Ondeo Nalco (M) Sdn Bhd

Vacuum Deaerator

(27 tons/hr)

Operation Manual

For

M/s XXXXXXXX

Vacuum Deaerator Manual Page 1 of 8 Eddy Yeong – Applied Services

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DESIGN PARTICULARS

Designed flow-rate 25,000 kg/hr

Inlet/outlet water temperature 160oF
Maximum oxygen content of treated water 0.02 cc/litre
Ejector steam inlet pressure 250 psig
Ejector steam temperature D&S
Normal operating vacuum 20.32" Hg. (Bar 30")
Extraction pump model ULNC65200
Pump motor 10 HP
Drive B.H.P. / Type 7.2 /TEFC Squirrel cage suitable for 415/3/50Hz

DRAWINGS

List of drawings incorporated together with this instruction manual are:

1. Operation instruction drawing

2. Chart for optimum deaeration under vacuum environment
3. Working principle of vacuum deaerator
4. Ejector spare parts drawing

GENERAL DESCRIPTION (see working principle of vacuum deaerator drawing)

The plant comprises mainly of the following: -

1. a size 60S spray-type deaerator, mounted vertically on a raised plinth.

2. a size C2 single-stage, steam operated ejector, mounted horizontally above the deaerator vessel, and
designed to maintain vacuum in the latter.
3. a 2" SIHI extraction pump, removing deaerated water from the main vessel and pumping it to the boiler
feed pumps and
4. various valves, frontal piping between deaerator and extraction pump.

OPERATION (see working principle of vacuum deaerator drawing)

Raw water from the an elevated feed tank enters the deaerator via two spray pipes and a series of brass spray
nozzles, which diffuses the liquid in order to promote the efficiency of the deaeration process. Air and other gases
liberated from the sprayed water are withdrawn by the ejector and discharged to the main feed tank as shown, via a 1
1/2" bore pipe, the end of which is submerged in order that the heat of the exhaust ejector steam is fully utilised to
heat up the feed water to deaerator.

The deaerated water falls into the well of the deaerator and is withdrawn by the extraction pump and directed to the
boiler feed pumps.

Provision is made for re-circulating a percentage of the deaerated water back to the deaerator, as the quantity
pumped normally by the extraction pump is in excess of the boiler feed pumps’ requirement. An advantage with this
system is that should the extraction pump fail for any reason during normal running, the boiler feed pumps will not
be starved, as a supply of un-deaerated water will be available through the re-circulation connection. The connection
is taken from the discharge main after the extraction pump’s discharge valve and it joins the deaerator inlet pipe
before the inlet valves.

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LIST OF VALVES (see working principle of vacuum deaerator drawing)

1. V1 - Ejector steam isolating valve (globe type)

2. V2 & V3 – Feed-water spray pipe isolating valves (diaphragm or butterfly type)
3. V4 – Extraction pump discharge isolating valve (butterfly type)
4. V5 – Extraction pump’s discharge non-return valve (swing type)

COMMISIONING (see operation instruction drawing)

It is assumed: -

1. That the plant is empty and isolated from all other plant in which case all valves are closed.
2. that an adequate electrical supply is available for the extraction pump motor and that the pump and motor
bearings are adequately lubricated.
3. that adequate steam and water supplies are available for the ejector and the deaerator, respectively.
4. that all testing etc, is complete and the plant is in readiness for commissioning.

To commission the plant proceed as instructed: -

1. Open heating steam control valve V14 to introduce live steam to the deaerator’s feed tank to bring up the
temperature of the feed water to its optimum temperature (160oF preferably).
2. Open the ejector steam isolating valve V12, and adjust it to maintain the working pressure specified on
page1.
3. Open the deaerator inlet valves V9 and V10.
4. Open the extraction pump air release cock (if fitted).
5. Slowly open the main feed tank outlet valve V13.
6. Immediately a water level is visible in the gauge glass, close the air release cock and start the extraction
pump.
7. Open the discharge valve V11. The valve should be opened fully.

The extraction pump is designed to operate on a free suction head, and therefore there is no cause for alarm if the
water level drops below the gauge glass during the early stages of running.

During the early stages of running, adjustments may be necessary to V12, in order to maintain the correct working
pressure of the steam. It is advisable to check pressures, temperatures, etc., in order to ascertain that the plant is
operating correctly.

It should be noted that under correct operating conditions, the deaerator vacuum will vary according to the water
inlet temperature (see chart for optimum deaeration under vacuum environment). In principle it is more easily to
maintain a lower vacuum condition. Therefore, it is most appropriate to operate at 20” vacuum and the required feed
water temperature is at 160oF (see chart). If need arises, introduce live steam to deaerator’s feed tank to bring the
temperature to its optimum temperature.

SHUTDOWN

To shut down the deaerator plant; -

1. Close the water inlet valves V9 and V10.

2. Close the extraction pump discharges valve V11.
3. Switch off the pump.
4. Close the ejector steam isolating valve V12.
5. Close the feed inlet valve V14.

Note: The extraction pump must not be switch off whilst the discharge valve is open!!!

The following sections are for recommended maintenance and trouble shoot problems of vacuum deaerator

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MAINTENANCE RECOMMENDATIONS

1 Extraction pump

During operation running no maintenance is required.

On general overhaul of the extraction pump it is recommended that the gland packing be changed. The
packing will harden and deteriorate with age and if allowed to do so to an excessive degree, it could
produce score mark on the spindle. The condition of the ring fitted round the shoulder of the impeller
should be checked on overhaul. Renew the ring if worn excessively.

During running, ensure that the pump and motor are kept clean and free from oil, grease, dust moisture
etc. Examine all cables regularly to ensure that clearing is adequate and that terminals are tight. Check
that the bearings are running smoothly and are well lubricated.

2 Valves

Regular greasing of valve stem, to ensure ease of movement, is the only routine requirement.

3 Ejector

Check the nozzle bores on overhaul. A special designed seam strainer is fitted in the top of the vapour
head and is easily removable to give access to the nozzle. If the bore has increased by more than 10%,
the nozzle should be renewed. Clear the strainer before replacing it.

4 Joints

All joints must be kept tight at all times during running, in order to prevent air leaking into the system
and imparting the efficiency of the plant. If a joint is broken to enable maintenance work to be carried
out, always renew the oil joint ring. Pay particular attention to joints below deaerator water level.

From time to time the spray pipes' nozzles may require renewal due to normal wear. These should be
examined on overhaul and renewed if badly worn.

TROUBLE SHOOTING

The deaerator design is one of the most effective and simple operating for most medium and low-pressure boilers.
Should the deaerator unit operation encounter problems, resulting drop in efficiency of oxygen removal, please
follow below step to trouble shoot and solve the problems. The problems usually can be traced to one (or more) of
four sources, which are:

1. THE EJECTOR
2. THE DEAERATOR VESSEL
3. THE EXTRACTION PUMP AND MOTOR
4. THE INLET WATER

The possible causes of trouble are outlined below under the respective headings given in the previous sentence.

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1 Ejector:

If the ejector is operating unsatisfactorily it cannot be maintaining the required vacuum conditions in
the deaerator vessel. When the performance is suspect, the first thing should be done is a check of the
deaerator vacuum (corrected to 20" Hg.) against the outlet water temperature. If the two correspond
then the ejector can be discard as a possible source of trouble. However, if the check is unsatisfactory
proceed to locate the fault, considering the following points: -

1. low steam pressure

2. high superheat
3. wet steam
4. leaking joints
5. worn, blocked or partially blocked steam nozzles
6. worn coming tube
7. high discharge pressure

Points 1. 2. & 3. can be checked easily and must be rectified at source. They are not, of course, due to
any fault in the deaerator unit.

Regarding point 4. it is most important that a regular check of all joints is must, particularly of those on
the pump suction branch where any leakage is direct into the deaerated water. The joint must be kept
tight.

In point 5. a blocked steam nozzle can be diagnosed easily, because there will be no vacuum. However,
where the vacuum is sub-standard, worn or partially blocked nozzles could be the cause. Clean out
blockages using a stiff wire (inserted carefully into the nozzle bore (details re access to nozzles are
given earlier in the maintenance section) and renew any nozzles in which the bore has increased by
more than 10%.

With point 6. the only permanent solution is a new combining tube.

Point 7. Possibly be caused by two things - ejector discharge piping which is too small or, where the
discharge piping is submerged, too deep immersion. Both these conditions will cause excessive back
pressure resulting in impairment of ejector performance. The remedy for undersized discharge piping is
obvious, by rectification of the point too deeply immersed discharged piping, requires reference to
design of the plant. Most plants are designed for 3 feet submergence, but this is not always the case and
the design should be checked.

2 Deaerator vessel

If the deaerator vessel is not functioning correctly, this will be because the incoming water is not being
sufficiently atomised by the spray nozzles. The cause of this is worn or partially blocked nozzles, or in
rare cases, leakage past the nozzle threads (The latter can be seen by inspection through the vessel sight
glass). Each nozzle should be inspected and either cleared or renewed.

3 Pump and motor

Both pump and motor can be the source of defective performance. The pump can cause trouble because
of leakages through glands (due to over tightening or faulty packing), or through joints as explained
earlier section. Trouble stemming from the motor will be due to a variance from the design speed: the
total head generated by the pump is related directly to the rpm of the motor and if the motor
connections are incorrect, the pump speed could be affected to a considerable degree, producing a
corresponding variation in generated head. Therefore it is always important to check that the motor
speed is correct, before initial running and after any rewiring or extensive maintenance.

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4 Inlet water

The deaerator is designed to operate with inlet water at a specific temperature and this should always be
maintained as far as is possible. If the deaerator is operating unsatisfactorily, the vacuum - water
temperature check as recommended in attached performance chart will reveal whether or not the water
temperature is a possible cause of the reduced efficiency. Water temperature which is above the design
figure will lower the head across the sprays and therefore, the latter will pass less water. Due to the
reduction in quantity at the deaerator’s sprays, the pump suction head will be lowered, possibly to the
extent that water will be by-passed direct into the boiler feed pump suction main, producing a
considerable rise in the dissolved oxygen content of this water. Also, the deaerator will be reduced, i.e.,
absolute pressure will increase, but the ejector capacity will improve, as gas release is easier at the
higher temperature.

Water at a temperature below the design temperature will increase the head across the sprays so that
more water is passed into the deaerator. This not only affects performance, in that load is increased and
gas released is made more difficult; but also, it causes the pump suction head to rise, with a consequent
risk of flooding.

Equally undesirable, because it produces similar conditions, is fluctuating water temperature; this
should be avoided under all circumstances.

Operation instruction drawing

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Chart for optimum deaeration under vacuum environment

Working principle of vacuum deaerator

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Ejector spare part drawing

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