BOILER TRAINING Mr. Customer – Site specific

BOILER TRAININGMr. Customer – Site specific

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Plant Cost Factorsper 1000 lbs. Steam

Fuel 74.9%Labor 10.0%

Equip Deprec 9.8%Electricity

2.5%Sewer 1.5%Water 0.8%

Chemicals 0.5%

Energy Loss Versus Scale Thickness

01234567

1/64 1/32 3/64 1/16

Scale Thickness (Inches)

Ener

gy L

oss

(%)

Iron & Silica High Iron Content "Normal" Scale

Firetube Boiler

Heat

Water rises nearthe tubes and fallsalong boiler walls

WATER TUBE BOILER

FIRE BOX

Downcomers

RisersRisers

Steam Drum

Mud Drum

Steam

Water and its Impurities

• pH 8.0• M Alkalinity 100 ppm• Chlorides 12 ppm• Calcium 75 ppm• Magnesium 30 ppm• Total Hardness 105 ppm• Phosphate .1 ppm• Silica 5 ppm• Iron .05 ppm•Conductivity 230 mmhos

H O2

:Boiler

Steam

CondensateLost

CondensateReturned

Blowdown

Process

Typical Boiler System

Deaerator

FW pump

Softeners

Makeup

:

Softeners (Sodium Zeolite)

Deaerator

FW pump

Softeners

Makeup

Softener Service Cycle

Hard

Soft

105 ppm hardness

0 ppm hardness

How It Works?

Na+

Na+ Na+

Na+ Na+

Ca+

Mg+

Na+

Na+

Ca+

Mg+

Resin Bead

Water Drop Resin Bead

Water Drop

Softener Backwash Cycle

Softener Brining Cycle

saltsolution

Softener Slow Rinse Cycle

Softener Fast Rinse Cycle

Softener Service Cycle

Hard

Soft

:

Deaeration

Deaerator

FW pump

Softeners

Makeup

Deaeration

STORAGESECTION

5psig 222 F

DEAERATINGSECTION

Deaeration

STORAGESECTION

5psig 222 F

TRAYS

Deaeration

STORAGESECTION

SteamInlet

5psig 222 F

Deaeration

STORAGESECTION

CondensateReturn

SoftMakeup

Steam

5psig 222 F

Deaeration

STORAGESECTION

Vent

CondensateReturn

SoftMakeup

Steam

5psig 222 F

To Feed Water Pumps

Solubility of Oxygen in Water

40 60 80 100 120 140 160 180 200 220 240

Temperature *F

24

68

10

12141618

20

ppmOxygen

10 psi 232 F = 0-5 ppb5 psi 222 F = 0-10 ppb0 psi 185 F = 3 ppm

ppb range

Boiler

Steam

Typical Chemical Feed Points

Deaerator

SulfiteFeedCONT.

Boiler

Steam

Typical Chemical Feed Points

Deaerator

BoilerTrt.

fed by FWpumps on

sample pointFeedwater

SamplePoint Boiler water

Boiler

Steam

Typical Chemical Feed Points

Deaerator

CondensateFeed PointAlternative

Sample Point

Chemical FeedHands free & Bulk

Deaerator

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AWBAWB

AWB

AWBAWB

Liquid Sulfite

InternalTreatment

Amine

Softeners

Bulk containers with productdirectly injected as noted.

Alkalinity

To steamheader

AWB

:

TESTING - SOFTENER

Deaerator

Softeners

Makeup

Sample PointSoftener

SOFTENER TESTING

• Hardness 0-1 ppm

TESTING - FEEDWATER

Deaerator

sample pointFeedwater

FEEDWATER TESTING

• Hardness 0-1 ppm

TESTING - BOILER WATER

SamplePoint Boiler water

BOILER TESTING

• Conductivity 4500 max Neutralized 2000-3000• Alkalinity 600-900• Sulfite 30-50

Image Industries Condensate Study

5

6

7

8

9

10

11

4-Feb

9-Feb

14-Feb

19-Feb

24-Feb

1-Mar 6-Mar 11-Mar

16-Mar

21-Mar

26-Mar

31-Mar

5-Apr 10-Apr

15-Apr

20-Apr

pH V

alue

Main C.R.

Wash C.R.

Line 1 LPHX

Line 2 LPHX

Product Usage701 2 Gal 1.5 Gal 1 Gal 2 Gal 1.5 Gal 1.25 Gal 1 Gal 705 1.5 Gal157 2 Gal 2.5 Gal157 L-1 Sat. .5 Gal157 L-2 Sat. 1.5 GalCost per day all treatment $124/day $123/day * $116/day * Protection for line 1 LPHX^ Protection for line 2 LPHX (Both) $72/day ^

TESTING - CONDENSATE

DeaeratorSample Point

TESTING

• pH 6.5 – 7.2• Conductivity Record• Hardness 0• Alkalinity 0

Blowdown

Boiler Blowdown

Bottom

Surface

Boiler Blowdown

Surface

NeedleValve

Boiler Blowdown

Surface

AutoBlowdown

Steam SystemA and W Blowdown Controller

Timed Sample Method

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Full portedgate valve

Throttling needle valve

Max. 4’ Max 3’

Flush valve

Sampling electrode

Motorized ball valve.Mount horizontally awayfrom heat, as near to flooras possible.

cross

A and W

To drain or cascade to other boiler.

110 VAC

Controller

Save some money and keep the boiler hot Boiler System

A and W Cascading Blowdown

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On Line Boiler Boiler in Hot Wet Storage

Boiler BottomBlowdown Boiler Bottom

Blowdown

BlowdownFlashTank

Drain

Flashed steam

Closed

Open

CheckValve

Closed

Open

Closed

Cascading blowdown from an operating boiler is used to keep the idle boiler filled with treated water and hot ready to bring on line. Insure idle boiler ventis open to completely fill boiler then close vent and allow blowdown to exit through the surface blowdownto the blowdown flash tank.

Open

Thank you for your business

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