Boiler Water Training PDF

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Water & Process Technologies

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Boiler Technical Training

At
Reliance Industries Limited
Hazira Manufacturing Division
K S Rajan
February 26, 2008
RIL-Hazira/BWT-Technical Training
GEWPT- Confidential Material
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BOILER WATER TREATMENT
• BASIC WATER CHEMISTRY

• BOILER DESCRIPTION
• OXYGEN PITTING & CONTROL
• CONDENSATE TREATMENT
• INTERNAL TREATMENT, COORDINATED
pH/PO4
• STEAM PURITY
• BOILER STORAGE
• DISCUSSION, Q&A
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Basics & Interpretation of Water Analysis
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“The Basics”
• Hydrologic Cycle
• Properties of Water
• pH and Alkalinity
• Langelier Saturation Index
• Analytical Expressions
• Water Analysis/Deposit Analysis
• Corrosion and Deposition & Monitoring
• Chemical Feed
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Properties of Water More Proof.
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•Density - 1 kg/l @ 4 oC ; 0.998 kg/l @ ambient temperature and

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

• 3 Categories
• SUSPENDED SOLIDS (Silt)
• DISSOLVED SOLIDS (Minerals)
• DISSOLVED GASES
• Where do these things come from?
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Hydrologic Cycle
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Impurities found in Water
• Dissolved solids present as ions

• Cations - Ions that carry net positive charges e.g. Calcium (Ca2+), Magnesium
(Mg2+), Sodium (Na+), Iron (Fe2+), Aluminium (Al3+)
• Anions - Ions that carry net negative charges e.g. Bicarbonates (HCO3-),
Carbonates (CO32-), Sulfate (SO42-), Chlorides (Cl-), Oxides (O2-), Hydroxides (OH-)
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Water Impurities Water & Process Technologies
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Impurity Concern Removal

Suspended Solids Fouling Clarification
Silt, Iron, Erosion Filtration
Microbiogical Underdeposit corrosion
Dissolved Solids Scaling Ion Exchange
Minerals, Corrosion Reverse Osmosis
Organics Evaporation
Pitting
Dissolved Gases General Corrosion Deaeration
O2, CO2, NH3 Corrosion products Steam Stripping
Dissolved Solids
Cations Anions
Temporary HCO3- Total
Hardness Ca++ Mg++ Alkalinity
possibly OH- & CO3--
Permanent
Hardness Cl- F-
Mineral
Na+ NO3- PO4 --- Acidity
K+
NH4+
SO4--
SiO2, possibly free CO2

Organic acids
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Dissolved Solids Commonly Found in Water More Proof.
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Cation Anion Chemical Name
Calcium Bicarbonate Ca(HCO3)2

Sulfate CaSO4
Magnesium Bicarbonate Mg(HCO3)2

Sulfate MgSO4
Sodium Bicarbonate NaHCO3

Sulfate Na2SO4
Chloride NaCl
Silica Oxide SiO2
Iron Bicarbonate Fe(HCO3)2

Hydroxide Fe(OH)3
Sulfate FeSO4
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Factors Affecting Solubility More Proof.
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•Temperature - Most salts increases except for Ca and Mg Salts

with increasing temperature
•Alkalinity - Most salt solubility increases with decreasing
alkalinity with the exception of Silica
•pH - most salts solubility increases as the pH drops
•Oxidation state - Fe and Mn salt solubility increases with
decreasing oxidation state
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Impurities found in
Water
• Turbidity - suspended solids
– silt, organic matters, precipitated
salts
• Color - suspended solids and
dissolved solids
• Dissolved gases e.g. CO2, O2, NH3,
H2S
• Organics - humus, vegetation, micro-
organisms
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Typical Water Analysis Water & Process Technologies
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Parameter Value
pH 7.3
Conductivity μS/cm 150
Alkalinity “P” as CaCO3, ppm 0
Alkalinity “M” as CaCO3, ppm 20
Sulfate as SO4, ppm 15
Chloride as Cl, ppm 10
Hardness, Total, as CaCO3, ppm 20
Calcium Hardness, as CaCO3, ppm 15
Magnesium Hardness, as CaCO3 ppm 5
Copper, Total as Cu, ppm 0.05
Iron, Total as Fe, ppm 1.5
Sodium, as Na, ppm 12
Phosphate, Total, as PO4, ppm <0.05
Silica (reactive), as SiO2, ppm 4
Turbidity, NTU 50
TSS, ppm 20
Color, Hazen 3
RIL-Hazira/BWT-Technical
TOC, as C, ppm Training 1
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Special Ions More Proof.
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• pH
• Hydrogen, H+
• Hydroxide, OH-
• Alkalinity
• Bicarbonate, HCO3-
• Carbonate, CO3--
• Hydroxide, OH-
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pH More Proof.
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• Hydrogen Ion Concentration

• Logarithmic Scale
• pH = -log [H+]
• Unit change in log scale
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How Does pH Apply

to Us?
• pH < 7: Acidic (corrosion)
• pH > 7: Alkaline (deposition)
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Alkalinity
Relationships •M-Alkalinity = Total
– Titration to pH = 4.3
– Sum of: HCO3- + CO3- + OH-
•P-Alkalinity = OH- + 1/2 CO3-

– Titration to pH 8.3
•OH-Alkalinity = 2P - M or titration
– Neutral barium chloride precipitates CO3-
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Conductivity Water & Process Technologies
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• Inverse of Resistance [mho]

• Measure of concentration of ions in solution
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Types of Solubility Water & Process Technologies
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Normal: Increases with Temperature

• Table Salt (NaCl)
• Sugar
Retrograde: Decreases with

Temperature
• Calcium Carbonate
• Calcium Phosphate
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How Do We Quantify What Is in the Water?
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Analytical Expressions Water & Process Technologies
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• “Concentration”
• units of solute per unit of solvent:
• PPM (parts per million)
– parts of solute per million parts of
solvent
• mg/l (milligrams per liter)
– 1 gram solute/1,000,000 grams
solvent
• PPB (Parts Per Billion)
parts of solute per Billion parts of solvent
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Analytical Expressions Water & Process Technologies
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•“Mg as CaCO3”
Magnesium expressed as its Equivalent weight
in Calcium Carbonate
100 (MW CaCO3) = 4.1

24 (MW Mg)
Analytical Infrastructure
Expressions Water & Process Technologies
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• Different Conventions
• We use “ppm as CaCO3”
• ppm ppm
• as substance factors as CaCO3
• Ca 50 2.5 125
• Mg 20 4.1 82
•
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Boiler
Boiler Descriptions
Descriptions
FIRETUBE BOILERS
ADVANTAGES DISADVANTAGES
High load swing capacity Low pressure
Ease of repair Capacity limit
Low space requirement Usually no superheater
Self contained package Usually no economizer
Relatively low cost Usually low efficiency
Ease of installation One fuel at a time
FOUR-PASS FIRETUBE BOILER

WATERTUBE BOILERS
– Economizer
– Steam drum
– Mud Drum
– Headers
– Boiler Bank
Typical Parts of a • Downcomers - Risers
Water Tube • Waterwalls
Boiler Includes:
• Screen tubes
• Arches
• Floor tubes
• Roof tubes
– Superheater
– Air Heater
WATERTUBE BOILERS
RISERS
DOWNCOMERS SUPERHEATER
STEAM SCREEN TUBES
DRUM
ECONOMIZER
WATER WALLS
MUD
AIR HEATER DRUM
Coal
140-150 C
To stack
Lower Water
BOILER DESIGN Walls Header
Comparison - Watertube vs. Firetube:
Water Tube Fire Tube

Steam
Steam
Feedwater Drum CBD Flue
Water
Risers Gases
Flue Mud
Drum Downcomers
Gases
IBD
WATERTUBE BOILERS
ADVANTAGES
Low to super critical WATERTUBE BOILER: A-TYPE
pressure
z Virtually unlimited capacity
z Typically high efficiency
z Superheaters
zEconomizers
z Multiple fuels
z Drum or once-through
z Package or field-erected
DISADVANTAGES
z High Cost
z Require Large Space
z Usually require higher quality
feedwater
z Sensitive to low load operation
Risers
Steam Exit Drum

W
BF
Downcomers
Sidewall Problem
Area
Flue
Gas
Burner Path
Steam Drum
D-Frame
Package Boiler
Downcomers
Furnace Wall
Tubes
Risers
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Babcock & Wilcox
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Coal FiredMore
Boiler
Power.
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Power Utility Boiler
Hot Reheat Water & Process Technologies
Simplified Flow Diagram
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HP Turbine More Power.
HP SH Steam
Sat Steam
Condenser MB MU
IP Turbine LP Turbine
B&W Boiler
BD
Cold Reheat
LP Heaters
Cond Polisher
HP Heaters
Deaerator
BFW
CAUSE AND EFFECT DIAGRAM FOR BOILER PROBLEMS
POOR pH CONTROL OXYGEN PITTING
POOR CHEMICAL
FEED CONTROL MECHANICAL
INADEQUATE DEAERATOR
BLOWDOWN OXYGEN PERFORMANCE
CONTROL IN-LEAKAGE
DOWNTIME
POOR BOILER CORROSION
FEEDWATER
QUALITY SCAVENGER
UNDERFEED DOWNTIME
CONDENSATE POOR CORROSION
CONTAMINATION EXTERNAL
TREATMENT
BOILER
CORROSION
POOR BOILER
FEEDWATER
QUALITY
STRESSED
CONDENSATE CONCENTRATING AREA
CONTAMINATION MECHANISM
POOR EXTERNAL
TREATMENT POOR CHEMICAL
FEED CONTROL
INADEQUATE EMBRITTLING WATER
BLOWDOWN CHARACTERISTICS
CONTROL
DEPOSITION STRESS CORROSION CRACKING

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FeedWater = Steam + Blowdown

Boiler Calculations
% Blowdown = 1 X 100
Cycles
FeedWater (kg/hr) = Steam Generation (kg/hr)

1 – (%blowdown)
100
FW= STM ( C )
C-1
Determining Cycles of Concentration Infrastructure
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•Feedwater vs. Boiler Water analysis
•BFW Cycles = [Boiler Conc.] / [FW Conc.]
• Cycles = Neutralized Boiler Water Cond. (umhos at 25C)

___________________________________________
Feedwater Cond. (umhos at 25C)
• Check via Chlorides, Silica
• Do not use compounds that routinely precipitate (phosphate,

hardness) or that are part of treatment (sulfite/sulfate)
•Demineralized or RO make-up – Tracer methods

• Molybdate
Infrastructure
Steam, Feed Water & Blowdown Relationships More Proof.
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% Blowdown = 100 / FW Cycles

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

• FW = 100 MM ppy steam X [20 / (20 – 1)] = 105.3
Feedwater = Steam + Blowdown

• BD = FW – ST = (105.3 – 100) MM ppy = 5.3 MM
ppy
Feedwater = Make-up + Condensate
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Oxygen Control
• Deaeration
• Chemical treatment
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Corrosion of Iron by Oxygen More Proof.
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O2
Fe(OH)3 O2
Fe2+ OH-
WATER
ELECTRON FLOW
ANODE CATHODE
ANODE REACTION CATHODE REACTION
Fe. = Fe++ 2e- 1/2 O2 + H2O + 2e- = 20H-
MECHANISM
• Iron Is Oxidized on the Surface (Anode) - Metal Loss
• Oxygen Is Reduced (Cathode)
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Oxygen Corrosion
• Corrosion Rate Doubles With Every

10 C Increase in Water Temperature
• Metal Loss is low
• Localized attack
• Pit Formation
• Rapid Failure
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Rapid Perforation ~ Equipment Failure More Proof.
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Oxygen Guidelines More Proof.
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Organization Dissolved O2 Level, ppb
ASME <7
TAPPI <7
ABMA NO RECOMMENDATION
EPRI <5
DEAERATOR 7
GUARANTEE
TYPICAL DEAERATOR 15 - 40
O2 LEVELS
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Types of Oxygen Scavengers
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• Solid
– Sodium Bisulfite
– Sodium Sulfite
• Non-Solids
– Hydrazine
– Hydroquinone
– Diethylhydroxlamine (DEHA)
– CARBOHYDRAZIDE
– ASCORBIC ACID
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RECOMMENDED
SULFITE CONTROL LIMITS
Residual (ppm SO3-) Pressure

30 - 60 < 40 bar
10 - 20 40 - 60 bar
ATTEMPERATION / DESUPERHEATING: NO
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Hydrazine More Power.
Reaction:
N2H4 + O2 N2 + 2H2O
Decomposition Reaction:
2N2H4 + HEAT + 2H2O 4NH3 + O2
Feedrates:
3 x (ppm O2 + Residual)
Control Limits:
0.1 ppm Residual N2H4 at Economizer Inlet
Attemperation / Desuperheating:
Yes
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Hydrazine
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Hydrazine More Power.
• Advantages:
– Doesn’t contribute to TDS
– True residual test
• Disadvantages:
– Poor reactivity with low temperature
– Expensive compared to Sulfite
– Suspect carcinogen
– Requires special handling / feed
equipment
– Decomposes to NH3, which can lead to
copper corrosion
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Organic O2 Scavengers More Proof.
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• Pressure > 900 psig (60 bar)
• BFW used for superheat attemperation
• Condensing turbine present
• High-Purity Makeup (Demin./RO)
• Coordinated PO4 / pH control
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HYDROQUINONE More Power.
OH
REACTION:
C6H6O2 + 1/2O2 H2O + C6H4O2
CONTROL LIMITS: OH
DISSOLVED OXYGEN TEST
IRON REDUCTION TEST
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HYDROQUINONE Water & Process Technologies
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ADVANTAGES More Power.
• DOES NOT CONTRIBUTE TO TDS

• FASTEST ORGANIC OXYGEN SCAVENGER
• REQUIRES NO SPECIAL HANDLING
• EXCELLENT FOR WET LAY-UP
• AVOIDS SULFUR CATALYST POISON
• NOT A LISTED CARCINOGENIC
OH O
+ O2 =
OH O
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Carbohydrazide More Proof.
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H 3
O 2
-N
REACTION: -C
N 2
H 3
N4H6CO + O2 2 N2 + 3H2O + CO2
DECOMPOSITION REACTION:
N4H6CO + H2O + HEAT 2N2H4 + CO2
2N2H4 + HEAT + 2H2O 4NH3 + O2
CORTROL-OS-5613
RESIDUAL(0.3-0.5 ppm product)
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Carbohydrazide
Advantages
• Low/no cation conductivity
contribution
– Does not form LMW organic
acids
– CO2 contribute to non degassed
cationic conductivity
• Well-accepted in Industry
• Much safer than hydrazine
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Variables Influencing More Proof.
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Scavenger Reaction
• Time
• Temperature
• pH
• Catalyst
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pH and Temperature Recommendations More Power.
OXYGEN SCAVENGER MINIMUM TEMP* MINIMUM pH*
SULFITES 80 OF (27 C) >8.5

HYDRAZINE 190 OF (88 C) >8.5
HYDROQUINONE (HQ) 80 OF (27 C) >8.5
HYDROXYLAMINES (HA)
>200 OF (> 93 C) >8.5
ASCORBIC ACID
180 OF (82 C) >8.5
CARBOHYDRAZIDE
>200 oF(> 93 C) >8.5
*FOR EFFICIENT OXYGEN SCAVENGING

PERFORMANCE
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Monitoring
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Ideal
Point
1
ECONOMIZER
1) Primary sample point for oxygen testing

2) Sample point necessary for deaerator studies and for
troubleshooting oxygen intrusion through the pump
MONITORING • pH
• Conductivity
• Hardness, silica
• Oxygen
• Corrosion
– metals analysis
– corrosion coupons
Millipore Iron Testing
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Feed Water and Condensate

System Treatment
• Ammonia
• Amines
• Condensate polishing
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Condensate Treatment
In The Condensate:
• Carbon Dioxide
CO2 + H2O H2CO3
H2CO3 H+ + HCO3-
pH DECREASES
Infrastructure
Feedwater Alkalinity Water & Process Technologies
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Is a Source of CO2 in Condensate More Power.
IN THE BOILER:
2HCO3- CO3= + H20 + CO2
CO3= CO2 + 2OH-
STEAM
CO2
FEEDWATER OH-
HCO3-
CO3=
BLOWDOWN
Infrastructure
Relative Corrosion Rate of Water & Process Technologies
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Copper Alloys and Carbon Steel vs pH More Power.
CARBON
STEEL
CORROSION
RATE
COPPER
7 8 9 10
pH
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Fundamental Amine
Characteristics
• Distribution Ratio
• Neutralizing Capacity
• Basicity
• Thermal Stability
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NEUTRALIZING AMINES Water & Process Technologies
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R - NH2 + H2CO3 R - NH3+ + HCO3-
R - NH2 + H2O R - NH3+ + OH-
10
9
CONDENSATE, pH
5 0 2 4 6 8 10 12 14 16
AMINE FEED (ppm)
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BASICITY
Neutralizing Basicity Constant
Morpholine 2
Ammonia 18
Ethanolamine 32
DEAE 66
MOPA 126
Cyclohexylamine 440
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DISTRIBUTION RATIOS More Proof.
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DR = Concentration in steam
Concentration in liquid
VAPOR
LIQUID
HIGH DISTRIBUTION LOW DISTRIBUTION

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

& Steam Purity
• Coordinated PO4 /pH

• Steam purity
Deposit Formation
• Deposition rate increases with heat flux (Btu/Ft2)

• Reduces Heat Transfer
• Increases tube wall temperature
• Induces corrosion
• Ultimately - Tube failure
Effect of Deposition on Heat Transfer
Tube Metal
Insulating
Scale
800°F
Fireside
Combustion
Gases
600°F
Fireside
500°F 500°F
Waterside Waterside
Scaled Tube Clean Tube

Surface Surface
Cause and Effect Diagram for Boiler Deposition
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Monitoring Tools
1. Monitor NaZ Performance: More Power.
2. Monitoring Boiler Feedwater/
Condensate Hardness Monitoring Tools
3. On-Line Hardness Analyzers 1. Boiler Feedwater/ Condensate
4. Equipment Inspections Iron Monitoring
5. Routine Blowdown Testing 2. Turbidity Monitoring
6. Data Tracking 3. Equipment Inspections
Hardness Salts Iron

Intermittent Intermittent
Contamination Contamination
Condensate Hardness
Contamination Condensate Corrosion
Poor NaZ Performance Chemical Underfeed
Chemical Underfeed Poor Blowdown Control
Poor Blowdown Control Poor Storage Practices

Deposition
Fouling
Poor Chemical Feed Control
Condensate Hydrocarbon High Boiler Silica

Contamination Poor Separation
Equipment Performance
Rapid Load Swings
Hydrocarbon Contamination
Poor Blowdown Control Header Pressure Swings
Hydrocarbon Superheater/Turbine Fouling

Monitoring Tools
Monitoring Tools 1. Steam Purity Monitoring
1. On-Line Total Analyzer 2. Routine Boiler Testing
2. Boiler Feedwater Inspection 3. On-Line Sodium Analyzer
4. Equipment Inspections
3. Equipment Inspections
5. Data Tracking
Infrastructure
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Coordinated Phosphate/pH Programs More Power.
z Used Primarily in high pressure boilers to

protect against caustic gouging
z Applicable for lower pressure boiler

systems on demin quality makeup
z Sodium (caustic) is primary feedwater

contaminant
z Iron may also be a problem polymers used

for iron control
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Coordinated PO4/pH Boiler Treatment More Power.
• To control boiler water pH......
• ......Create a buffer system

between PO4 and NaOH
Under-Deposit Corrosion
Infrastructure
High or Low Boiler Water pH More Proof.
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Corrodes Boiler Steel
RELATIVE
CORROSIVE
ATTACK
8.5 pH 12.7 pH
SAFE RANGE
1 2 3 4 5 6 7 8 9 10 11 12 13 14
pH
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Na: PO4 RATIO OUT OF CONTROL More Power.
EXCESS “SODIUM LEAKAGE”
Na2 HPO4 + 2NaOH Na3PO4 + NaOH + H2O

Low DSP Fed “Free Caustic”
4Na + 1PO4
Na:PO4 = 4:1
Infrastructure
PREVENTING CAUSTIC More Proof.
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CONCENTRATION
NaOH + Na2HPO4 Na3PO4 + H2O

Caustic Disodium Trisodium
Phosphate Phosphate Water
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Coordinated Phosphate/pH Control More Power.
2Na2 HPO4 + 2NaOH 2Na3PO4 + 2H2O

“Exact” DSP Fed
6Na + 2PO4
Na:PO4 = 3:1
Under-Deposit Neutralization
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C O O R D IN A T E D p H /P H O S P H A T E C O N T R O L
1 0 .8
1 0 .6
M A X IM U M B O U N D A R Y 3 .0 :1 M O L A R R A T IO
1 0 .4 ``F re e '' C a u s tic
R e g io n 2 .8 :1 N a /P O 4 C o n tr o l A r e a
1 0 .2 <900 psi
1 0 .0
2 .7 :1 N a /P O 4 C o n tr o l A r e a
9 .8 9 0 1 -1 5 0 0 p s i `` C a p tiv e ''
A lk a lin ity
pH AT 9 .6 R e g io n
2 .6 :1 N a /P O 4
25C 9 .4 C o n tr o l A r e a
1 5 0 1 -2 0 0 0 p s i C A U S T IC T R I-S O D IU M
9 .2 PHO SPHATE
9 .0
C o n tr o l A r e a V e c to r
2 0 0 1 -2 5 0 0 p s i
8 .8 C O N T R O L B O U N D A R Y C o n tro l D I-S O D IU M
C o n tr o l A r e a
>2600 psi
2 .2 :1 N a /P O 4 D ia g ra m PHO SPHATE
8 .6 M O L A R R A T IO
BLOW DOW N M O N O -S O D IU M
8 .4 CO NTRO L AR EA PHO SPHATE
2 5 0 1 -2 6 0 0 p s i
8 .2
1 .0 2 3 4 5 6 7 8 10 15 20 30 40 50 60
p p m O rth o p h o s p h a te , a s P O 4
Infrastructure
Caustic-Phosphate Equilibrium More Proof.
More Power.
Caustic Tri-sodium PO4
Di-sodium PO4
Blowdown
Mono-sodium PO4
Reality Check
Your 90 bar boiler has a pH 9.5 and PO4 of 30 ppm.
Boiler PO4 control range is 10 - 20 ppm
How should we respond?
[A]
Reality Check
Your readings for this 100 bar boiler are pH 10.2 and PO4 of 6. PO4
control range is 4 - 8 ppm.
What actions will put you back into control?
[A]
Acid Phosphate Corrosion
zAcid PO4 corrosion potential exists when

boiler water Na/PO4 ratio is less than 2.3
zSodium PO4 (Di or Mono) can react with

Magnetite or Iron to form Maricite (NaFePO4)
under high temperature (>300 C)
Infrastructure
Steam Purity More Proof.
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Importance of Steam Purity

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

Solid, liquid or vaporous
contamination in the steam
• Steam Quality
A measure of the moisture in
the steam
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Steam Purity
Guidelines • Turbine manufacturer (ppb
levels)
• Boiler manufacturer (ppm
levels)
• Industry professional
organizations
• Operations
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Turbine Manufacturers’ Steam Purity Limits More Power.
General Westing Allis

Electric house Chalmers
PARAMETER NORMAL 100 HR. 24 HR. NORMAL 2 WEEK 24 HR. NORMAL
Cation Cond. 0.2 0.5 1 0.3 0.3-0.5 0.5-1.1 0.1

uS/cm
Sodium, ppb 3 6 10 5 5-10 10-20 10
Chloride, ppb A A A 5 5-10 10-20 10
Silica, ppb A A A 10 10-20 20-50 10
Iron, ppb A A A 20 5
Copper, ppb A A A 2 1
Oxygen, ppb A A A 10 10-30 30-100 5
A - Governed by requirements of the steam-generator manufactureer
Steam Turbine - Problems
• Deposition
– Deposit thickness 0.1 mm reduces stage efficiency by
3%
• Surface Roughness
– Affects flow passage width
– Reduce stage efficiency
• LP Blade corrosion
– Stress corrosion cracking (NaOH, Cl)
– Pitting
– Erosion
Industrial Steam Turbines
Typical Sources of Impurities
Chemical Cleaning Makeup Water
Air In-Leakage Demineralizers

Water
and
Steam
Condenser Leaks Water Treatment

Chemicals
Corrosion Products Process Chemicals

STEAM PURITY
Steam Purity vs Steam Quality

• Steam purity is the solid, liquid, or vaporous contamination
in the steam
• Steam quality is the measurement of moisture in steam
Steam Purity Guidelines

• Turbine & Boiler Manufacturers
• Industry Professional Organizations
– (ASME, ABMA, EPRI, VGB, BS )
• Boiler Manufacturers
• Operations
Steam Purity
Guidelines
Normal Operation
Parameter ABB GE Westinghouse Mitsubishi

Na, ppb < 10 <20 < 10 < 10
SiO2, ppb < 20 < 20 < 20 < 15
Total Fe, ppb < 20 < 20 <5
Cu, ppb <3 <2
Cl, ppb < 15 <2
Cationic
Cond. us/cm <0.2 < 0.2 < 0.3 < 0.2
Steam Purity Guidelines
Abnormal Operation (Westinghouse)
* Time refers to continuous time in the range and also to total time in a 12-month period in the
range
Parameter 2-week * 24-Hour * Immediate

Shut Down
Cation Cond. 0.3 - 0.5 0.5 - 1.0 > 1.0
us/cm
Na, ppb 10 - 20 20 - 35 > 35
SiO 2, ppb 20 - 40 40 - 80 > 80
Cl, ppb 15 -30 30 - 50 > 50
SO 4, ppb 15 -30 30 - 50 > 50
CARRYOVER: MECHANICAL CAUSES
• STEAM SEPARATION EQUIPMENT
• STEAM DRUM LEVEL
• STEAM LOAD
• OVERFIRING
CARRYOVER:
CHEMICAL CAUSES
• FOAMING
– TDS
– Alkalinity
– Organics/ Polymer Overfeeding
– Antifoam
• SELECTIVE VAPOROUS CARRYOVER (GOVERNED BY DRUM
pH, PRESSURE AND TEMPERATURE
– Silica
– Others - Cl, SO4, Fe
ATTEMPERATION
WATER
• FEEDWATER
–Quality of Feed water
–Chemical Treatment
• SWEET WATER CONDENSER
–Source of Coolant
–Purity of Steam Source
• CONDENSATE
MONITORING STEAM PURITY
SODIUM
• On Line Analyzer
• Isokinetic Sampling
• Bottle Study (Na free
bottles)
• Saturated Steam
Infrastructure
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Boiler Storage
• Most oxygen corrosion occurs or is
initiated when boiler is off-line (wet
storage)
• Key to Success - Alkaline & oxygen-free

during wet storage
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Boiler Storage
• Dry Storage with a desiccant is
recommended for long-term storage
• What constitutes ‘long-term’?

– Off-season storage
– Rule-of-thumb: Normally recommend
dry storage if lay-up will be >1 month
and boiler will not be needed on short
notice
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Boiler Storage More Power.
• Wet storage is recommended when:

– Boiler is required for emergency
stand-by or on short notice
– Capacity required to meet peak
demand
– Unit will be out-of-service for
< 1 month
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Wet Storage Methods
1. Volatile Chemicals
2. Sulfite & Caustic
3. Cascade lay-up / Hot standby
4. Dry lay-up with desiccant
Infrastructure
General guidelines for wet More Proof.
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storage with chemicals
• Add chemicals to fill water as it is pumped
into boiler
• Fire boiler moderately after chemical

addition to circulate & distribute or utilize
external circulation pump
– Always follow boiler manufacturers
recommendations for firing the boiler
• Adjust pH/alkalinity with amine or caustic

consistent with the lay-up chemical being
used.
Infrastructure
General guidelines for wet storage of high-pressure More Proof.
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boilers with chemicals

• Weekly testing during wet storage
– Measure pH/Alkalinity
– Test dissolved oxygen and/or
scavenger residual
– Maintain dissolved oxygen level below
10 ppb
– Supplement scavenger/amine as
required
• Preventing oxygen ingress during storage:

– Connect surge tank (drum) filled with
lay-up solution to upper vent
– Alternative - 5 psig (0.34 bar) nitrogen
‘cap’
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Volatile Chemicals
• Required when:
– Above 900 psig (60 bar)
– Non-drainable superheaters
– Turbines
– High-purity make-up
• Sulfite is NOT suitable
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Volatile Chemicals More Power.
• Acceptable water for preparation of high-

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

into boiler
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Suitable volatile More Power.
oxygen scavengers
• Hydroquinone
– Fastest reaction with oxygen at
ambient temp
– Must use neutralizing amine with HQ
– Important - Amine MUST be
compatible
with HQ (or will develop sludge):
• Hydroxylamines
– Most volatile & compatible with
amines
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Suitable volatile More Power.
oxygen scavengers
• Hydrazine - 200 ppm as N2H4
– Excellent passivator at > 200 ppm as
N2H4, BUT:
– Not recommended - Safety hazard!
– Amine is not typically required
• Ascorbic acid - Not recommended:

– Poor thermal stability
– Acidic decomposition products
– Non-volatile
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Volatile Chemicals More Power.
• Special lay-up product - CorTrol OS7700
• HQ plus special low-volatility amine

package
• Avoids low pH excursions on re-start
• Feedrate: 2000 ppm product

– 4000 ppm in new systems (non-
passivated)
– Maintain pH above 10.5 throughout
Infrastructure
Dry Lay-up with Desiccant (Long-term More Proof.
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storage)
• Drain boiler
• Hot air/heat to remove all moisture
• Use desiccant (with color indicator)

– Silica gel
– Quick lime
– Activated alumina
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PRESENT TREATMENT PROGRAM AT HAZIRA
• CORTROL-5613-OXYGEN SCAVENGER
– FEED RATE 0.5-1.0 PPM
– RESIDUAL MONITORING.
• STEAMATE-NA8590
– CONDENSATE TREATMENT
– LOW DR AMINE
• TRI SODIUM PHOSPHATE
– FOR pH/PO4 coordination
• AMMONIA
– FEED WATER & STEAM pH CONTROL
Infrastructure
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More Power.
Thank You

Boiler Water Training PDF

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Infrastructure

Water & Process Technologies

Boiler Technical Training

BOILER WATER TREATMENT

• BASIC WATER CHEMISTRY

Basics & Interpretation of Water Analysis

•Density - 1 kg/l @ 4 oC ; 0.998 kg/l @ ambient temperature and

Impurities found in Water

• SUSPENDED SOLIDS (Silt)

• DISSOLVED SOLIDS (Minerals)

• Where do these things come from?

• Dissolved solids present as ions

Impurity Concern Removal

SiO2, possibly free CO2

Cation Anion Chemical Name

Calcium Bicarbonate Ca(HCO3)2

Magnesium Bicarbonate Mg(HCO3)2

Sodium Bicarbonate NaHCO3

Silica Oxide SiO2

Iron Bicarbonate Fe(HCO3)2

•Temperature - Most salts increases except for Ca and Mg Salts

• Hydrogen Ion Concentration

How Does pH Apply

•P-Alkalinity = OH- + 1/2 CO3-

• Inverse of Resistance [mho]

Normal: Increases with Temperature

Retrograde: Decreases with

How Do We Quantify What Is in the Water?

100 (MW CaCO3) = 4.1

FOUR-PASS FIRETUBE BOILER

Water Tube Fire Tube

Steam Exit Drum

POOR pH CONTROL OXYGEN PITTING

DEPOSITION STRESS CORROSION CRACKING

FeedWater = Steam + Blowdown

FeedWater (kg/hr) = Steam Generation (kg/hr)

•Feedwater vs. Boiler Water analysis

•BFW Cycles = [Boiler Conc.] / [FW Conc.]

• Cycles = Neutralized Boiler Water Cond. (umhos at 25C)

• Check via Chlorides, Silica

• Do not use compounds that routinely precipitate (phosphate,

•Demineralized or RO make-up – Tracer methods

 % Blowdown = 100 / FW Cycles

 Feedwater = Steam X [Cycles / (Cycles –1)]

 Feedwater = Steam + Blowdown

 Feedwater = Make-up + Condensate

• Corrosion Rate Doubles With Every

Organization Dissolved O2 Level, ppb

Residual (ppm SO3-) Pressure

• Pressure > 900 psig (60 bar)

• BFW used for superheat attemperation

• Condensing turbine present

• High-Purity Makeup (Demin./RO)

• Coordinated PO4 / pH control

• DOES NOT CONTRIBUTE TO TDS

2N2H4 + HEAT + 2H2O 4NH3 + O2

• Much safer than hydrazine

OXYGEN SCAVENGER MINIMUM TEMP* MINIMUM pH*

SULFITES 80 OF (27 C) >8.5

*FOR EFFICIENT OXYGEN SCAVENGING

1) Primary sample point for oxygen testing

Feed Water and Condensate

CO2 + H2O H2CO3

% Blowdown = 100 / FW Cycles

Feedwater = Steam X [Cycles / (Cycles –1)]

Feedwater = Steam + Blowdown

Feedwater = Make-up + Condensate