What is Boiler Corrosion?

“Boiler Corrosion is slow poison for Industrial Boilers. Talk to Experts and save your boilers
life:Thermodyne Team”
Corrosion is a phenomenon in which atmospheric oxygen in the air or water reacts with
the metal to form “oxides. Corrosion in industrial boilers is a phenomenon in which the
oxygen that is dissolved in the water inside theboiler reacts with the metal of the steam
boilers.
Ferrous component of the metal reacts with the atmospheric oxygen in the water to
undergo oxidation. This oxidation results in the formation of ferrous oxides. Ferrous
oxides lead to the formation of cavities and holes in the metal.

This gradual formation of cavities and holes in the metal is termed as pitting. Pitting is
the main host for the corrosion which ultimately destructs metal and its properties.

Boiler Corrosion Image

Causes of Boiler Corrosion

 Improper and unscheduled maintenance.
 Exposure of boiler metal to dissolved gases present in boiler water
 Oxygen present in boiler water
 Carbon Dioxide present in boiler water
 Unbalanced pH of boiler water
 Improper and unscheduled maintenance
 Exposure of metal to the dissolved gases i.e oxygen and carbon dioxide present in boiler feed
water
 Unbalanced pH of the water inside the Steam Boiler
 Improper and unscheduled maintenance
Boiler system corrosion is caused by the interaction of water
chemistry, the environment of the facility, operation procedures,
and materials used in the construction of the system. It costs the
industry billions of dollars every year through failures and
reduced performance. Finding a solution to your problem
requires discovery of the exact corrosion path then controlling
and avoiding future corrosion issues.
CAUSTIC EMBRITTLEMENT Over time, the concentration of sodium carbonate in the
boiler increases. Combined with water evaporation, the sodium carbonate forms
sodium hydroxide. This makes the water alkaline and results in caustic embrittlement
particularly in bends and joints. Adding sodium nitrate to water in the boiler is
recommended to combat caustic embrittlement.

PITTING The concentration of oxygen in the water is the main cause for severe
damage on the water side of boiler tubes by pitting. Water molecules go into the vapor
phase at higher temperatures resulting in more water vapor in the air. Cold water holds
more air. A deaerator can be used to heat the water with steam to remove oxygen.

SCAVENGERS Another solution is adding oxygen scavengers. The most common

oxygen scavenger used in low pressure systems is sodium sulfite (Na2SO3). Hydroserve
Technologies, Inc suggests, “In systems equipped with a deaerator, the sulfite should be
fed to the storage tank of the deaerator or to either the suction or pressure side of the
feed water pump. In systems which do not have a deaerator, the sulfite can be fed at
almost any point in the feed water system, including the condensate tank.”

VACUUM Large masses of air can also be introduced into the system by
vacuum. When the boiler is allowed to cool for any reason, the steam condenses. This
results in a vacuum that sucks air into the system through any source it can find. The
best protection against this occurrence is regular, thorough maintenance of the entire
system.

pH The frequency of pits is largely determined by how acidic the water is. Water
treatment chemicals known as volatile amines are derivatives of ammonia that either
neutralize acid or form a protective film. Ideally the pH should remain higher than 9.5.
Usually these procedures are followed by the use of oxygen scavengers to completely
expel remaining oxygen.
The only reason for draining water from a boiler is if it is required by an insurance
company, etc. When make-up water is refilled, more oxygen is brought in. If you must
drain water, be sure to add the proper chemicals back in to cause as little corrosion
potential as possible.

SELECTION OF MATERIALS “Because of their high chromium and nickel

content, INCOLOY alloys 800H and 800HT have excellent resistance to oxidation. The
chromium in these alloys promotes the formation of a protective surface oxide, and the
nickel enhances the protection, especially during cyclic exposure to high temperatures
The mechanical properties of INCOLOY alloys 800H and 800HT combined with their
resistance to high temperature corrosion, make them exceptionally useful for many
applications involving long-term exposure to elevated temperatures and corrosive
atmospheres.” (specialmetals.com) They are used in boiler tubes because of their high
resistance to cracking in alkaline conditions and to stress corrosion cracking.

We carry dual certified Alloy 800H/HT in plate, fittings, tube, pipe, bar, sheet, fastener
flanges, coil, and welding products. Pressure vessels and vessel components constructed
from 800H and 800HT® are approved under the ASME, Boiler and Pressure Vessel Code,
Section VIII, Division 1. Download our full Data Sheet and login to Request a
Quote. Our industry experts are always available to answer all your questions about
how we can help you with your alloy needs.

Corrosion measurement
Hydrogen gas sampling of the boiler steam is done to measure the corrosion potential of the boiler water. This test for
corrosion is based on the release of hydrogen gas when iron corrodes. Measuring the amount of hydrogen gas released
detects boiler water conditions and indicates if corrosion conditions exist in an operating boiler.

Basic corrosion prevention methods

The common methods for prevention of corrosion include:

 Filtration of solid suspended impurities & particles from water

 Removing dissolved oxygen from the boiler feedwater

 Maintaining alkaline conditions in the boiler water

 Keeping the boiler internal surfaces clean

 Protecting boilers during out of service periods

 Using a chemical treatment programme to counteract corrosive gases in steam and condensate systems

The selection and control of chemicals for preventing corrosion requires an understanding of the causes and
corrective measures.

What is erosion in boiler?

Erosion is caused by the velocity of steam across a surface. It used to be a big problem in older
boiler designs, where you could see the erosion around the steam outlet nozzles in the steam
drum, and also at the tube entry points in the tubeplate. Another form of erosion is “wire
drawing” across the seats of steam valves, where a valve is either leaking or only cracked open,
whence the high velocity steam cuts across the seat like a wire through cheese. Erosion can
occur anywhere in a system, usually where the steam flow changes direction (pipe elbows,
valves, nozzle outlets etc. It can be limited by using doubler plates which act as a sacrificial
surface to avoid damaging the boiler itself. Avoiding sharp piping bends is also a good idea.