Basic

Deaerator Science Revealed Q & A, 1-21-15

Q: Could you expand on the Turn Down capacities of the various designs please? I was always told Tray
Types have better turn down, could you elaborate on that a little.

A: The turndown for all of our DAs is 20:1 of the rated capacity. For Example, if a DA is rated for
100,000 PPH, it has the capability of going down to 5,000 PPH.

Q: If we have an RO System would it be money saved to utilize the RO Water as our DA make up water?

A: An RO system removes many of the impurities in the boiler feed water, and as such, definitely limits
(to a large degree) the amount of chemicals to be added; saving costs not only in chemicals, but water,
sewer charges, and fuel energy because of a reduction in blowdown. Be mindful though, RO water is
aggressive on ferrous metals so precautions need to be taken including installing stainless steel or PVC
piping, etc.

Q: How often should a DA tank be thoroughly inspected?

A: We would recommend at least annually during the boilers normal inspection.

Q: Where do you recommend that chemical scavenger be added?

A: In to the DA tank or where it is recommend by your chemical supplier

Q: Besides recovering condensate, are there other energy efficiency benefits that DA systems can
provide to system operators?

A: The DA saves on venting losses emanating from many atmospheric condensate/feed water tanks.

Q: Would a sparge tube in the DA tank be a less expensive alternative to a high pressure receiver tank?

A: A sparge tube is normally applied to an atmospheric feed water tank for the purpose of elevating
temperature to drive off some of the oxygen and carbon dioxide. It is never used in a DA system as it
incorporates its own system for elevating temperature, and never a high pressure receiver as its purpose
is to collect very hot condensate which requires no further heating.

Q: Does heating your condensate/feed water tank to 190F serve as the dearator tank?

A: Yes, to a certain extent. Raising the feed water temperature to close to boiling (212 deg. F @ sea
level) will drive off some Oxygen and CO2, saving some chemical use, but not anywhere near the
amount of reduction received through deaeration, 0.005 CCs/liter or 7 PPB.

Q: How is CO2 removed from condensate if not in D/A?

A: Probably the most effective way is through the use of both chemicals and mechanical equipment.
Mechanically, a dealkalizer can be applied which will remove the carbonates of alkalinity which when
heated form CO2. Then a chemical program including filming or neutralizing amines, injected into the
main steam header to protect steam and condensate lines from any residual CO2 the dealkalizer has not
arrested.

Q: On the slide with the high pressure condensate tank, it looked like it was a packaged skid mounted
system with feedwater pumps. Can you speak briefly how that interfaces with the DA tank which
obviously would not have feedwater pumps?

A: The high pressure condensate tank does have boiler feed pumps along with the DA. The DA feeds the
high pressure receiver with deaerated make-up water, and the high pressure receiver feeds the boiler.

Q: Does a tray/packed column design affect NPSHA any differently than a spray type?

A: No

Q: Old plant 150 lb with tray DA. Now a 15Lb system using old DA. What lb of steam should we use on
DA tank?

A: If we are interpreting this question correctly, We would use the 150lb steam because there is more
energy/heat within that steam. This decision ultimately comes down to the end user/engineer.

Q: Would it be safe to say that if all our water lines, DA tank, Return Condensate Lines etc. should be
insulated to maintain the heat for more efficient boiler supply water from DA? Currently ours is
uninsulated.

A: Absolutely!

Q: Are there deaerators for these type of small boilers that usually run between 5-10psig

A: Normally DAs are not applied to low pressure systems due to the cost of the system. However, they
can be used if requested by the end user/engineer.

Q: What damage can well water used as emergency make up water do to system? Is there anything to
do to lessen damage??

A: The well water would have to be analyzed for impurities, and then remedies(mechanical/chemical)
employed to reduce the possibility of component failure (plugging/corrosion) prior to entering the DA
system. In most cases you would never put raw well water into a boiler system without at least a water
softener.

Q: DA vents orifices are sized for 1/10 of 1% of the maximum capacity of the DA and not the operating
capacity. Is this correct?

A: Thats correct!

Q: If sent through a gas transfer membrane, could make-up water be injected directly into a high
pressure receiver tank?
A: We have not had a lot of experience with gas transfer membranes. If the O2 and CO2 are properly
removed and the water is at the correct temperature and pressure; this should not be an issue.

Q: You spoke of efficiency loss for not having insulated lines. Is there a simplified formula that should
be utilized to justify to corporate to help point out the savings that are generated for adding insulations?

A: 6 Steam Pipe @ 100 psig (338 Deg. F) radiates approx. 1650 Btu/HR/Foot. Figure 500 feet of
uninsulated pipe equals 826,000 Btu/HR (25 BHP). Production hours per year = 4000 HRs. At $0.50per
Therm (100,000 Btu) for natural gas = $16,520 WASTED! Annual fuel bill is $500,000/YR = 4%

Q: How much oxygen and carbon dioxide does a deaerator scavenge out of a boiler system?

A: CO2 = Trace, Oxygen down to 0.005 CCs/liter or 7 PPB.

Q: Should you consider boiler safety vale set pressure in determining feedwater pump supply pressure?

A: Yes, NBIC Section I states the pump should be sized with a capability of producing a pressure which is
3% greater than the highest safety valve setting on the boiler. If this code requirement is part of the
specification, and the operating pressure of the boiler is low, consider using a lower setting on the safety
valve and/or, employ a pump with the acceptable discharge pressure and use a throttling valve to
achieve required duty points.

Q: What safety valve testing do you recommend to ensure that safety valves are working properly?

A: Follow the same procedure your inspector recommends for the boiler.

Q: How is the boiler safety relief valve rate to be determined?

A: I believe you mean deaerator relief valves, they are said based on the full fail capacity of the PRV. This
capacity is given by the PRV manufacture. You need to ensure that the relief valve(s) can pass a least
that capacity to protect the deaerator.

Q: What type of DA should be used for: 1- 0 to 25% Condensate Return, 2 - 25 to 50% Condensate
Return, 3-50% to 100% Condensate Return?

A: DAs are recommended for makeup @ 25% or more.

Q: Are there applications for .03 deaerators and are they still produced by manufacturers.

A: Yes, they are produced, but more chemicals need to be used for supplemental purposes. As
mentioned before, its not only the cost of chemicals, you also increase blowdown losses including
additional Btu, water and sewer charges. When the ROI is properly run, the DA often wins out.

Q: How can we corroborate and make sure that the DA is doing efficiently its work?

A: There are test kits available from your water treatment consultant which measures the amount of O2
and CO2 present in the tank after deaeration.
Q: Please discuss energy recovery from the DA steam vent.

A: In most cases these is so little, it is not worth the expense to save it.

Q: What temperature is typical for Lo temp Condensate return versus high pressure?

A: Our definition on low temp returns is anything that is below the operation temperature and pressure
of the DA. Low temp returns will need to go back through the deaeration process. High temp returns
are anything above the operating temp and pressure and can be added directly in to the DA tank.

Q: What is the average ROI utilizing DA versus none?

A: It all depends on the size of the boiler load, the amount of make-up, and the cost of chemicals, Btus,
water & sewer charges which will be saved through the use of a DA. Payback can certainly be in the 1-5
year range depending on the situation.

Q: What do you find is the major variance in storage time for the storage/deaerator unit?

A: Most storage times are 10 minutes but we have seen ranges from 5 minutes to 20 minutes. Storage
time requirement are on a job by job basis.

Q: Is there an upper limit to the feedwater temperature coming to the DA for it to function effectively?

A: We have not seen an upper limit; if you have high temperature returns coming back to the DA, above
saturation temperature and pressure. It will be effectively have deaerated and doesnt need to go back
through the deaeration process.

Q: Please advise on the best ways to prolong the life of DA Tanks. Please include ways to prolong
longevity when initially specifying & purchasing DA Systems.

A: The best answer to this question is the use of a reputable water treatment consultant who
understands the customers water quality issues and can employ the proper remedial chemical program
to assure DA longevity. You could also select a 304 SS stainless steel or galvanized tank material when
ordering a new deaerator.

Q: When are intermittent feedwater pumps used and when are constant flow pumps used?

A: Intermittent pumps are normally employed when the feed water valve is of on-off operation. In the
case of a modulating feed water valve, the continuous pump in used.

Q: So regarding NBIC requirements, the pump at dead-head must produce pressure 3% above the boiler
SRV setting, but the flow rate is not stipulated...that rate could be a fraction of the boilers maximum
evaporation rate correct?

A: NBIC Section I requires that the boiler feed pump must be able to produce a pressure equal to or
greater than 3% above the highest boiler safety valve setting. We use the Dead head point to ensure
that he pump can meet this requirement. If you would use another point on the pump curve, say the
duty point; then you can be oversizing your pump. You will need to have a discharge throttling valve to
bring the pump to the proper pressure for your system.

Q: Are any carbonates in the feed water converted to CO2 in the DA or does this conversion happen
mostly at the higher temperatures in the boiler?

A: It occurs mainly if not entirely in the DA

Q: Does the make-up water percentage have an impact on the choice of DA type (spray, tray, ..) ?

A: No, there are other deciding factors which dictate the best use of a specific type of DA. Review the
presentation on the Cleaver Brooks website for details.

Q: How is CO2 removed from condensate bypassing D/A?

A: If the condensate is high pressure and has not seen atmosphere, it should not be a factor.

SFC 1/22/15