Professional Documents
Culture Documents
Water Treatment Handbook
Water Treatment Handbook
ASA
ID. NO. 08 173 REV. NO. 00 LOBO 09.97 5K COUNTRY OF ORIIGIN: NORWAY
Water
Treatment
Handbook
C H E M I C A L S
Marine Chemicals
Water Treatment
Handbook
A PRACTICAL APPLICATION MANUAL
1st Edition
REV. NO. 00
LOBO
09.97
5K
FOREWORD
This manual has been edited to specifically apply to Unitors Marine Chemical
Market. It has been prepared to give the marine engineer basic insight into
the chemical water treatment of marine propulsion boilers, low pressure
auxiliary and exhaust boilers, diesel engines, evaporators and other
associated equipment.
The purpose and design of Unitor marine chemical products is to provide
the marine engineer with the most environmentally-friendly products and with
the most practical and simple applications of their use.
Unitor has designed the Spectrapak test kits to accurately determine
chemical concentrations of the various products and systems they are being
used to check. The Spectrapak tablet system is the most practical and
economical testing system available to the marine engineer. Our water
treatment programmes are designed to utilize the simplest water testing
procedures along with the assistance of our worldwide service personnel and
Unitors Laboratories which provide the technical expertise required to
answer all questions in regard to marine chemical applications.
Unitors products have been designed to provide the ship operator with
a variety of products and systems to cover all requirements for the many
different types of boiler systems and crew requirements, which will be
detailed in this manual.
Unitor has introduced the most up-to-date log review system to utilize
todays technology in communications and computers to provide the operator
and marine engineer with a Rapid Response to our log review system.
Unitor is dedicated to providing the marine operator with the most reliable
products available in the marine chemical industry along with the many other
areas of expertise and standardisation worldwide. Our products and services
are available 7 days a week and we are committed to maintaining this for the
marine industry.
INDEX
Page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV
1 Water Treatment Philosophy and Overview . . . . . . . . . . . . . . . . . . . . . . .
2 Basic Chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
II
III
INTRODUCTION
This Product Applications Handbook has been designed to provide specific
information on the variety of chemical and related products and systems
available from Unitor.
This handbook will give all the information required to maintain these various products, including the application of individual chemical products to
properly maintain Low Pressure, Medium Pressure and High Pressure Boilers,
Diesel Engine Cooling Systems and Evaporators.
Single Function Treatment Products:
1. Hardness Control
2. Alkalinity Control
3. Oxygen Control (Hydrazine)
4. Catalysed Sodium Sulphite (Powdered & Liquid)
5. Condensate Control
6. Boiler Coagulant
Low Pressure Boilers, Water Treatments:
1. Combitreat (powdered)
2. Liquitreat
3. Condensate Control
TYPES OF WATER
General
Water could generally be described as the most important of all chemical
substances. Its chemical designation is H2O; the water molecule is composed
of 2 Hydrogen atoms and 1 Oxygen atom.
Natural water
Raw water is the description of the water to which we have daily access.
We can obtain our water from:
1. The ocean
2. Surface sources (e.g. from lakes)
3. Underground sources
The water will vary in composition.
The natural water cycle may be as below:
While it is evaporating from the surface of a lake or the ocean into the atmosphere, we can designate the water vapour H2O. In the atmosphere, clouds
will form, and during suitable humidity and temperature, the clouds will
deposit water (rain). While the rain is falling towards the earth, it absorbs
gases which are in the air, e.g. CO2 (Carbon Dioxide), SO2 (Sulphur Dioxide)
and O2 (Oxygen).
When the water hits the earth, it absorbs additional Carbon Dioxide (from
biological degradation). The rainwater which is now slightly acid will dissolve
various minerals from the soil.
IV
2 Basic Chemistry
The chemistry of water
It is necessary to examine some of the basic theories in order to understand
the various problems associated with water treatment.
While rain is falling through the air, it absorbs gaseous contaminants, e.g.
O2 (Oxygen), which solubility in pure water depends on temperature.
At 20 C, 9 mg/l O2 may dissolve, and
at 50 C approx. 5.5 mg O2/l,
2.1
2 / BASIC CHEMISTRY
Temporary hardness
Permanent hardness
Calcium Bicarbonate
Ca (HCO3)2
Magnesium Bicarbonate
Mg (HCO3)2
Calcium Sulphate
CaSO4
Magnesium Chloride
MgCl2
2.2
CONTRIBUTING ELEMENTS
WHICH AFFECT BOILER WATER TREATMENT
Most dissolved mineral impurities in water are present in the form of ions.
These ions contain an electrical charge which is either positive (cation) or
negative (anion). These ions can join together to form chemical compounds.
To know which ions will combine, we need to know their electrical charge.
Ions of concern to us include the following:
Positive
ions
Chemical
symbol
Negative
ions
Chemical
symbol
Sodium
Calcium
Magnesium
Hydrogen
Na+
Ca++
Mg++
H+
Chloride
Bicarbonate
Carbonate
Hydroxide
Cl
HCO3
CO3
OH
2 / BASIC CHEMISTRY
10
2 / BASIC CHEMISTRY
Besides the pure form of Silica (i.e. Silicon Dioxide), possible Silicate
deposits can form in combination with Calcium and Magnesium, which
are extremely insoluble in water and very difficult to dissolve and
remove.
Besides being an extremely difficult process, the chemical removal
of Silica and silicate deposits can also be very hazardous, since it
involves the use of Hydrofluoric Acid or Ammonium Bifluoride, both of
which are severely destructive to human tissue by inhalation, ingestion
and physical contact. In some instances, alternate acid and alkaline
washings have been used to successfully combat this problem.
The only alternative to chemical cleaning is mechanical removal.
2.2.8 Calcium Carbonate (CaCO3)
Calcium Bicarbonate alkalinity exists in almost all unprocessed fresh
water under normal conditions. Its solubility is about 300400 ppm
at 25 C. If heat is applied or a sharp increase in pH occurs, the Calcium
Bicarbonate breaks down to form Carbon Dioxide and Calcium
Carbonate.
While the bicarbonate salt has been shown to be moderately soluble in
water, the solubility of Calcium Carbonate at 25 C is only about 14 ppm.
This value continues to decrease as the temperature increases, becoming the least where the temperature is greatest. In a boiler, this would be
on the surface of the furnace tubes where contact is made with the
water. The resulting insoluble Calcium Carbonate precipitate forms
building block-like crystals which adhere not only to one another, but
also to the hot metal surfaces, resulting in a continuous, insulating
scale deposit over the entire heat exchange area.This deposit will continue to grow, building upon itself to form a thick coating until all the
Calcium Carbonate produced is exhausted. If suspended matter is also
present in the water, it can become entrained within the crystal
structure, creating a larger volume of deposit than that formed by the
Carbonate precipitation alone.
If this condition is allowed to continue, heat exchange efficiency
at the water/tube interface falls rapidly, resulting in an increase in fuel
consumption necessary to compensate for the decline in thermal
transfer and to regain design temperature as well as steam production
requirements. This increase in the furnace-side temperature needed
to run the system at optimum conditions exposes the metal surfaces
to overheating which, in turn, can cause blistering fatigue, fracture,
and failure of boiler tubes. In addition, if pockets of water become
trapped beneath the scale deposits and are in contact with the hot
metal surfaces, concentration of acid or alkaline materials may
occur and lead to the formation of local electrolytic cells (underdeposit corrosion).
11
Hydroxide
Alkalinity
Carbonate
Alkalinity
Bicarbonate
Alkalinity
P Alkalinity
=0
Equal to
total
P Alkalinity
less than
1/2 M Alkalinity
2 times
P Alkalinity
M Alkalinity
minus 2 times
P Alkalinity
P Alkalinity
equal to
1/2 M Alkalinity
2 times
P Alkalinity
*P Alkalinity
greater than
1/2 M Alkalinity
2 times
P Alkalinity
minus
M Alkalinity
2 times the
difference
between M
and P Alkalinity
P Alkalinity
equal to
M Alkalinity
Equal to
M Alkalinity
pH
The pH of a solution is a measurement of the concentration of active acid or
base (alkaline constituent) in a solution.
To give a precise definition, pH is the negative logarithm of the Hydrogen
ion concentration.
A simpler explanation of pH is that it is a measure of relative acidity or alkalinity of water. In other words, it reflects how acidic or alkaline the water is.
pH is the number between 0 and 14 which denotes the degree of acidity
or alkalinity.
A pH value of 7 indicates neutral. Below 7 indicates increasing acidity.
Above 7 up to 14 indicates increasing alkalinity.
Acidic
Neutral
Alkaline
10
11
12
13
14
12
2 / BASIC CHEMISTRY
13
3.1
CORROSION
14
Pitting corrosion.
Stress corrosion
15
3.2
SCALING
16
1) pH
2) Dissolved solids
3) Dissolved gases
4) Suspended solids
5) Micro organisms
6) Temperature
7) Velocity
8) Copper
17
3.3
Illustration of
Typical Conditions With
a Clean Boiler Tube
CARRYOVER
Carryover is any contaminant that leaves the boiler with the steam.
Carryover can be:
Solid
Liquid
Vapour
Effects of carryover:
Deposits in non-return valve
Deposits in control valves
Deposits in superheaters
Deposits on turbine
Causes of carryover:
Mechanical:
Priming
Soot blowing
Chemical:
Foaming due to:
High Chlorides
Suspended solids
High TDS
Oil
Boiler design
High alkalinity
Silica
18
19
4 Types of Boiler
What is a boiler?
A boiler is a steel pressure vessel in which water under pressure is converted into steam by the application of combustion. In other words, it is
simply a heat exchanger which uses radiant heat and hot flue gases, liberated
from burning fuel, to generate steam and hot water for heating and
processing loads.
There are two types: Fire tube boilers and water tube boilers.
4.1
Hot flue gases flow inside tubes that are submerged in water within a shell.
Pressures up to about 10 bar
Produce up to 14 tonnes of steam/hr
Can meet wide and sudden load fluctuations because
of large water volumes
Usually rated in HP
4.2
Typical packaged boiler. Packaged boilers include a pressure vessel, burner, all the controls, air
fans, and insulation. The boiler is tested at the manufacturers plant and shipped to the customer,
ready for use, when the fuel lines and piping and electrical connections have been installed.
Water flows through tubes that are surrounded by hot combustion gases
in a shell.
Usually rated in tons of steam/hr
Used for H.P. steam
High capacity
BOILERS HAVE SIX BASIC PARTS
1)
2)
3)
4)
5)
6)
Burner
Combustion space
Convection section
Stack
Air fans
Controls and accessories
Typical Scotch Marine firetube boiler (courtesy of Orr & Sembower, Inc.).
20
4 / TYPES OF BOILER
21
4.3
FIRETUBE BOILERS
4.5
In recent years, interest has been revived in high temperature hot water
heating systems for institutional, industrial and commercial plants. By
increasing the temperature and pressure of the hot water and increasing the
size of the generators, some advantages are gained over the low pressure
steam heating systems previously used. In other cases, special forced
circulation boilers have been designed, which consist of many rows of tubes
without a steam drum. In another type, heat is supplied by steam from
a standard type of boiler which heats the water in a direct contact heater.
This is referred to as a cascade system.
4.4
The coil type generator is a vertical coil with fuel combustion taking place
inside the coil. High quality feedwater and a closely monitored chemical treatment programme are mandatory. The most common problem is Oxygen
pitting on the inside portion of the coil near the fire. The two most common
name brands are Vapor-Clarkson and Clayton.
22
4 / TYPES OF BOILER
Medium-sized watertube boilers may be classified according to three basic tube arrangements.
23
5 Boiler Systems
4.6
FIRETUBE BOILERS
Advantages:
Lower initial cost
Few controls
Simple operation
Disadvantages:
Drums exposed to heat, increasing the risk of explosion
Large water volume, resulting in poor circulation
Limited steam pressure and evaporation
WATERTUBE BOILERS
Advantages:
Rapid heat transmission
Fast reaction to steam demand
High efficiency
Safer than firetube boilers
5.1
Disadvantages:
More control than firetube boilers
Higher initial cost
More complicated to operate
Storage tank
This tank will hold the make-up water to be supplied to the various
systems as they lose water through leaks and through evaporation.
Normally, this water is made by a low pressure evaporator (this will
be described later on). The water produced in this way is normally of
good quality if the evaporator is set up correctly. When it is introduced
to the boiler, it will require the minimum amount of treatment. However,
at some stage the vessel will very likely take water from ashore, and
the quality can vary considerably. This water would probably require
more treatment to correctly condition it for use.
Hot well, observation tank or cascade tank
This has a very important function for the dosing of chemical treatments. This is where all the water collects on returning from the various
areas where steam has been used. It is also where water enters the
system from the storage tank(s) to make up the quantity required in the
system. If the steam has been used for heating fuel, the returns from
that tank may contain oil, or if cargo heating has been used, some of
24
4 / TYPES OF BOILER
25
the cargo product may be returned with the steam. That is why this tank
is sometimes called the observation tank steam returns can be
inspected for contamination here. There is a series of plates and filters
in the hot well which allows the contaminating oil, etc., to be removed.
Any sort of contamination is definitely not wanted in the water entering
the boiler, as it would cause damage. Dosage of the combined product
boiler water treatment is normally carried out into the hot well.
The boiler:
The water is drawn from the hot well by the feed pump and pumped into
the upper drum of the boiler (this is normally called the steam drum).
From here it circulates in the boiler, is heated and turns into steam.
There are normally two different ways in which it is heated.
26
5 / BOILER SYSTEMS
27
6.1
7.1
6.2
UNITOR PRODUCTS
Combined Treatment
1. Liquitreat
2. Combitreat
Single Function Treatment
1. Alkalinity Control
LIQUITREAT
2. Hardness Control
7.2
3. Oxygen Control
COMBITREAT
NOTE: In addition to our combined product chemicals, Condensate Control should be used in all boiler systems to
keep the Condensate pH level between 8.39.0. Also, the hot well temperature is of great importance when it comes
to Oxygen scavenging (ref. basic chemistry at the beginning of the book). We recommend that you maintain a hot
well temperature of between 70 C and 90 C. For further recommendations on product dosage and control limits,
refer to the product data sheet in the Marine Chemicals Manual.
28
29
The tests recommended in order to maintain boiler water within the desired
level of quality when treating with Unitor Liquitreat/Combitreat are as follows:
A. P-Alkalinity Recommended Limits: 100300 ppm as CaCO3.
B. Chlorides 200 ppm maximum as Cl.
C. Condensate pH 8.39.0.
Dosage level of Liquitreat/Combitreat is based on the P-Alkalinity value of
the boiler water. However, Chlorides and condensate pH must also be
controlled and maintained as recommended. Knowledge of all relevant parameters is desirable to enable better interpretation and correct application
of treatment. To increase the condensate pH, use Unitors Condensate Control
in conjunction with your combined product boiler water treatment. It is
recommended that you dose Condensate Control on a continuous basis, to
maintain the condensate pH within the recommended range of 8.39.0
at all times.
8.2
CONTROLLING ALKALINITY
The alkalinity is a more accurate indicator of the boiler water condition than is
the pH. The Phenolphtalein (P) alkalinity is measured to determine whether
the correct conditions of alkalinity exist in the boiler to:
8.4
pH
8.5
CONDENSATE pH
8.6
TESTING REQUIREMENTS
8.6.1 Low Pressure Boiler Water Treatments:
A. Unitor Combined Treatment Products
a. Combitreat For systems up to 17.5 bar.
b. Liquitreat For systems up to 30 bar.
B. Test Equipment Unitor Spectrapak 310 Test Kit.
8.3
CONTROLLING CHLORIDES
The Chloride value will reveal any presence of dissolved salts in the boiler. An
increase, gradual or sudden, in the level of Chlorides is an indication of contamination by sea water, and Chlorides are often used as a reference point
when controlling rate of blowdown. Too high a Chloride level indicates that
undesirable amounts of salts are present, leading to possible foaming and/or
scale and deposit formation.
30
31
D. Mark the result obtained on the log sheets provided, against the
date at which the test was taken.
D. Calculate as follows:
Sulphite content = Number of Sulphite No. 2 L.R. tablets x 10.
E. After use, thoroughly rinse out the shaker tube before storage.
PLEASE NOTE! The Sulphite No. 1 tablet is used only to condition the
sample. Do not count this tablet when calculating the Sulphite level.
B. Add one Chloride tablet and shake to disintegrate; sample will turn
yellow if chlorides are present.
C. Repeat tablet addition until the yellow colour changes to
orange/brown.
Calculation:
Chloride ppm = (No. of tablets used x 20) 20
For example:
If 4 tablets are used then Chloride ppm = (4 x 20) 20 = 60 ppm.
D. Mark this result on the Spectrapak 310 log sheet, against the date
at which the test was taken.
8.6.4 pH test:
For boiler water pH test, 7.514.0.
For Condensate water, 6.510.0.
A. Take a 50 ml sample of water to be tested in the plastic sample
container provided.
B. Using the white 0.6 grm scoop provided, add one measure of the pH
reagent to the water sample, allow to dissolve stir if required.
C. Select the correct range of pH test strip and dip it into the water
sample for approximately 10 seconds.
D. Withdraw strip from sample and compare the colour obtained with
the colour scale on the pH indicator strips container.
E. Record the pH value obtained on the log sheet provided, against the
date at which the test was taken.
32
8.7
33
9.3
Hardness Control is a Phosphate powder product used in boiler water treatment to precipitate dissolved calcium hardness salts and to convert these
salts to non-adherent Calcium Phosphate sludge, which can be easily
removed by blowdown. Hardness Control is highly effective in achieving this
function; minimum dosages are required. Reduced dosage of chemicals minimises dissolved and suspended solids in the boiler water. Hardness Control
provides neutral reaction products in the boiler. A high level of dissolved and
suspended solids are the principal causes of carryover and priming.
Note here the term phosphate hide-out; as the temperature of the boiler
increases, less Phosphate can be held in solution in the boiler water. Therefore, testing and dosage of Phosphate to control hardness salts deposits
should be done when the boiler is under full load conditions. If the Phosphate
residual increases under low load conditions, this is an indication of a dirty
boiler, and increased bottom blows should be carried out to remove the sludge.
The sludge holds excess Phosphate and re-dissolves when the boiler water
temperature is reduced. For further recommendations on product dosage and
control limits, refer to the Marine Chemicals Manual.
9.2
9.1
HARDNESS CONTROL
ALKALINITY CONTROL
Alkalinity Control is used to obtain the correct pH level necessary for the
Phosphate treatment to react with Calcium salts. In addition, Alkalinity Control
is used to maintain the required alkalinity in the boiler water to prevent acid
corrosion. By adopting simple testing procedures to determine the
Phenolphthalein alkalinity (P-Alkalinity) and the total alkalinity (M-Alkalinity),
we can determine the amount of free caustic present in the boiler water by
using the formula 2(P) M = OH. If a positive number is obtained, free caustic
(OH-Alkalinity) is present in the boiler water.
34
35
9.4
9.5
CONDENSATE CONTROL
9.6
9.7
The following diagram depicts a typical Low Pressure Boiler System. Note
injection point for chemicals; when dosing chemicals, the recommendation to
achieve the best possible results is to always dose all chemicals in the diluted
form on a continuous basis.
1 Dosage to hot well or feed tank. All chemicals can be dosed at these points.
However, the recommended dosage of Alkalinity Control and Hardness
Control is either no. 2 feed line or no. 3 chemical feed injection directly to
the boiler. Oxygen Control and Sulphite should preferably be dosed to the
feed tank on a continuous basis.
All combined products can be dosed into the hot well.
2 Dose to injection no. 2 is required to the feed line by means of a pressure
injector or dosage pump. Dosage should be continuous, however water can
be shock treated.
3 Dosage direct to boiler no. 3. All chemicals can be dosed to this point by
means of pressure pot injector or dosage pump. Alkalinity Control or
Hardness Control is best controlled at this location and and the use of
Hydrazine, Sulphite or Condensate Control is recommended on
a continuous basis in the condensate system.
BOILER COAGULANT
36
37
1.
2.
3.
4.
5.
6.
7.
E. To the other cell add one Phosphate tablet, crush and mix until
completely dissolved.
38
F.
Equipment
A. 200 ml sample bottles
B. Lovibond 2000 comparator
C. Phosphate disc 3/70
D. 10 ml molded cells
E. Hydrazine disc 3/126*
F. Sulphite test tube*
* Optional. Either the Hydrazine Test Kit (Spectrapak 312) or the Sulphite Test Kit must be utilised.
The one to be used depends on the Oxygen scavenger in use. Please note that Sulphite is not
adviceable to use in boilers above 30 bar.
B. Add one Chloride tablet and shake to disintegrate. Sample will turn
yellow if Chlorides are present.
C. Repeat tablet addition, one at a time (giving time for the tablet
to dissolve), until the yellow colour changes to permanent
red/brown.
39
B. Using the white 0.6 grm scoop provided, add one measure of the pH
reagent to the water sample, allow to dissolve stir if required.
E. Record the result obtained on the log sheet provided, against the
date on which the test was taken.
C. Select the correct range of pH test strip and dip it into the water
sample for approximately 10 seconds.
D. Withdraw the strip from the sample and compare the colour
obtained with the colour scale on the pH indicator strips container.
Record the result on the log sheet provided, against the date
on which the test was taken.
Wait 2 minutes and place the cell in the right hand compartment
of the comparator.
G. Hold up to the light and rotate the disc until a colour match
is obtained.
40
E. Record the pH value result on the log sheet provided, against the
date at which the test was taken.
D. Record the result on the log sheet provided, against the date on
which the test was taken.
D. After use, thoroughly rinse out the shaker tube before storing.
Please note: The Sulphite No. 1 tablet is used only to condition the
sample. Do not count this tablet when calculating the sulphite level.
10.3.5 pH Test
7.514.0 For boiler water
6.510.0 For condensate water
41
11 High Pressure
Boiler Water Control
1. Log form Coordinated Boiler Water Treatment Log, no.311/312,
or ask for special form above 30 bar pressure.
2. Frequency Samples should be drawn, tested and results logged
minimum every third day.
* This is an optional extra (to the Spectrapak 311). This test must be performed below 21 C.
A cooling coil should be fitted at the sampling point or the sample should be cooled
immediately under cold running water. Cloudy samples should be filtered before testing.
42
43
SPECTRAPAK TEST
UNITOR TREATMENT
Water to be
analysed
Spectrapak
water analysis
Control
limits
Unitor
treatment
products
Feedwater
Hardness
Oxygen (optional)
Chlorides
0
< 10 ppb
< 5 ppm
Oxygen Control
Boiler water
P-Alkalinity
M-Alkalinity
pH (coordinate)
Phosphate (coordinate)
Hydrazine
Chlorides
Silica
Cond.
Reference
Reference
9.610.2
1025 ppm
0.050.10 ppm
< 20 ppm
< 3 ppm
< 300 S/cm
Alkalinity Control
Alkalinity Control
Alkalinity Control
Hardness Control
Oxygen Control
Condensate
pH
8.39.0
Chlorides
Ammonia
< 5 ppm
< 0.3 ppm
Condensate
Control
44
45
Ph-meter
PC 22 Photometer in a case
9 V-Battery
12 V-Mains adapter
Cells
Conductivity meter
Stoppers
Measuring cylinder 100 ml
Test tube brush
Stirring rod
Cleaning kit
Manual
Guarantee-Certificate
Reagents
Ammonia
Silica
P-Alk
M-Alk
Hardness
Phosphate
Hydrazine
Chloride
Optional dissolved Oxygen test. The set is very easy to use and gives a quick
accurate answer. The test results given can easily be compared with
similar equipment in a lab.
(Unitor recommends using the Chemetrics dissolved Oxygen test. Consult
the Unitor office to arrange availability.)
11.3.1 Spares
Standard spares are available from your local Unitor Marine Chemical
representative. Order all spares from the on-going supply list provided
with these test instructions. A Replacement Tablet Reagent Pack.
Estimate 3-monthly requirements.
11.3.2 Safety
Reagents are for chemical testing only; not to be taken internally. Keep
away from children. Wash hands after use.
Hardness.
46
47
11.5.2
48
49
50
Adjustment
All dosage recommendations given above are estimations only, will vary depending
on local conditions as makeup water quality, type of boiler and boiler load.
The testing point for Condensate pH should be up-stream (before) from the dosage
point of Condensate Control.
51
Testing can be done at the discharge from the feed pump. However, if high
dissolved Oxygen residuals are found, water in the storage area of the de-aerator
should be checked to ensure no air is leaking into the feed pump.
Boilers are likely to suffer more from corrosion during periods when not in use
or laid up. They must be protected. Proper layup procedures are essential.
Corrosion will occur if :
A. Low pH conditions occur.
B. Oxygen is present in the boiler water.
The procedure starts 23 days before the layup date
1 Test the boiler treatment levels and blow down the boiler at regular intervals to reduce potential sludge. The boiler should not be laid up dirty.
2 Raise the treatment levels for alkalinity to the maximum allowable level for
that boiler pressure.
3 The boiler should then be treated with a high level of Oxygen Control after
it has been isolated from the main steam line. Gentle firing of the boiler
should be used to fully circulate the treatment with the boiler vented.
150200 ppm Hydrazine is dosed into the boiler. (This works out at
1.25 litres/tonne of water.)
NB! Full water capacity must be used to calculate this not working capacity.
4 The vent cock on top of the boiler should be opened and the boiler filled
with feedwater that is as hot as possible (90 C).
5 The boiler should be given a headof water to ensure that the boiler is kept
full of water. This is achieved by connecting a hose of a drum of treated
water to the boiler vent cock to make up for any losses due to leaks.
6 Where super heaters are in place, the manufacturers instructions must
be followed.
7 This principle of wet layup can be used for exhaust gas economisers, etc.
8 Wet layup of boilers is for the short term. A different procedure should
be used for a long term layup .
Returning to Service
Drain the boiler of excess Hydrazine, refill with water and warm through in the
normal way.
52
53
13 Boiler Blowdown
Blowdown is the mechanical process employed to remove and lower
excessive concentrations of dissolved and suspended solids in boiler water.
This procedure must be exercised on a regular basis to prevent solids from
building up which in turn can result in steam carryover leading to contamination of the after-boiler system. In addition, the consequential concentration
and accumulation of sludge and scale in the boiler can cause heavy deposits
to collect on heat exchange surfaces. Once formed, these deposits reduce
heat transfer and restrict water circulation, causing the boiler to operate at
less than its optimum design efficiency. In order to compensate for the loss
in thermal transfer, the fuel consumption must be increased to raise the
temperature on the furnace-side of the boiler. This in turn can cause
overheating and tube failure.
In general, most feedwater and makeup water is processed and monitored
prior to entering the boiler to ensure that the concentrations of naturallyoccuring solids are at a minimum. If done properly, only small amounts of
these contaminants are allowed to get through. These, however, will
concentrate in the system and therefore must be dealt with by the addition
of water treatment chemicals.
Solids concentrations in boiler water are usually determined by
a conductivity meter which displays a visual readout of the ability of the
boiler water to transmit an electrical current. This characteristic, called
the specific conductance, is directly related to the solids content of the
solution being measured. The greater the solids concentration, the higher
the reading. The scale on the meter usually measures the results in units
of electrical conductance as either siemens or microohms per centimeter
at 25 C. This value can be multiplied by a specific factor to determine
the dissolved solids concentration. Some meters have scales that read
directly in parts per million of total dissolved solids. Thus, these devices
are called both conductivity and TDS meters. In some systems, these
meters are permanently installed to continuously monitor boiler,
condensate and feedwater. Understand and know the conductivity meter
you are using.
An upper limit for the maximum allowable concentration of dissolved
solids is usually specified for a system based on the characteristics of
that system. Operational temperature and pressure are normally given
primary consideration. The higher the value of these parameters, the
lower the tolerance of the system for dissolved and suspended solids and
therefore the lower the specification limit. Once this value has been
reached or exceeded, the system must be blown down to reduce the solids
content as much as possible without sacrificing other aspects of the
system operation.
54
13 / BOILER BLOWDOWN
The Chloride residue is used as a reference value for the TDS level, and is
used to determine blowdown requirements. An upper Chloride concentration
limit is prescribed for the system being monitored.
Blowdown as percent is expressed as:
Cl in feedwater x 100
Cl in boiler.
= % Blowdown
55
J. During this period, make short blowdowns from drums and headers,
adding water as necessary to maintain the initial level.
K. After twenty-four hours, shut down the boiler and allow to cool until
the pressure drops to zero.
L. Open all vents and drains and allow boiler to drain.
M. While draining, or as soon as possible after draining, flush the boiler
with high-pressure, hot, fresh water.
N. Inspect the system, removing any sludge or scum which may have
accumulated during the cleaning process.
O. If results of the cleaning are unsatisfactory, repeat the procedure.
P. Secure boiler and return to service.
Q. If system is to be laid up, do so in accordance with recommended
wet or dry procedure.
56
% by Volume of
Tankleen Plus in Water
12 %
23 %
35 %
57
Refer to Descalex and Descaling Liquid Product Data Sheet for additional
information.
Degree of
Contamination
Descaling Liquid
in Water
Descalex
in Water
Light
Moderate
Heavy
510%
1015%
1520%
35%
510%
1015%
58
59
15 Diesel Engine
Cooling Water Treatment
15.1 PROBLEM AREAS
There are four key areas which must be considered when treating diesel
engine cooling water systems.
15.1.1 Scale
Scale results when a compound precipitates from the water phase
because its solubility has been exceeded. Scale is a dense, adherent
deposit of minerals and is tightly bonded to itself and to metal surfaces.
Scale forming on metal surfaces requires four simultaneous factors:
A.
B.
C.
D.
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61
The steam heater is used to warm the engine up from cold. An air
separator is normally installed to get rid of entrained air in the system.
The water added to the expansion tank is termed make-up water.
Distilled water shall preferably be used for these cooling systems.
This is normally made onboard by a fresh water evaporator (or
generator). A useful way of increasing the plant efficiency is to utilise
the heat taken from the engine to provide a heat source to the
evaporator.
If evaporated water cannot be used for make-up, then fresh shore
water will have to be used. This is normally much higher in impurities.
The engine water temperature is in the region of 65 C to 75 C at the
inlet to the engine. It is maintained at this temperature by controlling
the cooling. The cooler is bypassed if the temperature drops.
15.2.2 Corrosion
As mentioned above, this is the main problem in diesel engine cooling
systems. The water contains some Oxygen, and if it is untreated, an
ideal environment will exist for all types of corrosion.
180
360
540
720
Dieselguard NB Kg/1000 L 2.88 2.52 2.16 1.80 1.44 1.08 0.72 0.36
The chart below can be used to determine the dosage requirement necessary to achieve a Nitrite residual level between the
minimum and maximum specification range limits.
180
360
540
720
900
11.3
9.7
8.1
6.5
4.9
1080 1260
3.3
1.7
14402400
0
When initially dosing a cooling water system, it is typical that the initial dosage may
vary from vessel to vessel, or system to system.Total passivation of the cooling
water system will consume more product than when making Nitrite up as maintenance dosages. The quality of make-up water will also affect initial dosage rates.
62
63
64
65
66
C. pH test
a. Dip one of the test strips into the water sample so that the colour
zone is completely immersed.
b. Compare the colour obtained with the reference, and read off the
printed pH value.
c. Mark the result obtained on the log sheet provided, against the
date on which the test was taken.
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68
from the space between the upper (water) and the lower (oil) cylinder liner
O-ring. This is to check for leakages.
The bores should be inspected when the engine is running. If leaks are
indicated, NO descaling should be performed unless the engine can be
dismantled and the cylinder liners pulled out immediately after the descaling
operation. Otherwise, you cannot be sure that all acid is flushed out/
neutralised, and corrosion of the sealing surface may occur.
69
70
71
CHEMICALS
Unitor ASA
72
73
CHEMICALS
CHEMICALS
Unitor ASA
Unitor ASA
74
75
CHEMICALS
Unitor ASA
Nitrite
pH
Cl
P-Alkalinity
Cl
pH
P-Alkalinity
M-Alkalinity
PO4
Cl
pH
Hydrazine/Sulphite
PC 22 Test Kit:
P-Alkalinity
M-Alkalinity
PO4
Cl
pH
Conductivity
Hardness
Ammonia
Hydrazine
Silica
Samples to be tested: Boiler water
Feed water
Condensate return
Make up water
Engine cooling water
17.2 TESTING
Boiler water:
76
P-Alkalinity
M-Alkalinity
Cl
PO4
pH
Hydrazine/Sulphite
Conductivity
Silica
Appearance
77
Feed water:
Cl
Conductivity
Make up water:
Cl
Hardness
Silica
Condensate return:
Cl
pH
Ammonia
TEST DAILY
AS REQUIRED
TEST WEEKLY
EVERY FOUR DAYS
AS REQUIRED
17.3 TROUBLESHOOTING
78
Fault
Action
P-Alkalinity
Too high
Too low
Blowdown
Dose Alkalinity Control to the boiler
M-Alkalinity
Too high
Blowdown
Chlorides
Too high
Blowdown
pH
Too low
Too high
Phosphate
Too high
Too low
Blowdown
Dose Hardness Control
Blowdown
Check for source of Oxygen leakage
Increase chemical dosage
Conductivity
Blowdown
pH
Check pH of condensate. If too low, increase dosage of Condensate Control.
If too high, decrease dosage of Condensate Control.
Phosphate
If unable to maintain a Phosphate reading after dosing Hardness Control,
check the make-up water for Chlorides.
Hydrazine/Sulphite
Check temperature of feedwater. In most cases, the higher the temperature
of the feedwater, the lower the dosage of Oxygen Control or Sulphite.
Conductivity
If conductivity readings remain high after blowdown, check for:
Too high
C) Heat exchangers
Always check the Chlorides of the feedwater, condensate return and make-up
water when Chloride readings in the boiler continue to be above maximum
limits. If you have steam on deck, check the return lines.
B) Condenser
A) Chloride levels/leaks
B) Condensate return
C) Phosphate level
Fault
Action
Too low
Dose Dieselguard NB
or Rocor NB Liquid.
Stop dosing of chemical until the
Nitrite level is back down below the
max. limit.
Too high
pH
Too low
Chlorides
Too high
79
Nitrite
If Nitrite readings remain low after dosing Dieselguard NB or Rocor NB
Liquid, you may have a bacteriological problem. The cooling water
should then be analysed with appropriate test dip slides which can be
ordered from Unitor. Unitor also has available an effective biocide called
MAR-71, which is specially developed for bacteriological problems.
pH
Increase chemical dosage. If Nitrite level is within recommended limits,
dose Alkalinity Control to increase the pH.
17.3.3 Sea water cooling treatment
To avoid fouling in sea water systems, Unitor has developed a very
effective Amine-based dispersant of marine growth such as Shellfish
Algae and micro-organisms in order to prevent the a.m. problem.
Because of its filming properties, the product also acts as a corrosion
inhibitor.
Bioguard can be used in both static and flowing systems such as
ballast tanks and looped cooling systems.
80
The diagram on the previous page shows the typical dosage layout.
This can be modified to suit a particular situation. Although the
product will gradually clean fouled systems, treatment should
preferably be started on a clean system.
Dosage for sea water cooling systems:
Dose 0.6 ltr Bioguard for every 100 m3 of seawater flowing through the
system per hour. The system throughput is to be determined either from
the rating of the pump(s) or from the system specifications. Treatment is
necessary in coastal waters and should commence three days before
entering these waters and continue for three days after leaving coastal
waters. The calculated dose should be given over a one-hour period
and repeated every 48 hours.
Dosage for static ballast tanks:
Dose one litre of Bioguard per 100 m3 of water prior to ballasting,
followed by a monthly dose of 2 litre per 100 m3.
NB! Bioguard should only be diluted with fresh water prior to dosing
if necessary.
81
18 Evaporator Treatment
THE FRESH WATER EVAPORATOR (OR GENERATOR)
There are two main types:
THE VACUUM or FLASH EVAPORATOR
and
THE STEAM HEATED EVAPORATOR
82
18 / EVAPORATOR TREATMENT
83
19 Marine Equipment
19.1 SOME COMMON MARINE EQUIPMENT
19.1.1 High Pressure Boilers > 30 bar
Babcox & Wilcox Combustion Engineering
Foster Wheeler IHI
19.1.2 Low Pressure Boilers < 30 bar
Sunrod Aalborg Cochran Osaka Kawasaki MHI
19.1.3 Slow Speed Diesel Enginees < 120 rpm
Mitsubishi Sulzer MAN B & W Gtavrken Fiat GMT
19.1.4 Medium Speed Diesel Engines 120900 rpm
Wartsila Sulzer Pielstick Enterprise MAN B & W
MaK Deutz Bergen Diesel Daihatsu
19.1.5 High Speed Diesel Engines > 900 rpm
Hitachi Yanmar EMD Cummins Caterpillar
19.1.6 Evaporators
Alfa-Laval Desalt Atlas (bought by Alfa-Laval) Nirex
Maxim Weir
84
18 / EVAPORATOR TREATMENT
85
Notes:
86
20 / NOTES
Notes:
87
Notes:
88
20 / NOTES