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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?
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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.
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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
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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
Pressure (psig)
30.0
40.0
50.0
60.0
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
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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
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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
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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
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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
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
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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
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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
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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
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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)
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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
Deaerator
stainless steel pipe or tubing capped at the ends with hole in end caps
Water line
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.
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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.
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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
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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.
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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.
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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
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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
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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.
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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
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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.
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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
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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.
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