GNX MARINE SYSTEMS Doku-Ne.: ‘SMS 3-0002-00461/2 Issued on: 07.02.2005 OPERATING INSTRUCTIONS, Issued by: 11001HN BOILER FEEDWATER AND FEEDWATER TREATMENT Operating Manual This document consists of 24 page(s) 1 SAACKE MARINE SYSTEMS. ‘Suedweststrasse 13, 28237 Bremen, GERMANY Tel.:+49 421 6495 138, Fax:+49 421 6495 363, email: marine@saacke deGNX MARINE SYSTEMS Doku-Nr.: ‘SMS 3-0002-00481/2 Issued on’ 07.02.2008 OPERATING INSTRUCTIONS, Issued by: 1100/HN Boiler Feedwater Data Sheet: and 1-177910-00 Feedwater Treatment Page 1 of 24 List of contents Page General Solubility of oxygen in water at atmospheric pressure Corrosion within boilers Boiler water test The treatment of boiler water Care of idle boiler Boiling out Boiler water treatment, control and dosing chartGN Doku-Nr.: ‘SMS 3-0002-0046//2 Issued on: 07.02.2005 OPERATING INSTRUCTIONS Issued by: 11001HN General Data Sheet: 1-177910-00 Page 2 of 24 Introduction. Water is in fact, a chemical compound containing hydrogen and oxygen, classified as the "Universal Solvent’ and seldom found in nature in its pure form. There are three main types of water used aboard ships 4. Fresh or shore water 2. Sea and estuarine waters 3, Evaporated sea water All three kinds of water are contained with solids and gases of one type or another so even though it looks clear it contains appreciable amounts of impurities. Impurities in boiler feedwater. The presence of impurities in boiler feedwater is a constant source of concern to the operating personnel, because it affects not only the efficiency of the boiler, but also its safety. The purpose of boiler water treatment. The primary need for water treatment is simply to eliminate the harmful influence of the impurities which may find their way into the boilers via the boiler feedwater system, Without the correct chemical treatment of the water, the following problems can, and do, arise in the boilers and the feedwater system since the steel surfaces are completely unprotected if not treated. 1. Scale forming salts present in sea water and harbour water, which can enter the boiler feedwater system by carry-over of salty moisture with the vapour from the evaporating plant, by salt water leakage from evaporators into the condensed steam in the evaporator heating coils, by salt water leaks in condensers, through leaky bottom blow valves in idle boilers. Scale and deposits can also be found by presence of oil - heavy fuel oil, cargo oil or lubricating oil - caused by leaks into the steam side of oil heaters and into steam heating coils in HFO bunker tanks, day- and settling tanks, cargo tanks, cargo heaters and lubricating oil from bearings of turbines and rotary pumps. Corrosion in several forms caused by dissolved oxygen in the boiler feedwater which enters the system through air leaks in those parts of the system which operate at pressures below atmosphere, such as condensers, low pressure turbines and pumps. In addition, air is absorbed by the feedwater wherever it is exposed to the atmosphere, as itis through vents to feed tanks, open feed- and filter tanks and through open drains.GYD MARINE SYSTEMS Doku-Nr.: ‘SMS 3-0002-0046//2 Issued on: 07.02.2005 OPERATING INSTRUCTIONS, Issued by: HOON General Data Sheet: 1-177910-00 Page 3 of 24 Corrosion in the feed system, feed tanks and condensers can give rise to the transport of corrosion products of iron oxide and copper or copper oxide into the boiler which is a collector for such deposits and debris. Carry-over caused by the impurities brought with the feedwater concentrate in the boiler reaching the concentration where soluble salts and suspended solids are carried over with the steam. A carry-over may also occur with an excessive amount of the chemicals used in the treatment of the boiler feedwater due to improper feedwater treatment. Effects of feedwater contamination. Sea water leaks result in progressive contamination of boiler water because of the, increasing concentration of salts in the boiler due to the residue of evaporation Furthermore, even then boiler feedwater is within its allowed limits of impurities, the concentration of salts within the boiler increases in proportion to the rate of evaporation (steaming rate) of the boiler. Atypical sample of sea water contains the following salts Sodium chloride (NaCl) 25 600 ppm Magnesium chloride (MgCl) 330 ppm Magnesium sulphate (MgSO) 1.960 ppm Calcium sulphate (CaSO,) 4220 ppm Calcium carbonate (CaCOs) 180 ppm Other salts in varying amounts in sea water near mouths of rivers, harbours, and bays etc. may also be present. Sodium chloride (ordinary table salt) is comparatively harmless to boiler materials. It will, however, cause priming (water carry over), which results in the building-up of a thick crust in superheater tubes, steam valves, steam lines and even on turbine blading in cases of excessive and frequent priming. In the case of superheaters, the heat transfer characteristics of the tubes are impaired by this salt crust, which will cause "bumied-out” tubes. Magnesium chloride in boiler water breaks down into hydrochloric (muriatic) acid, which attacks the boiler drum and tube surfaces, causing acid corrosion which manifests itself by pitting of the surfaces. This acid effect is controlled by rendering the boiler water slightly alkaline with boiler treatment. Magnesium and calcium sulphates precipitate into a hard scale in the hottest portions of the boiler, ie. the interior of the tubes nearest the furnace. This scale has about one- fortyeight of the heat conductivity of steel. When this scale reaches the thickness of about that of an egg-shell, the water inside the tube cannot receive and carry away the(GN MARINE SYSTEMS Doku-Nr.: ‘SMS 3-0002-0046//2 Issued on: 07.02.2005 OPERATING INSTRUCTIONS Issued by: 11001HN General Data Sheet: 1-177910-00 Page 4 of 24 heat fast enough from the tube metal to keep its temperature below its fusion temperature, resulting in the tubes "burning-out’. Boiler treatment is used to prevent the formation of this scale. Calcium carbonate is comparable to chalk. It is harmless to boiler metals unless it can concentrate in "dead pockets’ in the boiler, in which case carbonic acid (COs) may form, resulting in acid corrosion. This is controlled by (1) proper boiler design to eliminate "dead pockets’ and (2), the use of boiler treatment to render the boiler water| slightly alkaline. "Sea water’ contamination occurring while an engineering plant is operating close to beaches, or in harbours and rivers, will introduce silicates into the boilers. Silicate scales are thin, transparent, brittle and hard. Because of their transparency they are hard to detect. ‘A very thin scale can cause tube failure due to overheating. They are controlled by use of boiler treatment and by careful distiling plant operation while in such locations, Oil present in boiler water will cause foaming and moisture carry-over at small quantities, It will also form a heat resisting film, sometimes a carbonised layer, over the tube or shell surfaces ultimately resulting in tube or plate material failure due to overheating also at a very thin layer. The oil will manifest itself by forming an oily ring inside the water gauge glasses at the water level. Oil is controlled primarily by careful inspection of the drain water from fuel or cargo oil steam heating coils, and in care in the lubrication of machinery where oil may come in contact with steam or water. The use of boiler treatment will reduce the foaming effect of oil, but once a boiler has been contaminated with oil, its water sides must be “boiled out" by filing the boiler with a strong mixture of fresh water and boiler treatment and then, using steam from another boiler (via the boiling-out connections on or near the bottom blow fittings), boiling the mixture for two or three days. Instructions for boiling out are contained in the last pages in this chapter. Dissolved oxygen in boiler water has become a serious cause of corrosion in modern boilers. By stress corrosion, or corrosion fatigue failures, the corrosion attack plays a great role and is mostly caused by dissolved oxygen in the feedwater. The rate of corrosion attack might then increased rapidly and so much that serious pittings is encountered in the boiler drum and tube surfaces. Therefore, the amount of dissolved oxygen present in the boiler feedwater is mainly controlled by heating in hotwell or cascade tanks by mechanical deaeration, into the boiler water surface, as well as by chemical scavenge. Corrosion products enter the boiler in the form of iron oxide, remain suspended in the water and cause priming and foaming. They shall be removed by bottom and surface