PRESERVATION OF BOILERS
The boiler life is more while in service
than when it is idle.
There are boilers, which are operated for
8-9 months in a year. There are boilers,
which act as standby.
While in service, waterside parameters are being
monitored by most of the boiler users. When the
boiler is running, the gas side surfaces are dry,
except at the low temperature zones where flue
gas condensation is experienced.
However, the boiler when idle, both gas side
and water side are to be taken care of to
prevent corrosion.
WATER-SIDE CORROSION
Water, left inside the boiler without properly treating for
oxygen removal, leads to corrosion.
The attacks on metals take place due to improper pH
level too.
The corrosion results in isolated pits or craters where in
the parent material thickness is reduced.
This leads to generation of loose oxides, which again
lead to further deposit related failures.
Tube failures can occur at craters where thickness is
less.
GAS-SIDE CORROSION
More corrosion can take place on the gas-side of an idle
boiler than when the boiler is in operation.
Gas side corrosion results from attack on the metal of
the boiler by sulphur compounds. These accumulate in
soot deposits, which can contain up to 30% sulphuric
acid, which is hygroscopic, i.e. absorbs moisture from
the atmosphere.
The soot becomes wet, and allows the acid formation
and leads to attack on boiler steel. Corrosion under ash
deposits do take place depending of the sulphur and the
fuel moisture.
PRESERVATION METHODS
One of the following methods is used for preservation
of boilers.
¾ Dry preservation
¾ Wet preservation under hydraulic pressure
¾ Wet preservation with nitrogen capping
Obviously the gas side has to be put in to dry
preservation only. Water-side can be put in to
preservation under any of the three methods.
GAS SIDE PRESERVATION OF WATER
TUBE / FLUE TUBE BOILERS
When boilers are laid- off it is important that the
gas-side is thoroughly cleaned and all soot / ash
deposits are removed. This is much more easily
done with the boiler hot. The soot is then much
drier and more readily removed.
water washing can be practiced, where boiler is
provided with water washing arrangement /
suitable for water washing.
GAS SIDE PRESERVATION OF WATER
TUBE / FLUE TUBE BOILERS
For Oil fired boilers,
Having cleaned the boiler it is advisable to
dust all the heating surfaces with hydrated
magnesia to neutralize any acid that is
remaining. This can be done by blowing
the powder through the flues by means of
small vacuum cleaner arranged to blow.
Where boilers are connected to separate chimneys it is
best to leave the gas side fully ventilated, i.e. open up
the burner, or remove it, and leave the exit damper, if
any, fully open.
Where boiler outlets are connected to common chimney
this cannot be done otherwise flue gases may discharge
back into the boiler house through the idle boiler. In this
cases the exit damper must be shut and the dusting with
magnesia carried out all the more thoroughly.
Flue tube boilers are easily amenable for gas side
cleaning. This can be done by opening the II pass / III
pass doors.
In the case of water tube boilers, the manholes provided
for Superheater, Economiser, Airheater, MDC, ESP
sections are to be opened to clean the ash / soot
deposits thoroughly. Due to varying climatic conditions,
and due to insulation, the inside of the boiler is never
warmer. However it can be made warmer, by adding
high watts lamps. Room heaters or hot air generators
can also be used as source of hot air supply.
In addition, silica gel or slaked lime – Ca (OH)2 can be
kept inside the boiler in trays. At periodical intervals the
silica gel / Slaked lime must be inspected and replaced.
WATER SIDE PRESERVATION OF
SHELL TYPE BOILERS
HEADERING WITH OPERATING BOILERS.
It may be practical to leave the boiler under
steam supply from other boiler. In such a
case, the water quality must be monitored for
residual sulphite level and pH. The pH must
be maintained at 10 and at least 150 ppm of
sodium sulphite should be maintained. For this
purpose the boiler must have separate
chemical dosing arrangement.
WET PRESERVATION UNDER HYDRAULIC
PRESSURE
In this case, the boiler is always kept under hydraulic
pressure of 5-kg/cm2 pressure. Water quality must be
monitored for residual sulphite level and pH. The pH
must be maintained at 10 and at least 150 ppm of
sodium sulphite should be maintained. This method
can be adopted for an idle period of upto three months.
DRY PRESERVATION
Drain and dry boiler with hot air, place a small electric
heater in the bottom of the boiler & leave man doors
open to allow good ventilation. High wattage lamps
may also serve the purpose. The dry preservation
method will be the best and easiest method for the
shell type boiler.
WATER SIDE PRESERVATION OF
WATER TUBE BOILERS
1. DRY PRESERVATION
The dry preservation method is effective provided the
boiler is completely drainable. If Superheater /
Economiser sections are completely drainable then this
method can be practicable.
¾ The headers should have removable hand-hole
plates wherein silica gel or hydrated lime can be
kept inside for absorbing moisture.
¾ Heaters can be placed inside the headers. The
warm climate will ensure the metal surfaces
are dry. Similarly the drum / drums should be
kept dry by means of room heaters.
¾ Volatile corrosion inhibitors can also be used to
contain corrosion in idle boilers.
If the boiler has non-drainable superheater sections,
getting rid of water will be difficult. Hence this method
can not be adopted for such boilers.
2. WET PRESERVATION
In this method the boiler should be filled with DM
water with a pH of 10 and hydrazine dosed to 200
ppm. It is a fact that the steel corrodes at the least
rate, when pH of 10. The boiler filling must be proper.
It is necessary to back fill the boiler from Superheater
section and ensure the water overflows from
Superheater to the steam drum. The water should be
filled from the lowest point to ensure the air is properly
released from the boiler. After this, any one of the
following should be implemented.
¾ Maintain 5 kg/cm2g pressure in the boiler my
means of a hand pump. Every day the
pressure should be monitored.
¾ Instead of pressurizing, the space above the
water surface can be sealed by Nitrogen gas,
which is inert. This is known as Nitrogen
blanketing. The recommended scheme is
shown below. The nitrogen is maintained at
pressure of 0.35 kg/cm2 g to avoid air
ingress. In this case the Superheater section
will not be filled with water.
Periodical testing of water has to be done to
ensure the water pH is maintained at 10 and the
hydrazine levels are maintained at 200 ppm. A
pump arranged for recirculation will be
necessary for higher capacity boilers, where the
water hold up volume is more.
CONCLUSION
Preservation leads to following benefits
While restarting the boiler, the carryover possibility is
eliminated since no suspended corroded particles will be
present in boiler water.
Phosphate hide out will not be experienced.
Under deposit corrosion is eliminated. Pin hole failures
will be avoided.
End
