Recommendations For Boiler Department

PREPARED BY: SHAHRUKH ANWAR

Boiler Water Report
 Boiler Feedwater Temperature
Problems:

• Feed water temperature is very low (38 C).Maintain temperature at 80 C at least.

• Low feed water temperature cause thermal shock which damages boiler tube.
• Low temperature water has also dissolved oxygen which cause oxygen pitting and leakage of boiler tube
• Softener is continuously in operation which reduces feed water temperature
Solutions:
 Boiler Water TDS Level
Problems:

• Feed water TDS is high (800 ppm) which ideally should be less than 300 ppm.
• All boiler blow down water TDS is very high (9000 ppm). Normal limit is 3000 ppm.
• No record of when operator blow down valve. But result shows operator rarely operate blow down valve.

Solutions:
 Boiler Water Hardness Level
Problems:

• Feed water Hardness is high (250 ppm). It should be less than 10 ppm
• No spare softening vessel is present so when operator is recharging softening plant, hard water is being used.
• Operator does not recharge softener on time which increases boiler harness level.
• Hardness will cause scaling of boiler tube, hence reducing boiler efficiency

Solutions:
 Boiler Water Phosphate Level
Problems:

• Boiler water phosphate level is low (10 ppm). It should be above 40 ppm.
• This is causing scaling of boiler tubes.

Solutions:
 Boiler Water Sulphite Level
Problems:

• Boiler water Sulphite level is low (6 ppm). It should be above 40 ppm.

• This is causing oxygen pitting and tube leakage.

Solutions:
 Conclusion

• Improving condensate recovery will solve 50% of all boiler issues.

• This will greatly reduce boiler fuel cost as well as chemical cost.

• Automating softener will ensure softener operate when only needed.

• Continuous operation of softener reduces feed water temperature which is a problem.

• Install chemical dosing pump to ensure continuous dosing of boiler chemical.

• Issue a logbook to maintain record of parameters of boiler water