Feedwater Path  161

The bubbles grow in size and group  together.  Small area of the tube wall surface is covered
with a film of steam vapour. This is known as  partial film boiling. In this stage of boiling
process, the wall surface is totally covered by a film of steam vapour and the liquid does not
come in contact with the wall. This thin layer of vapour which has low thermal conductivity,
insulates the surface. So, the temperature of the tube increases dramatically.
This   situation continues until the affected surface is covered by a stable blanket of steam,
preventing contact between the heat transfer surface and the liquid in the centre of the flow
channel. The condition after the formation of stable steam blanket is known as  film boiling.

9.9  BLOWDOWN
Due to the continuous evaporation of boiler water, salt concentration in the boiler water
increases. Also, due to phosphate treatment, some non-adherent sludge is formed. So, total
dissolved solids (TDS) level of the boiler water increases. To adjust this total dissolved solid
level, some quantity of boiler water is removed from the boiler and the same quantity of fresh
water is added. By doing so, concentration of non-desirable dissolved salts is maintained.
This process is called blowdown process and the water drained out is called blowdown.
Blowdown quantity in a boiler is calculated by the following formula:
TDS fw 3.28
Percentage blowdown   100 12.77%
TDSblr  TDS fw
28.96 3.28
where
TDSfw = TDS level of feedwater and
TDSblr = permissible TDS level of boiler water
EXAMPLE 9.1  Permissible limit of the boiler water TDS of a 250 t/hr boiler operating at
120 kg/cm2 is 70 mg/L. If the TDS of boiler feedwater is 5 mg/L, then calculate (i) percentage
blowdown and (ii) Blowdown quantity.
TDS = Ke x EC, Ke = (0.55-0.8)
Solution mg/l
 5 
(i) Percentage blowdown =   100  7.7%
 70  5 
12.77 64.2
 Percentage blowdown 
(ii) Blowdown quantity     Evaporation quantity
 100  8.2 t/h

 7.7 
  250  1000
 100 
 19250 kg/hr
Blowdown may be continuous or intermittent. In continuous blowdown, some quantity
of boiler water is continuously taken out from the boiler drum and continuous fresh water
make up is given. In this method, the salt concentration is maintained constant as shown in
Figure 9.28.
162  Practical Boiler Operation Engineering and Power Plant

Figure 9.28  TDS level in case of continuous blowdown.

In case of intermittent blowdown, blowdown is given from the bottom mud drum to remove
the settled sludge. Boiler water salt concentration is monitored regularly. Blowdown is given for
a short duration when concentration level goes beyond a predetermined value. And blowdown
is stopped at a recommended lower concentration level. The concentration level varies between
higher and lower limit, as shown in Figure 9.29.

Figure 9.29  TDS level variation in case of intermittent blowdown.

Due to blowdown, some loss of energy takes place, as the blowdown water contains
significant amount of sensible heat. The loss is significant when blowdown quantity is more.
Suitable arrangement is made to utilise the sensible heat of this blowdown water.
Blowdown water is collected from the boiler drum through a header placed just below the
normal water level of the steam drum. Water is drained through a flash tank. In flash tank, the
pressure of water drops significantly. As the water contains a lot of sensible heat corresponding
to the drum pressure, so flash steam is produced. This steam can be utilised suitably. Normally,
this steam is used in the deaerator for feedwater heating.
Before draining out the blowdown water, heat can be removed from this water by placing
a heat exchanger (Figure 9.30).

9.10  GAUGE GLASS

Gauge glass is a glass tube or a pair of flat glass plates fitted to the boiler drum to provide
a visual indication of the water level of a boiler drum. Through this device, water level and
general condition of the water in a boiler is determined. This glass is manufactured from highly
chemical and corrosion resistant low expansion borosilicate glass. This glass is well known for
its clarity and mechanical strength.
The gauge glass may be flat type or reflex type (prismatic glass). It is easier to observe
water level in a boiler in flat gauge glass design. Reflex gauge has a single vision slot in
which light can enter the gauge chamber to determine the liquid level. One side of the glass
is prism-shaped.