Professional Documents
Culture Documents
Training Program
Auxiliary Boiler 12 Ton/Hr , 12 Barg
By. PT Basuki Pratama Engineering
1
Items of Training
I. Preface
II. Utilizing Equipments
III. System Description
IV. Operation Sequence
V. Maintenance
VI. Boiler Operation Water Treatment
PREFACE
2
What is that Steam Boiler BHS-12000-LO ?
3
1 Unit Steam Boiler BHS-12000-LO (10QHA01AC101)
Capacity : 12 Ton/Hr , 12 Barg
Design / Operating Pressure : 12 Barg / 9 Barg
Efficiency : 89 % (min)
Type of Fuel : Diesel Oil
Max Fuel Consumption @ Full load : 812 Kg/Hr
4
1 Unit Superheater (10QLB11AC001)
Steam Capacity : 10,000 Kg/Hr
Steam Temperature : 260 oC
Operating Pressure : 8 Barg
Design Pressure / Temp. : 12 Barg / 300 oC
Test Pressure : 18 Barg
5
1 Unit Feed Water Tank w/Deaerator
(10QLA11AC101 / 10QLA11BB101)
Operating Pressure : 0.13 Barg
Design Pressure : 1 Barg
FWT Capacity : 12,000 Ltr
Deaerator Capacity : 12 M3/Hr
FWT Dimension : Dia 1900 x 4200 S/S
Deaerator Dimension : Dia 650 x 1400 S/S
6
1 Unit Blow Down Tank (10QHF01BB001)
Dimension : Dia 600 x 1,200 S/S
Design Pressure / Temperature : 1 Barg / 120 oC
Operating Pressure : Atmospheric
c/w : Vent Head & Silincer
7
3 Units Sample Cooler
(10QUA03AC001 ; AC002 ; AC003)
8
1 Unit Boiler Dosing Device (10QLF11AP201)
9
Process Flow Diagram
10QLF11AP101
BOILER DOSING DEVICE
10
Front Control Panel
11
Feed Water System
Logic Diagram
Feed Water Tank
FIELD INPUTS CONTROL SWITCHES LOGIC LAMP INDICATORS (LCP) FIELD OUTPUT
SOLENOID VALVE #1
HIGH LEVEL REGULATION NAND ON
L2
WATER INLET VALVE 1
AUTO/OFF/MANUAL L13
S7 AND
1
AUTO SOLENOID VALVE 1
OPEN
OR S
10QLA11 AA002
FCV 159
MANUAL R
SOLENOID VALVE 1
WILL CLOSE WHEN
LEVEL REACH L2
OFF
SOLENOID VALVE #2
NAND ON
WATER INLET VALVE 2
AUTO/OFF/MANUAL L14
S8 AND
2
AUTO SOLENOID VALVE 2
OPEN
OR S
10QLA11 AA007
FCV 161
MANUAL R
SOLENOID VALVE 2
WILL CLOSE WHEN
LEVEL REACH L3
OFF
12
Feed Water Tank
L1
Instrument
L2
By-pass level indicator 5 switch (LIS 144) :
Used for control level feed water tank and level indicator
Solenoid valve 1 (FCV 159) and Solenoid valve 2 (FCV 161) :
Valve water inlet feed water tank
L3
Pressure switch (PSL145) :
Used for monitoring of pressure in water tank.
L4
System Description
Pressure switch
Water inlet valve can operate manually and automatically with selector switch
L5
water tank valve in control panel. Auto status, valve operate depend on level
switch. If water level :
Above L1; valve1 & valve2 close, alarm FWT high, digital input FWT on, and
disturbance indicator FWT high ON.
By-pass level
Above L2; valve1 & valve2 close. indicator
Above L3; valve1 open & valve2 close
Below L4; valve1 & valve2 open
Below L5; valve1 & valve2 open, alarm FWT low, FWP off, digital input FWT
low, disturbance indicator FWT ON.
If pressure feed water tank below setting (set=0.1 bar), pressure switch signal
to digital input feed water tank pressure to low
Solenoid valve
Logic Diagram
Dosing System
FIELD INPUTS CONTROL SWITCHES LOGIC LAMP INDICATORS (LCP) FIELD OUTPUT
Solenoid Valve
Service Water Inlet
DOSING PUMP 2
FCV 159 1 ON
2 FCV 161
DOSING PUMP 2
AUTO/OFF/MANUAL OR L2
S2 AND
OFF
13
Feed Water Tank Dosing Pump
Instrument
Dosing pump :
Supply hydrazine and amine from feed water tank
dosing to feed water tank
Mixer pump :
Mix hydrazine and amine in feed water tank dosing
System Description
Dosing device can operate manually and
automatically with selector switch dosing pump2 in
control panel. Auto status, dosing device operate
depend on solenoid valve1 water inlet feed water
tank. Dosing pump
Mixer
14
Logic Diagram
Daily Fuel Tank
FIELD INPUTS CONTROL SWITCHES LOGIC LAMP INDICATORS (LCP) FIELD OUTPUT
BY PASS LEVEL
INDICATOR
10QHH01
OIL LEVEL
HIGH
OIL HIGH
L1 L16
OIL LEVEL
LOW LEVEL REGULATION
LOW
L3
L17
INTERLOCK
TO BURNER
OIL LOW (OFF BURNER)
L4
S9 AND L15
LCV 239
AUTO
10QHH01
OR S AA002
OFF
L2
Instrument
Above L1; valve close, digital input fuel oil tank level high on, and indicator oil to
high on.
Above L2; valve close
Above L3; valve open
Below L4; valve open, indicator oil to low on, alarm oil tank to low, burner off
(manual ON)
Below L5; valve open, digital input fuel oil tank level to low on
Solenoid valve
15
Oil Measurement
Instrument
Oil flow meter (FQI 190) :
Used for measuring oil flow daily fuel tank to boiler
Oil totalizer :
Display water totalizer in control panel
Oil flow rate :
Recorder
Display water flow in control panel
Recorder :
Record oil flow in control panel.
System Description
Flow meter signal to oil totalizer, oil flow rate, oil flow recorder, and
auxiliary analog output (4-20mA) fuel firing rate (terminal X3 74;75).
16
Saturated Steam Temperature
Instrument
Temperature sensor PT 100 ( TE 221) :
Measuring saturated steam temperature
Temperature display (TI 141) :
Display saturated steam temperature in control panel
System Description
Temperature sensor signal to temperature display for saturated steam
temperature. Sensor PT 100
Temperature Display
Logic Diagram
Blow out
FIELD INPUTS CONTROL SWITCHES LOGIC LAMP INDICATORS (LCP) FIELD OUTPUT
S12
SELECTOR
OPEN
OFF
10QLB11
AA903
SERVO MOTOR
CLOSE
BLOW OUT
BLOW OUT
10QLB11AA903
10QLB11
CF01 P
FT I
137
FT 137 BUILT IN SET POINT=2 Bar
D
Press. After
PRESS. TRANSMITTER
FOR TEMP. Super Heater
COMPENSATION
START
PID CONTROL
Controller Burner
17
Steam Flow Meter and Blow Out Steam
Instrument
Steam flow meter (FT 137) :
Used for measuring steam from boiler
Steam display and controller (FC139) :
Steam display
Display steam flow in control panel and controller
Valve blow out (FCV 224) :
Valve for steam start up
System Description
Flow meter signal to steam totalizer, steam display controller, and steam
flow recorder in control panel. Blow out valve can operate manually and
automatically with selector switch blow out in control panel. Auto status,
valve open (blow out steam) if pressure super heater not reach (set = 2
bar) and burner not OK.
Logic Diagram
Super Heater
FIELD INPUTS CONTROL SWITCHES LOGIC LAMP INDICATORS (LCP) FIELD OUTPUT
10QLB11
CF01
> 960 kg/hr FLOW
FT
137
18
Super heater
Instrument
Temperature sensor PT 100 ( TE 211) :
Measuring super heater temperature steam
Temperature display and controller (TIC 213;TI 210) :
Display temperature super heater steam in control panel
and control damper super heater Actuator damper
Actuator damper super heater : super heater
System Description
Temperature sensor signal to temperature super heater display in control panel
and auxiliary analog output (4-20mA) super heater steam temperature (terminal
X3 76;77).
Damper operate regulation if flow steam reach 960 kg/h and pressure > 7.7 bar. Temperature steam display
and controller
If temperature 280°C digital input super heater temp. high on.
If temperature 300°C disturbance indicator super heater temp. to high on
Instrument
Pressure Transmitter :
Pressure Transmitter are used to measure pressures in liquids
and gases. The pressure is converted into an electrical signal
Pressure super heater display and controller :
Display Pressure super heater steam in control panel
and control damper burner
Actuator steam out : Pressure super heater steam
display and controller
Actuator for control valve saturated steam out Pressure Transmitter
System Description
Valve saturated steam out operate with selector switch main
steam valve in control panel ( open-close valve ).
if pressure reach 8 bar in pressure display control panel operator
can operate this switch.
Valve
19
Blow Down Tank & Drain System
Logic Diagram
Blow Down Tank
FIELD INPUTS CONTROL SWITCHES LOGIC LAMP INDICATORS (LCP) FIELD OUTPUT
TEMPERATURE CONTROL
10QHF01
TIC231
BLOWDOWN TANK
S3 ON
BLOWDOWN TANK
AUTO/OFF/MANUAL L3
AND
AUTO
OR S 10QHG01
AA002
OFF
20
Blow Down Tank
Instrument
Temperature sensor PT 100 ( TE 232) :
Measuring blow down tank temperature
Temperature controller (TIC 231) :
Control for blow down tank temperature
Solenoid valve (TCV 233) :
Valve service water inlet blow down tank
Temperature controller
System Description
Service water inlet valve can operate manually and automatically Sensor PT 100
with selector switch blow down tank valve in control panel. Auto status, valve
operation depends on setting temperature (set = 50°C). If temperature over
setting valve open and conversely.
if temperature increase (>60°C), digital input blow down tank discharge
temperature high on.
Solenoid valve
21
Steam Boiler System
Instrument
Blow down controller (PRS-7b) :
Generates a control pulse which, after the preset blow down
interval, operates the three way solenoid valve.
Three way solenoid Valve :
Solenoid for control valve intermittent blow down Schematic layout
Valve intermittent blow down (BDV 115) :
Intermittent blow down valve boiler
Sightglass (FG123) :
Visual supervision of condensate conditions in heat
exchangers and flow conditions pipelines. It clearly indicates
loss of live steam, banking up of condensate or the presence
of air.
Sightglass
Logic Diagram
Surface Blow Down
FIELD INPUTS CONTROL SWITCHES LOGIC LAMP INDICATORS (LCP) FIELD OUTPUT
10QHA01
CT01QP DESALTING
REGULATOR AND
CE CONDUCTIVITY
124 LIMITER
SWITCH
LKER 1
ELECTRODE DESALTING ON/OFF OPERATION
CONDUCTANCE
10QHA01
BT001 10QHA01
AA005
SERVO MOTOR
DESALTING VALVE
22
Steam Boiler System
Instrument
Conductivity Electrode (CE 124) :
Monitoring of condensate return to boiler to detect water any
penetration of acid, alkalis etc.
Continuous blow down controller (LRR 1-5b) :
Automatically controlled continuous blow down to reduce blow
down wastage and increase operating safety.
Control Valve (CCV 122) :
Motorized control valves for continuous blow down system of
steam boiler. Conductivity
electrode
System Description
Surface blow down can operate manually and automatically with
selector switch blow down valve in control panel.
Automatic system work depends on value setting. If condensate
boiler over setting value, valve open and operate conversely
Logic Diagram
Boiler Water Level Control
FIELD INPUTS CONTROL SWITCHES LOGIC LAMP INDICATORS (LCP) FIELD OUTPUT
HIGH WATER
LEVEL
10QHA01
CL05QN L7 AUDIBLE
ALARM
LEHH BS
103 HIGH & LOW WATER
LEVEL CONTROL LOW WATER
HIGH WATER NRS 1-2b LEVEL
ELECTRODE
10QHA01 L6
CL04QN
10QHA01
LELL
104
ELECTRODE
10QHA01
CL07QN OFF Burner (Auto ON)
LT CONTINUOUS
WATER LEVEL
106 CONTROL 10QHA01
NRR 2-2e AA026
CONTINUOUS WATER
LEVEL PROBE
A MOTORIZED VAVE
SERVO MOTOR
10QHA01
CL08QN
ZS
23
Steam Boiler System
Instrument
Level electrode (LELL 104; LEHH 103) :
Signaling of level conductive (Low level alarm, high level alarm).
Level electrode (LELL 105) :
Signaling of level conductive (Extra low level alarm).
Level Probe (LT 106) :
Level probe for modulating level control boiler.
Level Switch (NRS 1-2b) :
Control for low level and high level boiler
Level Switch (NRS 1-7b) :
Control for extra low level boiler
Level controller (NRR 2-2e) :
Control valve for feed (fill) or drain (discharge) for modulating level
boiler
Actuator Valve (LCV 184) :
Motorized control valve modulating level boiler.
Lamp indicator (LI 107) :
Indicator for dangerous level water in boiler.
boiler level :
Indicator level boiler in control panel
System Description
Control valve
If extra low level (LELL 105) reach, lamp water level extra low on, digital
input boiler water level to low on, alarm extra low level boiler, and extra
low level indicator in panel.
Indicator lamp
Level boiler
24
Steam Boiler System
Instrument
Pressure switch regulation (PSHL 110) and Pressure switch limiter
(PSHH 111) :
Used for controlling and monitoring of pressure in steam boiler.
System Description
If pressure boiler over pressure switch regulation setting (9.5 bar); burner interlock Pressure switch
(auto operate), pressure high indicator panel on, display fault in panel, and digital
input steam pressure high on.
If pressure boiler over pressure switch limiter setting (10 bar); burner interlock
(manual operate), pressure high indicator panel on, digital input steam pressure to
high on
Pressure limiter
Logic Diagram
Operation Burner
FIELD INPUTS CONTROL SWITCHES LOGIC LAMP INDICATORS (LCP) FIELD OUTPUT
BURNER
ON
AUTOMATIC
BURNER
CONTROLLER
BURNER START/ LAL 2.25 L21
FAILURE RESET
10QHH01
10QHA01 DPOO1
CP03QN * MANUAL RESET ON
PSHL PRESSURE SWITCH
110 AND
PRESSURE BOILER DISTURBANCES
NOT HIGH
10QHH01
WATER LEVEL AV101
EXTRA LOW
BLOWER MOTOR
10QHH01
AND AV101
WATER LEVEL LOW
COMPOUND REGULATOR
SERVO MOTOR
S13
START PID
CONTROLLER
AUTO
1. Control Blow Out
BURNER CONTROL
2. Pressure saturated
steam control
DECREASE OR S
10QHH01
R AV101
INCREASE
OFF 10QHH01
AV101
10QHH01
CR001 IGNITION TRANSFORMER
FLAME SENSOR
FLAME INTENSITY
25
Logic Diagram
Control Damper Burner
FIELD INPUTS CONTROL SWITCHES LOGIC LAMP INDICATORS (LCP) FIELD OUTPUT
10QLB11
CP01QB P
PT I T 10QHA01
207 AV101
COMPOUND
REGULATOR
POSITION
START
START CONTROLLER PID CONTROL
Burner controller
CONTROLLER IN MANUAL MODE
OPEN/STOP/CLOSED
A
Control blow Out
REF. SH. NO. 33
SWITCH S13
5. Burner
Instrument
Automatic burner controller :
Used to control Burner of steam boiler.
Light oil Burner
Burner Controller
System Description
Burner operate with push button (start / stop burner).
Damper burner can operate manually and automatically with selector
damper switch in control panel.
Burner off if one of this condition happens : Boiler pressure too high,
boiler extra low, and oil low level and must start again.
Operating burner control with automatic burner controller.
Time sequence diagram shows burner operation system
Regulation burner depends on pressure saturated steam
Burner
26
Time Sequence Diagram
DOSINGPUMP1
FWP1 3 ON
4 FWP2
DOSINGPUMP1
AUTO/OFF/MANUAL OR L1
S1 AND
AUTO DOSINGPUMP1
START
OR S
10QLF11 AP101
HV177
MANUAL R
OFF
27
Boiler Dosing Pump
Instrument
Dosing pump :
Supply phosphate from boiler dosing to feed water
tank
Dosing pump
Mixer pump :
Mix phosphate in boiler dosing
System Description
Dosing device can operate manually and
automatically with selector switch dosing pump2 in
control panel. Auto status, dosing device operation
depends on solenoid valve1 water inlet feed water
tank.
Mixer
Logic Diagram
Feed Water Pump Operation
FIELD INPUTS CONTROL SWITCHES LOGIC LAMP INDICATORS (LCP) FIELD OUTPUT
S5 F.W PUMP 1
OPERATION
SELECTOR FEED WATER
AUTO/OFF/MANUAL L9
AND F.W. PUMP 1 3
AND F.W. PUMP 1
AND S 10QLA11 AP101
AUTO
R
AND OR OR
MANUAL
OFF
S6
SELECTOR FEED WATER
PUMP1/OFF/ PUMP2
OR F.W PUMP 2
OPERATION
PUMP 1
L10
F.W. PUMP 2 4
PUMP 2 F.W. PUMP 2
OR AND S 10QLA11 AP102
OFF OR R
DEAERATOR
LEVEL NOT LOW
BOILER
LEVEL NOT HIGH AND
AND
AND
AND
PUMP 1 TRIP
PUMP 2 TRIP
28
Feed Water Pump
Instrument
Feed water pump (130) :
Pump from feed water tank to boiler
Pressure Indicator (PI 131) :
Indicate pressure in line feed water pump
System Description
There has two feed water pump operate interlock.
Feed Water Pump
Each feed water pump can operate manually and automatically with selector
feed water pump in control panel.
In auto status, pump operation depends on high level boiler, and feed water
tank level low.
If a pump trips, trip pump indicator in control panel on, display feed water
pump trip in control panel, digital input feed water pump trip on.
pressure gauge shows pressure in line of feed water pump
Pressure Indicator
Instrument
Temperature sensor PT 100 ( TE 140) :
Measuring flue gas temperature
Temperature display (TI 141) :
Displaying flue gas temperature in control panel
System Description
Temperature sensor signal to temperature display for flue gas
temperature. Sensor PT 100
Temperature Display
29
Feed Water Measurement
Instrument
Feed water flow meter (FQI 175) :
Used for measuring water flow from feed water tank to boiler
Water totalizer :
Display water totalizer in control panel
Water flow rate :
Recorder
Display water flow in control panel
Recorder :
Record water flow in control panel.
System Description
Flow meter signal to water totalizer, water flow rate, and water flow
recorder.
Flow rate
Totalizer
30
Control Panel
31
8. Operate dosing pump 1(dosing feed water tank)
- selector switch dosing pump 1in auto position
9. Operate blow down tank
- selector switch blow down tank valve in auto position
10. Check alarm and disturbance indicator
No sound/indicator alarm and disturbance indicator no fault.
V. Maintenance
32
Operating Log Book
A. Records of daily checks and servicing operations as well as other checks must be
kept in an operating log book and signed daily by the responsible boilerman
(operating personnel). In the case of some installation, this operating log book may
be demanded as a prerequisite for the operating permit. Recurring test carried out
by the technically competent person must also be entered in this operating log
book. The forms appended to these operating instruction should be used for this
purpose. When using boilers with superheaters, the operator must enter details of
the hot steam temperature at brief intervals (at least every 30 minutes) in a
separate sheet, along with details of the date and time, if no use has been made of
a hot steam temperature control and if the superheater is installed in the are of high
exhaust gas temperature. Here damage may occur if operation is not carried out
conscientiously.
B. The boilerman’s superior must convince himself at least weekly of proper operation
and servicing of the steam boiler installation and must note this on the rear of the
sheet in the operating log book along with his signature and the date
A. Prior to start up of the installation and when each shift commences, the operating personnel (boilerman) must convince themselves of
the installation’s proper operating condition.
B. The function of the water level limiters must be checked daily and at the start of each shift, unless they are self monitoring,i.e. special-
design, devices. External devices must be blown out
C. Temperature and pressure limiters need not be checked daily. The intervals for these units depend on their nature-refer to weekly
checks and servicing.
D. The time intervals for checking safety valves must be agreed by the operator and technical expert considering the service life of the
sealing faces, daily checking is not recommended.
E. Blowing out
Water level indicators and external feed water controllers and limiters must be blown out, attention being paid to the necessary
operating sequence for shut-off and blown out valves.
F. Checks of all fire systems
f.1. Keep the fire chamber free from residues and coke sediment
f.2. Smoke-free combustion
f.3. Correct oil temperature – when using heavy fuel oil
f.4. Suitable oil pressure
G. Checks to be carried out when using heavy fuel oil
g.1. Gas pressure
H. Water analysis
Refer to the operating log book and the water directives
Note
Pay attention to the operating instructions issued by the supplier of the water treatment plant. Devices or checking the feed water
generally do not suffice for checking the boiler water. Please enquire in cases of doubt.
I. Boiler blow down
J. Check sealing points and lock them and, if necessary, retighten them and renew the packings
K. Important note
If controllers are rendered inactive by malfunction, the installation must be observed continuously if its operation is continued. If safety
devices should fail, please inform our Customer Service and, if necessary, shut down the installation and inform the installer for the
installation of BASUKI representative in your area, or directly to us (refer to our contact address & phone/fax numbers)
33
Weekly Checking and Servicing
A. Maximum water level ensuring facility in the case of hot steam boilers.
Semi-annual Checks
34
Operating Logbook for Aux. Steam Boiler
35
Operating Instruction for Aux. Steam Boiler
36
Phosphate Dosing System Line
37
Blow Down System Line & Boiler Sample Line
Source of corrosion :
Dissolved gas: oxygen,
carbon dioxide, and ammonia.
Oxygen is the most aggressive.
Cause pitting corrosion
• Make-up water introduces soluble oxygen.
• The condensate return system contains soluble
oxygen
38
Boiler Waterside Corrosion
Waterside Deposition
Boiler deposits result from hardness salts, metallic oxides, silica and a number
of other feed water contaminants that can enter the system.
Minimizing the adverse impact of these contaminants is the role of the boiler
water treatment program.
Even the best controlled systems occasionally have upsets that cause
excessive amounts of contamination to pass into the boiler. Some examples
would be:
39
Mechanism of Deposition
• Reaction:
10Ca2+ + 6PO43- + 2OH- Æ 3Ca3(PO4)2·Ca(OH)2 Calcium hydroxyapatite
40
Embrittlement
Caustic embrittlement or
intercrystalline cracking
Catastrophic results
Causes:
1. Leakage of boiler water
2. Concentrated caustic soda occurs from the concentrated boiler
water.
3. There is high metal stress in the area of caustic concentration and
leakage.
External Treatment
To improve the quality of this source prior to its use
as boiler feed water, including reducing contaminants.
Applied to water prepared for use as boiler feed water, refers to the
chemical and mechanical treatment of the water source.
Internal Treatment
To minimize impurities after the best and most appropriate external
treatment of the water source, boiler feed water (including return
condensate)
41
Steam Plant Operation- Feed Water Preparation
Minimize hardness
Ex : Calcium and Magnesium, migratory iron, migratory copper, colloidal
silica, consistent with boiler design and operation parameters.
Objectives :
• Providing the highest temperature water for injection to the boiler, from
ambient temperature to 103 ºC to prevent boiler from thermal shock
42
Deaeration (Mechanical and Chemical)
• Designed to minimize
saturated dissolved O2
content in the supplied
de-mineralized water
and to achieve a suitable
O2 content fed to the
boiler
Saturated steam (1243 kg/hr, temperature 105-180 ºC, pressure 9 bar (g) )
The dissolved oxygen leaving the deaerator will be ± 7 ppb to protect auxiliary
boiler system from corrosion with residual hydrazine approximate 0.1 ppm.
Excessive oxygen content in 2. Check steam pressure reducing valve. Check valve for free operation, and see that
deaerator effluent control line is connected to the connection provided in the deaerator.
3. Check water and, if possible, steam flow rates vs. design. Trays or scrubber and inlet
valves are designed for specific flow ranges.
Temperature in storage tank does 1. Improper spray from spray nozzle. Check nozzle for sediment or deposit on seat or
not correspond within 3 º C of broken spring.
saturation temperature of the 2. Excessive free air due to leaking stuffing boxes on pumps upstream of deaerator that
steam have negative suction head. Repair stuffing box or seal with deaerated water.
1. Trays collapsed-possibly from interrupted steam supply or sudden supply of cold water
causing a vacuum.
Excessive consumption of 2. Condensate may be too hot. Water entering the deaerating heater must usually be
oxygen scavenger cooled if the temperature is within 20 º F of saturation temperature of the steam.
Check the design specification to determine what inlet water temperature was originally
intended.
1. Improper operation of inlet control valve. Adjust as necessary.
Low pressure 1. Check for improper operation of steam pressure reducing valve.
43
The Effect of pH On Corrosion Rate
Effect of pH on the Corrosion Rate of
Steel. Water Chemistry Upsets Result in
Decrease or Increase of pH of Boiler
Water, Resulting in Tube Deposits or
5 7 Corrosion.
4 9
2 3 6 10 11 12 14 approximate pH
Relative Corrosion Rate
Mineral Carryover
Definition:
Carryover is generally considered to be any
contaminant that leaves a boiler steam drum with
the steam.
Causes:
Mechanical Factor: Priming (sudden pressure
while load rises)
Chemical Factor: Foaming (by alkalinity, organic
and synthetics contaminant), Selective vaporous
carryover
Effects:
1. Deposition in regulators and valving
2. Deposition in superheaters
3. Deposition in control valves and turbines
4. Process contamination
44
Carbon dioxide Corrosion
Source:
Alkalinity in feed water
HCO3 Î
CO3 heat Î CO2
Air in- leakage
Organic material
Characteristics:
Reaction:
CO2 + H2O ÍÎ H2CO3
H2CO3 ÍÎ H+ + HCO3-
Caustic Corrosion
Characteristics :
Often occurs in High Pressure Boiler
Localized corrosion
Contributed by deposit accumulation (Iron,
copper, etc)
Boiler operation excess maximum capacity
Massive load fluctuation
Reactions :
Fe2O3 + 2NaOH Î 2NaFeO2 + H2O
FeO + 2NaOH ÎNa2FeO2 + H2O
Fe +2NaOH + 2H2O Î 2NaFeO2 + H2O
45
Internal Boiler Water Treatment
Use internal conventional program :
• Hydrazine
Magnetite build up
N2H4 + 6Fe2O3 Æ 4Fe3O4 + N2 + H2O
Sludge
Thermally unstable
Corrosive volatile gas
REAKSI HYDRAZINE
Oxygen scavenging,
N2H4 + O2 Æ N2 + 2 H2O
Stochiometric reaction,
dosage of 35 % solution – 8.6 ppm/1 ppm residual
oxygen
Poisonous,
LD50 rating – class 5 toxin – 82 mg/kg
46
Neutralizing Amines
Function:
To neutralize the carbon dioxide and then provide small
additional amounts to buffer the pH to 8.5 or 9.5.
WATER SPECIMENT
47
QUALITY WATER PARAMETER
1. Demin Water Outlet 2. Boiler Feed Water
Spec. conductivity : < 1.0 uscm Spec. conductivity : < 5.0 us/cm at 25 deg.C
Silica: : < 0.02 ppm SiO2 Silica : < 0.02 ppm SiO2
pH: : 6.5 ~ 7.5 pH : 8.5 ~ 9.5
Sodium: : < 0.005 ppm Na Hydrazine : < 0.2 ppm N2H4
Iron : 0.02 ppm Fe Iron : <0.02 ppm Fe
3. Boiler Water
Spec. Conductivity: < 150.0 us/cm at 25 deg.C
Silica : < 2 ppm SiO2
pH : 9.5 ~ 10.5
Phosphate : 3.0 ~ 10. ppm PO4
4. Steam
Spec. Conductivity: < 5.0 us/cm at 25 deg.C
Silica : < 0.02 ppm SiO2
pH : 8.5 ~ 9.5
Iron : <0.02 ppm Fe
Function:
To maintain the solids content of the boiler water within prescribed limits
Basic Calculation
% Blow down :
Concentration of dissolved solids in Feed water =
Concentration of dissolved solids in blowdown
Quantity of blow down/Feed water
% Make up :
Concentration of dissolved solids in Feed water =
Concentration of dissolved solids in Make-up water
Quantity of make–up/ Feed water
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Blow down in Action
CR = 1/%blowdown x 100 =
The greatest danger to steam boilers is today the uncontrolled absorption of atmospheric oxygen
by the boiler water during shut down periods.
Oxygen has a corrosive effect – particularly during start-up, but also during shut down periods.
Method
1. Wet conservation binds the oxygen of the water held in the boiler.
oxygen binding agents are: Hydrazine & Sodium sulphite
2. Dry conservation ensures that no moisture remains in the boiler effectively preventing
corrosion of the steel
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HYDRAZINE WET CONSERVATION PROCEDURE
1 g (atmospheric) oxygen in the water is bound by 1 g hydrazine (N2H4) = 7
g commercial, approx. 24% hydrazine hydrate (N2H4.H2O)
g/m3 g/m3
Boilers with alkalinization and
fully demineralized feed
water
≤ 50 h (weekend) 20 - 30 140-210
1 month 50 – 100 350 – 700
longer 100- 350 700 - 2000
Boilers with alkalinization and 150 - 450 1000 - 3000
only softened feed water
irrespective of time
c. To prevent varying oxygen concentration and therefore the creation of air entrainment
elements, the steam boiler must be completely filled with hydrazine-containing boiler water.
d. All gate – and screwdown stop valves must be closed completely after filling the boiler with
hydrazine-containing boiler water and kept closed during the conservation treatment.
e. If within the shut down period the hydrazine concentration must be topped up.
Circulate the boiler water to ensure through mixing.
f. When the boiler is restarted, the water level is reduced to normal provided that higher N2H4
contents in the initial steam are acceptable.
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SODIUM SULPHITE WET CONSERVATION
PROCEDURE
1 g (atmospheric) oxygen in the water is bound by 9 g commercial, approx.
92% moisture-free, sodium sulphite (Na2SO3)
b. In the case of wet conservation the pH value of the sodium sulphite – containing solution
should be at 10 or higher. Apart from caustic soda and phosphate, as present in the boiler
water and sufficient for alkalinization, an extra addition of ammonia may also be successful
c. To exclude different oxygen content and therefore the formation of the air entrainment
elements, the steam boiler must be completely filled with sodium sulphite containing boiler
water. In superheaters or feed water preheater the sodium sulphite containing.
d. All gate and screw down stop valves must be closed after the boiler has been filled with
sodium sulphite containing boiler water and kept closed during the conservation treatment.
d. If within the shutdown period the sodium sulphite excess drops below 500 g/m3, the sodium
sulphite concentration must be topped up.
e. Before restarting the boiler, the boiler water condition must be adjusted to the specified values
(pH-value, sodium sulphite content)
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Test Procedure Wet Conservation
• Purpose
Testing for excess of oxygen binding agent in the case if wet conservation
i. Hydrazine measurement
Hydrazine forms in an acid solution with p-dimethylaminobenzaldehyde, depending on
concentration, a yellow to red colored quinoid compound for color comparison
• Reagents
1. The water sample to be tested for hydrazine content must first be cooled to < 40°C
(sampling is best carried out with a cooling agreement). The boiler water may first have to
be filtered.
2. 5 ml of this water sample is filled up to the first calibration mark into the empty ampoule, 5
ml hydrazine reagent is filled in to reach the second calibration mark, and then shaken
twice. The test liquid will turn yellow. Now the reference ampoule or color comparison
sheet nearest to this color shade is determined. The value shown on this ampoule or the
sheet indicates the hydrazine (N2H4) content in kg/l of the water sample.
3. If the test liquid shows yellow color shades which are not covered by the comparison
scale, the N2H4 – content is situated above 1 mg/l. These values, too, can be determined
more accurately by first diluting 1 ml of the water to be tested with 99 ml cold tap water,
mixing 5 ml of this diluted water with 5 ml reagent and comparing against the color scale.
The value found must then depending on the dilution used – be multiplied by 100.
4. The reagent must always be stored in a dark and cool place. Storage life approximately 1
year (see use-by date printed on the label). The effectiveness of the reagent solution can
be verified at any time by mixing 5 ml tap water with 5 ml reagent, after which there must
be, no coloration exceeding the zero value of the color scale.
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Test Procedure Wet Conservation
ii. Sulphite measurement
The process is intended to provide a simple check of the addition of sodium sulphite
necessary to bind the oxygen in the boiler water
In an acid solution, iodine oxidizes sulphite to sulphate and is then itself reduced to iodide.
Excess iodine produces a blue coloration in combination with starch solution. Nitrites,
sulphides and larger quantities of organic substances have an interfering effect (KMnO4 –
consumption over 60 mg/l)
• Reagents
Phosphoric acid D.1.14 (25%)
0.01 standard iodine solution (Store in a cool place in a brown bottle)
Starch solution, approx. 1%
• Instruments
300 ml Erlenmeyer flask
10 ml graduated pipette
20 ml burette, 0.1 ml graduation
1. 100 ml of the sample, cooled to room temperature and filtered clear is filled into a 300
ml Erlenmeyer flask and acidified with 3 ml phosphoric acid (reagent a)
3. Using a burette, 0.01 standard iodine solutions (reagent b) is now added until the
sample turns blue.
4. 1 ml 0.01 standard iodine solution corresponds when using 100 ml sample solution to
approx. 6.3 mg/l sodium sulphite (Na2SO3)
Quick test
Small test sticks can be used for a quick determination of the sulphite content (e.g.
Sulphite Test made by Fa.Merck)
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Alkaline Boiling Out Procedure
• Purpose
Alkaline boiling is carried out to removal of oils, fat and silica in newly installed
boilers, and drying the heat insulating material of boilers.
• Applicable Item
Auxiliary Boiler BHS-12000-LO
• Application
• Fill the demineralized water to the Feed Water Tank approximate ½ of volume (6 m3)
• Fill the phosphate dosing tank with 500 liter Demineralized Water.
• Transfer the mixing solution to Feed Water Tank by Hand Transfer pump. Measured
the pH of the solution in the feed water tank. The pH of the feed water tank < 11.5
but higher than 10.5
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Alkaline Boiling Out Procedure
• Now the solution in the boiler will be approximate ½ of volume of the Boiler.
3. Turn on the burner and heating the boiler until the temperature of mixing
solution is 140 °C – 145 °C or boiler pressure 2.5 bar(g) – 3 bar(g). The rate
of the heating of the boiler must not exceed about 50 °C per hour by
adjusting the burner combustion rate.
4. Maintain the temperature 140 °C – 145 °C or boiler pressure 2.5 bar(g) – 3 bar(g) for 4
hours than cool down the boiler by ambient temperature. The cooling rate must not
exceed 50 °C per hour.
6. After the boiler temperature is about 70 °C than slowly drained the solution
up to ¾ solution level of the boiler while take the solution sample for
analyzing than feeding the new solution to the boiler. The concentration of
the cleaning agents while draining & feeding must not fall below ½ of the
initial level.
7. After the boiler water have been drained approximate ¾ the volume of the
boiler, or the Feed Water Tank have transfer the solution approximate 12 m3,
than closed the drained valve, repeat the point j to full fill the boiler with the
solution again.
9. Drain out all the water in the boiler and make a new solution to the Feed Water
tank same as point 1 but the pH < 9.5 but not less than 8.5. than full fill the boiler
with this solution. If the boiler ready to run the water level of this solution shall
be at the normal level.
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THE END
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