DEAERATORS DESIGN AND FABRICATION

OCTOBER 1993

PAGE 1 OF 9

EGE 13-B-25 1993

TABLE OF CONTENTS 1. 2. 3. 4. Scope References Definitions Design 4.1 General 4.2 Mechanical 4.3 Piping Connections 4.4 Instrumentation and Controls 4.5 Materials Performance Test Guarantees

5. 6.

1. SCOPE This Guide provides requirements for the design, fabrication, and performance of mechanical deaerators used for treating boiler feedwater. 2. REFERENCES The following publications form a part of this Guide. The references cited with dates in this Guide were used in its development. For all references which have been superseded, revised, and/or corrected, the user of this Guide is obligated to determine if the latest versions of the cited references have any impact on the content of this Guide or its use. MTC (Guide Sponsor) should be consulted if there are any concerns or questions.
Mobil Engineering Guides EGE 00-B-5 EGE 00-B-21 EGE 00-C-4 EGE 11-B-22 EGE 12-B-1 EGE 13-D-25 EGE 16-B-1 EGE 16-B-10 EGE 31-B-1 EGE 32-B-1 EGE 32-B-3 EGE 32-B-8 EGE 32-B-17 EGE 34-B-10 (1989) (1993) (1993) (1989) (1993) (1993) (1993) (1988) (1989) (1989) (1985) (1987) (1992) (1991) Equipment Sound Levels Pressure Containing Equipment Welding and Weld Inspection Equipment and Packaged Units General Purchasing Requirements Waste Heat Steam Generators Design and Fabrication Pressure Vessels Design and Fabrication Deaerator Data Sheet Piping General Design Piping Instruments Steel Structures Design and Fabrication Instrumentation General Requirements Instrumentation Liquid Level Instrumentation Control Valves Instrumentation Pressure Relief Devices Thermal Insulation Hot Service

MOBIL ENGINEERING GUIDE EGE 13-B-25 1993

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ASME (American Society of Mechanical Engineers) Codes Boiler and Pressure Vessel Code: (1992) Section I, Power Boilers (1992) Section VIII, Pressure Vessels, Division 1 PTC 12.3 (1990) Power Test Code Deaerators

Standard Methods for the Examination of Water and Wastewater (APHA/AWWA) 4500-CO2 (1989) C. Titrimetric Method for Free Carbon Dioxide

HEI (Heat Exchange Institute) (1992) Standards and Typical Specifications for Deaerators

3. DEFINITIONS

Deaerator A mechanical device for removal of dissolved gases, primarily oxygen and carbon dioxide, from water. For the purpose of this Guide, only thermal deaerators that deaerate by contacting water with steam and elevating the temperature will be considered. In cases where the storage section is a separate vessel, the device described above is referred to as either the deaerator section or the deaerator heater. Integral Deaerator A mechanical deaerator (tray or spray type) in which part or all of the scrubbing steam is generated in an evaporative coil in the main flue gas stream of an HRSG (heat recovery steam generator). The evaporative coil is connected to the deaerator storage drum which also serves as a low-pressure steam drum. Operating Pressure The (steam) pressure inside the heater section maintained and controlled by letdown from the makeup steam source. The deaerator outlet water temperature will be at the steam saturation temperature corresponding to this pressure. Outlet Capacity The total quantity of hot water leaving the deaerator, including condensed inlet steam and condensate return. Spray Deaerator (also known as a spray-atomizing or spray-scrubber deaerator) Inlet water is sprayed into a steam atmosphere and falls onto a spray deck or catchment from which it flows into the atomizer/scrubber where it is mixed with the incoming steam. Storage Section An area in a deaerator that contains a specified volume of deaerated water. It may be contained in the lower portion of an integral unit or in a separate vessel located below the deaerator heater. Tray Deaerator (also known as a spray-tray deaerator) Inlet water is sprayed into a steam atmosphere and falls onto a bank of trays through which steam passes. Steam flow may be co-current, cross-current, or counter-current to the water flow. Vent An opening in the deaerator through which the noncondensible gases and a small quantity of steam are released. Vent Condenser An area in a deaerator where steam is cooled and condensed by the incoming water.

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EGE 13-B-25 1993

4. DESIGN 4.1 General

4.1.1 The design and construction of the deaerator shall comply with the requirements of this Guide, EGE 13-D-25, and all applicable local codes and regulations. In case of conflict, the most stringent requirement shall apply. 4.1.2 The deaerator shall be capable of providing deaerated water continuously at any rate from 10 to 110 percent of the design outlet capacity specified on EGE 13-D-25. The oxygen concentration of the incoming water shall be calculated assuming the water is fully saturated with air at the lowest expected temperature. 4.1.3 Deaerator steam consumption shall be no less than 3 percent by weight of the design outlet capacity to provide adequate steam scrubbing of gases from the water. The temperature rise across the deaerator shall be no less than 5.5C (10F) for tray deaerators and 16.7C (30F) for spray deaerators. A pressure controller shall control the rate of steam flow to the deaerator. 4.1.4 Direct-contact vent condensers are preferred and shall be designed to remove noncondensible gases from the heater with a minimum loss of steam to the atmosphere. The quantity of vented steam shall not exceed one percent of the total deaerator steam consumption. 4.1.5 The capacity of the water storage vessel shall be no less than ten minutes, based on the design outlet capacity specified on EGE 13-D-25. This capacity is measured from the normal water level to the low water level unless otherwise specified on EGE 13-D-25. 4.1.6 The deaerator design and materials shall be suitable for continuous operation outdoors unless otherwise specified on EGE 13-D-25. All external surface exposed to weather conditions shall be selfdraining and protected against corrosion. 4.1.7 Equipment and component parts of the unit shall be of standard manufacture, subject to the specific requirements of this Guide. Component parts need not be produced by the same manufacturer, however, the deaerator supplier shall guarantee all components regardless of source. 4.1.8 The deaerator pressure vessel components and storage tank shall be designed and constructed in accordance with the ASME Boiler and Pressure Vessel Code (Section VIII), EGE 12-B-1, and EGE 00-B-21. Integral deaerators for HRSG applications shall be designed and constructed in accordance with the ASME Boiler and Pressure Vessel Code (Section I), EGE 11-B-22, and EGE 00-B-21. 4.1.9 4.2 4.2.1 Deaerator suppliers shall meet the requirements of EGE 00-C-4. Mechanical Corrosion allowance for carbon steel pressure parts shall not be less than 3 mm (1/8 in.).

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4.2.2 Tray enclosures shall not be welded directly to the deaerator heater pressure vessel shell. Supports for the enclosure shall be of bolted design. Bolt heads shall be tack welded to one of the mating parts. After completion of the assembly, all nuts shall be tack welded to the part they restrain. The entire internal structure shall be constructed to provide a limited freedom of movement through the use of bolted joints. 4.2.3 Spray valves shall be designed so they can be readily inspected and individually removed from the unit via accessways or handholes. 4.2.4 The spray valves shall be self-adjusting and shall uniformly distribute water for a flow range of 10 to 110 percent of design rating. The spray valve pressure drop at 110 percent of design rating shall not exceed 21 kPa (3 psi). Spray nozzle design shall be subject to Mobil review. 4.2.5 The storage vessel overflow shall be located at a distance approximately equal to 10 percent of the height of a vertical vessel or the diameter of a horizontal vessel [but not less than 150 mm (6 in.) or more than 300 mm (12 in.)] from the top of the vessel. The high water level alarm shall be a minimum of 75 mm (3 in.) below the overflow level. 4.2.6 Accessways with hinged covers shall be provided for the deaeration and storage sections. These accessways shall have a minimum internal diameter of NPS 18 (NPS = nominal pipe size, inch) and shall be of adequate size to permit removal of all internal assemblies. 4.2.7 Drains shall be located flush with the bottom of each section so that complete drainage can be assured. 4.2.8 Pump suction nozzles shall extend 75 mm (3 in.) up from the bottom of the storage section. Each nozzle shall be furnished with a vortex breaker. 4.2.9 The storage section shall be equipped with two welded support saddles, one fixed and one sliding.

4.2.10 When specified, the insulation of the deaerator and storage vessel shall be as indicated on EGE 13-D-25 and in accordance with the requirements of EGE 34-B-10. 4.2.11 The deaerator and storage vessel may be constructed as two separate and distinct pressure vessels. 4.2.12 Deaerator design shall incorporate the following in addition to the ASME code:

(a) Vessels shall be postweld heat treated (PWHT). The PWHT temperature shall be the greater of the requirements of EGE 00-B-21 or the ASME Code specified. (b) Internal weld seams shall be ground smooth.

(c) Wet fluorescent magnetic particle testing (WFMT) shall be performed for all nozzles and pressure containing welds after PWHT. (d) All vessel and head seams, longitudinal and circumferential, shall be 100 percent X-rayed.

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EGE 13-B-25 1993

4.2.13

Auxiliary Equipment

The deaerating heater shall include the following items, except when specified on EGE 13-D-25 as furnished by others. (Figure 1 illustrates nomenclature for a typical deaerator.) (a) A water inlet regulating valve with an external float controller complete with equalizing lines and shutoff valves. If block valves for isolating the control valve and a bypass valve are not specified, a means of manual operation of the valve shall be provided. (b) Two gage glasses for full-range vision on storage tanks. On horizontal tanks, the gage glasses shall be located at each end of the storage tank. On vertical storage tanks, they shall be 180 degrees apart. The gage glasses shall span all level switches and controllers. (c) Float switches for high- and low-level alarms shall be mounted on flanged nozzles separate from those of the gage glasses. The nozzles shall be provided with block and drain valves. A plugged tee shall be provided upstream of the drain valve to facilitate calibration. (d) A low-level alarm shall be provided with a contact for remote display.

(e) Relief valves, which may be mounted on the deaerating heater vessel or on the steam supply line to the vessel. The relief valve sizing shall meet the requirements of the applicable ASME Code (Section I or VIII) or local codes, whichever is more stringent. (f) A vacuum breaker valve.

(g) An emergency overflow control valve with an external float controller or overflow trap, or other overflow arrangement as specified on EGE 13-D-25. The control valve shall be provided with a block valve. The block valve shall be located to allow removal of the control valve for maintenance while the deaerating heater is in service. (h) An oxygen-scavenger (sodium sulfite, hydrazine, etc.) chemical feed connection in the storage compartment of the vessel. The distribution pipe should extend through a sufficient length of the drum to ensure proper mixing of chemicals. The distribution pipe should be perforated and closed at the far end. (i) Separate pressure gage connections for the steam space of the deaerator and for the lower part of the water storage tank. (j) Thermowells, to be installed in the steam space of the deaerator (just above the scrubbing section), in the downcomer of the deaerator, and in the water storage section. (k) A sample connection for deaerated water shall be located on the storage vessel to provide a representative sample. (l) A continuous vent connection with restriction orifice, or a gate valve with a 1.5 mm to 3 mm (1/16 in. to 1/8 in.) drilled hole in the gate for the direct contact vent condenser. The vent shall discharge at a safe location and shall be provided with a rain hood or elbow to keep out the rain. (m) Structural steel saddles.

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A B C D E F G H I

Deaerator Section Relief Valve Noncondensible Gas Vent Makeup Water Inlet Deaerating Steam Inlet Equalizer Downcomer Accessway Storage Section

J K L M N O P Q R

Overflow Outlet Support Saddle Drain Vacuum Breaker Level Gage/Alarm Column Level Controller Thermometer Pressure Gage

FIGURE 1 TYPICAL DEAERATOR NOMENCLATURE

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EGE 13-B-25 1993

(n) (o)

Davits, when the individual weights of the relief valve or the vacuum breaker exceed 34 kg (75 lb). Insulation clips or supports.

(p) Hot-dip galvanized steel ladders, platforms, and walkways, in accordance with EGE 31-B-1, for safe operation and maintenance of the deaerator. 4.3 Piping Connections

The supplier shall provide, as required, the following connections in accordance with EGE 16-B-1. Connections shall be flanged, except for NPS 1 and smaller connections which may be socket welded or screwed. A nozzle orientation drawing shall be submitted with the proposal.
Condensate inlet Makeup water inlet Steam inlet Equalizing lines Balancing lines Downcomer Pump suction (two) Pump recirculation (two) Drain Overflow Chemical injection Level gage (four) Level control (two) Level alarm (two) Thermowell (three) Pressure gage (two) Relief valves Sample Atmospheric vent Silencer for vent Vacuum breaker Sized by supplier Sized by supplier Sized by supplier Sized by supplier Sized by supplier Sized by supplier Sized by Mobil Sized by Mobil Sized by supplier Sized by supplier NPS 1 NPS 2 NPS 2 NPS 2 NPS 1/2 NPS 1 Sized by supplier NPS 1 Sized by supplier Sized by supplier Sized by supplier

4.4

Instrumentation and Controls

All instruments and control valves furnished with deaerator units shall be in accordance with EGE 32-B-1, EGE 32-B-3, EGE 32-B-8, and EGE 32-B-17. Instrumentation piping shall be provided in accordance with EGE 16-B-10. A simplified P&ID for a typical deaerator is provided in Figure 2. 4.5 Materials 4.5.1 The parts of the deaerator that come in contact with nondeaerated water shall be Monel or Monel-clad carbon steel for sodium cation treated makeup water. Use Type 316L stainless steel or 316L stainless steel cladding for demineralized makeup water.
NOTE: Austenitic stainless steels (300 series) are subject to stress corrosion cracking in the presence of chlorides. If cloride levels in the incoming water exceed 2 ppm, consult the MTC Facilities Group for a materials recommendation for deaerator "wetted" parts.

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EGE 13-B-25 1993

4.5.2 Heating, deaerating, and distributing trays shall be fabricated from Type 430 stainless steel for sodium cation treated makeup water. Use Type 316L stainless steel for demineralized makeup water. 4.5.3 4.5.4 steel. Spray valves shall be Type 316L stainless steel with Monel trim. The water inlet pipe, the chemical feedpipe, and the vent condenser shall be Type 316L stainless

4.5.5 Material for deaerator shell, heads, and components that are not mentioned above shall be fully killed carbon steel (SA-516). 5. PERFORMANCE TEST The guaranteed performance test shall be in accordance with ASME PTC 12.3 and shall be expanded in scope if necessary for verification of guaranteed performance data. The performance test shall be conducted after plant startup. 6. GUARANTEES The manufacturer shall guarantee the following items at all loads from 10 to 110 percent of design outlet capacity: (a) Incoming water shall be heated to the temperature corresponding to the saturation temperature of the deaerator at the operating pressure. (b) The free carbon dioxide content of the water shall be zero parts per million as determined by 4500-C02 C. Titrimetric Method for Free Carbon Dioxide (also known as the "APHA" Method). (c) The residual oxygen content of the water shall not exceed 0.005 cc/liter (7 ppb by weight) as determined by the procedures given in ASME PTC 12.3, Part II, Section 1. (d) The deaerator shall operate within the noise level limits of EGE 00-B-5 unless further limited by project specifications.

MOBIL ENGINEERING GUIDE DEAERATOR DATA SHEET

SI (METRIC) UNITS ISSUE 1 2 3 MFR, TYPE, & NO. *Design Outlet Capacity, kg/h Steam: Press., kPa gage Temp., C WATER TO UNIT: *Condensate: High Temp., C *Condensate: Low Temp., C *Water Makeup: Temp., C Inlet Regulating Valve, kg/h Max. Pressure in Unit, kPa gage DESIGN & CONSTRUCTION Pressure, kPa gage: Design ARRANGEMENT OF UNIT: Shell: Head: Trays: Material Outside Diameter, mm Material Material Total Tray Stack Volume, mm Accessways: Spray Valve: Storage Tank: Material Number Number Material of Valve/Valve Springs Material Outside Diameter, mm Distance Between Normal Water Level and Top of Storage Tank, mm Insulation Type/Thickness, mm: Deaerator Density of Support Clips: Deaerator Length of Support Clips, mm: Deaerator Vent Condenser Type: (Direct Contact) (Shell & Tube) Direct Contact, Material: Shell & Tube: Surface Area, m Tubes Pressure Losses, kPa: Inlet Reg Valve Spray Valves *Height Limitations: (Yes) (No) Height, m Weights, kg: Empty *Inlet Steam Control Valve: Mfr, Type, & Size Float Controller: Mfr, Type, & Size Relief Valve: Mfr, Type, & Size Vacuum Breaker: Mfr, Type, & Size Gage Glasses: Mfr, Type, Size, & Arrangement Float Switch: Mfr, Size, & Material Level Alarms: Mfr & Type *Alarm Circuit: Volts Thermometers: Mfr, Size, & Range Pressure Gages: Mfr, Size, & Range Overflow: *(Control Valve) (Overflow Trap) (Loop Seal) *Items designated by an asterisk shall be completed by Mobil. All other items shall be completed by supplier. Phase Hz Setting, kPa gage Capacity, kg/h Setting, kPa gage Operating Full MECHANICAL EQUIPMENT
2

EGE 13-D-25a 1993

Page 1 of 2 JOB NO. ITEM NO. NO. REQD

APPROVED 4 5 6

ISSUE

APPROVED

JOB NAME ITEM NAME LOCATION/UNIT

PROPOSAL NO. & DATE OPERATING CONDITIONS *Storage Capacity: m (Min.) (Min.) (Min.) (Min.) (Min.) (Max.) (Max.) (Max.) kg/h (Max.) kg/h (Max.) kg/h Min. Upstream Press., kPa gage (Min.) (Max.)
3

Minutes kg/h Reqd

Operating

Hydro Test Thickness, mm Overall Length, mm Thickness, mm Thickness, mm Number Size, mm Size, mm Thickness, mm Overall Length, mm Storage Tank Storage Tank Storage Tank

Material: Shell Tubesheet Vent Condenser Total )P, kPa Shipping

MOBIL ENGINEERING GUIDE DEAERATOR DATA SHEET

SI (METRIC) UNITS MECHANICAL EQUIPMENT - Contd Inlet Water Control Valve: (Direct Float Oper) (Air Oper); Air Press., kPa gage Mfr, Type, & Size Float Controller: Mfr, Type, & Size Overflow Trap: Mfr, Type, & Size *Furnish Block Valves & Bypass for Inlet Reg Valve: (Yes) (No)

EGE 13-D-25a 1993

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REMARKS:

MOBIL ENGINEERING GUIDE DEAERATOR DATA SHEET

CUSTOMARY UNITS ISSUE 1 2 3 MFR, TYPE, & NO. *Design Outlet Capacity, lb Steam: Press., psig Temp., F WATER TO UNIT: *Condensate: High Temp., F *Condensate: Low Temp., F *Water Makeup: Temp., F Inlet Regulating Valve, lb/h Max. Pressure in Unit, psig DESIGN & CONSTRUCTION Pressure, psig: Design ARRANGEMENT OF UNIT: Shell: Head: Trays: Material Outside Diameter, in. Material Material Total Tray Stack Volume, in. Accessways: Spray Valve: Storage Tank: Material Number Number Material of Valve/Valve Springs Material Outside Diameter, in. Distance Between Normal Water Level and Top of Storage Tank, in. Insulation Type/Thickness, in.: Deaerator Density of Support Clips: Deaerator Length of Support Clips, in.: Deaerator Vent Condenser Type: (Direct Contact) (Shell & Tube) Direct Contact, Material: Shell & Tube: Surface Area, ft Tubes Pressure Losses, psi: Inlet Reg Valve Spray Valves *Height Limitations: (Yes) (No) Height, ft Weights, lb: Empty *Inlet Steam Control Valve: Mfr, Type, & Size Float Controller: Mfr, Type, & Size Relief Valve: Mfr, Type, & Size Vacuum Breaker: Mfr, Type, & Size Gage Glasses: Mfr, Type, Size, & Arrangement Float Switch: Mfr, Size, & Material Level Alarms: Mfr & Type *Alarm Circuit: Volts Thermometers: Mfr, Size, & Range Pressure Gages: Mfr, Size, & Range Overflow: *(Control Valve) (Overflow Trap) (Loop Seal) *Items designated by an asterisk shall be completed by Mobil. All other items shall be completed by supplier. Phase Hz Setting, psig Setting, psig Operating Full MECHANICAL EQUIPMENT
2

EGE 13-D-25b 1993

Page 1 of 2 JOB NO. ITEM NO. NO. REQD

APPROVED 4 5 6

ISSUE

APPROVED

JOB NAME ITEM NAME LOCATION/UNIT

PROPOSAL NO. & DATE OPERATING CONDITIONS *Storage Capacity: ft (Min.) (Min.) (Min.) (Min.) (Min.) (Max.) lb/h Min. Upstream Press., psig (Max.) (Max.) (Max.) lb/h (Max.) lb/h (Min.) (Max.)
3

Minutes lb/h Reqd

Operating

Hydro Test Thickness, in. Overall Length, in. Thickness, in. Thickness, in. Number Size, in. Size, in. Thickness, in. Overall Length, in. Storage Tank Storage Tank Storage Tank

Material: Shell Tubesheet Vent Condenser Total )P, psi Shipping

Capacity, lb/h

MOBIL ENGINEERING GUIDE DEAERATOR DATA SHEET

CUSTOMARY UNITS MECHANICAL EQUIPMENT - Contd Inlet Water Control Valve: (Direct Float Oper) (Air Oper); Air Press., psig Mfr, Type, & Size Float Controller: Mfr, Type, & Size Overflow Trap: Mfr, Type, & Size *Furnish Block Valves & Bypass for Inlet Reg Valve: (Yes) (No)

EGE 13-D-25b 1993

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REMARKS: