DEAERATOR:

De aerator is mechanical device in which dissolved gases in demin water are removed
mechanically. Mechanical de aeration causes removal of CO2 and almost all dissolved
oxygen contained in demin water. It further increases the demin water temperature,
which is beneficial in steam generation. Further oxygen scavenging is chemical
attained by oxygen scavenger’s treatment (i.e. 19p, Elimin-ox, Hydrazine etc).
It is a pressure vessel where steam and water is mixed. The temperature rises and the
non-condensable dissolved gases are liberated and removed.

FUNCTION:

The de-mineralized water is received at de aerator from water purification unit. Even
very low oxygen contents are to be avoided in BFW, because it leads to localized
corrosion of the boiler metal, resulting in pitting and eventual metal performance,
tube failure, weakening of the shell, therefore measurable level of oxygen is
acceptable.
The function of the de aerator is to remove as much oxygen as well as CO2 gas
entrained in the DMN as possible after the physical operation. Oxygen scavenger (like,
Hydrazine, Eleminox, sodium sulphite is introduced into water storage tank to scavenge
the oxygen chemically still entrained. It should be noted that due to its acidity, CO2
lower the PH of water, which is favorable for the rusting reaction of oxygen with, steal,
that’s why the removal of CO2 is desirable.
The function of a de aerating feed water heater is to remove non-condensable gases and
to heat boiler feed water. A de aerator feed water heater consists of pressure vessel in
which water and steam are intimately mixed under controlled conditions. When this is
properly achieved, water temperature rises, non-condensable dissolved gases are
liberated and removed and the effluent water may be considered corrosion free from an
oxygen or carbon dioxide standpoint.
A de-aerating feed water heater is the watchdog of boiler plant as it protects the feed
pumps, piping, boilers and any other piece of equipment that is in the boiler feed and
return cycle from the effects of corrosive gases. It accomplishes this by reducing the
concentration of non-condensable gases; i.e., O2 and CO2, to a level where they are no
longer a factor.
The de aerator feed water heater is connected to a storage tank located immediately
below the heater. This storage tank provides buffer capacity for variation in feed water
demand.
 PRINCIPLES OF DE-AERATION:
The solubility of gases in water decreases with an increase in temperature of liquid. The
partial pressure of vapor increases and consequently decreases the solubility of
dissolved gases in the water.
There is a physical law, which states that the solubility of any gas in a liquid is directly
proportional to the partial pressure of gas above the liquid surface.Experience has
shown that more rapid and more complete removal of non-condensable gases from a
liquid is obtained when the liquid is vigorously boiled or scrubbed by condensable or
carrier gas bubbles.
Therefore the de aerator must,
V Heat the feed water to as high a temperature as possible; i.e. to the temperature
corresponding to the steam pressure.
V Vigorously boil and scrub the heated with fresh steam which can carry to the liquid
surface any traces of O2 or CO2.
V Maintain the partial pressure of the O2 and CO2 in the steam atmosphere as low as
possible, particularly at the point where the de aerator water separates from the steam.
V Continually withdraw non-condensable gases from the heater at the rate at which
they are being liberated.
V Have an efficient vent condenser to concentrate the non-condensable gas mixture in
the vapor as it leaves the heater in an attempt to avoid wasting steam.
 VENT PIPING OF DE-AERATOR:

The vent piping should be installed with no sharp bends or traps that could obstruct the
flow of gases. The ideal vent pipe rises vertically from the heater to the valve located
above the junction of the vessel in a short length of pipe above the valve. This is
normally satisfactory where a slight amount of steam vapor can be tolerated in the area
of the de-aerating heater. Where this is not possible, and it becomes necessary to pipe
the vent line to the outside atmosphere, precautions must be taken to avoid consistently
long lines with a great number of turns. Horizontal runs should be avoided whenever
possible and, where necessary, should have a slight slope toward the heater and a drip
line at the lowest point to permit draining of condensate from the vent line.
Venting procedure:
The valve should normally be open one or more turns to allow for complete removal of
the gases. To determine the correct amount of piping required, the vent valve should be
set approximately ½ stem travel and the effect on the operating temperature noted.
If no appreciable effect on the temperature is noted after a period of one hour, oxygen
tests should then be made to determine the effectiveness of venting; satisfactory
reduction of oxygen is obtained when tested by a recognized sampling and testing
procedure.
Tightening the vent can further decrease the vent setting of the valve can be further
decreased by tightening the vent outlet the temperature of the steam shown in a
thermodynamic table, the indication is that venting is not adequate and that the vent
valve must be opened further.
In EAPCL an RO is installed at d/s of vent valve to control the velocity of steam and
adequate venting of steam. The vent valve must be opened& car sealed.

OPERATING DESCRIPTION:
A de-aerating heater utilizes steam by spraying the incoming water into an atmosphere
of steam in the pre-heater section. It then mixes this water with fresh incoming steam in
the de-aerator section.
In the first stage, the water is heated to within two degrees of steam temperature and
virtually all of the oxygen and free carbon dioxide are removed. This is accomplished
by spraying the water through self-adjusting inlet valves, which are designed to produce
a uniform spray film under all conditions of load, and consequently a constant
temperature, and uniform gas removal is obtained at this point.
From the first stage section, the preheated water containing minute traces of dissolved
gases flow into the second stage or tray section. This section consists of a series of trays
where the water is intimately contacted with an excess of fresh gas free steam. The
steam passes into this stage and it is mixed with the preheated water. De-aeration is
accomplished at 20-105% of the rated flow if conditions are maintained in accordance
with design criteria. Very little steam is condensed here as incoming water has a high
temperature caused by the preheating. The steam rises to the first stage and carries out
the small traces of residual gases. This mixture of steam and non-condensable gases
pass through a first stage compartment to the vent condenser. In the pre-heater most of
the steam is condenses and the remaining gases pass through to the vent condenser
where most remaining steam is condensed and the non-condensable gases vent to the
atmosphere. A very small amount of steam is passed to the atmosphere, which assures
that the de-aerating heater is adequately vented at all times.
The water, which leaves the second stage falls, is de-aerated and is heated to within 1-2
C of the steam temperature corresponding to the pressure within the vessel.
De mineralized water from storage tank VE-8604 delivered by PU-8604 A/B is feed to
VE-8808 condensate of process unit is used as heat source. This heated water at 80 C
is feed to de-aerator.
De-aerator comprises two cylindrical vessels. One is placed vertically over the other,
which is horizontal. Major de aeration is obtained in upper part, which contains
perforated trays. Demin water falls over trays while steam is injected from the bottom
of storage vessel. Demin water falls on trays to increase the surface area for better heat
transfer and steam splits the downward flowing water. At saturated temperature
maximum amount of dissolved oxygen is removed by mechanical de aeration. Gases
removed from de-aeration are vented to atmosphere through vent valve & R.0 at the top
of de-aerator. The temp of feed water rises to 110C at design pressure 0.42 kg/cm2.
The heated water accumulates in low tank called accumulator (storage tank). Eliminox
is injected into the bottom of storage tank.
Condensate recovery is a regular operating feature of de-aerator as make up water along
with demin water. Down stream of de-aerator, PO4 and Amine solution are injected in
BFW to control the PH and scale.
The de-aerating section has an orifice type vent. The vent flow is controlled by orifice.
The degasifying section has a 1 vent on top. R.O is controlled the velocity of steam.
 INSTRUMENTS:
*A level indicator controller LIC-8101 is installed on the treated water inlet to de
aerator to maintain water level in the de aerator drum.
*A pressure indicator controller PIC-8808 is provided to control pressure 0.3 kg/cm2.
PT-8808 reads the pressure from the drum top.
*A pressure switch is provided to avoid the excess temperature in de aerator .At
pressure above1.0 kg/cm2 (120C) the PIC-8808 will be tripped and close the steam
supply to the vessel.
*A high level cut in switch LSHH-8808 set at 1.26m is provided it will actuate XSV-
8808 to open and discharge excess water to the check pit through the flash vessel (VE-
8809) the XSV resets in auto after the vessel goes below the LSHH limit.
*LT-8808 is provided to control the level from DCS.
*GLG-8808 has been provided to monitor the level in case of failure of transmitter.
*At 0.54cm the LSLL-8808 actuates and the BWF pumps trip to protect the pump and
vessel itself.
*PT-8103 is installed on the common header to monitor and actuate this interlock
which actuates at 9.0 kg/cm2
*A vacuum breaker safety is provided to protect the de aerator from rupture due to
vacuum it is set at 20-inch water gauge.
*One-pressure safety valves PSV-8808 is provided to protect the de aerator from
explosion due to high pressure.

DE AERATOR START UP PROCEDURES:

The following procedures should be followed when commencing operation of a de

aerator heater, after the unit has been completely installed, and all equipment has been
tested and checked.
1.The start up period should be carefully planned so that wastage of water and steam to
the drain do not unduly overload existing facilities such as pumps, engines, heaters, etc.
2.Flush out all lines and tanks with water until here is no apparent indication of foreign
matter or rust. Spray valves should be freed of all large scale and debris.
3.Manipulate manually all controls; see that each is working freely and the shipping
stops have been removed.
4.Check all instruments to ascertain that that are operating and indicating correctly.
5.Open vent valve from vent condenser to atmosphere.
6.Close outlet valve from storage tank to feed pumps.
7.Start flow of inlet water and slowly increase from 50to 60% of design rate.
8.Open valve, admitting steam into tank slowly. Some rumbling may occur but this may
be disregarded with the cold tank. Check steam gauge in heater and make absolutely
certain that positive steam pressure is maintained.
9.Filling the tank with water will purge most of the air form the vessel. As the water
approaches operating level, increase the steam flow.
CAUTION: filling the tank with steam and then flooding with cold water subjects the
tank to undue stresses caused by vacuum created by rapid condensation. The open vent
provides some relief to this condition, but caution is urged.
10.As the water reaches the operating level, check the operation of inlet controller,
make adjustments at all controllers, and manually continue the flow of water until high-
level controls operate. Check operating level of controllers and alarms, if any.
11.When a considerable volume of steam is escaping from the vent valve, start
throttling back on the vent valve until a 60 cm to 90 cm plume of vapor can be seen
issuing from it. The water temperature should rise to within 2 C of saturation
temperature of steam at heater pressure. A lower water temperature indicates that
pockets of air have not been completely purged. If this course, open steam valve wide,
then open vent valve fairly wide for a few seconds, then throttle back to force pockets
to the vent. The correct vent opening can only be determined by oxygen tests on the
effluent water.
NOTE: Efficient removal of the non-condensable gases from the de-aerating heater
requires that the vent valve be opened sufficiently to allow complete discharge of the
gases passed to the vent condenser outlet pipe. The maximum concentration of the non-
condensable gases, such as oxygen and carbon dioxide, passing out of the vent depends
on the degree of condensation produced by the steam and gas mixture.
Passing through and around the spray created by the spray valve. The optimum
condition is when the unit is venting all non-condensable gases with the minimum
steam.
12.Open Steam Valve Wide.

Keep checking water temperature until the unit comes within 1C to 2 C of steam
temperature; when it does, the unit is now ready for service and the outlet valve may be
opened and vent valve throttled back in accordance with instruction shown under
venting procedure. When the unit is operating, the storage water temperature should be
at the saturated temperature of the steam at the heater pressure.
 TROUBLE SHOOTING GUIDELINES:

It is important to operate the de aerator within its design limitations of temperature,

pressure, and temperature differential, flow and water quality. Operation outside the
design parameters may lead to premature failure or loss of serviceability through
cracking, wear, erosion or corrosion.

The following is a list of some of the operating practices to be avoided and their
probable consequences. This list cannot be comprehensive and the best general rule is
to adhere to the specified design conditions.

Excessive Cold Make-Up

This may lead to excessive steam velocities and consequent erosion of parts in the
steam path. In addition, the de aerator may not be able to remove the extra oxygen load
imposed, and corrosion of internal paths may result.
 Too High an Operating Level in the Storage Section
This may result in water being carried at high velocity into the de aerator internals, with
consequent damage.

Shocking With Cold Water

During start-up, it is essential that the de aerator not be heated with steam and then
contacted with cold water. Thermal shock may lead to failure of internal parts.

Using Too High a De aerating Steam Temperature

The stresses in the vessel may exceed the allowable if the temperature differential
between the parts contacted by superheated steam and those contacted by cold water is
excessive due to the inlet steam temperature exceeding the design value.

Insufficient Vent Valve Opening or Erratic Spray Valve Action

This may cause entrainment of water in the plume discharging to the atmosphere or the
absence of a steam plume or a plume that appears to be puffing. This signals improper
operation of the vent condenser.
Excessive Cycling
The de aerator is designed for steady state operation or for reasonable variations in load
of a few times a day. Excessive rapid cycling can lead to premature failure.

Vibration
Components of the external system can sometimes generate disturbances, which induce
vibration within the de aerator. Such situations should be corrected as quickly as
possible, before internal damage to the de aerator occurs. Vibration can also start when,
in a scrubber-type de aerator, the minimum flow is not maintained.

Water Quality
Chlorides, caustics and other impurities can lead to stress-corrosion cracking in the de
aerator and other system components. Attention to water quality is important in
obtaining good equipment life.