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CORROSSION
1. A complex electrochemical reaction attack a large or a small pinpoint area 2. Associated with the reaction of oxygen with metal & also contribute by pH, chemical compounds & others 3. Occur when BFW has excess acidity/alkalinity, high level of O2 and CO2, high temp / high level of ammonia /sulfur-bearing gases 4. Prevention: maintaining pH levels in boiler feed water, removing dissolved O2 from water, use chemical treatment, & following established out-ofservice & blow-down procedures
DEPOSIT
1. High temp cause impurities precipitate & adhere to the hot metal surfaces of the boiler, forming scale (layer) 2. Dissolved bicarbonate of calcium & magnesium break down & form insoluble carbonates cause deposit tube failure 3. Carbonate D, phosphate D, sulfate deposit & etc
Internal
Complements the external process and helps protect the internal components of the boiler system
Primary location water treatment is at boiler Common tests on boiler feed water include pH and the presence of particulate matter (measured in ppm), iron, oil and silica
De-aeration
De-aerator device used to remove air from water
Located at the end of the condensate return header & used as primary boiler feed source
In BFW treatment Designed to remove Dissolved Oxygen by heating the water with steam cause Dissolved O2 leads to boiler corrosion 2 types :
Spray de-aerator :- inject steam directly into the water Tray de-aerator :- steam enters at the bottom & water enters at the top. Water drops over a series of sieve trays (provide good contact between liquid & heated vapor
Blow-Down
Term used to describe the process in which water is removed from the boiler system As suspended solids concentrate in the water, chemical treatment reaches a point at which it is no longer effective. So removal of a portion of the treated water is necessary. Is depends upon the amount of suspended solid the boiler can handle (5-10% of total capacity) Blow-down is controlled through an instrument designed to measure the electric conductivity of the water Blow-down ports are - located on the bottom of the boiler so accumulated sludge can be removed
BOILER MEDIUM
Physical Properties Of Water
In purest form is colorless, odorless, and tasteless The only organic substance occurs in 3 states at atm temp range: ice (solid), steam (gas), water (liquid) Boils at 212F (100C) at atm pressure Increase Pressure boiling point rise It takes 1 British thermal unit (Btu) to raise the temp of 1 pound (lb) of water one degree Fahrenheit (F). It takes 970 Btu to change 1 pound of water to steam This heat energy (latent heat of vaporization) is stored in the steam & when it condenses, the energy is given off Thus much of the heat from burning fuel can be absorbed by boiler water, transported with the steam, & released at the points of use E.g: 1 lb of boiler feed water at 72F requires 140 Btu to reach 212F & additional 970 Btu to change to steam. A total of 1,110 Btu is stored in the steam
SIMPLE BOILER
Consists of :
heat source water-containing drum water inlet steam outlet
Operations :
As heat is added to the drum, the temp increases until the water boils As the steam rises, it is captured in a line & sent on for further processing
Furnace
Economisizer section
Tubes
Drums
Steam System
As steam flows from the boiler to the plant, it begins to cool & formed condensate Condensate cause problems as it flows with the steam Slugs of water can damage equipment and lead to a condition known as water hammer Device known as steam traps are used to remove condensate. Steam traps are grouped into 2 categories: Mechanical Thermostatic. Mechanical steam traps include : inverted buckets floats Thermostatic traps include bellows-type traps
Float-type traps have a float that rests on the top of the condensate A rod to the outlet valve attaches the float. The position of the float determines the position of the valve As the level in the trap increases, the float lifts, allowing condensate to flow Components:
A body, An inlet & outlet A bonnet A float A rod A valve
One of the popular steam traps is the thermostatic steam trap because it cheaper and selected more frequently than other type This type of trap responds to the temperature differences between condensate and steam Operation:
steam enters the bottom of the trap and comes into contact with the bellows Condensate causes the bellows to contract and open. Steam causes the bellows to expand and close