 7 ppb results from increased steam use, venting, and operating pressure. Cost savings relative to increased steam use and venting can easily be quantified based on Examples 2.7.1 and 2.7.2.

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

243

Section 2.7

DEAERATORS AND FEEDWATER TANKS

Figure 2.7.12 Deaerator performance study

FEEDWATER TANKS
Feedwater tanks are typically installed in lowpressure plants (usually less than 100 psig; 689 kPag). They are a much simpler piece of equipment than a deaerator and mechanical removal of dissolved oxygen will be much less efficient.

Mechanical questions: For what boiler(s) or system does this specific feedwater tank provide feedwater? How many feedwater tanks are present in this system? What is the design flow rate through the feedwater tank? What are the design temperatures and flows for all makeup and condensate streams? Does condensate and makeup mix before the feedwater tank or enter separately? What is the return (entry) point for any hightemperature condensate streams? Where are the sample points located, and what are their estimated lag times based on line length and diameter? What is the sample line metallurgy?

THE SURVEY The first step in servicing or troubleshooting a feedwater tank is to complete an MOC survey. The list of appropriate questions is somewhat shorter than the list for deaerators. The survey should include questions in each of the MOC areas. Answers to the MOC questions will help establish expected versus existing performance of the feedwater tank, as well as identify potential problem areas.

244

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

Section 2.7

DEAERATORS AND FEEDWATER TANKS

What dissolved oxygen concentration is the feedwater tank designed to supply? Operational questions: What is the actual water flow through the feedwater tank? What is the condition of the vent (steady, sputtering, an invisible space between the top of the vent and the plume, etc.)? What is the source, pressure, and temperature of the steam used by the feedwater tank? What is the tank temperature? What is the temperature and flow rate of all high-temperature condensate streams? What is the temperature and flow rate of all makeup and low-temperature condensate streams? Do sample lines flow continuously or only as needed? If only as needed, how much flush time is provided before sampling? What are the date and findings of the latest oxygen testing done without scavenger? What are the date and findings of the last internal inspection, e.g., tank, welds, etc.? Chemical questions: What products/chemicals are fed to the feedwater tank? What is the dosage of these products? Are the products fed neat or diluted? Are multiple products mixed together before or at the injection point? What are the point(s) of injection for all products fed into the feedwater tank? Is a quill used, and how far does it extend into the feed point? What is the metallurgy of the feed system? What is the measured dissolved oxygen concentration in the feedwater tank effluent with oxygen scavenger? What is the feedwater pH in the feedwater tank after scavenger injection?

TROUBLESHOOTING POOR PERFORMANCE Figure 2.7.13 shows a well designed feedwater tank. Condensate returns through a sparge line near the bottom of the tank. Makeup enters through a sparge line just under the waterline. The density difference between the cold makeup and hot condensate allows some natural circulation to occur. A steam sparge should also be present to control tank temperature and will provide additional mixing. Sample points should be available for all incoming and outgoing lines, e.g., condensate, makeup, and feedwater discharge. Any sample consistently above 100F (38C) requires a sample cooler. Evaluate Original Design and Installation Obtain original design parameters and feedwater tank specifications Troubleshooting begins at the same point used for deaerators evaluation of existing equipment and installation against the original design and installation. As previously, obtain original design parameters and specifications for the feedwater tank. Record all manufacturers design criteria and specifications on the survey form. Obtain an original drawing of the vessel. Note the positions of all inlets, outlets, baffles, gauges, and sensors. Obtain current system diagram and determine current operating parameters Go to the feedwater tank and prepare a drawing of the unit, as it currently exists. Note the position of all inlets, outlets, gauges, thermocouples, and other sensors. Obtain accurate flow and

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

245

Section 2.7

DEAERATORS AND FEEDWATER TANKS

Figure 2.7.13 Properly designed feedwater tank

temperature data for all influent streams and for the steam supply. Note flow swings. Do not average flow information but record the actual flow ranges. Diagnostic TRASAR can be used for calibration of flow meters and verification of estimated flow rates. Evaluate Current On-Line Performance Check operating temperature The feedwater tank must be kept at a temperature as high as possible. Since the tank is not pressurized, this will be less than 212F (100C). Higher temperatures minimize the content of dissolved oxygen and other gases. (See Figure 2.7.14). A constant temperature above 185F (85C), ideally above 195F (91C), should be maintained with a supplementary steam sparge, if necessary.

If a large portion of makeup is used, heating the feedwater can substantially reduce the amount of oxygen scavenger required by lowering the oxygen content. (See Example 2.7.3.) Not only is there a savings in the amount of scavenger fed, but also a reduction in the amount of solids present in the feedwater. (Sulfite becomes sulfate when it reacts with oxygen.) The lower solids reduce the amount of blowdown needed to maintain chemical control limits in the boiler. The cost of heating the feedwater tank with steam is offset by the higher energy content (temperature) of the feedwater entering the boiler. The overall system energy requirements for the system stay essentially the same, except for a small increase in radiation and vent losses from the feedwater tank. Radiation losses can be

246

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

Section 2.7

DEAERATORS AND FEEDWATER TANKS

Figure 2.7.14 Dissolved oxygen solubility vs. temperature

Oxygen, ppm

Oxygen, ccL

minimized by maintaining good insulation on the tank. As temperatures approach 212F (100C), the possibility of feedwater pump cavitation increases. Water close to its boiling point can flash to steam in the low-pressure area at the eye of the pump impeller. Bubbles of steam are formed in this area and then collapsed when the pressure rises again at the pump outlet. Cavitation is noisy and can quickly damage the pump. Raising the feedwater tank as high as possible above the boiler and generously sizing the pipework on the suction to the feedwater pump increases the temperature at which cavitation is likely to occur. Check feedwater tank metallurgy Cast iron and mild steel are the most common materials of

construction for feedwater tanks, but with the typical operating conditions present, both are prone to oxygen corrosion. Type 304L stainless steel will greatly improve the life expectancy of the feedwater tank. Check feedwater tank capacity The feedwater tank serves as a hot condensate receiver, cold water makeup addition point, hot feedwater storage reservoir, and feedpoint for various chemical treatments. Ideally, the tank should be large enough to hold a 1-hour supply of feedwater at maximum steaming rate. It should also be large enough to accommodate peak condensate returns or surges. Lastly, the larger the tank, the longer the time available for oxygen/oxygen scavenger reactions to occur.

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

247

Section 2.7

DEAERATORS AND FEEDWATER TANKS

EXAMPLE 2.7.3 FEEDWATER TANK SULFITE DEMAND CALCULATION

Feedwater Tank Sulfite Demand Calculation

Temperature 140F (60C) 190F (88C) Oxygen Concentration from Figure 2.7.14 (ppm) 4.7 1.5

Current New (Goal)

The boiler is operating at 120 psig (827 kPag) and 20 cycles of concentration (COC). It is producing 15000 lb/hr (6804 kg/hr) of steam. Based on 20 cycles, it will require 15789 lb/hr (7162 kg/hr) of feedwater. Feedwater = (Steam)(COC)/(COC - 1) = (15000 lb/hr)(20)/(20 - 1) = 15789 lb/hr = (6804 kg/hr)(20)/(20 - 1) = 7162 kg/hr Sulfite usage under these two conditions can be calculated using the oxygen and residual sulfite factors found in the product CPP. For this example, we will use the following: Oxygen factor = 22.8 ppm product/ppm dissolved oxygen (DO) Residual factor = 4.56 ppm product/ppm sulfite residual Boiler water sulfite target = 45 ppm sulfite, as SO32 (30-60 ppm SO32) Current Sulfite Usage Sulfite Needed to Scavenge Oxygen Feedwater dosage = (feedwater DO)(oxygen factor) = (4.7 ppm DO)(22.8 ppm product/ppm DO) = 107.2 ppm product Sulfite Needed to Provide Boiler Residual Feedwater dosage = (boiler sulfite residual/boiler cycles)(residual factor) = (45 ppm sulfite/20 cycles)(4.56 ppm product/ppm sulfite) = 10.3 ppm product The total sulfite product required in the feedwater is the sum of the sulfite needed to scavenge oxygen and the sulfite needed to provide the desired boiler residual. Total feedwater dosage = 107.2 + 10.3 = 117.5 ppm product

248

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

Section 2.7

DEAERATORS AND FEEDWATER TANKS

EXAMPLE 2.7.3 FEEDWATER TANK SULFITE DEMAND CALCULATION (CONTINUED)

New Sulfite Usage Sulfite Needed to Scavenge Oxygen Feedwater dosage = (feedwater DO)(oxygen factor) = (1.5 ppm DO) (22.8 ppm product/ppm DO) = 34.2 ppm product Sulfite Needed to Provide Boiler Residual Feedwater dosage = (boiler sulfite residual/boiler cycles)(residual factor) = (45 ppm sulfite/20 cycles)(4.56 ppm product/ppm sulfite) = 10.3 ppm product The total sulfite product required in the feedwater is the sum of the sulfite needed to scavenge oxygen and the sulfite needed to provide the desired boiler residual. Total feedwater dosage = 34.2 + 10.3 = 44.5 ppm product Sulfite Product Difference The difference between the current sulfite dosage and the new (goal) is 117.5 - 44.5 = 73 ppm sulfite product. The difference in the sulfite product usage is: U.S. Units (73 ppm)(15789 lb/hr feedwater)/1000000 = 1.2 lb/hr or 28 lb/day Metric Units (73 ppm)(7162 kg/hr feedwater)/1000000 = 0.52 kg/hr or 13 kg/day

Plants with larger steam loads may not be able to size the feedwater tank to meet the characteristics listed above. They should have an additional treated water storage tank or a condensate tank capable of accommodating condensate return volumes. Check vent The feedwater tank must be vented to prevent buildup of pressure and to discharge the noncondensable gases removed from the water. The vent should be fitted with a vent head, which incorporates an internal baffle to separate entrained water.

The plume should be visible and steady, although it will typically not be as large or strong as for a deaerator. Check entry point of makeup and condensate As previously mentioned, condensate should enter through a sparge line close to the bottom of the tank. Makeup should enter through a sparge line just below the water surface of the feedwater tank. This provides some natural circulation. Cold makeup that enters along the bottom will likely be drawn directly into the feedwater line take-off, sending colder water to the boiler.

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

249

Section 2.7

DEAERATORS AND FEEDWATER TANKS

Both sparge lines should be constructed of 304L stainless steel to prevent early replacement from oxygen corrosion. Check dissolved oxygen The dissolved oxygen concentration in the effluent of a feedwater tank will depend on the temperature of the tank. The higher the temperature, the lower the oxygen. Refer to the previous discussion of dissolved oxygen testing under Deaerators. ahead of the tank will increase scavenger consumption. Feed of scavenger to the feedwater line after the tank will reduce scavenger consumption, but increase residual oxygen present. The presence of residual scavenger does not guarantee that all oxygen has been removed. Treatment injection should be at the point farthest from the feedwater take-off so that the entire tank receives treatment and maximum reaction time is available. It should be injected below the waterline using a NALQUILL injector. All products must be fed continuously. A bypass should be installed around the oxygen sample point so that oxygen sampling can occur without shutting off the scavenger feed. (See Figure 2.7.4.) Check chemical preparation and feeding All liquid products should be fed neat. Dry products must be prepared properly to minimize activity loss. Turn the agitator off as soon as mixing is complete. Use a floating cover on the solution tank. Use high quality condensate or demineralized makeup as the water source whenever possible. Never mix other products in with catalyzed sulfite. Polymers, chelants, phosphates, and alkalizing agents (e.g., caustic or amines) will consume or precipitate the sulfite catalyst. Failure to follow these recommendations will cause a loss in product activity. Check feedwater pH after scavenger injection Most chemical scavengers require a minimum pH of 8.5 for optimum oxygen removal. Raw feedwater changes, condensate problems, untreated condensate, removal of amines from condensate treatment program, and high oxygen scavenger dosages reduce the feedwater pH to unacceptable levels.

EVALUATE CHEMICAL FEED AND CONTROL PROCEDURES Check oxygen scavenger Catalyzed sulfite is the only acceptable chemical oxygen scavenger for these systems. Systems vary widely. Steam sparging to a temperature above 185F (85C), residence time at temperature in excess of 20 minutes, and product stoichiometry up to five times theoretical may be required in individual circumstances. Such high sulfite feed rates will require additional caustic feed to counteract the boiler water alkalinity consumption, if an acidic sulfite product is used. Adjusting the pH of the makeup water before the sulfite addition ensures a rapid chemical reaction rate. Check chemical dosage Calculate the theoretical dosage based on dissolved oxygen versus the actual amount being fed. The actual amount fed is best measured by a pump drawdown cylinder mounted on the suction line of the chemical feed pump. Calculations for the theoretical dosage of a given product are found in the Confidential Product Profile (CPP). Deviations from theoretical can be caused by decreased feedwater tank temperature (higher oxygen), oxygen inleakage at the feedwater pump, and higher feedwater flows. Check treatment chemical feedpoint(s) Oxygen scavenger must be fed to the feedwater tank, not before it or after it. Feed of scavenger

250

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

Section 2.7

DEAERATORS AND FEEDWATER TANKS

DAILY OPERATION CHECKS The following items should be checked daily to ensure that the feedwater tank is functioning properly. Temperature of the water The temperature of the water in the dome should be above 185F (85C), ideally above 195F (91C), and should be maintained with a supplementary steam sparge, if necessary. Feedwater tank venting The plume should be visible, steady (not puffing), and without entrained water. Water level gauge glasses These should be checked to ensure that an adequate storage level is being maintained by the makeup regulating valve. Overflow valve The overflow valve should be closed and not bleeding off steam. If the unit has a loop seal, check that this has not blown and that steam is not being lost for lack of a water seal. Oxygen scavenger level Correlate scavenger residuals/demand to normal feedwater operation. A severe change in treatment demand versus normal may signify an operational problem.

Feedwater oxygen Feedwater oxygen should be checked once/week minimum with oxygen scavenger on. Tank pH Tank pH should be checked once/day minimum and maintained at 8.5 or above. Usually, these simple checks will verify that the feedwater tank is operating correctly.

INSPECT THE FEEDWATER TANK DURING OUTAGES Feedwater tanks are important to the plant operation and should be inspected annually. During the inspection, be sure to check the following: All injection and recirculating ports should be free from obstructions. A dark or shiny spot across from the port may indicate excessive velocity of the flow. Make sure the vent is straight up from the feedwater tank and is free from restrictions. Insure that the waterline in the tank is at its proper level. The amount and location of all corrosion and deposits should be recorded. All welds should be visually inspected for cracking.

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

251

Section 2.7

DEAERATORS AND FEEDWATER TANKS

For your notes:

This page has been intentionally left blank.

252

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

Section 2.7

DEAERATORS AND FEEDWATER TANKS

For your notes:

This page has been intentionally left blank.

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)

253

Section 2.7

DEAERATORS AND FEEDWATER TANKS

For your notes:

This page has been intentionally left blank.

254

CONFIDENTIAL, For Nalco Employee Use Only 2007 Nalco Company Boiler Water Applications and Best Practices Guide Book 314 (10-07)