ISGEC John Thompson

SECTION-16

PROTECTION OF IDLE
BOILER

181
 ISGEC John Thompson

SECTION - 16

PROTECTION OF IDLE BOILERS

Unless proper storage procedures are followed, severe corrosion may

be occur in idle boilers. The method of protecting idle boilers depends
primarily on the length of downtime. Atmospheric corrosion of ferritic
materials rapidly in the presence of oxygen and moisture. The oxides
produced are objectionable and can be transported to critical heat
transfer areas as well as to the turbine. Also, through the wall, pit
type corrosion can occur. Boiler with the their numerous complex
circuits and bends, it is usually impossible to completely dry a boiler
in preparation for storage. Draining all circuits while hot may
temporarily dry the surfaces; however, unless dry air can be
continuously circulated to eliminate all the water vapour from the
unit, recondensation will again result in moist conditions. For this
reason, wet lay-up normally offers the most positive methods of
protection for components in boiler.

16A.1 WET METHOD

The boiler should be cleaned and inspected and then filled upto the
normal water level. Treated water should be used with hardness not
more than 10 p.p.m.
Sufficient quantity of Tri Sodium Phosphate should be added to
neutralize the hardness of treated water in the Boiler and to maintain
residual phosphate around 100 and 150 p.p.m. Sodium Sulphite
Solution also to be added with the water to maintain concentration
approximately 600 p.p.m.
Light up the Boiler and slowly raise the temperature of Boiler water
upto 100 deg. C. All the Vent Valves at the top should be opened.
When steam start blowing through the Vent valves freely firing should
be stopped. This procedure is essential to expel all the dissolved
gases and to activate reaction of phosphate with the hardness present
in the boiler water. After cooling down the Boiler for approximately
four hours slowly increase the water level and fill up the Boiler and
Superheater (if provided). Water should come out through the Vent
Valves and then these valves should be closed to box up the Boiler.
Care should be taken to expel all the air inside the Boiler. Check the
boiler water and maintain the concentration of chemicals as follows:-

1) PH Valve - between 11 to Care should be taken so that PH Valve

11.5 should not exceed 12
2) Residual Phosphate Between 100 to 150 P.P.M
3) Sodium Sulphite Reserve Between 100 to 150 p.p.m
or Hydrazine Around 300 P.P.M

Section # 16 Page 1 of 2
 ISGEC John Thompson

Test should be conducted on a weekly basis and addition of the

treatment chemical should be made as necessary to maintain the
recommended minimum concentration.

When the Boiler is returned to service, complete water of the boiler

should be drained out and the boiler should be cleaned with high
pressure water jet. After cleaning boiler treated water should be
filled upto the normal water level.

Nitrogen or other inert gases may also be used for storage purpose. A
slight positive pressure of the gas is maintained after the boiler has
been filled to the operating level with deaerated feed water. This
method has been exployed in some high pressure utility stations or
similar installations where short period of standby service are
frequently required.

16A.2 CARE FOR EXTERNAL SURFACE

When the boiler down time is in weeks, it is essential to take some

protection for the external surface of boiler tubes. In such case only
dry storage method should be adopted. Care should be taken to seal
all the areas through which air can infiltrate.

Silica get or quick lime may be placed in an open tray inside the
boiler. Frequent check up is required to find out the condition of the
absorbing materials, time to time.

Section # 16 Page 2 of 2