Preface
Much time were spent in trouble shooting for industrial water application in various geographical locations and observed, the people are involved in operation, and they need to acknowledge the
fundamental of boiler water chemistry & preventive. This can help to shoot out the water base trouble in day-to- day system operation. this text cover the contents of fundamental water chemistry related boiler water operation and simplify to understand the boiler water system operation, identify the problem during the operation and preventive action. I thank to the entire author for
their valuable contributions in my professional life and avail me to increase the significance of the
book, whose briefs are included attend of chapter.
Brajendra K. Singh.
Contents
1 BOILER SYSTEM
1.1 Boiler System
1.2 ASME guideline
2. WATER & IMPURITIES
2.1 WATER AS A SOLVENT
2.2 Fresh water & Common impurities
2.3 Surface water and groundwater characteristics
3 BOILER WATER & VARIABLE
3.1 Water parameters and effective control of boiler water treatment pH
3.2 pH value & relation with H+ & oH concentration
3.3 Alkalinity
3.4 Silica
4 EXTERNAL TREATMENT
4.1 Principal of sodium zeolite softening
4.1.2 Advantages
4.1.3 Limitations
4.2 Demineralization
4.2.1 Principles of Demineralization
4.2.2 Equipment and Operation
4.2.2 Advantages and Limitations
4.2.3 Limits
4.3 Dealkalization
4.3.1 Sodium Zeolite/Hydrogen Zeolite (Split Stream) Dealkalization
4.3.2 Sodium Zeolite/Chloride Anion Dealkalization
4.3.3 Weak Acid Cation Dealkalization
4.3.4 Direct Acid Injection
4.3.5 Advantages and Limitations of Dealkalization Systems
4.4 Counter flow and mixed bed deionization
4.4.1 Counter flow Cation Exchangers
4.4.2 Mixed Bed Exchangers
4.5 Decarbonators and Degasser
4.6.1 Weak Acid and Weak Base Resins
4.6.2 Regenerant Reuse
4.7 Condensate polishing
4.8 Common ion exchange system problems
4.8.1 Operational Problems
4.8.2 Mechanical Problems
4.9 Resin fouling and degradation
4.9.1 Causes of resin fouling
4.9.2 Causes of irreversible resin degradation
4.9.3 Prevention
4.9.4 Inspection and cleaning
4.9.5 Resin testing and analysis
4.10 Deaeration
4.10.1 Tray-Type Deaerating Heaters
4.10.2 Spray-Type Deaerating Heaters
4.10.3 Check List Deaerating Heater and Operational Guide
5. INTERNAL TREATMENT
5.0 Steam System Operation
5.1 Feed Water Monitoring
5.2 Feed water is defined as follows
5.3 Deaeration (Mechanical and Chemical)
5.3.1 Source of boiler problem
6. BOILER WATER PROBLEM
6.1.1 Scaling
6.1.2 Depositions
6.2 CORROSION
6.2.1 Stress Corrosion Cracking
6.2.2 Caustic Embrittlement
6.2.3 Fatigue and Corrosion Fatigue
6.2.4 Stress-Induced Corrosion
6.2.5 Dissolved Oxygen corrosion
6.2.6 Chelant Corrosion
6.2.7 Caustic corrosion
6.2.8 Steam Blanketing
6.2.9 Acidic Attack
6.2.10 Bimetallic Corrosion Due to Copper
6.2.11 Hydrogen Attack or Embrittlement
6.3 Carry over
6.3.1 Type of Carry over
6.3.2 Mechanical Carry-over
6.3.3 Vaporous Carry-Over (Volatility)
7. BOILER WATER CONDITION
7.1 pH correction
7.2 Scale/corrosion control & Phosphate treatment
7.2.1 Coordinated Phosphate Treatment
7.2.2 Congruent Phosphate Treatment (CPT)
7.2.3 Equilibrium Phosphate Control (EPT)
7.3 Corrosion control & Oxygen scavenger
7.3.1 Oxygen Scavenger & reaction Mechanism
8. DETERMINATION BOILER WATER PARAMETERS
8.1 1.1 Methodology of blow-down control
8.2 Determine Specific conductivity & Blow down Control
8.3 Steam purity
8.4 Measurement of steam purity
8.5 Non-solids and dissolved solids containing feed water
8.6 Boiler water from non-solids and dissolved solids containing
feed water
8.7 Requirements of steam for turbines in continuous operation
8.8 Boiler water & silica chemistry
9. WET PRESERVATION BOILER SYSTEM
9.1 Short term, wet standby protection of boilers
9.2 Long-term dry storage
9.3 Storage under steam pressure
2. 10. 3. HP BOILER START UP PROCEDURE
11. BOILER SYSTEM TUBE FAILURE
11.1 Reason behind Super heater Tubes failure
11.2 Boiler system design error & tube failure
11.3 Boiler Tube Failure Analysis
12. TURBINE STEAM DYNAMICS
12.1 System Overview
12.2 Turbine Steam Dynamics System
12.3 Flow Matrix Solution
12.4 Control Valve/Stop Valve Flow
12.5 High Pressure Turbine Stage Pressure and Enthalpy
12.6 Moisture Separators
12.7 Intercept Valve Flow
12.8 Low Pressure Turbine Stage Pressure and Enthalpy
12.9 Turbine Efficiency and Turbine Work
12.10 Low Pressure Turbine Exhaust Hood Pressure and
Temperature
12.11 Chest and Shell Temperatures
12.12 Turbine Drains
12.13 Turbine Frictional Loss
Much time were spent in trouble shooting for industrial water application in various geographical locations and observed, the people are involved in operation, and they need to acknowledge the
fundamental of boiler water chemistry & preventive. This can help to shoot out the water base trouble in day-to- day system operation. this text cover the contents of fundamental water chemistry related boiler water operation and simplify to understand the boiler water system operation, identify the problem during the operation and preventive action. I thank to the entire author for
their valuable contributions in my professional life and avail me to increase the significance of the
book, whose briefs are included attend of chapter.
Brajendra K. Singh.
Contents
1 BOILER SYSTEM
1.1 Boiler System
1.2 ASME guideline
2. WATER & IMPURITIES
2.1 WATER AS A SOLVENT
2.2 Fresh water & Common impurities
2.3 Surface water and groundwater characteristics
3 BOILER WATER & VARIABLE
3.1 Water parameters and effective control of boiler water treatment pH
3.2 pH value & relation with H+ & oH concentration
3.3 Alkalinity
3.4 Silica
4 EXTERNAL TREATMENT
4.1 Principal of sodium zeolite softening
4.1.2 Advantages
4.1.3 Limitations
4.2 Demineralization
4.2.1 Principles of Demineralization
4.2.2 Equipment and Operation
4.2.2 Advantages and Limitations
4.2.3 Limits
4.3 Dealkalization
4.3.1 Sodium Zeolite/Hydrogen Zeolite (Split Stream) Dealkalization
4.3.2 Sodium Zeolite/Chloride Anion Dealkalization
4.3.3 Weak Acid Cation Dealkalization
4.3.4 Direct Acid Injection
4.3.5 Advantages and Limitations of Dealkalization Systems
4.4 Counter flow and mixed bed deionization
4.4.1 Counter flow Cation Exchangers
4.4.2 Mixed Bed Exchangers
4.5 Decarbonators and Degasser
4.6.1 Weak Acid and Weak Base Resins
4.6.2 Regenerant Reuse
4.7 Condensate polishing
4.8 Common ion exchange system problems
4.8.1 Operational Problems
4.8.2 Mechanical Problems
4.9 Resin fouling and degradation
4.9.1 Causes of resin fouling
4.9.2 Causes of irreversible resin degradation
4.9.3 Prevention
4.9.4 Inspection and cleaning
4.9.5 Resin testing and analysis
4.10 Deaeration
4.10.1 Tray-Type Deaerating Heaters
4.10.2 Spray-Type Deaerating Heaters
4.10.3 Check List Deaerating Heater and Operational Guide
5. INTERNAL TREATMENT
5.0 Steam System Operation
5.1 Feed Water Monitoring
5.2 Feed water is defined as follows
5.3 Deaeration (Mechanical and Chemical)
5.3.1 Source of boiler problem
6. BOILER WATER PROBLEM
6.1.1 Scaling
6.1.2 Depositions
6.2 CORROSION
6.2.1 Stress Corrosion Cracking
6.2.2 Caustic Embrittlement
6.2.3 Fatigue and Corrosion Fatigue
6.2.4 Stress-Induced Corrosion
6.2.5 Dissolved Oxygen corrosion
6.2.6 Chelant Corrosion
6.2.7 Caustic corrosion
6.2.8 Steam Blanketing
6.2.9 Acidic Attack
6.2.10 Bimetallic Corrosion Due to Copper
6.2.11 Hydrogen Attack or Embrittlement
6.3 Carry over
6.3.1 Type of Carry over
6.3.2 Mechanical Carry-over
6.3.3 Vaporous Carry-Over (Volatility)
7. BOILER WATER CONDITION
7.1 pH correction
7.2 Scale/corrosion control & Phosphate treatment
7.2.1 Coordinated Phosphate Treatment
7.2.2 Congruent Phosphate Treatment (CPT)
7.2.3 Equilibrium Phosphate Control (EPT)
7.3 Corrosion control & Oxygen scavenger
7.3.1 Oxygen Scavenger & reaction Mechanism
8. DETERMINATION BOILER WATER PARAMETERS
8.1 1.1 Methodology of blow-down control
8.2 Determine Specific conductivity & Blow down Control
8.3 Steam purity
8.4 Measurement of steam purity
8.5 Non-solids and dissolved solids containing feed water
8.6 Boiler water from non-solids and dissolved solids containing
feed water
8.7 Requirements of steam for turbines in continuous operation
8.8 Boiler water & silica chemistry
9. WET PRESERVATION BOILER SYSTEM
9.1 Short term, wet standby protection of boilers
9.2 Long-term dry storage
9.3 Storage under steam pressure
2. 10. 3. HP BOILER START UP PROCEDURE
11. BOILER SYSTEM TUBE FAILURE
11.1 Reason behind Super heater Tubes failure
11.2 Boiler system design error & tube failure
11.3 Boiler Tube Failure Analysis
12. TURBINE STEAM DYNAMICS
12.1 System Overview
12.2 Turbine Steam Dynamics System
12.3 Flow Matrix Solution
12.4 Control Valve/Stop Valve Flow
12.5 High Pressure Turbine Stage Pressure and Enthalpy
12.6 Moisture Separators
12.7 Intercept Valve Flow
12.8 Low Pressure Turbine Stage Pressure and Enthalpy
12.9 Turbine Efficiency and Turbine Work
12.10 Low Pressure Turbine Exhaust Hood Pressure and
Temperature
12.11 Chest and Shell Temperatures
12.12 Turbine Drains
12.13 Turbine Frictional Loss
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