Post on 05-Jul-2018
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Low and Medium Pressure Boilers
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Purposes of Steam Generation
« Fuel heating
« Comfort heating and cooling
« Cargo heating« Tank cleaning
« Steam driven equipment
« Propulsion on steam ships
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Fire Tube Boiler
Designed with
hot gases
in the tubes andwater/steam
outside the tubes
on the shell side
h hh hh h hh hh h hh hh
Steam Outlet
Sludge Feedwater
Blowdown
FurnaceTube
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Water Tube Boiler
Designed withwater/steam in the
tubes and hot
gases outside
the tubes in
the combustionchamber
Steam Drum
Saturated Steam
Continuous Blowdown
Hot Gases
Waterwall(Risers)
Downcomer Tubes
Bottom Blowdown
Feedwater
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Hotwell
AuxiliaryBoiler
ExhaustGas
Economizer
Distilled Water Tank
Seawater Inlet
HeatExchanger
Main Steam While in Port
Condensate Return
DistilledWater
Feedwater
FeedPump
Distilled Water Makeup
Boiler Water Boiler Water
Boiler Water
Boiler Water
CirculatingPump
RecirculatingFeedwater
Main Steam While at Sea
MakeupPump
Evaporator
Pre-Boiler
Boiler
After-Boiler
Simple Motor Vessel System
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The Purpose of an Effective Boiler Water Treatment Program
« Minimize corros ion process
« Prevent formation of scale and deposits onheat t ransfer sur faces
« Maintain high level of s team purity« Maintain maximum equipment efficiency
« Maintain lowest overall operating cost
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Minimizing Boiler Water Related Problems
• Starts with high qualitydistilled makeup water –Less than 20 mmhos conductivity
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Functions of Boiler Water Treatment
1. To inhibit the corrosion process throughout the system2. To render any scale forming constituents harmless in
the boiler water 3. To prevent carry-over of solids from the boiler to the
power and heating plant system
Deposits
Scale
Corrosion
Waterside Related
Problems
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Common Water Impuri ties From Scale
§ Calcium
§ Magnesium
§ Silica
Scale Formation
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Principal water-related problems “ Scaling”
« Scaling is the formation of a crystalline, interlockedlayer of mineral substances on heat transfer surfaces
« Severe scaling normally occurs only within the boiler
« Typical scale formed are predominantly acarbonate/sulfate complex of Calcium and magnesium§ Calcium carbonate CaCO3§ Magnesium sulfate MgSO4
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« If unchecked, scaling will lower boi ler efficiency
« It will retard heat t ransfer
« Eventually scale buildup will cause the tubes to overheat and rupture
« Scale can also accelerate corrosion
Phosphate/Alkali treatment
5CaCl 2 + 3Na 2 HPO 4 + 4NaOH = Ca 5 (OH)(PO 4 ) 3 +10NaCl + H 2 O
MgCl 2 + 2NaOH = Mg(OH) 2 + 2NaCl
Principal water-related problems “Scaling”
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Calcium Formed Scales
Inadequate treatment Internal treatment/Sludge
Calcium Carbonate Calcium Phosphate- hydroxyapatiteCalcium Sulfate is normal fluidCalcium Silicate
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Calcium Scale
Scanning Electron Micrographs
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Solubility of CaSO4
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Magnesium Formed Scales
Inadequate treatment Internal treatment/SludgeMagnesium hydroxide from Magnesium silicate - normal
insufficient phosphateand high alkalinity
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Silica Formed Scales
Silicon Dioxide
a) Quartz
Ø Carried into boiler system as sand or precipitatesfrom boiler water
b) Amorphous
Ø Non-crystallized but aging can crystallize andform quartz
Combines with many elements to form
tenacious sil icate deposits
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Scale Impedes Heat Transfer
Water
Scale
Steam
To Stack
BTUs
BTUs
BTUsBTUs
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>1482 ° C >1482 ° C
Water side
Fireside
Clean tube Fouled tube
383
333
303293
° C
° C° C
Temperature Profile Across HP Boiler Tube
S
cale
° C
Bulk Water Temperature
Metal Surface
Temperaturewith Scale
353 ° CMetal SurfaceTemperatureno Scale
Fireside
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Iron Deposits in Boiler SystemsOxides
a) Magnetite - passive, ideal protection
b) Hematite - rusts
Deposits In the Boiler Systems
Copper Deposits In Boiler SystemsMetal
Ø Improper acid cleaning
Ø Ammonia/dissolved oxygen corrosion of copper and copper
alloysØ Erosion in condensate or pre-boiler
Oxide
Ø Corrosion product from alloys in system
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Sources of Deposits
Internal Boiler Inadequate Water
Water Conditioning TreatmentCalcium phosphate Calcium carbonate
Magnesium silicate Calcium sulfateMagnesium Calcium silicate
hydroxide Iron oxide
Internallyformed
deposits
Process Contaminants(organics and inorganics)
Feedwater
MudDrum
Feedwater hardness
Condenser leakage
Cooling water treatmentRaw water leakage
Boiler
Corrosion products fromcondensate and feedwater
systems (iron/copper)
SteamDrum
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Effects of Deposits on Heat Transfer Loss
0 1 2 3 4 5 6 7 8
.24
.20
.16
.12
.08
.04
% LOSS OF HEAT THROUGH DEPOSIT FORMATION
D E P O S I T T H I C K N E S S C M
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Deposits Impede Heat Transfer
Scale and Iron Oxide Mixtures
Porous deposits trap water resultingin under deposit corrosion
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Heavily Scaled-Tube
Prone to Under-Deposit Corrosion
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Deposits Impede Heat Transfer
Scale and Iron Oxide Mixture
Porous deposits trap water resultingin under deposit corrosion
Scale and Oil Mixture
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Blistering
Smooth Uncracked Blister Failure Has NotOccurred Yet
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Blistering
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Principal water-related problems - “ Corrosion”
4 main categories of corrosion which will damage a
boiler/feed system if left unchecked are :
Ø Mineral acid corrosion - mostly in boiler
Ø Carbonic acid corrosion - mostly in the condensate
Ø Oxygen corrosion -most severe in boiler
Ø Differential concentration (under deposit corrosion) - mostsevere in the boiler
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Principal water-related problems - Mineral acid corrosion
Ø Seawater ingress, condenser in leakage and/or distiller
carryover creates mineral acids in the boiler
Ø Mineral Acid corrosion
Fe + 2HCl = FeCl2 + H2
Maintain “P” alkalinity between 100 -150 ppm and “T” alkalinity less than
2 “P” alkalinity or pH 10.8 - 11.0
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RELATIONSHIP BETWEEN P-ALKALINITY AND T-ALKALINITY
Phenolphthalein Alkalinity
Ø P-Alkalinity - includes the titration of all hydroxyl ions and one-half of thecarbonate ions
Total alkalinity
Ø T-Alkalinity - is a continuation of titration after the “ P-Alkalinity” has been
determinedØ The titration determines bicarbonate formed by conversion carbonate to
bicarbonate in the “P-Alkalinity” titration and/or any bicarbonate originallypresent in the water.
THUS,
P = OH-
+ 1/2 CO3- -
T = OH-
+ CO3- -
2P = 2OH-
+ CO3- -
\ 2P - T = OH-
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Acidity, Alkalinity and pH Ranges
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Free Mineral
Acidity (FMA)
CO2 escapes quickly intoenvironment
5000mg/l
500 50 5
Bicarbonate Alkalinity
Free CO2 Gas
Acidity
mg/l CaCO2
5 50 500 5000mg/l
OH Alkalinity
mg/l CaCO2
Carbonate Alkalinity
Hydroxyl Alkalinity
M e t h y l
O r a n g e
E n d p o i n t
N e u t r a l i t y
H = O H
“ M ”
P h e n o l -
p h t h a l e i n
E n d p o i n t
“ P ”
pH
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0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
High
Low
Rate of CorrosiveAction
pH ScaleAcidCaustic
AlkalinityNeutral Neutral at
Boiler Conditions
TheoreticalCorrosion
Rate
Corrosive ActionUnder Normal BoilerConditions
Effect of HighOxygen Content
General Wastage Pitting Attack Increased
Foaming
I s o
l a t e d P
i t t i n g
R e c o m m e n
d e
d A l k a
l i n
i t y
Effect Of pH On The Rate Of Corrosion
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4.5
3.5
2.5
0 02 4 6 8 10
pH
5.6
1.5
12
0.5
14
a c
i d i
c f i l m
s t a
b l e f i l m
d i l u
t e a
l k a l i n e
f i l m
acid alkaline
AverageMetal Loss mm
per year
Corrosion Rate
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Principal water-related problems - Carbonic acid corrosion
Ø Carbonic acid is formed when CO2 dissolve in thecondensate
Ø CO2 is generated by the thermal breakdown of
bicarbonates in seawater ingress
Ø Carbonic Acid corrosion
CO 2 + H 2 O = H 2 CO 3
Cu ++
+ H 2 CO 3 = CuHCO 3 + H +
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Low pH Condensate Corrosion
Carbonic Acid Attack
Condensate System Corrosion
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Carbonic Acid Corrosion
Low pH Corrosion
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Principal water-related problems - Oxygen corrosion
Ø Direct corrosive attack on boiler steel by oxygen occurs bycathodic depolarization of electrochemical cells at the
metal/water interface
Ø Most low pressure systems subjected to atmospheric oxygen
ingress
Ø Keep cascade tank temperature as high as possible
Ø Reduce the remaining dissolved oxygen with an oxygenscavenger
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Effects of Oxygen Corrosion
a) Most severe in boiler
b) Metal ions Precipitate as Oxides
c) By-corrosion products TransportedTo Boiler
d) Reduce Heat Transfer
e) Lower than rated capacity
f) Equipment Failures
g) Repair, and Replacement
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Common Methods to Remove Oxygen
Ø Maintain hotwell temp as high as possiblewithout losing feed pump suction
Ø Deaerators remove most oxygen by thermal-mechanical means
Ø Efficient deaerators reduce oxygen to < 0.007ppm
Ø Use chemical oxygen scavenger to remove
remaining oxygen
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12
8
4
0-1 21 43 66 88 110
Temperature in Degrees Centigrade
Oxygen Contentml per liter
Solubility Of Oxygen In Water
At Atmospheric Pressure
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Corrosion rate,mm per year penetration
7.5
5.0
2.5
00 2 4 6 8 10
Oxygen, ppm
49°
C 32°
C
9° C
Effects Of Oxygen Concentrations
Mild effectat low temp.
Increasing temperature increases corrosion rate
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Oxygen Corrosion
Ø Occurs in anypart of steam
generatingsystem
Ø Readilyrecognized by
sharp-edged pits
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Air Oxygen Gas Phase
Water Oxygen Liquid Phase
- Cathode -
High O2
OH OH
Solid Phase
G a s
L i q u
i d
S o l i d
ProtectiveCoating
- Cathode -
+ Anode +
e ee
e
H
HO2
Porous Tubercle of
Corrosion Products
High O2
OH
O2
HFe (OH)3
Fe3O4
Fe(OH)2
Crater
Fe++
H+H+
H2 H2
Localized Iron Corrosion Or Pitt ing
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Oxygen starved areacovered
by deposit is anodic
High oxygen areais cathodic
Under Deposit Corrosion
Local Corrosionq Potential differences
between areas on thesame metal
q Results from variation
in oxygen content
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Profile View of Under Deposit Corrosion
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Principal water-related problems - “ Sludge”
Ø Sludge are combination of suspended material in the water,and it includes:§ Loose corrosion products§ Insoluble mineral precipitates.§ Significant proportion of suspended material are
generated outside the boiler § Oil contamination
Ø Baked-on sludge” on heat transfer surface acts as a heatinsulator
Ø Excessive sludge loading from outside boiler may distortsthe relationship of suspended to soluble constituents of theboiler water
Ø This will render in-built program controls less effective
Liquid Coagulant - Sodium Carboxymethylcellulose to bringsludges to low point to be blown-down.
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Low and Medium Pressure Boilers
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Boiler Treatment Chemicals
Standard Boiler Water Treatment Program§ GC – Alkal in ity Treatment & Magnesium Hardness Treatment
§ Adjunct B – Calcium Hardness Treatment
§ SLCC-A – Condensate pH Treatment
§ Amerzine – Oxygen Scavenge Treatment
§ Liquid Coagulant – Sludge & Oil Treatment
Multi-function Treatment Program
§ AGK-100 + Amerzine or AGK-100 + Drewplex OX§ Drewplex AT + Drewplex OX or Drewplex AT + Amerzine
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Successful Boiler treatment program
« Boiler make-up water should be dist illed or goodquality water
« Boiler samples for testing must be representative
« Simple and accurate test methods
« Control boi ler water and condensate treatmentwithin limit
« Regular blow down schedule in accordance with theboi ler makers recommendations
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Sampling
Test resul ts are meaningful and useful only when the samples tested are representative of
the water in the system at the time of testing.
§ Boiler Water Sampling
§ Condensate and Feed water Sampling
Sampling procedure
§ Samples should be cooled to 250C through a sample cooler before testing
§ Al low sample s tream to run for 5-10 minutes to flush line before collect ion
§ If analysis is delayed, sample should be kept tightly capped in a clean sample bott le.
Sampling Procedure for boiler water
§ Sampling line is usually from steam drum. Sample cooler should be used
Sampling Procedure for condensate and feed water
§ Sampl ing l ines are located at§ Af ter condenser § Cascade outlet or from the suction or discharge of the feed water pump
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Adjunct B : Calcium Hardness Treatment
« Di-sodium Phosphate
« To provide a phosphate reserve
« To precipitate calcium as calcium phosphate, asoft non-adherent sludge that can easily be
blow-down; .
« The carbonates, sulfates and other ions combinewith sodium and remain in solution
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GC: Alkalinity & Magnesium Hardness Treatment
§ Sodium Hydroxide alkalinity
§ To raise the boiler water alkalinity, in order to maintain the hydroxyl ionconcentration in the optimum range for the formation of good protective
magnetite on the steel surfaces
è Fe + 2NaOH Na2FeO2 + H2
è Na2FeO2 + 4H2O 6NaOH + Fe3O4 + H2
§ And to help in the format ion of non-adherent sludge instead of scalewhen hardness enters the boi ler, It reacts with the bicarbonates and
chlorides of magnesium and calcium; to precipitate harmless non-
adherent sludge and sodium chloride which remains in solution
è MgCl2 + 2NaOH Heat Mg(OH)2 + 2NaCl
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Hydroxide Alkalinity
Calcium Phosphate Magnesium Silicate
Soft non-adherent sludgeseasily removed by bottom blowdown
Hydroxyapatite Serpentine
Adjunct-B + GC / AGK-100 / Drewplex AT
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SLCC-A : Condensate pH Treatment
« Morpholine including in SLCC-A, AGK-100 and Drewplex AT
« To prevent after boiler sections low pH corrosion. Theneutralizing amine neutralizes carbonic acid and raise thecondensate pH.
« OC4H4N + H2 CO3 OC4H9N.H2CO3
« To protect heating coil in fuel storage tank
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AMERZINE: Catalyzed Hydrazine, oxygen scavenger
« To scavenge the residual dissolved oxygen
« N2H4+ O2 N2+ H2O
« It also reacts with Ferric Oxide (Fe2O3 ) to form blackmagnetite, Ferrous Oxide (Fe3 O4) which retardscorrosion
« It also converts the Cupric Oxide (CUO) on condenser
tubes to the protective Cuprous Oxide CU2O film« Disadvantage - identified as a Carcinogen
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DREWPLEX OX : Catalyzed oxygen scavenger
« Accelerates rate of oxygen removal
« Enhances total system oxygen corrosion protection
« It also reacts with Ferric Oxide (Fe2O3 ) to form
black magnetite, Ferrous Oxide (Fe3 O4 ) whichretards corrosion
« Passivates feedwater & condensate metal surface
« Save to use« Contributes no dissolved solids
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Polymer in DREWPLEX AT
Disperseu Polymers will be adsorbed onto flocculent particles
– Impart a like charge to the particles
– Reduces the tendency of the particles to combine
u Inhibits scale formation by dispersing it
u Making it easily blown down
u The polymers will prevent iron oxides that returned to the boilerfrom depositing
Crystal growth modification
u Polymers are adsorbed onto growing crystals
- Disrupt their lattice structure
- Retard the crystal normal growth pattern
u Resulting in soft, and less adherent scale
u Thus preventing dense build-up of crystalline scale on the
heating surfaces
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LIQUID COAGULANT
LIQUID COAGULANT™ Reacts with the positive chargesand forms a protection over the oil droplet to keep it from
sticking to the metal surface
Oil Droplet Has Approximately
80% Negative Charge And 20%
Positive Charge
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AT
Drewplex AT Boiler Water Treatment
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AGK-100
AGK-100 Boiler Water Treatment
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CASCADE Tank
§ Recommend to convert cascade tank into deaeratorwhich extract the dissolved gases by raising thetemperature to a level where they come out of solution.
§ Keeping cascade tank temperature around 80-90 °C toreduce level of dissolved gases.
§ Keeping cascade tank in closed condition to preventgases contacted with water and dissolved into water
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Boiler Blow-down
§ Proper boiler blow-down procedures are essential to ensure theeffectiveness of any boiler water treatment program. It is of
primary importance.
§ Continuous (scum) blow-down from below the water level in thedrum or steam separator to reduce the TDS in the boiler water to
a desired level.
§ Bottom blowdown from the low points in the boiler primarilyremoves settled solids.
§ It is prudent to practice frequent bottom blow-down of shortdurations (10 - 12 seconds) to remove sludge at the low point of
the boiler.
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Feedwater Quality
Good (
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Hotwell
AuxiliaryBoiler
ExhaustGas
Economizer
Distilled Water Tank
HeatExchanger
Main Steam While in Port
Condensate Return
Feedwater
FeedPump
Distilled Water Makeup
Boiler Water Boiler Water
Boiler Water
Boiler Water
CirculatingPump
RecirculatingFeedwater
Simple Motor Vessel System
DREWPLEX ® AT Boiler Water Treatmentand DREWPLEX OX Corrosion Inhibitor
Sampling and Dosing
Main Steam While at Sea
MakeupPump
1 DREWPLEX AT boiler water treatment andDREWPLEX OX corrosion inhibitor continuousdosing with BWT™ dosing system.
2
2 Feedwater DEHA sample point.Requires cooler.
3
Continuous blowdown sample point for hydrate alkalinity,phosphate and conductivity.Requires cooler.
4
Makeup water.
5
Condensate sample point for pH.5
43
For testingprogram click
here
1
Sample Cooler
Sample Cooler Feedwater
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DREWPLEX ® AT Boiler Water Treatment and DREWPLEX OX Corrosion InhibitorDosing
BWT™ Dosing System
60 LiterPolyethylene
Tank
• Πυµπ ανδ τανκ σετ το χοντινυουσλψ δοσε
∆ΡΕΩΠΛΕΞ ΑΤ τρεατµεντ ανδ ∆ΡΕΩΠΛΕΞ ΟΞχορροσιον ινηιβιτορ.
• ΠΧΝ 0124−65−1
• 17 βαρ δισχηαργε πρεσσυρε ωιτη πολψπροπψλενε δοσινγηεαδ
Γραϖιτψ ∆οσινγ
Χοντρολ βψ φλοωµετερ
For testingprogram clickhere
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Control Tests Frequency Control Limit Sample PointHydrate Alkalinity Daily 30-65 ppm Boiler water Neutralized Conductivity Daily 700 mmhos max Boiler water DEHA Daily 0.4-0.8 ppm Feedwater
Reference Tests Frequency Sample Point
Phosphate Daily Boiler water Hardness Weekly Feedwater Condensate pH Weekly Condensate
Motor Vessel (0-450 psig or 0-32 bar)
DREWPLEX ® AT boiler water treatmentand
DREWPLEX OX corrosion inhibitorTesting Program
Decision Tree
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Hotwell
AuxiliaryBoiler
ExhaustGas
Economizer
Distilled Water Tank
HeatExchanger
Main Steam While in Port
Condensate Return
Feedwater
FeedPump
Distilled Water Makeup
Boiler Water Boiler Water
Boiler Water
Boiler Water
CirculatingPump
RecirculatingFeedwater
Simple Motor Vessel System
DREWPLEX ® AT Boiler Water Treatmentand AMERZINE ® Corrosion Inhibitor
Sampling and Dosing
Main Steam While at Sea
MakeupPump
1 DREWPLEX AT boiler water treatment andAMERZINE corrosion inhibitor continuousdosing with BWT™ dosing system.
2
Continuous blowdown sample point for hydrate alkalinity,hydrazine, phosphate and conductivity.Requires cooler.
3
Makeup water.
4
Feedwater.
5
Condensate sample point for pH.5
3
42
1
Sample Cooler
For testingprogram click
here
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DREWPLEX ® AT Boiler Water Treatment and AMERZINE ® Corrosion InhibitorDosing
BWT™ Dosing System
60 LiterPolyethylene
Tank
• Πυµπ ανδ τανκ σετ το χοντινυουσλψ δοσε
∆ΡΕΩΠΛΕΞ ΑΤ τρεατµεντ ανδ ΑΜΕΡΖΙΝΕ χορροσιονινηιβιτορ.
• ΠΧΝ 0124−65−1
• 17 βαρ δισχηαργε πρεσσυρε ωιτη πολψπροπψλενε δοσινγηεαδ
For testingprogram click
here
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Control Tests Frequency Control Limit Sample PointHydrate Alkalinity Daily 30-65 ppm Boiler water Neutralized Conductivity Daily 700 mmhos max Boiler water Hydrazine Daily 0.03-0.1 ppm Boiler water
Reference Tests Frequency Sample Point
Phosphate Daily Boiler water Hardness Weekly Feedwater Condensate pH Weekly Condensate
Motor Vessel (0-450 psig or 0-32 bar)DREWPLEX ® AT Boiler Water Treatmentand
AMERZINE ® Corrosion InhibitorTesting Program
Decision Tree
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Hotwell
AuxiliaryBoiler
ExhaustGas
Economizer
Distilled Water Tank
HeatExchanger
Main Steam While in Port
Condensate Return
Feedwater
FeedPump
Distilled Water Makeup
Boiler Water Boiler Water
Boiler Water
Boiler Water
CirculatingPump
RecirculatingFeedwater
Simple Motor Vessel System
AGK ® 100 Boiler and FeedwaterTreatment
Sampling and Dosing
Main Steam While at Sea
MakeupPump
1 AGK 100 boiler and feedwater treatment continuousdosing with BWT™ dosing system. Supplementwith AMERZINE corrosion inhibitor as needed.
2
2
3
Makeup water.
4
Feedwater.
5
Condensate sample point for pH.5
Continuous blowdown sample point for hydratealkalinity, phosphate, hydrazine andconductivity.Requires cooler.
3
4
For testingprogram click
here
Sample Cooler
1
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BWT™ Dosing System
60 LiterPolyethylene
Tank
• Πυµπ ανδ τανκ σετ το χοντινυουσλψ δοσε ΑΓΚ−100
τρεατµεντ. Συππλεµεντ ωιτη ΑΜΕΡΖΙΝΕ ® corrosion
inhibitor as needed.
• ΠΧΝ 0124−65−1
• 17 βαρ δισχηαργε πρεσσυρε ωιτη πολψπροπψλενε δοσινγηεαδ
AGK ® - 100 Boiler and Feedwater TreatmentDosing
For testingprogram click
here
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Control Tests Frequency Control Limit Sample PointHydrate Alkalinity Daily 30-65 ppm Boiler water
Neutralized Conductivity Daily 700 mmhos max Boiler water Hydrazine Daily 0.03-0.1 ppm Boiler water
Reference Tests Frequency Sample PointPhosphate Daily Boiler water Hardness Weekly Makeup water Condensate pH Weekly Condensate
Motor Vessel (0-450 psig or 0-32 bar)
AGK ® -100 Boiler and Feedwater TreatmentTesting Program
Supplement as necessary with AMERZINE ® Corrosion Inhibitor.
Decision Tree
M i St Whil t S
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Hotwell
AuxiliaryBoiler
ExhaustGas
Economizer
Distilled Water Tank
HeatExchanger
Main Steam While in Port
Condensate Return
Feedwater
FeedPump
Distilled Water Makeup Boiler Water
Boiler Water
Boiler Water
CirculatingPump
RecirculatingFeedwater
Simple Motor Vessel System
Standard Treatment withAMERZINE ® Corrosion Inhibitor
Sampling and Dosing
Main Steam While at Sea
MakeupPump
1 ADJUNCT B™ phosphate boiler water treatmentand GC™ concentrated alkaline liquid slugdosing into bypass pot feeder.
2
3
4
Makeup water.
5
Feedwater.5
Condensate sample point for pH.
AMERZINE® corrosion inhibitor andSLCC-A™ condensate corrosioninhibitor continuous dosing into feedwater.
1
3Continuous blowdown sample point forphenolphthalein and total alkalinity, phosphate,hydrazine, chloride and conductivity.Requires cooler.
4
6
For testingprogram click
here
2
Sample Cooler
6
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Standard Boiler Water Treatment with AMERZINE ® Corrosion InhibitorDosing
BWT™ Dosing System
60 LiterPolyethylene
Tank
• Πυµπ ανδ τανκ σετ το χοντινυουσλψ δοσε ΑΜΕΡΖΙΝΕ
χορροσιον ινηιβιτορ ανδ ΣΛΧΧ™- A condensate
corrosion inhibitor.
• ΠΧΝ 0124−65−1
• 17 βαρ δισχηαργε πρεσσυρε ωιτη πολψπροπψλενε δοσινγηεαδ
• Βψ πασσ ποτ φεεδερ το σλυγ δοσε Α∆ϑΥΝΧΤ Β™phosphate boiler water treatment and GC ™concentrated
alkaline liquid.
• ∆ιλυτε προδυχτσ ωιτη χονδενσατε.
BypassPot
Feeder For testingprogram click
here
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Control Tests Frequency Control Limit Sample PointP Alkalinity Daily 100-150 ppm Boiler water T Alkalinity Daily
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Hotwell
AuxiliaryBoiler
ExhaustGas
Economizer
Distilled Water Tank
HeatExchanger
Main Steam While in Port
Condensate Return
Feedwater
FeedPump
Distilled Water Makeup Boiler Water
Boiler Water
Boiler Water
CirculatingPump
RecirculatingFeedwater
Simple Motor Vessel System
Standard Treatment withDREWPLEX ® OX Corrosion Inhibitor
Sampling and Dosing
Main Steam While at Sea
MakeupPump
1 ADJUNCT B™ phosphate boiler water treatmentand GC™ concentrated alkaline liquid slug dosinginto bypass pot feeder.
2
3
4
Makeup water
6
Condensate sample point for pH.
DREWPLEX® OX corrosion inhibitor andSLCC-A™ condensate corrosion inhibitorcontinuous dosing into feedwater.
1
3Continuous blowdown sample point forphenolphthalein and total alkalinity, phosphate,hydrazine, chloride and conductivity.Requires cooler.
3a
3a Feedwater DEHA sample point.Requires cooler.
4
6
For testingprogram click
here2
Sample Cooler
Sample Cooler
Feedwater
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BWT™ Dosing System
60 LiterPolyethylene
Tank
Standard Boiler Water Treatment with DREWPLEX ® OX Corrosion InhibitorDosing
• Βψ πασσ ποτ φεεδερ το σλυγ δοσε Α∆ϑΥΝΧΤ Β™phosphate boiler water treatment and GC ™concentrated
alkaline liquid.
• ∆ιλυτε προδυχτσ ωιτη χονδενσατε.
• Πυµπ ανδ τανκ σετ το χοντινυουσλψ δοσε∆ΡΕΩΠΛΕΞ ΟΞ χορροσιον ινηιβιτορ ανδ ΣΛΧΧ™- Acondensate corrosion inhibitor.
• ΠΧΝ 0124−65−1
• 17 βαρ δισχηαργε πρεσσυρε ωιτη πολψπροπψλενε δοσινγηεαδ
BypassPot
Feeder For testingprogram clickhere
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Control Tests Frequency Control Limit Sample PointP Alkalinity Daily 100-150 ppm Boiler water T Alkalinity Daily
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DREWPLEX AT & OX Control Chart
DREWPLEX AT & OX C t l Ch t
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DREWPLEX AT & OX Control Chart
New Boiler Treatment
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New Boiler Treatment
Conditions:§ Mill scale and rust on water side of new boiler should be removed to prevent p itting.
§ New boiler water contains very high disso lved oxidation so lids and suspend material.It will deposi t on heating surface to retard heat transfer.
§ High frequency blowdown required to remove dissolved and suspend material. Water
and chemical consumption are high by continuous blowdown.§ Tube plate may have residual of emulsion o il or anti-rust coating.
Recommendation:
§ Before sea trial, boil ing out new boiler by chemical (3% LAC solut ion).
§ Af ter bo il ing out , fi ll water and chemical t reatment to prevent ox idation .
§ Af ter sea tr ial , boi ler water wi ll be contaminated by solid and material from pipingsystem. Recommend to drain all water and flush boiler and cascade tank by jet water.Fill water and chemical immediately to prevent oxidation. .
LAC B ili O t
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LAC Boiling Out
New Boiler waterside
before chemical clean
New Boiler waterside
after chemical clean
B ili t N PO
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Boiling out – Na3PO4
Before After
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Di l E i S t C li
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Three Main Diesel Engine Systems Require Cooling
« Engine Jacket
« Piston Areas« Fuel Valves
Diesel Engine System Cooling
Cooling Water System divided by 2 major systems
1. HT Cooling System
2. LT Cooling System
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Minimizing Cooling Water Related Problems
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• Starts with high qualitydistilled makeup water – Less than 20 mmhos conductivity
Minimizing Cooling Water Related Problems
Common Problems
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« Mineral Scale
« Deposits
« Corrosion
Common Problems
Mi l S l
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§ Hardness introduced into the system from seawater in-leakage orshore water makeup
•Calcium carbonate•Calcium sulfate
Types
•Hard scale insulates metal surfaces andimpedes heat transfer
•Equipment damage•Potential for under deposit corrosion•Localized overheating and metal failure
Consequences of Inadequate Treatment
•Use good quality distilled makeup water•Treat with polymeric antiscalants that
hold scale particles in suspension untilthey can be removed by bleed off
Minimization
• High heattransfer sections
Found In
Mineral Scale
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TempGradient Across
1MMScale
1mm Mineral Scaleon Water Side
Clean Cylinder Wall
570o C
270o C
70o C
Temperature
Gradient Acr oss
25 mm liner
Temperature
Gradient
Acr oss
25 mm liner
Effect of Scale on Temperature of CYLINDER WALLS
CombustionSide
Combustion
Side
Water
Side
Water
Side
Deposits
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§ An accumulation of suspended solids that can come from manydifferent sources
•True scale•Corrosion products•Oil contamination
•Bacteria contamination•Mixtures of above
Types
•Insulate metal surfaces and impede heattransfer
•Bacteria can form a biofilm•Equipment damage•Potential for under deposit corrosion•Localized overheating and metal failure
Consequences of Deposits Minimization
•Use good quality distilled water makeup•Treat with with polymeric antiscalants
that hold particles in suspensionuntil they can be removed by bleed off
Found In
•Oil in fuel valve area•Bio in cooler areas•Scale/corrosion in high
heat transfer areas
Deposits
Bacteria Contamination
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« Biological growths enter coolingwater at head tanks or othersystem openings
« Growth destroy nitri te used forprotective mono-molecular film
« Growths insulate heat transfersurfaces
« Found in LT Cool ing WaterSystem.
Growth
Bacteria Contamination
Controll ing Bacteria Contamination
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« Loss of ni trite or increase of nitrate may be indication ofcontamination
« Treat with microbiocide if detected
« Do not use shore water
« Do not use water that has been in contact with marinesanitation device vent
Controll ing Bacteria Contamination
Corrosion
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Galvanic•Cavitation/erosion•Under deposit
•Low pH
Types
•Loss of metal•Equipment damage•Repair, replacement and labor costs
•Unscheduled outages
Consequences of Inadequate Treatment
•Gal-low temp areas•Cav/ero-high flow•Dep/pH-anywhere
Found In
§ Loss of metal through electrochemical reversion to its orig inalstate
Minimization
•Use good quality distilled water makeup•Treat with good scale and corrosion
inhibitor •Minimize dissimilar metals•Ground electrical equipment•Reduce or change water flow•Use more resistant metals•Redesign cooling water circuits
Corrosion
Galvanic Corrosion
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§ The action between different metals form a galvanic couple
Galvanic Corrosion
Galvanic Series Of Metals
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Galvanic Series Of Metals
Gold and PlatinumSilver Chromium-Nickel-Iron (passive)Copper LeadTinBronzes
BrassesNickelStainless SteelChromium-Iron (active)CadmiumIron
ChromiumZincAluminumMagnesium
Cathode is the protected end
Anode is the corroded end
• Metals near the bottom of the
series act as anodes and suffer
corrosion when coupled with
metals near the top of the
series.• Galvanic couples of metals
close together in the series
usually corrode more slowly
than couples composed of
metals f rom the extreme endsof the series
Cavitation/Erosion Corrosion
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« Appears as shallow pitting or gouging
« Occurs in areas with high f low rates and rapidpressure changes causing gas bubbles to be created
and then to collapse§ The col lapsing gas bubbles attack the metal
« Mechanical action§ Changes in water direction§ Induced vibrations
Cavitation/Erosion Corrosion
Cavitation
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CoolingWater
Cylinder Liner
Sleeve
Magnitude of Deflection
(exaggerated for example)
CoolingWater
StaticCondition
During eachpower stroke
cylinder sleevedeflects in
the plane of the piston rod/crank rotation
Bubbleformationand sleevedeflectionreturningto normal
Bubblescollapse
and energyis releasedcausing
metal damage
NormalBubble
Directionof energy
releasewhen thebubble
collapses
Cavitation
Cavitation
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Cavitation
Cavitation on
cylinder liner
Impingement
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Impingement
cathode cathode
Protective coating is lost due to turbulenceand wants to reform.
Impingement
anode
Minimizing Corrosion
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« Galvanic§ Minimize dissimilar metals in cooling water circui t§ Ground electrical generation equipment
« Cavitation§ Reduce or change water flow rate in localized areas§ Use more resistant metals§ Redesign of cooling water ci rcuits§ Apply protective chemical t reatment barrier
Minimizing Corrosion
LIQUIDEWT™ cooling water treatment
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LIQUIDEWT cooling water treatment
« Nitrite-based for medium and slow speed engines
« Provides passivation corrosion protection with a thin,impervious fi lm of nitri te that minimizes the potential
between the anode and cathode areas thereby minimizingcorrosion and metal loss
« Contains alkalinity to protect against low pH corrosion
« Contains a polymer to keep scale in suspension« Contains multi-metal protection for non-ferrous metals
LIQUIDEWT
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Sodium nitrite + multifunctional inhibitors
§ Liquid form - pH buffered
§ Compatible with anti-freeze materials
§ Control limits is 10,000-15,000 ppm
§ May be used for medium to large capacity systems
§ Initial dosage is 8 ltr/ton of water
§ Safe as heating source for evaporator
§ Contains scale inhib itor
§ Protects ferrous & non-ferrous metals
§ Simple (CWT) Titrets tests to check reserve
Controlling LIQUIDEWT™ cooling water treatment
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« Weekly testing
« Easy to use ampoules
« Easy to use Control and Dosage Chartto modify treatment accordingly
« CWT Titret1 Test Kit§ Control between 1.2-1.8 units
§ Product code 0367-01-2
Controlling LIQUIDEWT cooling water treatment
Nitrite
1Registered trademark of CHEMetrics, Inc.
DREWGARD CWT
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DREWGARD® CWT diesel engine cooling water treatment« Non-nitrite formula does not promote bacteria« Provides excellent aluminum protection for high speed engines« Provides passivation corrosion protection wi th a thin,
impervious fi lm of organic material
« Polymer keeps scale in suspension« Contains multi-metal protection for non-ferrous metals« Contains alkalinity to protect against low pH corrosion
DREWGARD CWT
Controlling DREWGARD® CWT treatment
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Controlling DREWGARD CWT treatment
§ Weekly testing§ Easy to use ampoules
§ Easy to use Control and Dosage Chart
to modify treatment accordingly
§ Silica Ampoule Test Kit§ Product code 0376-01-3
§ Silica Dilut ion Kit§ Product code 1AA2805
§ Control at 350-450 ppm SiO2Silica
Testing for Chloride
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§ Less than 100 ppm in system water § Less than 50 ppm in MAN B&W 4-stroke engines
§ Chloride LMP Test Ki t
§ PCN 0373-01-9
§ Sample Pretreatment§ PCN 0374-02-5§ Removes interference from non-ferrous corrosion
inhibitor
Testing for Chloride
Detecting Cooling Water Problems
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§ If there is a sudden loss of treatment look for:§ System leakage§ Increased makeup requirement§ Presence of bacteria
§ If there is foaming look for:§ Oil contamination§ High nitrite reserve
§ If the chloride reading is high look for:
§ Salt water in-leakage§ Poor quality makeup water
Detecting Cooling Water Problems
Dosing Cooling Water Treatments
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« Shot dose via by-pass potfeeder into main circulation
« Shot dose into head orexpansion tank
« Pump into main circulation
By-passpot feeder
Dosing Cooling Water Treatments
Cooling System Commissioning
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g y g
§ Check
§ Clean by FERROCLEAN5% solut ion for 24 hours.
§ Drain and flushing .
§ Dose LIQUIDEWT
immediately.
Rust and deposit in piping system should be removed to stopoxidation and under deposit corrosion
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High Purity Water
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« Necessary for steam generation
« Makeup to diesel engine and cooling systems
« Special tank cleaning rinsing
« Domestic applications
g y
Evaporators
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p
Well maintained and properlyoperated evaporators
reduce dissolved solidsto approximately
2 ppm
Seawater contains almost35,000 ppm dissolved solids
Heating Medium For Evaporation Process
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g p
« Low-pressure steam
« Hot water § Diesel engine jacket water
Evaporation Process
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p
« Heat is transferred to seawater under vacuum
« Resulting vapor is condensed into distil late
« Dissolved sol ids are left behind§ Accumulated and concentrated for overboard discharge
« Brine density needs to be limited§ As dissolved solids increase, the tendency to form scale on
heating surfaces also increases
§ Increase in solids would lead to increase in carryover anddisti llate purity would be affected
Evaporator Problems
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Scale is introducedfrom seawater
True scale from inadequate treatmentCalcium CarbonateCalcium SulfateMagnesium Hydroxide
DepositsSludges formed from polymer treatmentCalcium CarbonateCalcium SulfateMagnesium Hydroxide
CorrosionNot usually found
p
Scale Decreases Evaporator Output
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0
50
100
80
Time
TreatedUntreated Acid Cleaning
%
Design
Output
p p
Foaming and Carryover
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§ High concentration of dissolved solids in brine§ Increases surface tension§ Vapor bubbles and gases are not released§ Bubbles burst and droplets containing concentrated salts go
into vapor spaces and are carried over into distil late
§ Organic substances may cause foaming
§ Minimize by proper management of the water level and
brine control
g y
Low Pressure Thin-Film Distiller
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Condenser
Demister
Evaporator
Brine Ejector Orifice
Air Ejector
Over Board
Ejector PumpTo FreshWater Tank
ToBilge
Salinometer
ElectricPanel
Jacket Water
Sea Water
In
Out
Out
In
AMEROYAL ®
treatment
From Sea
FreshWater Pump
Evaporator Scale
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Synthetic Polymers Inhibit Scale
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§ Scale forming salts tend to stay in solution
§ Salts that precipitate are irregular in crystal shape
because of their molecular attachment to the polymer § Precipitates can not pack together to form scale
AMEROYAL® evaporator treatment
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« Scale prevention§ Scale forming salts tend to stay in solut ion§ Salts that precipi tate are irregular in crystal shape
because of their molecular attachment to thepolymer
« Recommended for temperatures up to 100ºC
« Dosage is 30 mls per ton of disti llate produced
« Contains an antifoam§ Reduces surface tension of the brine§ Reduces water entrainment in the vapor
Removing Scale
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AMEROYAL® evaporator treatment wil l remove exist ing
scale§ If scale is th ick and dense, on-line removal may take
considerable time
SAF-ACID™ descaling compound§ Use for off-line cleaning i f time does not permit on-line
cleaning§ Once heat transfer surfaces are clean, treat with AMEROYAL
evaporator treatment to prevent future scale buildup
Feeding Evaporator Treatments
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§ Treatment solution must be fedcontinuously
§ Treatment must be fed before the
first heat exchanger
§ Use DREW FWG dosing system§ Tank and flowmeter § 0-200 cc/min flowmeter with control
valve§ 60 liter HPE tank
DREW™ FWGdosing system
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System: seawater cooling
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Problem:
§ Loss of heat exchanger efficiency
Cause:
§ Biological fouling
Solution:
§ Seawater cooling treatment
Simplified Sea Water Cooling System
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Primary cooling and
various heat exchangers
Evaporators
Fire fight ing system
Ballast uses
Tank c leaning
Primary Sea Water Cooling System Problem
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• Deposits orencrustation’s ofmarine micro andmacro-biologicalgrowths
• Left unchecked seagrowths can completelyplug inlet area of seachests, strainers,
condensers, heatexchanger water boxes
Plate Cooler Bio-Fouling
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Detecting Seawater Fouling
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• Seawater growths act asheat transfer barriers
• Check heat transfer flow – Is output normal? – Are heat exchanger
temperatures normal?
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Seawater treatment dosing system
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SWT Dosing Unit Educator Dosing Unit
AMERSPERSE 280
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Biocide action
§ kills marine growth
Dosage
§ 1.5 ltr/100 ton/hr over 100 mins.
Frequency
§ 2 x week - coastal,
§ 1 x week in open ocean
Pre-cleaning - required
pH - 11.5
Odor - Hydrogen sulfide, pungent
DREWSPERS SWD
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Dispersing action§ Removes sl ime layers; not possible for marine growth to adhere
and mature
Dosage
§ 0.6 ltr/100 ton/hr over 60 minutes
Frequency:
§ 2 x week - coastal
§ 1 x week - open ocean
Precleaning - required
§ Odor - slight ly ammoniac, pleasant
Dosage Schedule
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DREWSPERSE® SWD seawater dispersant
Harbor Anchorage & Shelf Zone
Deep Sea Zone
Dose Every Third Day
Starting And Finishing
At Point B
Dose Once
Mid Voyage
To Maintain Flow
Dose Every
Third Day
Starting And
Finishing
At Point C A B C D
Feeding systems
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§ Tankset gravity feed systems
§ Eductor feed system
§ Metering pump
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Fuel quality & problems
Crude Oil Models
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Group
Paraffinic
Naphthenic(>4 carbon)
Asphaltic
Cn + H2n + 2
CnH2n
CnH2n - 6
H H H H H H
H C C C C C C H
H H H H H H
H H
Low Sulphur
Low Ash
High Wax Content
High Cetane
North Africa/Indonesia
Medium-to-High Sulphur
Medium Cetane
C Rings Saturated with H
Middle East/Alaska
High Asphaltenes
High Ash
Venezuela/Mexico
CCC
C
C C
CH CH
CH CH
CH CH
H H
H H
H HH H
H H
Hydrocarbon Structure General Formula
Energy of Combustion
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« Hydrocarbons Burn with Oxygen:
• C + O2 CO2 7.8 Kcal/gm (14,000 btu/lb)• 2C + O2 2CO 2.2 Kcal/gm (4,000 btu/lb)• 2H2 + O2 2HO2 17.1 Kcal/gm (30,000 btu/lb)• S + O2 SO2 2.2 Kcal/gm (4,000 btu/lb)
« Carbon - Hydrogen Ratio:• ΜΓΟ Χαρβον (70%) + Ηψδρογεν (30%) + Συλπηυρ (τραχε)
• ΗΦΟ Χαρβον (85%) + Ηψδρογεν (12%) + Συλπηυρ/Ιµπυριτιεσ
(3%)
Chemical Reaction Energy Produced
Fuel Standard: ISO 8217 - 2010
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Fuel Standard: ISO 8217 - 2010
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Summary - Important Fuel Properties
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t Viscosity – Fuel Purchase Specification – Fuel Handling – Atomization – Ignition Quality Calculation
t Density – Water Separation – Ignition Quality Calculation
t Flash Point – Storage Safety
t Pour Point – Low Temperature Handling
t Carbon Residue – Smoke and deposits
t Asphaltene Content – Deposits – Particulates
u Ash Co n t e n t
– De p o si t su Va na d i u m
– Hi g h Te mp . Co r r o si o n
u Su l p h u r
– L u b e P r o p e r t i e s
– L o w Te mp . Co r r o si o n
u Wa t e r Co n t e nt
– He a t i ng Va l u e
u I g n i t i o n P r o p e r t i e s
– Smo o t h Op e r a t i o n
u Ca t a l y st Co nt e nt
– L i ne r We a r
– I nj e c t o r We a r
– F u e l P u mp We a r
Viscosity
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The viscosity of fuel oil is a measure of itsresistance to flow.
u Te mp e r a t u r e = Vi sc o si t y
u Ch a ng e s i n v i sc o si t y f o r f u e l i s no t l i ne a r wi t h c h a ng e s
i n t e mp e r a t u r e
u Hi g h i nj e c t i o n v i sc o si t y i nc r e a se s f u e l d r o p l e t si z e
Ø I nh i b i t s f u e l - a i r mi x i ng
Ø R e su l t s i n i g ni t i o n d e l a y
Ø I nc r e a se s u nb u r ne d c a r b o n d e p o si t s
u Co mmo n mi sc o n c e p t i o n : “Lower viscosity fuels are better
quality than higher viscosity fuels”. Not True. Additional
blending often creates more incompatibility.
Density
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u T h e d e nsi t y o f t h e f u e l wi l l d e t e r mi ne i t s a b i l i t y f o r wa t e
a nd se d i me n t se p a r a t i o n
u Use d t o c a l c u l a t e t h e i g n i t i o n q u a l i t y o f t h e f u e l ( CCAI )
u R e q u i r e d t o c a l c u l a t e t h e a mo u nt o f f u e l d e l i v e r e d ,
v e r su s t h e a mo u nt p a i d f o r
Ø F u e l i s r e c e i v e d b y v o l u me ( c u b i c me t e
Ø Bu t p a i d f o r b y i t s ma ss ( me t r i c t o ns)
Ø R e q u i r e s a c c u r a t e d e nsi t y f o r q u a nt i t y
Mass (Kg at 15o
C)Density =Volume (Cubic Meters)
}
Quantity Calculation (using Density)
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2000 tons of 380 cSt ordered @ $500/t
Density on delivery receipt…..985 kg/m3
Actual Density(lab analysis)….975 kg/m3
Difference in Quantity..........….....20 tons
Shipowner overcharged.......…US$ 10,000
(0.985 - 0.975) x 2000 x $500 = overcharge
Water Content
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Fresh water contamination is not a serious problem,provided it can be effectively removed from the fuel.
u Wa t e r i s g e n e r a l l y i nt r o d u c e d i nt o f u e l s f r o m l e a k i ng st e
c o i l s, t a nk c o nd e nsa t i o n o r i ng r e ss o f r a i n wa t e r t h r o u g h
u I SO 8 21 7 : 20 0 5( E ) f u e l st a nd a r d s a l l o w f o r wa t e r c o nt e n t
0 . 3% i n Di e se l F u e l a nd u p t o 0 . 5% i n He a v y F u e l Oi l .
u Hi g h wa t e r c o nt e nt r e p r e se nt s a l o ss i n b o t h mo ne y ( p a i d f o r
wa t e r no t f u e l ) a nd a v a i l a b l e e ne r g y ( wa t e r d o e s no t b u r n) .
u Se a wa t e r h a s e mu l si o n- f o r mi ng t e nd e n c i e s
Ø Di f f i c u l t t o r e mo v e wa t e r f r o m e mu l si o ns
Ø F u e l sl u d g e wi l l f o r m i n st o r a g e t a nk s
Ø So d i u m i n t h e f u e l wi l l c a u se c o r r o si o n p r o b l e m
Flash Point
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The lowest temperature at which flammable vapors,
formed above the fuel, will ignite.
u M i ni mu m F l a sh P o i nt i s 60oC f o r M DO a nd HF O.
u M i ni mu m F l a sh P o i nt i s 4 3oC f o r M GO ( DM X g r a d e ) .
u Fuels received with a flash point below the minimum isin violation of Safety of Life at Sea (SOLAS). Correctiveaction should be taken immediately.
u F u e l s st o r e d a t t e mp e r a t u r e s b e l o w t h e i r f l a sh p o i nt ma y st i l
d e v e l o p f l a mma b l e v a p o r s i n t h e h e a d sp a c e o f c l o se d t a nk s.
u As a g e ne r a l r u l e , st o r e d f u e l s sh o u l d b e ma i nt a i ne d a t
l e a st 1 0oC b e l o w t h e i r f l a sh p o i nt .
Pour Point
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The lowest temperature at which fuel oil will continue to flow.
Below this temperature, wax in the fuel will begin to separateout, reducing the oils ability to flow.
u I d e nt i f i e d a s 3oC a b o v e t h e t e mp e r a t u r e a t wh i c h t h e o i l c e a se
t o f l o w.
u I nc r e a se s v i sc o si t y wh e n b e l o w t h e p o u r p o i nt , ma k i ng p u mp i nd i f f i c u l t .( p u mp d a ma g e )
u P r e c i p i t a t i o n o f wa x f r o m f u e l s i n st o r a g e t a nk s wi l l r e q u i r
h e a t i ng t o a t e mp e r a t u r e a b o v e t h e p o u r p o i nt t o r e - l i q u e
( p o t e nt i a l h e a t e r f o u l i ng )
u P r e c i p i t a t e d wa x f r o m f u e l s wi l l a l soc l o g f i l t e r s.
u St o r e f u e l a t a mi ni mu m o f 5oC a b o v e P o u r P o i nt .
Fuel Storage Temperatures (Guideline)
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Headspace
Fuel Oil
≈ ≈
≈ ≈ ≈ ≈ ≈
≈ ≈
≈ ≈ ≈
≈ ≈ ≈ ≈
≈ ≈
u Flash Pt. = 63oC
u Pour Pt. = 10oC
Fuel Analysis Storage temperaturerange between15oC and 53oC
u 5OC above Pour point
u 10OC below Flash Point
StorageGuideline}
Carbon Residue
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The fuel’s Carbon Residue indicates the potential to formcoke or carbonaceous deposits during combustion.
u Hi g h c a r b o n r e si d u e f u e l s wi l l b e mo r ed i f f i c u l t t o b u r nc o mp l e t e l y ,
e sp e c i a l l y wh e n e ng i ne s a r e r u na t l o w l o a d.
u Unb u r ne d c a r b o n d e p o si t swi l l a c c u mu l a t e i n t h e c y l i nd e r s, o n
t u r b o c h a r g e r r o t o r s a nd i n t h e wa st e h e a t b o i l e r ( e c o no mi z e r )
u Unb u r ne d c a r b o n d e p o si t s c r e a t e ap o t e nt i a l f o r e x h a u st t r u nk
f i r e sa nd e x p l o si o ns. ( p o t e nt i a l t u r b o c h a r g e r d a ma g e )
u Ca r b o n d e p o si t sc o nt a i n a sh me t a l sr e su l t i ng i n c o r r o si v e d e p o si t s
u F u e l s p r o d u c e d f r o m t h et h e r ma l c r a c k i ng p r o c e ss(Visbreaking)have a higher Micro Carbon Residue (MCR).
Asphaltenes
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Asphaltene Micelles
Very HighC/H Nucleus
Successively LowerC/H RatioSame C/H Ratio as
Continuous Phase (Maltenes)
u Complex hydrocarbon molecules with high carbon-to-hydrogen ratiou Precipitate from the fuel (incompatibility) causing fuel sludge
u Contribute to increased engine particulate emissions & deposits
u Molecular size from 1 micron to more than 100 microns
Composition of Combustion Particulates
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Soot & OrganicCompounds
Water (w/Sulphate)
Sulphate
Heavy Metals59.0%
17.8%
22.2%
0.9%
257.24
77.61
96.79
3.95
ParticulateComposition mg/kWh
Total Particulate mass 100% = 0.436g/kWh
u Particulate composition for MAN B&W7L40/45 engine aboard a ferry shipburning 180 cSt fuel oil.CIMAC Congress - Copenhagen 1998
Due tocarbon residue& asphaltenes
Sediment
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Inorganic matter such as grit, clay and sand containedin the fuel, expressed as “Total Sediment”.
u Se d i me nt wi l l c a u se sl u d g e i n u n st a b l e f u e l s.
u F i l t e r p l u g g i ng , h e a t e r f o u l i ng a nd p u r i f i e r o v e r l o a
u Se d i me nt c a n a l so c a u se we a r t o f u e l i n j e c t o r s.
u Si nc e r e si d u a l f u e l i s a wa st e p r o d u c t o f t h e r e f i ne r y ,
o f t h e c r u d e o i l se d i me nt a c c u mu l a t e s i n ma r i ne f u e l s.
u Se d i me nt c a n g e n e r a l l y b e r e mo v e d f r o m f u e l b y se t t l ii n st o r a g e t a n k s, f i l t r a t i o n a nd c e nt r i f u g i ng .
Purifier Overload
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u High sediment, asphaltenes and incompatibility can lead topurifier overload and filter plugging
Ash Content
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Fuel Ash content is the measure of the inorganic,non-combustible elements (metals) present in the fuel.
u Va na d i u m, so d i u m, c a l c i u m, ma g ne si u m, z i nc , l e a d , i r o n
a nd ni c k e l ; a s we l l a s, a l u mi nu m a nd si l i c o n (catalyst fines)
from the refining process.
u Ash a c c e l e r a t e s we a r t o f u e l p u mp s, i nj e c t o r s a nd c y l i nd e r
l i ne r s.
u Ash d o e s b u r n d u r i ng c o mb u st i o n, b u t f o r ms i no r g a ni c a sh
d e p o si t s o n e n g i ne e x h a u st v a l v e s a nd t u r b o c h a r g e r s.
u So me a sh d e p o si t s a r e h i g h l y c o r r o si v e ( v a na d i u m) .
Ash Melting Points
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Ash ComponentVanadium trioxide
Vanadium tetroxideVanadium pentoxideSodium metavanadateSodium pyrovanadateSodium orthovanadateNickel orthovanadate
Ferric metavanadateFerric vanadateCalcium sulfateFerric sulfateMagnesium sulfateNickel sulfateSodium sulfateAluminum oxideCalcium oxideFerric oxideMagnesium oxideNickel oxide
FormulaV2O3V2O4V2O5Na2O V2O52Na2O V2O53Na2O V2O53NiO V2O5
Fe2O3 V2O5Fe2O3 2V2O5CaSOFe2(SO4)3MgSO4NiSO4NaSO4Al2O3CaOFe2O3MgONiO
••
••
••
Melting Pt. oC1970
1970675630640850900
8608551450
480 to Fe2O31125 to MgO840 to NiO
88020502572156528001990
Decomposes atDecomposes atDecomposes at
{Near exhaustvalve surfacetemperature
Ash Deposits
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u Corrosive ash deposits will cause turbocharger rotor imbalanceand vibration, leading to bearing wear and possible failure
Vanadium
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ash has potentially damaging effects within
the engine, especially in combination with sodium.
u Va na d i u m ( a nd so d i u m) o x i d i z e d u r i ng c o mb u st i o n a nd
f o r m l o w me l t i ng p o i nt sa l t s, wh i c h a d h e r e t o e x h a u st
v a l v e s, c a u si ng c o r r o si o n t o t h e v a l v e s a nd se a t s.
u T h e melting-point temperature of vanadium is 1970 oC,
but drops to its eutectic (lowest melting) point of 525 oC
when the vanadium-to-sodium ratio is 3:1.
u Sp e c i a l c o r r o si o n r e si st a nt a l l o y s (nimonic steel) are
used, along with continuous rotating valves to dislodgeash build-up and avoid repeated contact between the
same areas of the exhaust valve and seat.
Vanadium-Sodium Ratio
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§ Vanadium alone in fuel does not usually cause problems.
§ Sodium levels in fuels leaving refineries are 50 ppm or less.
§ 1% sea water contamination adds 100 ppm sodium.
§ Vanadium/Sodium together form ashes during combustion.
Ø Highly corrosive, dissolve protective oxide layer.Ø Corrosion is accelerated by sulphur in the fuel.Ø Occurs at low melting points (near 525oC) and “sticky”.
§ Exhaust valve deposits result in grooving of seating area.Ø Loss of power Ø High exhaust temperaturesØ Fouling of the turbochargers and exhaust gas boiler
900
Vanadium-Sodium Ratio
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900
800
700
600
500
10 20 30 40 50 60 70 80 90 1000
0102030405060708090100
Na2O %
V2O5 %
Vanadium-Sodium% ratios relate tomolecular weights
A s h M e l t i n g T e m p e r a t u r e
O C
Vanadium PentoxideV2O5
Sodium Vanyl VanadateNa2O.V2O4.5V2O5
Critical RatioVanadium/Sodium
Penta Sodium Vanadate5Na2O.V2O4.11V2O5
•
•
Sodium Meta Vanadate
Na2O.V2O5
Sodium Ortho Vanadate3Na2O.V2O5
EutecticPoints
Exhaust Valve Corrosion
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u Grooved valve seating area caused by ash and sulphur corrosion
u Results in high exhaust temperatures, deposits and loss of power
Sulphur
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Sulphur occurs naturally in crude oils, and is the principal
non-hydrocarbon component of heavy fuel oil.
u M o d e r a t e a mo u nt s o f su l p h u r c r e a t e su l p h i d e l a y e r s t h a t
e a si l y sh e a r , p r o v i d i ng d r y l u b r i c i t y t o f u e l i nj e c t o r s.
u Va na d i u m- So d i u m c o mp o u nd s f o r me d d u r i ng c o mb u st i o n
wi l l c a t a l y z e ( a i d ) t h e c o nv e r si o n o fsulphur dioxide (SO2 )
to form sulphur trioxide (SO3 ).
u Wi t h t h e a d d i t i o n o f wa t e r ,sulphuric acid (H 2 SO4 ) will be
formed. (turbocharger casing corrosion)
u Su l p h u r c a n r e d u c e t h e c y l i nd e r l u b e o i lBase Number
(mg KOH/g), destroying lubrication effectiveness.
Sulphur Trioxide-Dew Point Relationship
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§ During combustion sulphur is oxidized to sulphur dioxide (S + O2 SO2).§ Sulphur dioxide, in the presence of oxygen (excess air) and catalyzed by vanadium
pentoxide (V2O5) is further oxid ized to sulphur trioxide (SO2 +1/2O2 SO3).
§ Sulphur Trioxide, in the presence of water, condenses to form sulphuric acid(SO3 + H2O H2SO4).
Dew Point OC
SO3 ppm
Dew Point as a function of SO3
150
100
10 706020 30 40 50
50.
Corrosion occurs in theexhaust system (stack)when the temperaturefalls below the dew point
SECA Area
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Catalyst Fines Content
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Referred to as “Cat Fines”, these are small particles ofaluminum-silicon used in Fluid Catalytic Cracking (FCC)process.
u T h e f l u i d z e o l i t e c a t a l y st ( a l u mi nu m- si l i c o n) i s e x p e nsi v e
a n d r e c i r c u l a t e d t o t h e r e f i ne r y r e g e ne r a t o r f o r r e - u se .
Bu i l d - u p i n t h e F CC f r a c t i o na t o r r e su l t s i n c a r r y - o v e r a nd
f u e l c o nt a mi na t i o n.
u T h e c o st t o r e mo v e t h e m f r o m a l o w- v a l u e “ r e f i ne r y wa st e ”
p r o d u c t i s t o o e x p e nsi v e .
u Ca t a l y st f i ne s a r e v e r y a b r a si v e a n d c a u se a c c e l e r a t e d
we a r t o f u e l p u mp s, i nj e c t o r s a nd e ng i ne s.
Ignition Quality of Marine Fuel
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u Marine Fuels are a mixture of heavy residual oil and cracked
distillates, which can lead to poor ignition quality when blended
u Shell Research and British Petroleum have developed a simple-to-use indicator of ignition quality, the Calculated Carbon AromaticityIndex (CCAI) for HFO and the Cetane Index Indicated (CII) forMDO/MGO
u CCAI and CII are unit-less numbers allowing ranking the ignitionqualities.
u CCAI - the lower the number, the better the ignition characteristics.
u CII - the higher the number, the better the ignition characteristics.
u Ignition characteristics improve with increasing viscosity anddecreasing density.
CCAI-CII
Fuel (in)Stability & (in)Compatibili ty
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« Instability: A single fuel with a low initial total sediment , degrades
over time to a signif icantly higher sediment level.
« Incompatibility: Two fuels, each with low total sediment , when mixedresult in a blended fuel with significantly higher sediment.
« General Rules to Avoid ProblemsØ Segregate new and old bunkers if possible.
Ø Do not mix paraffinic (MDO) and visbroken (HFO) fuels.
Ø Try to match density and viscosity of fuels.
Ø Test fuel and compare results to previous analysis before mixing.
HFO quality
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500cSt@50ºC HFO quality
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DREW Fuel and Lube Test Cabinet
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Ø Mechanical TreatmentØ Chemical Treatment
Diesel Engine Fuel System
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MainEngine
Ç
Supplypump
Heavy fuel oil
settling tank
Purifiers
Waste oilstorage tank
Dieseloil
tank
Waste oilpump
To aux. boileror incinerator
HFO recirculation
Fuel oil
sludge
Vent tank
From MDOStorage TanCirculatingpump
Filter 50microns
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Waste Oil
è
è
in
out
Share asphaltene to
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Benefits of Homogenizer
u Sludge Reduction (Installed in HFO Purifying System)
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u Sludge Reduction (Installed in HFO Purifying System)Ø Complied with IOPP for sludge reduction
Ø Increase usable fuel 0.5 – 0.75%, cost saving
Ø Keeping purifiers in peak performance with lesser deposit.
Ø Reduce maintenance of purifiers.
Ø Reduce waste oil quantity.
Ø Reduce Incinerator operation hour 50%.
u Improving combustion (Installed in HFO Service system)Ø Shearing asphaltene to
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Fuel Treatment – Chemical
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Type of fuel treatment
« Additives for Tank Storage and Handling System
§Sludge Dispersant and Fuel Stabilizer
§Microbiocide for Bacteria Control
« Fuel Additives for Combustion and Deposits
§Combustion Catalyst (improver)
§Ash Deposit and Slag Modifier
« Soot Treatment
« Low Sulfur Fuel Treatment
C t ff ti l t i t t t f l f
AMERSTAT® 25
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Cost-effective solut ion to protect your fuel from
microbial growth
• Seeks oi l and water interface to targetmicrobial growth
• Maintains fuel stabil i ty toprevent fuel degradationand microbial wastesludge formation
AMERSTAT® 25
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• Protects from all types of microbialgrowth for all marine fuel oil grades
• Unparalleled dosagetreatment ratesInitial: 1 to 12500Maintenance: 1 to 25000
§ Kills sulfate reducing bacteria (SRB)to prevent H2S production
• Minimizes metal corrosionas a result of microbial growth
• Maintains cleaner fuel storage tanksand fuel filters
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AMERGY-222
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Before After
Dose to Fuel Storage before bunkering
Dosage: 1/6,000 - - 1/15,000
Emissions Profile
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Air O2 = 21%N2 = 79%
FuelS = 2.7 %HC = 97.3 %
Lube
S = 0.05%Ca = 2.5%HC = 97%
Exhaust~76% N2~12.5% O2 !!!~6.5% CO2~5% H2O900~1300 mg/kg NOx
400~500 ppm SOx500~1500 ppm CO~200 ppm HC~120 mg/Nm2 PM
41.7% Heat Energy
49.3% Work
Combustion Catalyst
Problem:
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Problem:
§ Complex hydrocarbon structures, high carbon residue and asphaltene levels.
§ Reduced vaporization o f fuel creates ign ition delay and incomplete combustion.
§ Loss of energy, smoke, soot and coke deposits
Solution:§ Blend of solvents, dispersing agents and “ noble metal” catalysts.
§ Catalysts oxid ize, drawing oxygen into the “ fuel-rich” combustion zone
to mix with hydrocarbons.Manganese, cerium, iron, zirconium, barium
and calcium are common combustion catalysts.
§ Drew Product: AMERGIZE, AMERGY-1000
Deposit and Slag Modifier
Problem:
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Problem:§
Greater concentration of ash components in today’s fuels.§ Vanadium and sodium wi ll form corrosive ash deposits, which will adhere
to hot metal surfaces .
§ Vanadium Pentox ide deposits will convert SO2 to SO3, increasing the
potential for cold temperature corrosion.
Solution:
§ Blend of solvents, dispersing agents and “ noble metal” deposit modifier
catalysts.
§
Create different ash compounds from combustion with h igher melting pointsthan metal surface temperatures..
§ AMERGIZE is most cost -effective deposi t mod if ier.
Generator Engine’s Fuel Combustion
« Main engine about 100 RPM:§ 100 combustion /m = 0 6 second/combustion = 1 66 Combustions/S
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§ 100 combustion /m = 0.6 second/combustion = 1.66 Combustions/S.
« Generator Engine about 720 or 900RPM:§ 360 combustion/m = 0.16 S/combustion = 6 combustion/S.§ 450 combustion/m = 0.13 S/combustion = 7.5 combustion/S.
« M/E and G/E are using same fuel.§ Carbon Residue about 14-16%, longer time required to mix with air to have
complete combustion.§ Asphal tene about 6-10%, easy to clustering and compat ib il it y problem.Longer time required for combustion .
« Generator engine has higher RPM than ME, T/C will have more deposit andshorter component life time by incomplete combustion.
« G/E’s fuel consumption is much lower than M/E. Recommend to use fueladditive to improve combustion.
AMERGIZE Shop Test Record
AMERGIZE, dosage: 1/200025% t t 262 5 F l 172 / /h (13% i )
No Fuel Treatment
25% output: 262 5 ps Fuel cons: 198 g/ps/hr
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25% output : 262.5 ps, Fuel: 172g/ps/hr (13% saving)
50% output : 525.0 ps, Fuel: 157 g/ps/hr (5.42% saving)
75% output: 787.5 ps, Fuel: 158 g/ps/hr (2.5% saving)
85% output 892.5 ps, Fuel: 160 g/ps/hr (1.2% saving)
100% output 1050 ps, Fuel: 163 g/ps/hr (0% saving)
25% output: 262.5 ps, Fuel cons: 198 g/ps/hr
50% output 525,0 ps, Fuel cons: 166 g/ps/hr
75% output 787.5 ps, Fuel cons: 162 g/ps/hr
85% output: 892.5 ps, Fuel cons: 162 g/ps/hr
100% output 1050 ps, Fuel cons: 163 g/ps/hr
AMERGIZE Sea Trail Data
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AMERGIZE Performance in Generator Engine
NO FUEL TREATMENT AMERGIZE
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Exhaust Gas Deposits Treatment
Restore Efficiency
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Restore Efficiency
• Removes existing deposits
• Maintains heat recovery
transfer surfaces clean
• Eliminates stack f ires
• Minimizes acid corrosion E x h a u s t G a s B
o i l e r
O u t p u t %
Relationship of Exhaust
Gas Boi ler to Main Engine Load
LT-SOOT Release
Economizer exhaust-side powder treatment
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p
§ low activation temperature (200ºC) catalyst
• bring oxygen into soot and convert to dry and loose
powder type deposit.
• maintains heat recovery transfer surfaces clean
§ effective at low engine loads
• minimizes likelihood of stack fires
• improves soot blower performance
• Followed by soot blowing, this is the most cost-effective method to treat exhaust gas economizer
LT Soot Release Dosing Unit
• Air driven dosing unit for
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soot treatment to reduce
soot deposit in Economizer
and exhaust gas boiler
• Manual operation
DREWCLEAN EST – Economizer soot treatment
§ A special l iquid treatment that catalyzes soot to dry and non-adherent to
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§ A special l iquid treatment that catalyzes soot to dry and non adherent to
heat transfer surface, maintains entire heat transfer area clean§ Improves soot b lower performance and reduce low temperature
corrosion.
§ Effective at low temperature down to 200°C
§ The product is normally dosed 1 liter per day whenengine is operating
§ The EGT dosing system can be adjusted to providethe exact dosing desired. It is recommended to injectDREWCLEAN EST every 8 hours, with an injection of12 to 15 minutes.
§ For optimum result, soot blow shou ld be operatedbetween 30-90 minutes after chemical inject ion
Low Sulphur Fuel Problems
L S l h f l (
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u Low Sulphur fuel (
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p y,
which may cause clogging of fuel filters and separators and stickingof fuel injection pumps asphaltene deposits on plunger and barrel)
Fuel sulphur content versus lubricant BN
1. Where the sulphur content in the fuel is above 1.5 %, the use of approved70BN cylinder oil is recommended.
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70BN cylinder oil is recommended.
2. Where the sulphur content in the fuel is below 1.5 %, approved 40BN cylinderoil is recommended.
3. Using LFO or LSHFO with 70BN cylinder lubricant should be avoided,because the excessive calcium ash in BN is likely to deposit on the pistoncrown land. These deposits may become very hard and contact between thedeposits and the cylinder liner wall can cause bore polishing and lead to
wear 4. The sulphur in the fuel oil has a lubricating effect .
5. The use of DO and GO with a sulphur content close to zero and, might causefuel pump and fuel valve wear and, consequently, the risk of sticking.
6. Generator engine lube oil system may not changed whi le fuel changed,
above problems may have higher risk than Main engine
Changeover between HFO & MGO Fuels
Changeover between High and Low-Viscosity Fuels
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§ T o p r o t e c t t h e i nj e c t i o n e q u i p me nt a g a i nst r a p ima y c a u se st i c k i ng / sc u f f i ng o f t h e f u e l v a l v ea nd su c t i o n v a l v e s, t h e c h a ng e o v e r i s t o b e c ama k e r ’ s c h a ng e o v e r p r o c e d u r e.
§ According to the inst ruct ion manual, the temperature should not be changed bymore than max. 2ºC/min.
§ For example, diesel oil is to be changed to HFO:1. The system contains 40ºC diesel oil2. The diesel oil is heated to 80ºC before adding the HFO. This takes (80 �