Professional Documents
Culture Documents
FOR HP BOILERS
OVERVIEW
CORROSION MECHANISMS
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
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297OC 297OC 297OC
285OC
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Dearators :
** corrosion , pitting
Economizer :
** pitting , corrosion , hydrogen damage
EFFECT OF IMPROPER WATER
CHEMISTRY FOR BOILER SYSTEMS
** general corrosion , pitting ,caustic gouging ,
hydrogen damage , deposit induced overheating
EFFECT OF IMPROPER WATER
CHEMISTRY FOR STEAM SYSTEMS
Reheaters and Superheaters
** pitting , corrosion , overheating (SHS), exfoliation (RH)
Turbine :
** corrosion , stress corrosion cracking , pitting , galvanic
corrosion , crevice corrosion , deposition & fouling
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
*** GUIDELINES
---- normal operation
---- critical periods
~~ start up
~~ condenser leakage
. ~~ shutdown ( lay-up)
*** MONITORING
*** MEASUREMENT
Bharat
Bharat HeavyElectricals
Heavy Electricals Limited
Limited, Tiruchirapalli
TIRUCHIRAPALLI
CRITERIA
boiler design
pressure of operation
thermodynamic & engineering principles
type of water treatment ( boiler )
*** phosphate , AVT , etc
objectives
To achieve the expected steam purity
To minimize corrosion
To reduce deposition
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
TURBINE
Chemistry limits established for steam
. leading to the basis for establishing
boiler water chemistry limits and hence
the feedwater and condensate chemistry limits
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
3 FACTORS OF CORROSION
Metal
Oxygen / force
HP IP Turbine LP Turbine
Turbine
Attemperation
Condenser
Blowdown
Makeup
treatment
Deaerator system
Condensate
polisher
Boiler
LP Heaters
HP Heaters
BFP
New units
Internal surfaces of heat exchanger tubes to
be clean --- before put into service
Oil, grease , sand etc removed by alkali boilout
Chemical cleaning ( acid pickling ) for removal
of rust and millscale
Thin , dense , uniform layer of magnetite to be
formed on the internal surfaces of the tubes to
protect from corrosion ( passivation )
Saponification of oil
O
||
H2C O CCH2 CH3
O
||
H C O CCH2 CH3 oil
molecule
O
||
H2C O CCH2 CH3
O
||
H2C O H NaOCCH2 CH3
O
||
H COH NaO CCH2 CH 3
O
||
H2 C O H NaO CCH2 CH3
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Why passivation ?
Magnetite , Fe3O4 Ferric oxide , Fe2O3
colour black brownish red
binding nature tightly binds to flakes off easily
base metal from base metal
Significance protects the does not protect
w.r.to corrosion base metal the base metal
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
11.5
11
10.5
pH 10
9.5
8.5
0 5 10 15 20 25 30 35 40
10.6
10.4
10.2
10
9.8
pH
9.6
9.4
9.2
9
8.8
0 2 4 6 8 10 12
ppm
PO4 NaOH
Operation of Drum-type Boilers 165 to 180 kg/cm2
Hotwell Operational Control limits Boiler water control
conditions limitations
Total solids none TDS < 25 ppm normal
(recommended) pH 9.1 9.8
< 0.05 ppm PO4 5 10 ppm
Total solids Volatile treatment TDS < 25 ppm If on volatile
(acceptable) not suitable ; pH 9.1 9.8 treatment , change
< 0.25 ppm Back to guideline PO4 5 10 ppm to PO4 treatment
values soon
pH
Dissolved oxygen
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
2 Fe 2 Fe2+ + 4 e
O2 + 2 H2O + 4 e 4 OH
-------------------------------------------
2 Fe + O2 + 2 H2O 2 Fe(OH)2
An Electrochemical reaction
water
OH--
O2 Fe2+
Electron flow
ww
Tube
Fe
4 6 8 10 12 14
acidic alkaline
pH
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Corrective actions
Control of dissolved oxygen and ammonia in feed water
Effects of pre-boiler corrosion severe during start-ups when
chemical control is difficult
Proper care and attention during condenser leakage
Condensate purification plants : to minimize soluble and
insoluble materials
Alternate materials : Titanium , stainless steel
Air-inleakage control : Expansion joints between turbine and
condenser ; turbine seals, diaphragms ; condensate pump seals
Dearator performance
Steam temperature and pressure and quantity
Tray alignment etc
Monitoring of dissolved oxygen . On-line
CAUSTIC DAMAGE
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Caustic corrosion
Irregular thinning of waterwall tube due to the corrosive
action of sufficiently concentrated NaOH
Under porous deposits , NaOH builds up from safe
level to corrosive level
Corrosion occurs by concentrations at the local tube wall
& not by concentrations existing in the bulk boiler water
Concentrated NaOH first attacks the protective magnetite
Fe3O4 + 4 NaOH === 2 NaFeO2 + Na2FeO2 + 2H2O
Further attack of NaOH on boiler metal
Fe + 2 NaOH === Na2FeO2 + H2
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Corrective actions
Hydrogen damage
Hydrogen damage occurs in boilers operated with low pH
water chemistry
by aggressive anions like chlorides
concentration of acidic species under deposits
During periods like condenser leakage , specially in sea
cooled power plants , lots of acidic species are introduced
MgCl2 + 2 H2O Mg(OH)2 + 2 HCl
Atomic hydrogen , so formed , can diffuse into steel and react
with iron carbide in steel
Fe3C + 4 H 3 Fe + CH4
Methane , being a bigger molecule, can not diffuse easily
Grain boundaries affected ; internal structure of the tube
damaged , making it brittle
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Corrective actions
Restoration water chemistry
condenser leakage
pH
Dissolved Oxygen
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Deposition
Even a relatively thin deposit layer significantly reduce heat
transfer . Leading to overheating of the tubes
Na3PO4 + H2O
NaOH + Na2HPO4
Boiler water with
Na3PO4 , Na2HPO4 , NaOH
enter through the pores
of the deposit and water
only comes out as steam
leaving the solids to
concentrate
Remedy :
Upgrade analytical system to detect organics in feed
water , and boiler water
organics to be removed condensate polisher
Bharat Heavy Electricals Limited TIRUCHIRAPALLI
Steam Chemistry
Carryover influenced by
solids become more soluble at high pressures
some like silica carry over as vapour
drum level , drum design (internals) , foaming