Eko Handoko

Basic
Knowledge of
Boiler System

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 Agenda
 Mechanical and Chemical Deaeration
 Flow Diagram of Boiler System
 Oxygen Control System
 Deaeration: Deareation Using Steam
 Oxygen Corrosion: reason we remove O2
Oxygen Scavenging: (Sulfite, Erythorbate/Citric
Acid, Hydrazine, Organic Volatile Oxygen
Scavengers, DEHA, MEKOR, Hydroquinone,
Carbohydrazide)
2

Eko Handoko
 Agenda
 Oxygen Scavengers: (Sulfite, Hydrazine,
Carbohydrazide, Diethylhydroxylamine,
Methyl Ethyl Ketoxime, Erythorbic Acid,
Hydroquinone)
 TheSulfite Chemical Type: Advantages and
Disadvantages
 Hydrazine: Advantages and Disadvantages
 Carbohydrazide: Advantages and
Disadvantages
 Diethylhydroxylamine (DEHA): Advantages and
3
Disadvantages Eko Handoko
 Agenda
 MethylEthyl Ketoxime (MEKO): Advantages
and Disadvantages
 Erythorbic Acid:Advantages and Disadvantages
 Hydroquinone:Advantages and Disadvantages
 FeedWater for Boiler System and Location of
Feedpoint
 Location of Sample Points
 Deaeration Monitoring: DO (Dissolved Oxygen )
Analyzers and Chemets
4

Eko Handoko
 Agenda
 Deaeration Monitoring and Testing Oxygen
Scavengers in residual FW and in feed water
 Testing for Oxygen Removal
 Sampling Requirements
 Boiler Internal Treatment Class High Pressure Boiler
ASME Guidelines for Parameter Monitoring
 ASME Consensus on Operating Practices
 Boiler Pressure <600 PSIG, ( < 42 Kg/cm2 ) (Program:
Precipitating Phosphate, Chelant/Polymer, All
Polymer, Coordinated Phosphate/Polymer
5

Eko Handoko
 Agenda
 Internal Boiler Treatment Recommendations for 600-
750 psig (42-53 kg/cm2)
 Boiler Pressure 600-750 psig (42-53 kg/cm2 )
(Program: EDTA, Polymer, Alkalinity, Silica, Turbidity,
NTU, Hardness, TDS)
 Coordinate pH / Phosphate Control
 Coordinated Phosphate Treatment
Test Recommendations (pH, Conductivity,
Hardness, Silica, Iron, Copper)
 Steam and Return Line Treatment
 Primary Causes of Condensate Corrosion (Carbon
6
Dioxide, Oxygen, Ammonia)
Eko Handoko
 Agenda
 Alkalinity Breakdown Forms Carbon Dioxide
 Oxygen Source and corrosion
 Ammonia Source and corrosion
 Condensate Treatment
 Steam Treatment
 Vapor/Liquid Distribution Ratios
 Filming Amines and FDA Control for Amines
 Condensate Corrosion Control, Polishing Mechanical
Consideration and Monitoring
 Example of Boiler Water Treatment Report
7

Eko Handoko
Flow Diagram of Boiler System

Eko Handoko
Oxygen Control System

Pre-Treatment

Process

Process

Process

Blowdown Flash
Low
flash tank tank
pressure
steam Condensate
Receiver

Eko Handoko
Deaeration:
(Caused of Gas/Oxygen Solubility)
 Mechanical Scrubbing
 Deaerators

 Gas solubility in a liquid decreases with increasing

liquid temperature
 Removal efficiency is increased when gas and
liquid are thoroughly mixed
 Gas solubility in a liquid is directly proportional
to the partial pressure of the gas at the liquid
surface

Eko Handoko
Deareation

 Henry’s Law
 C=kP
C = Total concentration of gas in
solution
P = Partial gas pressure above
solution
k = Proportionality constant
known as Henry’s Law
Constant
Eko Handoko
 Oxygen Content vs. Boiler Feed Water
Temperature (some of BFD is from condensate
so the Temperature is hot)
TEMPERATURE oC
0 10 21 32 43 54 66 77 88 99 110 121
16 22.9 ppm

14 20.0
OXYGEN CONTENT, CC PER LITER

12 17.2
10
GAUGE PRESSURE POUNDS
8
10 14.3
6
4
8 2 11.4
0
6 4 8.6
VACUUM INCHES
8 MERCURY
4 12 5.7
16
2 20 2.9
24
28 0.0
0
50 70 90 110 130 150 170 190 210 230 250

TEMPERATURE °F Eko Handoko

Deareation
 Reduction in partial pressure of gas in the
atmosphere contacting the liquid
 Two Methods
 Vacuum
Turbine Condenser Method
 Introduce new gas while unwanted gas is
vented
Deaerators Using Steam

Eko Handoko
Deareation Using Steam

Make-up Condensate

Water Box Vents

Sprays Steam Inlet

Trays
Steam Equalizer
Downcomer

Storage Tank

To BFW Pump Eko Handoko

Oxygen Corrosion

ANODE: Natural Metal Electrically Charged Metal Electrons

Fe0 Fe+2 + 2e-

CATHODE: Electrons Oxygen Water Charged Ion

2e- + 1/2 O2 + H2O 2(OH-)

Hydroxyl Ions Form Hydroxide or Oxide

Corrosion Products
O2 OH-
Metal Ions Dissolve

Active
Anodic
Less Active Area
Electron flow
Cathodic
Area

Eko Handoko
Oxygen Scavenging
 Chemical Oxygen Scavenging
 Sulfite
 Erythorbate/Citric Acid
 Hydrazine
 OrganicVolatile Oxygen
Scavengers
DEHA
MEKOR
Hydroquinone
Carbohydrazide
Eko Handoko
Oxygen Scavengers

 Sulfite
 Hydrazine
 Carbohydrazide
 Diethylhydroxylamine
 Methyl Ethyl Ketoxime
 Erythorbic Acid
 Hydroquinone

Eko Handoko
The Sulfite Chemical Type

 Na2SO3 (Disodium Sulfite)

 NaHSO3 (Sodium Bisulfite)
 Na2S2O5 (Sodium Metabisulfite)
 (NH4)2HSO3 (Diammonium Bisulfite)
 NH4HSO3 (Ammonium Bisulfite)

Sulfite Reaction:
 2Na2SO3 + O2 = 2Na2SO4

Eko Handoko
Sulfite Advantages and Disadvantages

 Advantages
 Fast Reacting
 Inexpensive
 Easily Tested
 Disadvantages
 Contributes Solids to Boiler Water
 Decomposes to SO2 at 600 PSIG

Eko Handoko
Hydrazine
 N2H4 + O2 = 2H2O + N2

 3N2H4 = 4NH3 + N2
 N2H4 = N2 + 2H2

 Advantages
 Contributes No Solids
 Passivates Boiler Metal
 Inexpensive
 Disadvantages
 Inhalatory Carcinogen
Eko Handoko
Carbohydrazide
(H2N-NH)2C=O
 (H2N-NH)2C=O + 2O2 = 2N2 + 3H2O + CO2
 (H2N-NH)2C=O + H2O = 2N2H4 + CO2
 Advantages
 Reacts Like Hydrazine
 Contributes No Solids
 Low Vapor Pressure
 Disadvantages
 Contributes CO2 To Steam
 Releases N2H4
 Expensive Eko Handoko
Diethylhydroxylamine (DEHA)
 (CH3CH2)2NOH
 4(CH3CH2)2NOH + 9O2= 8CH3COOH + 2N2 + 6H2O

 Advantages
 Rapid Reaction
 Passivates Boiler Metal
 Protects Condensate Systems
 Disadvantages
 Expensive
 Contributes organic carbon

Eko Handoko
Methyl Ethyl Ketoxime (MEKO)

 CH3(CH3CH2)C=NOH
 2CH3(CH3CH2)C=NOH + O2 =
2CH3(CH3CH2)C=O +N2O + H20
 Advantages
 Passivates Boiler Metal
 Protects Condensate Systems
 Disadvantages
 Expensive
 Contributes organic carbon

Eko Handoko
Erythorbic Acid
 (CH2OH)(CHOH)-C4O2(OH)2
 (CH2OH)(CHOH)-C4O2(OH)2 +1/2 O2 =
(CH2OH)(CHOH)-C404 + H20
 Advantages
 Passivates Boiler Metal
 Rapid Reaction
 Food Additive
 Disadvantages
 Expensive
 Adds organic carbon to boiler water

Eko Handoko
Hydroquinone
 C6H4(OH)2
 2C6H4(OH)2 + 13 O2 = 12 CO2 + 6 H20
 Advantages
 Rapid Reaction
 Protects Condensate System
 Passivates Boiler Metal
 Disadvantages
 Restricted to pH 8 - 10
 Expensive
 Organic carbon donor and CO2
donor
Eko Handoko
Feed Water for Boiler System

 Feed as far upstream as possible

 Feed to a point of maximum agitation

Eko Handoko
Location of Feedpoint

DEAERATOR
Order of
2
Preference
3

Attemperation take-off
Eko Handoko
Location of Sample Points
Make-up
4
Condensate

5 1. DA dropleg
2. FW after pump
3. FW after economizer

DEAERATOR 4. Make-up
5. Condensate
2 3
1

Economizer
Eko Handoko
Deaeration Monitoring
 Dissolved Oxygen Survey
 DO (Dissolved Oxygen ) Analyzers
 Chemets
 Verify Deaerator temperature and steam pressure
are in agreement with steam table

Testing Oxygen Scavengers

 Test residual in feedwater
 Sulfite may be tested in boiler water
 Monitor O2 in feedwater
Eko Handoko
Testing for Oxygen Removal

Sample Point Primary Secondary Testing and

Testing Troubleshooting
1. DA dropleg (1) +2
DO pH, Fe, Fe
(1)
2. FW after DO
pump
3. FW after Fe, Fe+2 Fe, Fe+2
economizer
4. Make-up pH, temperature, Fe, Fe+2

5. Condensate pH, temperature, Fe, Fe+2

(1) Continuous monitor preferred

Eko Handoko
Sampling Requirements

 Cooled to less than 90oF

 Sample flow throttled at outlet only
 Stainless steel sample lines
 Continuous flow
 Adequate velocity

Eko Handoko
Boiler Internal Treatment Class
High Pressure Boiler Treatment

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Internal Boiler Treatment

 A good rule to follow is to minimize the amount of

Total Dissolved Solids and Total Suspended Solids
in a boiler
 This helps to keep the boiler tubes as clean as
possible
 Which helps keep the boiler as efficient as
possible and minimizes the opportunity for
underdeposit corrosion and tube damage
 The higher the boiler pressure, the “cleaner” the
boiler water must be

Eko Handoko
Boiler Internal Treatment Considerations

 Departure From Nucleate Boiling means the steam

formation rate is so high, that the existing water flow
in the boiler tube cannot flush the tube surface
 Thus the steam bubble point remains in one location
and can get so big that no water gets to that point on
the tube
 That becomes what is referred to as sheet steaming;
and that is when severe boiler tube damage occurs;
as very little cooling of the tube metal now happens
and we severely overheat the tube and it will rupture
 This is a primary design parameter that boiler
manufacturers use in constructing their boilers
Eko Handoko
Boiler Internal Treatment

 The ASME Guidelines booklet is a very

useful tool for you in selecting a
treatment program and controlling boiler
water, feedwater and condensate quality
to keep the boiler as clean as possible
and minimize the potential for
underdeposit corrosion
 You will notice the recommendations are
boiler pressure specific; and that the
water quality gets better as the pressure
goes up

Eko Handoko
Boiler Internal Treatment

 The reason for that decreasing level of TDS

and TSS has to do with the heat flux increase
per square inch; as boiler designers built
higher pressure boilers.
 Increasing the amount of energy transmission
per square inch of tube surface will tend to
increase the fouling potential

Eko Handoko
Boiler Internal Treatment

 As steam is created, the solids that are in

that former droplet of water are left
behind as the steam bubble moves off
the tube surface
 This can cause deposits to form if the
amount of solids left behind exceeds the
flushing capability of the next water
droplet that comes to that point on the
tube surface

Eko Handoko
Boiler Internal Treatment

 The boiler designer tries to have heat flux at the

level where Nucleate Boiling occurs
 Nucleate boiling is “pinpoint in nature”
 Ideally, that point moves around on the boiler
tube surface; enhancing the flushing action we
talked about in a previous slide
 That flushing effect helps keep deposits from
forming
 And the lower the level of solids, the better that
same water flow rate will be at sweeping the
solids away from the tube surface
Eko Handoko
Boiler Internal Treatment
 Remember, the only thing keeping the boiler tube
from melting is the heat carried away by the
water and steam
 Boil it to dry and little heat is removed from the
tube metal; and it will become “plastic” and blow
like a bubble
 Most boiler tube metal will become plastic about
10000 F
 And the furnace temperature is about 25000 F

Eko Handoko
Boiler Internal Treatment

 We recommends using ASME’s “Consensus On

Operating Practices For The Control Of Feedwater
And Boiler Water Chemistry In Modern Industrial
Boilers” for general guidance on how to treat your
boilers
 ASME is: American Society of Mechanical Engineers
 ASME is an organization that establishes metallurgical
and design standards for boilers and pressure vessels
 OR; EPRI Guidelines, if you are in the electric power
industry
 EPRI is: Electric Power Research Institute

Eko Handoko
ASME GUIDELINES

Watertube Boiler With No Superheater, Turbine,

Or Process Restriction On Steam Purity
FW dissolved oxygen < 7 ppb (with DA)
Feedwater pH 8.3 - 10.5

Boiler Feedwater Boiler Water

Total Total Specific
Drum Hardness Silica Alkalinity Conductance
Pressure
(psig)
Iron
(ppm Fe)
Copper
(ppm Cu) (ppm
CaCO3 ) (ppm
SiO2) ( ppm
CaCO3 ) ( µmhos/cm
)
unneutralized

0-300 < 0.100 < 0.050 < 0.5 < 150 < 1000 < 7000
300-600 < 0.050 < 0.250 < 0.3 < 90 < 850 < 5500

Eko Handoko
ASME Consensus on Operating Practices

Eko Handoko
Boiler Pressure <600 PSIG Options
( < 42 Kg/cm2 ) Program
Boiler Pressure <600 PSIG Options
( < 42 Kg/cm2 ) Program include:

 Precipitating Phosphate
 Chelant/Polymer
 All Polymer
 Coordinated Phosphate/Polymer

Eko Handoko
Precipitating Phosphate
<600 PSIG ( < 42 Kg/cm2 )
 Feedwater Quality Control Poor to
Fair
 Most Forgiving of Programs
 Relatively Large Level of Sludge
Formation
 Sludge Conditioning Crucial to
Boiler Cleanliness

Eko Handoko
Precipitating Phosphate Guidelines
< 600 PSIG ( < 42 Kg/cm2 )

 PO4 30-60 ppm (Filtered)

 Alkalinity 100-200 ppm (OH)
 TDS <3500 mmhos unneutralized
 Silica 40-150 ppm

Eko Handoko
Chelant/Polymer
<600 PSIG ( <42 Kg/cm2 )

 Good Control of Feedwater Quality

 Substoichemetric Feed
 SS Injection is very important

Eko Handoko
Chelant/Polymer Guidelines
<600 PSIG ( <42 Kg/cm2 )

 EDTA 90-95% of FW Hardness

 Alkalinity 50 - 150 ppm (OH)
 Silica 40 - 150 ppm
 Turbidity <5 NTU
 TDS <3500 mmhos unneutralized

Eko Handoko
All Polymer Treatment
<600 PSIG ( < 42 Kg/cm2 )

 Excellent Control of Feedwater Hardness

 Excellent Pretreatment of Make Up
 Ability to Minimize Upset Affects

Eko Handoko
All Polymer Treatment Guidelines
<600 PSIG ( < 42 Kg/cm2 )

 FW Polymer Dose <0.2 ppm

 Polymer Dosage 10 - 12 ppm Active
 Alkalinity 50 - 150 ppm (OH)
 Silica 40 - 150 ppm
 Turbidity <10 NTU
 Hardness < 5 ppm
 TDS <3500 mmhos unneutralized

Eko Handoko
Internal Boiler Treatment
Recommendations for 600-750 psig
(42-53 kg/cm2)

Eko Handoko
Boiler 600 - 750 PSIG
( 42 - 53 Kg/cm2 )

 Same Products as <600 PSIG (<42 Kg/cm2 )

 No Precipitating Phosphate Treatments
Recommended; but you will see it used
 Need for cleaner boiler tube surfaces
 Coordinated PO4 more realistic
 Check ASME Guidelines if using
Demineralized boiler make up water

Eko Handoko
Boiler Pressure 600-750 psig (42-53
kg/cm2 ) Treatment Program
Program for Boiler 600-750 psig (42-53 kg/cm2 )
 EDTA 90-95% of FW Hardness
 Polymer 3-7 ppm Active Polymer
 Alkalinity 50-90 ppm (OH)
 Silica <30 ppm
 Turbidity <5 NTU
 Hardness < 5 ppm
 TDS <1500 mmhos unneutralized

Eko Handoko
Boiler Pressure 600-750 psig (42-53
kg/cm2 ) Treatment Program

 Only One Recommended Program

 Coordinated Phosphate
 Polymer Supplement a good idea
 You will see Chelant/Polymer and All
Polymer treatment programs when the
plant uses only softened water make up
 Do not recommend Precipitating Phosphate
at all

Eko Handoko
Boiler Pressure 600-750 psig (42-53
kg/cm2 ) Treatment Program

 Polymer 5-20 ppm active

 Alkalinity Chart
 Silica <20 ppm
 Turbidity <5 NTU
 Hardness < 5 ppm
 TDS <1200 mmhos
unneutralized

Eko Handoko
Boiler Pressure > 900 PSIG
( > 63 Kg/cm2 ) Treatment Program
 ASME Guidelines and Coordinated Phosphate Treatment
 Polymer Supplement up to 1800 psig(127 Kg/cm2 ) are possible

ASME Guidelines
 Refer to ASME Consensus On Operating
Practices For The Control Of Feedwater And
Boiler Water Chemistry In Modern Industrial
Boilers
 EPRI Guidelines May Be Used By Utility
Companies
Eko Handoko
Coordinated Phosphate Treatment

 This program is a corrosion control

program only; it DOES NOT work for
deposit control
 This treatment program ASSUMES make up
water, feedwater and condensate qualities
are very, very good
 If you have continuing hardness, or
contamination getting to the boiler; get
off this program or you will have a lot of
deposits and tube failures

Eko Handoko
Coordinated Phosphate Treated Boiler Systems
 Will typically have:
 At least demineralized make up water (Do not
even think of Coordinated Phosphate with
anything less!!)
 Some kind of condensate polisher
 Very good daily monitoring of chemistry in the
feedwater, boiler and condensate systems
 Very good standard operating procedures to
minimize corrosion and minimize TDS/TSS from
getting to the boilers
 Routine deposit weight density and deposit
analysis of tube deposits Eko Handoko
Coordinated Phosphate Treatment

 This treatment uses the pH affect on iron

corrosion rates to minimize boiler tube
corrosion by maintaining proper pH
 Proper pH control is maintained by using
sodium phosphate compounds
 Orthophosphate levels help with metal
surface passivation

Eko Handoko
Corrosion BOILER
of steel vs CORROSION
METAL boiler water pH
PROPER pH RANGE FOR OPERATION

Corrosion of steel vs boiler water pH

Relative corrosive attack

8.5 pH
12.7 pH

Safe range

1 2 3 4 5 6 7 8 9 10 11 12 13 14
Eko Handoko
Coordinated Phosphate Treatment

 Phosphate materials used include:

 Monosodium Phosphate NaH2PO4 (Acidic pH Effect)
 Disodium Phosphate Na2HPO4 (Neutral pH Effect)
 Trisodium Phosphate Na3PO4 (Alkaline pH Effect)
 (mostly used to increase pH with combination with
amine and Na3PO4 also make deposit softer and easy
to be clean during BLOWDOWN)
 Trisodium Polyphosphate (Alkaline pH Effect)
 Caustic may be used to adjust pH

Eko Handoko
Coordinated Phosphate Treatment

 Over a period of time, it was found

that maintaining the sodium to
phosphate ratio between of 2.2:1 to
3.0:1 gave the best protection from
iron corrosion in boilers
 Further experience refined these
limits and are seen in the following
control graph

Eko Handoko
Coordinate pH / Phosphate Control

Eko Handoko
Coordinated Phosphate Treatment

 Remember, you can treat a lower

pressure boiler at the treatment
ranges recommended for a higher
pressure boiler
 You may NOT treat a higher
pressure boiler at treatment ranges
recommended for a lower pressure
boiler ( Higher pressures need less
TDS, remember?)

Eko Handoko
Coordinated Phosphate Treatment

 Since we rely on the pH and orthophosphate

readings to give us a sodium to phosphate
ratio; anything that affects that relationship
must be accounted for in determining
whether we are avoiding chemistry
conditions that might induce corrosion
 Ammonia and amines will affect pH readings
 A refinement of the traditional coordinated
phosphate treatment program is called
Equilibrium Phosphate Control

Eko Handoko
Coordinated Phosphate Treatment
Test Recommendations

 Make Up Water:
 pH
 Conductivity
 Hardness
 Silica
 Iron
 Copper

Eko Handoko
Coordinated Phosphate Treatment
Test Recommendations
 Feedwater:
 pH
 Conductivity
 Hardness
 Silica
 Iron
 Copper
 TSS
 Oxygen Scavenger/ORP
Eko Handoko
Coordinated Phosphate Treatment
Test Recommendations
 Boiler Water
 pH
 Conductivity
 Orthophosphate
 Ammonia
 Hardness
 Total Alkalinity
 Silica and
 Copper
 TSS Eko Handoko
Coordinated Phosphate Treatment
Test Recommendations
 Steam
 pH and Conductivity/TDS
 Sodium

 Condensate:
 pH and Conductivity
 Iron
 Copper
 Hardness
 TSS
Eko Handoko
Steam and Return Line Treatment

Eko Handoko
Condensate System

Pre-
Treatment
Process

DEAERATOR
Process

Process

Blowdown Flash
Low
flash tank tank
pressure
steam Condensate
Receiver

Eko Handoko
Typical Condensate Return

Industry Typical % Return

Chemical 30-60
Cogen 20-80
Paper 40-65
Petrochemical 65-85
Power 95-99
Refining 10-60
Steel 5-50

Eko Handoko
Primary Causes of Condensate Corrosion

 Carbon dioxide
 Oxygen
 Ammonia

Eko Handoko
Carbon Dioxide Sources

 Breakdown of feedwater alkalinity

2 HCO3- ® CO3= + H2O + CO2 Bicarbonate
Carbonate Waterheat Carbon Dioxide

CO3= + H2O ® 2OH- + CO 2

Carbonate Water heat Hydroxide Carbon Dioxide

 Air inleakage

 Organics breakdown

Eko Handoko
Carbon Dioxide

 Dissolves in the condensate forming carbonic acid

CO2 + H2O « H2CO3 « H+ + HCO3 -
Carbon Dioxide Carbonic Acid
Bicarbonate

Eko Handoko
Alkalinity Breakdown Forms Carbon Dioxide

Ca
HCO3
Mg CO3 Carbon
CO
Dioxide
2

Softener

Na HCO3 Boiler
Ground Level CO3

Water Table
CO3 Fe
HCO3 Heat
Ca
Mg Cl CO3 CO2
SiO2 SO4 Heat
HCO3 CO2
Deep Well

Eko Handoko
pH Values of
Solutions of Carbon
Dioxide in Pure
Water at Various
Concentrations

Eko Handoko
Corrosion of Carbon Steel and Copper
Depends on pH of Water

25

Carbon Steel
Corrosion Rate

Copper

7 8 9 10 11
pH
Eko Handoko
Oxygen Sources

 Air in-leakage - pumps, traps,

vacuum systems, vented receivers
 Inefficient deaeration operation
 Raw water intrusion - pump seals,
heat exchanger leaks

Eko Handoko
Oxygen

ANODE: Natural Metal Electrically Charged Metal Electrons

Fe0 Fe+2 + 2e-

CATHODE: Electrons Oxygen Water Charged Ion

2e- + 1/2 O2 + H2O 2(OH-)

Hydroxide or Oxide
Hydroxyl Ions Form Corrosion Products

O2 OH-
Metal Ions Dissolve

Active
Anodic
Less Active Electron flow Area
Cathodic
Area

Eko Handoko
Oxygen Corrosion

 O2 attack results in
pitting type
corrosion.
 Rapid localized
metal loss
 Combined
corrosion rate of
carbon dioxide and
oxygen is 10 to 40%
faster than the sum
of either alone....
Eko Handoko
Ammonia Sources
 Chemical/thermal decomposition
 Naturally occurring in raw water

Ammonia Corossion
 Very aggressive against copper and its alloys in
presence of oxygen
 Local concentration determines aggressive nature
 Can cause stress corrosion cracking
 May also cause grooving or general thinning
Eko Handoko
Ammonia

Dissolved Oxygen Maximum Allowable

ppb Ammonia, ppm

0 to 20 0.5

20 to 50 0.3

>5 Any level may be

0 a problem

Eko Handoko
System Survey
 A complete system survey is the key to any effective
treatment strategy
 The survey defines system needs and limitations

Key Considerations in System Survey

 Make-up water quality
 % Condensate return
 Potential for system contamination
 System configuration and complexity
(steam uses)
Eko Handoko
Chemical Condensate Treatment
 Neutralizing amines
 Filming amines
 Oxygen corrosion inhibitors

Condensate Treatment
 Corrosion Control
 Metal Transport
 Mechanical Considerations
 pH Control
 Neutralizing Amines
 Corrosion Control
 Oxygen Scavenging
 Filming Amines
 Condensate Polishing Eko Handoko
Steam Treatment

 Avoiding Carry Over

 Silica
Turbine Blade Protection
 Solids
Turbine Blade Protection
Superheater Tube Deposition
and Corrosion
 Water Droplets
Water Hammer
Turbine Blade Damage
Eko Handoko
Steam Treatment

 Steam Purity Testing

 Sodium Studies
 Cation Conductivity
 Silica Analyzers
 Periodic Samples for Testing
 Hardness (Ultra Low Level)
 Silica
 Iron

Eko Handoko
Neutralizing Amines Are Characterized by:

 Vapor/liquid (V/L) distribution ratio

 Molecular weight
 Basicity
 Component blend ratio

Eko Handoko
Vapor/Liquid Distribution Ratios

16
Relative V/L Ratio

12

0
0 200 400 600 800 1000
Pressure (PSIG)

Ammonia Carbon Dioxide Cyclohexylamine

Morpholine Diethylaminoethanol

Eko Handoko
Amine Neutralizing Ability

11

9
pH

5
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0
ppm Amine / ppm CO2
Cyclohexylamine Morpholine Diethylaminoethanol

Eko Handoko
Neutralizing Amines Are Effective Against:
 Carbonic acid and Other acids

Simple Acid/Base Neutralization

 Amine hydrolysis in water:
R-NH2 + H2O « R-NH3+ + OH-
Neut. amine water Neut. amine hydroxide
 CO2 hydrolysis in water:
CO2 + H2O « H2CO3 « H+ + HCO3-
carbon dioxide water carbonic acid bicarbonate
 Net reaction:
R-NH2 + H2CO3 « R-NH3+ + HCO3-
Neut. amine carbonic acid Neut. amine bicarbonate
Eko Handoko
Neutralizing Amine Limitations/ Considerations
 Not effective against oxygen
 Not best choice in high alkalinity waters
 Not all locations will have same pH - a blend of
amines is typically required
pH CONTROL
Neutralizing Amines Form Amine Carbonate, Ammonium and
Hydroxide ions in Water
Relative Basicity

Amine 72deg 298deg 338deg

Cyclohexylamine 489 61 32
Morpholine 3.4 4.9 3.8
Diethylaminoethanol 68 11.3 9.2
Ammonia 20.6 6.9 4.6
Eko Handoko
Neutralizing Amine Activity
 The Neutralizing amine forms a carbonate to complex the
H2CO3 created by the CO2 in the steam
 The Neutralizing Amine also raises the condensate pH through
the formation of R-NH3+ and OH- (R-NH2 + HOH)
 The Deaerator strips the carbonate off and allows the
neutralizing amine to recycle

pH Control
 Distribution Ratio
 Amine in Vapor Phase/Amine in Liquid
 pH and Temperature Affect DR
 DR Above 1 means it travels farther
 DR Below 1 means it drops out faster
Eko Handoko
Volatile Amine Loss Through the Deaerator

 % Loss Per Minute

 Morpholine 1.0
 DEAE 3.0
 Cyclohexylamine 1.7

Eko Handoko
Filming Amines

 Long chain
amines that CO2 O 2 O2
absorb onto the O2 CO2
metal surface O2
CONDENSATE
O2 O2 CO2
 Function at the O2
CO2
O2
O2

lower pH range of O2
CO2
O2 CO2
6.5 to 9.0 CO2
CO2
O2 CO2
Metallic
wall Protective filming
amine layer
Eko Handoko
Filming Amines
 Protect against acids, O2, and ammonia
 Dosage dependent on surface area and not contaminant
concentration
 Cost effective in high CO2 systems

Filming Amines Limitations/Considerations

 Film formation takes time
 pH control still necessary
 Overfeed may cause sticky deposits and
“gunk” ball formation
 Should be fed after turbines and
condensate polishers
 Will clean up old deposits Eko Handoko
FDA Limits For Amines

 Morpholine 10.0 ppm

 DEAE 15.0 ppm
 Cyclohexylamine 10.0 ppm
 Ammonia No Limit
 Octadecylamine 3.0 ppm
 Soya Amine Zero ppm
 Total amine may not exceed 25 ppm in the
steam and each amine may not exceed its
individual limit

Eko Handoko
pH Control
 Distribution Ratio
 Cyclohexylamine Long Piping Runs
 Diethylaminoethanol Intermediate
 Morpholine Short Piping Runs
 For Complex Systems a Blended Product is Desirable
 Neutralizing Amines
 Eventually Degrade To:
 Ammonia

 Carbon Dioxide; or
 Acetic Acid
 Need to Be Aware of Effects on Water Test Results
 Need to be aware of their effects on steam purity
Eko Handoko
Condensate Corrosion Control
 Oxygen Scavenging
 Condenser Air Removal Sections
 Chemical Addition and Make Up Water Addition Point
 Monitoring
 Water Samples and Dissolved Oxygen Monitoring

 Filming Amines
 Physical Protective Film
 Particulate Contaminates Form Gunkballs
 ODA
 Soya Based
 Starting Feed
 Gradually introduce
 Old Rust will slough off
Eko Handoko
Condensate Polishing

 Filtration
 Particulate Removal
 Ion Exchange
 Ion Removal
Hardness
Metals
Silica
 Mixed Bed Preferred, or Two Vessel
Demineralizer

Eko Handoko
Condensate Mechanical Consideration

 Air Ingress
 Causes oxygen corrosion
 Produces particulate and ionic metals
 Reduces Turbine Efficiency with Back
Pressure
 Condenser/Heat Exchanger Leaks
 Process Contamination
 Hardness Contamination
 Carbonate Alkalinity

Eko Handoko
Condensate Monitoring

 pH 8.2 - 8.8 Normally

 Conductivity Low, Normally < 10
 Iron < 10 ppb
 Copper < 10 ppb
 Hardness Micro Hardness: Zero
 Millipore Testing is useful

Eko Handoko
Summary

 Keep Your Water As Clean as Possible

 Keep Good Records
 Understand the Interrelationships of:
 Operations to Chemical Treatment
 Chemical Treatment to Upset Conditions
 Mechanical Improvements are good

Eko Handoko
Example of Boiler Water Treatment Report
Demin Water Graph of pH Demin Water

Summary pH Demin Water

•Based on our monitoring, we observe that most of demin water pH are
already within our new range of recommendation at 6-7.5. We have changed
control range parameter for demin water at 6-7.5.

Eko Handoko
Example of Boiler Water Treatment Report
Graph of Conductivity Online Demin Water

Summary Conductivity Demin Water

•Conductivity of demin water mostly is still below our new maximum range of
recommended at 0.5 uS/cm, some of the data in 7 August is out of range but it is
getting normal again. We have changed control range to max 0.5 uS/cm.

Eko Handoko
Example of Boiler Water Treatment Report
Condensate Water Graph of pH Condensate Water

Summary pH Condensate Water

•Based on our monitoring, we observe that most of condensate polisher water pH
are already within our new range of recommendation at 6-7.5. We have changed
control range parameter for demin water at 6-7.5.

Eko Handoko
Example of Boiler Water Treatment Report
Graph of pH Feed Water FW6

Summary pH Feed Water

•Based on our monitoring, we observe that most of feed water pH are already
within our new range of recommendation at 7-9.2. We have changed control
range parameter for demin water at 7-9.2.
•We already install caustic line ijection after T1000 to support controlling feed
water pH. action by adjusting our chemicals consumption of Chemical 9708
(amine) and caustic (NaOH) to increase pH Feed Water whenever there was pH
reduction.
Eko Handoko
Example of Boiler Water Treatment Report
Graph of Conductivity Feed Water FW6

Summary of Conductivity Feed Water

•Conductivity of feed water mostly is still below our new maximum
range of recommended at 20 uS/cm. We have changed control range to
max 20 uS/cm.
Eko Handoko
Example of Boiler Water Treatment Report

Graph of pH Boiler Water BW6

Summary of pH Boiler Water

•Based on our monitoring, we observe that most of boiler water pH are
already within our new range of recommendation at 9.2-10.5. We have
changed control range parameter for demin water at 9.2-10.5.
Eko Handoko
Example of Boiler Water Treatment Report
Graph of Conductivity Boiler Water BW6

Summary of Conductivity Boiler Water

•Conductivity of boiler water mostly is still below our maximum range
of recommended at 1000 uS/cm.

Eko Handoko
Example of Boiler Water Treatment Report

Graph of PO4 Boiler Water BW6

Summary of Phosphate Level Boiler Water

•Phosphate level is within our new recommended range between
1-10 ppm. We have changed control range parameter to 1-10.

Eko Handoko
Example of Boiler Water Treatment Report

Initial Treatment Program

No Chemical Dosage Kg/Day Program
ppm
For 1 boiler For 2 boiler
1 (amine) 1 2.71 5.4
pH regulator
2 carbohydrazine) 0.3 0.56 1.12
oxygen Scavanger
3 (PO4) 0.5 6.6 13.2
pH regulator and deposit control

Summary
• We recommend to monitor all parameter closely to maintain al monitoring
parameter within our recommended range. We will cooperate with mill to
adjust chemical consumption or any activities related to our boiler water
treatment.
Should you need any enquiries and extra service, please feel free to contact us.
Thank you for your kind cooperation.

Best Regards
Eko Handoko Eko Handoko
Example of Boiler Water Treatment Report

Eko Handoko
Example of Boiler Water Treatment Report

Eko Handoko
Example of Boiler Water Treatment Report

Eko Handoko
Example of Boiler Water Treatment Report

Eko Handoko
Example of Boiler Water Treatment Report

Eko Handoko
Thank you

117

Eko Handoko