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1
Top 10 for Boiler Water Treatment
Western Regional Boiler Association
March 11, 2015
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#11
Ultra Low Range Hardness Testing
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Continued Increase in Boiler Feedwater Hardness
275 PPB (0.275 PPM) Average hardness
Nexguard dosage recommendation: 9.5 PPM
#10
Temperature Correction for “High Purity” pH Testing
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Condensate Testing
Dedicate IRON test glassware. False high iron. Expect <0.025 ppm
Do not adjust sample flow
Replace pH meter as required, once/6 months
Adjust for temperature
# 9
Myron 6P – Reliable pH and Conductivity Measurement
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9
Replacement pH Probe
#8
Know Your Boiler Mass Balance – Diagnostic Study
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11
#7
Deposit Weight Differential - How Clean are your Boiler tubes?
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#6
Operator Procedures
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BOILER CONTROL
CONDENSATE
Amine 1820
* Consult your Program Administration Manual for further guidance *
IN
RANGE
OUT OF
RANGE
LOW HIGH
1. Leaking
blowdown valve
2. Manual
blowdowns are too
long/often
3. Decrease
surface blowdown
setting
4. Reduced steam
production
5. Change in
feedwater quality
1. Conduct manual
blowdown daily
2. Increase surface
blowdown setting
3. Change in
feedwater quality
4. Increased steam
production
CONDUCTIVITY 2500 - 3500 mmhos
IN
RANGE OUT OF
RANGE
HIGH
1. Regenerate
softener
2. Check brine
level
3. Check valve
setting
4. Have resin
analyzed
5. Run elution
study
SOFT WATER Hardness < 1.0 ppm
pH 8.2 - 9.0
IN
RANGE
OUT OF
RANGE
LOW HIGH
1. Chemical pump
malfunction or lost
prime
2. Feed tank
empty
3. Increase the
chemical pump
setting and record
on log sheet
4. Process
contamination
1. Boiler water
carryover
2. Chemical pump
malfunction
3. Decrease the
chemical pump
setting and record
on log sheet
4. Process
contamination
IN
RANGE
OUT OF
RANGE
Conductivity < 25 mmhos
HIGH
1. Boiler water
carryover
2. Process
contamination
#5
Automated Amine Feed
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Start Auto Amine control
Before Auto
pH variation: 7.2-10.3
#4
Continuous Feedwater Corrosion Monitoring
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Two New Technologies:
3D TRASAR Technology for Boilers™
Measures and controls scale inhibitor chemistry
Nalco Corrosion Stress Monitor™
Measures and controls pre-boiler corrosion environment
Stimson Start-up
Feedwater (DA) Temp vs. ORP
2. Corrosive feedwater - High ORP
1. Low DA temp - Inadequate Pegging Steam
High O2 >100 ppb
3. Oxygen Scavenger INCREASED
4. DA Pegging Steam ON, Set Point
increased to 6 psi
5. At-Temp ORP in range, O2 <20 ppb
New Boiler Automation Technology
Automatically responds
Maintain optimum treatment levels
Directly measures
ppm
22310
0
5
1 0
1 5
2 0
2 5
3 0
3 5
4 0
4 5
0 1/10 /9 9 0 1 /2 0/99 01 /3 0 /9 9 0 2/09 /9 9 0 2 /1 9/99 03 /0 1/99 0 3/11 /9 9 0 3/21 /9 9
Da te
Optimum Operation
Detect
System
Upsets
TRASAR Automation
0
5
10
15
20
25
30
35
40
45
01/10/99 01/20/99 01/30/99 02/09/99 02/19/99 03/01/99 03/11/99 03/21/99
D ate
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20
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10/11/1997 20/11/1997 30/11/1997 10/12/1997 20/12/1997 30/12/1997 09/01/1998 19/01/1998
Date
ppm
22310
TRASAR Automation
Direct control of scaleInhibitor chemistry
ppm
22310
0
5
1 0
1 5
2 0
2 5
3 0
3 5
4 0
4 5
0 1/10 /9 9 0 1 /2 0/99 01 /3 0 /9 9 0 2/09 /9 9 0 2 /1 9/99 03 /0 1/99 0 3/11 /9 9 0 3/21 /9 9
Da te
Optimum Operation
Detect
System
Upsets
TRASAR Automation
0
5
10
15
20
25
30
35
40
45
01/10/99 01/20/99 01/30/99 02/09/99 02/19/99 03/01/99 03/11/99 03/21/99
D ate
0
5
10
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35
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10/11/1997 20/11/1997 30/11/1997 10/12/1997 20/12/1997 30/12/1997 09/01/1998 19/01/1998
Date
ppm
22310
TRASAR Automation
ppm
22310
0
5
1 0
1 5
2 0
2 5
3 0
3 5
4 0
4 5
0 1/10 /9 9 0 1 /2 0/99 01 /3 0 /9 9 0 2/09 /9 9 0 2 /1 9/99 03 /0 1/99 0 3/11 /9 9 0 3/21 /9 9
Da te
Optimum Operation
Detect
System
Upsets
TRASAR Automation
ppm
22310
0
5
1 0
1 5
2 0
2 5
3 0
3 5
4 0
4 5
0 1/10 /9 9 0 1 /2 0/99 01 /3 0 /9 9 0 2/09 /9 9 0 2 /1 9/99 03 /0 1/99 0 3/11 /9 9 0 3/21 /9 9
Da te
Optimum Operation
Detect
System
Upsets
TRASAR Automation
ppm
22310
0
5
1 0
1 5
2 0
2 5
3 0
3 5
4 0
4 5
0 1/10 /9 9 0 1 /2 0/99 01 /3 0 /9 9 0 2/09 /9 9 0 2 /1 9/99 03 /0 1/99 0 3/11 /9 9 0 3/21 /9 9
Da te
Optimum Operation
Detect
System
Upsets
ppm
22310
0
5
1 0
1 5
2 0
2 5
3 0
3 5
4 0
4 5
0 1/10 /9 9 0 1 /2 0/99 01 /3 0 /9 9 0 2/09 /9 9 0 2 /1 9/99 03 /0 1/99 0 3/11 /9 9 0 3/21 /9 9
Da te
Optimum Operation
Detect
System
Upsets
TRASAR Automation
0
5
10
15
20
25
30
35
40
45
01/10/99 01/20/99 01/30/99 02/09/99 02/19/99 03/01/99 03/11/99 03/21/99
D ate
0
5
10
15
20
25
30
35
40
45
10/11/1997 20/11/1997 30/11/1997 10/12/1997 20/12/1997 30/12/1997 09/01/1998 19/01/1998
Date
ppm
22310
0
5
10
15
20
25
30
35
40
45
01/10/99 01/20/99 01/30/99 02/09/99 02/19/99 03/01/99 03/11/99 03/21/99
D ate
0
5
10
15
20
25
30
35
40
45
10/11/1997 20/11/1997 30/11/1997 10/12/1997 20/12/1997 30/12/1997 09/01/1998 19/01/1998
Date
ppm
22310
TRASAR Automation
Direct control of scaleInhibitor chemistry
-0.8
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LP
#3 A
T-T
OR
P v
s E
PB
RE
(V
)
Phase 2: LP #3 AT-T ORP Controlled
Feed Of Eliminox
Phase 1: AEPCO Controlled Feed Of Eliminox
Baseline Monitoring LP #3 AT-T ORP
LP #3 AT-T ORP Set Point = -350 mV
Figure 1: LP #3 AT-T ORP Results During Phase 1 and 2 of AEPCO Trial
Direct control of preboiler corrosion
NCSM Automation-0.8
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2/2
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0:0
0:0
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6/1
2/2
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6 0
:00
:00
LP
#3 A
T-T
OR
P v
s E
PB
RE
(V
)
Phase 2: LP #3 AT-T ORP Controlled
Feed Of Eliminox
Phase 1: AEPCO Controlled Feed Of Eliminox
Baseline Monitoring LP #3 AT-T ORP
LP #3 AT-T ORP Set Point = -350 mV
Figure 1: LP #3 AT-T ORP Results During Phase 1 and 2 of AEPCO Trial
Direct control of preboiler corrosion
NCSM Automation
#3
Automated Chemical Inventory
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Tank Level Monitoring
#2
Blowdown Heat Recovery
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Blowdown/Condensate Heat Exchanger
90%
Energy Saved!
Boiler Blowdown at 150 psig
1,000 lb/hr at 364° F
Hf = 336 BTU/lb
Heat Flow = 336M BTU/hr
Useable Heat Flow = 308M BTU/hr
To Sewer Waste at 86° F
Hfg = 58.2 BTU/lb
Heat Flow = 58.2M BTU/hr
Useable Heat Loss = 30.8M BTU/hr
Clean BD HX efficiency gives
90% removal of heat
Make-Up water picks up
Heat Flow = 278M BTU/hr
Make-Up at 60°F
27.4M BTU/lb
BD HX
150 psig boiler
Blowdown Heat Recovery
#1
Managing your data
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3D Trasar – Stimson Forest Grove
Scale Control NexGuard Trasar
Corrosion control At-Temp ORP
BFW pH
BFW Conductivity
Boiler Blowdown
Turbidity
Temperature
Tank Level
Amine Conductivity
Softener Hardness
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Possible root cause: Low inventory, blocked feed
Description: Relay has been under failsafe condition for a while. But even with30% relay duty concentration
is still dropping. This indicates either the product container may be empty or a leak or blockage may exist in
the feed line. Prior to this during normal operation (auto) concentration decreased less in 1400 minutes
indicating reduced feed rate (conductivity is not dropping that much). Please check the above issues.
Graph attached
Nalco 360™
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Top 10 for Boiler Water Treatment
Western Regional Boiler Association
March 11, 2015
LION CAM-3 SECURITY ALERT
ALERT LEVEL: 1A
ACTION: IMMEDIATE
THREAT LEVEL: HIGH
AUTOMATED REPORT SUMMARY
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LION SEC CAM 3A 17:21:56 03102105
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LION CAM3
01:29:22
03112015
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LION CAM3
01:29:22
03112015
LION CAM-3 SECURITY ALERT
ALERT LEVEL: 1A
ACTION: IMMEDIATE
THREAT LEVEL: HIGH
AUTOMATED REPORT SUMMARY