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The targets of successful boiler water treatment are to prevent the scale to minimize corrosion and
carryover.
Major benefits of boiler water treatment:
A/ SCALE FORMATION
Thickness of
scale
1) 1/2 mm
2%
2) 1 mm
4%
3) 2 mm
6%
4) 4 mm (1/8 ")
10 %
5) 8 mm (1/4")
20 %
6) 16 mm (1/2 ")
40 %
7) 30 mm (1")
80 %
Calcium and magnesium are the major hardness components and primary source of scale in boiler
and feed system heat exchanger equipment.
Deposits will cause the temperature of the metal to increase until overheating, metal softening,
blistering and failure occurs
Chloride stress corrosion and Transgraular cracking will occur where there is stainless steel.
Oxygen pitting, high levels of dissolved oxygen will result in pitting and scabs will form over the
pits.
Caustic stress corrosion where there are deposits present hydroxyl ions will collect and cause
corrosion, crating and grouping of tube metal.
Acid attack: An excess of hydrogen ions will corrode tube metal, which will create a methane gas,
which will stress the tube and cause it to crack.
Corrosion in your boiler can reduce its life and may cause serious accidents.
D/ FOAMING/ CARRYOVER
System slugs will normally break and release dry steam in the steam drum.
A high concentration of suspended dissolved solids in boiler water will stabilize steam slugs and
prevent them from braking.
This will result in carryover, which enables wet steam and water to impinge on turbine blades,
valves, and create water hammer which can damage piping and pipe hangers.
Maximum limits for different boiler water to get good quality steam.
BOILER
PRESSURE
(PSIG)
TOTAL DISSOLVED
SOLID
( TDS)
0 - 300
3500
700
125
301-450
3000
600
90
451-600
2500
500
50
601-750
2000
400
35
751-900
1500
300
20
901-1000
1250
250
1001-1500
1000
200
2.5
1501-2000
750
150
1.0
ABOVE 2000
500
100
0.5
ALKALINITY SILICA
(PPM)
(PPM)
TDS Range
Boilers are normally operated in the range 2000 - 3500 TDS.
TDS (ppm) Conductivity (s/cm)
Relative Density
1.00000
1000
2000
1.00091
2000
4000
1.00182
3000
6000
1.00273
4000
8000
1.00364
steam consumption (steam used in the process and not returned as condensate to the
boiler)
steam consumption (steam used in the process and not returned as condensate to the boiler)
qS = steam consumption (kg/h) fc = Total Dissolved Solids - TDS - in the feed water (ppm)
bc = maximum allowable Total Dissolved Solids - TDS - in the boiler water (ppm)
A Total Dissolved Solids (TDS) standard calibration solution should contain the same types of dissolved solids known
to be in the test solution. Failure to do so will result in significant discrepancies between the ppm or ppt reading and
the actual ppm or ppt of TDS in the test solution.
The easiest way to obtain a TDS standard calibration solution is to use a ready-made standard solution that has the
same types of dissolved solids as the solution to be tested. These ready-made solutions offer convenience and
accuracy. They are commonly formulated with either KCl, NaCl, CaCO 3 or a 442 natural water formulation (40%
sodium sulfate, 40% sodium bicarbonate and 20% sodium chloride) to meet the majority of applications. Choose a
ready-made calibration solution according to the following guidelines:
Choose a TDS standard calibration solution that contains the same types of dissolved solids to be tested.
Choose a TDS standard calibration solution that has a ppm or ppt value as close as possible to the value of
the solution to be tested. If this is not reasonable because of the variations in the test solution, it is best to
calibrate the TDS standard that has a ppm or ppt value in the upper one-third of the TDS indicator's
measurement range.
The following is a list of ppm TDS standard calibration solutions available for Eutech Instruments, with their
contents and applications described. Standardization values of the calibration solutions are based on
conditions of 25oC.
Application
Use With
EC-CON-2764BS
TDScan High
1380 ppm
EC-CON-447BS
TDScan Low
It is possible that the above list will not contain a calibration solution appropriate for some applications. One solution to
this problem is to have "tailor-made" ppm TDS standard calibration solutions. This is done by formulating a mixture of
salts in relative proportions that simulate the solution to be tested, then dissolving this mixture into distilled water. This
should be performed according to the formula:
1 mg salt mixture/liter of distilled water = 1 ppm TDS, or in other words
X ppm TDS = X mg of salts + one liter of distilled water
Remember that "X" mg of salts is the number of milligrams of a mixture of salts that's proportions simulate your test
solution, NOT "X" milligrams of each salt in the mixture.
An appropriate value for "X" is determined by the following rule:
Try to choose a ppm or ppt for a calibration solution as close as possible to the expected ppm or ppt values of test
solutions. If the test solution's TDS value is expected to vary a great deal, it is best to choose a ppm or ppt value for
the calibration solution that is in the upper one-third of the TDS indicators measurement range.
Note TDScan Low, TDScan High are like all other dissolved solids testers in that they use the detected conductivity of
a solution to give a direct reading in ppm (parts per million) or ppt (parts per thousand) of TDS. The relationship
between Conductivity and TDS is greatly affected by the types of dissolved solids or salts present in the solution. It is
absolutely necessary to use a calibration solution similar in dissolved solids content to the solution to be tested in
order to get acceptable accuracy. Also it is recommended that the calibration solution be at the same temperature as
the test solution to minimize temperature effect errors.