Western Region Boiler Association

Conference
March 13, 2012

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Crane Water University

Deaeration

Our Qualifications:
A Century and a Half of Experience

Crane Environmental, Inc. is a leading supplier of specialized

water purification solutions for the worlds industrial, commercial
and residential markets.
Crane Environmental, Inc. is the integration of several powerful
and well-known niche companies and brands in the water industry:
Cochrane, Chicago Heater, Belco Water, Westinghouse
Condenser, and Environmental Products USA
Founded in 1863, Crane-Cochranes earliest steam and water
purification systems set industry standards for innovations, quality,
and customer service; and today, over 140 years later; Crane is
still providing leadership in water purification solutions.

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Deaerators

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Leading in Deaeration

Complete Line of Deaerators

Unique Parallel Downflow Design

High Efficiency Design

State-of-the-Art Lock-N-Load Spray
Nozzles

Large, Custom Engineering Capabilities

International Manufacturing Base

Our Qualifications: Installations

Crane has the largest installed base of deaerators worldwide

Crane has shipped approximately 200 deaerators of 1M pph or
larger since 1987.
Crane estimates that we have shipped over 25,000+ deaerators
worldwide since we invented the deaerating feed water heater
beginning in the early 1900s.
Crane maintains approximately 1.2 million drawings starting from
December 29, 1905!

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The Deaerator
WHAT Is It?
WHY Have One?
HOW Does It Work?
WHEN Is It Recommended?
WHERE Is It Located?

What is a Deaerator?
A device that is a part of the boiler feed water
treatment system
A device that removes dissolved gases (oxygen and
carbon dioxide) from water by Mechanical Means

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Source of Dissolved Gases

The Atmosphere
Natural Processes
Biological Activity
Process Atmosphere

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Water Quality Requirements

T.S.S

<2 ppm

Clarification; pressure filters,

microfiltration

Conductivity

<1-15 mhos

Softening, Separate Bed

Demineralizer (TDS, Alk, Silica),
Reverse Osmosis, IX, EDI

Oxygen

<7 PPB/.005 cc Mechanical (Deaeration) or

per liter (ABMA) Chemicals

Oxygen Removal Through Chemical use

Chemicals are the primary method used in smaller size

boiler applications (under 10,000 PPH, under 50 psi)
Chemicals are a supplemental protection, even in
systems utilizing a deaerator, to protect piping systems
Chemicals can add solids to the boiler water
Chemicals can increase boiler blowdown volumes
Chemicals are costly. An increase in consumption
usually means that deaerator is not working properly.
Chemical usually referred to as an oxygen scavenger

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Oxygen Removal Through Chemical use

Sodium Sulfite
Needs contact time and minimum temperature to
react
Adds solids to boiler water
Increases boiler blow down
Used in lower pressure boiler applications (<600
psig)
Expensive
Hydrazine
Can decompose to form ammonia that can attack
copper in the system
Does not add solids to the system
Needs special handling (suspected carcinogen)
Utilized in higher pressure boiler applications (>
600 psig)
Very expensive
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Why Have a Deaerator

It is the American Boiler Manufacturer Associations (ABMA)
standard to recommend equipment that will provide
dissolved oxygen levels of less than 7PPB (.005 ccs per
liter)

To Prevent Corrosion by removing damaging gases

Oxygen: causes rusts and pits in steel surfaces
Carbon Dioxide: thins steel

To Improve Process Efficiency

Improves Thermal Cycle Efficiency
Preheats Boiler Feed Water

Oxygen in the system speeds

corrosion (oxidation) of pipes,
causing pitting
such as shown here.

Provides Storage Capacity to accommodate plant load

swings

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How Deaerators Work

The Cardinal Principles of
Deaerator Operation
Bring Water To Boiling Point
(Saturation Temperature)
By Heating
By Reducing Pressure
Agitate The Liquid
Via tray stack (tortuous path)
Scrubber (steam)
Atomizing valve
Dilute and Vent Released Gases to
atmosphere
Vent pipe

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How Deaerators Work

Venting
Dissolved Gas
Saturation
Point

Agitation

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How Deaerators Work

Saturation of the Water
Water is introduced in to the deaerator which is a complete
steam filled atmosphere
Heat water to full saturation temperature (boiling point),
corresponding to the steam pressure in the unit see
steam table
The solubility of any gas is zero at the boiling point of the
liquid, but complete gas removal is not possible unless the
liquid is kept at boiling temperature

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How Deaerators Work

Agitation of the water can be
accomplished by:
Tray Stack
Scrubber
Atomizing Valve
Packed Column

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How Deaerators Work

Vent Gases
Adequate steam must be passed through the water to scrub out and carry
away the gases after release
It is mandatory that the volume of scrubbing steam be sufficient to
produce the low partial gas pressure, and it is equally mandatory that
these conditions prevail throughout the deaerating section
Removed gases exit through vent pipe to atmosphere at top of deaerator

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When is a Deaerator Recommended?

When to use a Deaerator
Usually when the boiler capacity exceeds 10,000 PPH and is a higher
pressure > 30psi

When using oxygen scavenging chemicals becomes a cost constraint or

the dissolved oxygen content in the system cant be properly controlled

When the boiler plant requires reduction of chemical use for either
environmental or cost-reduction purposes

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Types of DAs
Deaerator Technologies
Spray Tray (tray type)
Parallel Downflow
Counterflow

Spray or Scrubber Type

Atomizing Type

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DEAERATOR DESIGN
INFORMATION

Conditions for Proper Deaeration

Proper distribution of sprayed water to the top of the tray stack
Sufficient volume of steam to reduce the partial pressure of the noncondensable gases
Sufficient steam to heat to saturation temperature
High steam/water interaction surface area and increased reaction time
Mechanical scrubbing, mixing action
Continuous, effective venting
Proper design, including proper selection of the deaerator
Proper operation
Proper maintenance of the deaerator

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Types of Water to be Treated by Deaeration

Make-up Water
Softened Raw Water
Demineralized Water
(usually in Boiler
pressures (>400psig)
Steam
Condensate Return

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Mechanical Design Parameters

DA Outlet capacity in Pounds Per Hour

(#/hr)
Operating Pressure (psig)
Operating Temp (F)
Process Condition provided is:
Normal
Maximum
Abnormal (i.e % condensate return,
feed water changes)
Storage Volume
Volume required in Minutes,
Gallons or Cubic Feet

Design Pressure-Internal & External

Design Temperature
Corrosion Allowance
Radiography
Quality/Construction/Inspection
Requirements
Connection Reinforcement Design
Considerations
Seismic Load Requirements

Mechanical Design Parameters

NACE (National Association of Corrosion Engineers)
RP590
1/16 corrosion allowance
Spot x-ray
PWHT
MT
Blend ground on vessel weld seams

HEI (Heat Exchange Institute) DA Standard (Optional)

1/8 corrosion allowance
Full x-ray exam on longitudinal weld seams
Post Weld Heat Treatment (PWHT)
Magnetic Test (MT) on internal nozzle-to-vessel weld joints
Minimum vessel wall thickness
All Stainless Steel Internals
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Mechanical Design Parameters

Vessel Design Parameters
Shell/Head Material
A516-70 will be used unless otherwise specified. Exception will be
made for Carbon Steel (CS) vessel with SS cladding/lining.
Nozzle Material
CS except solid SS connection will be used for water inlet and vent
connection)
Connection Style
Raised Face Slip On, Raised Face Weld Neck, Raised Face Long
Weld Neck, Butt Weld, Socket Weld, Coupling, etc.
Manway Size
Deaerator and Storage Tank

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Mechanical Design Parameters

Vessel Design Parameters (continued)
Design Pressure (30 psi if not specified)
Internal (psig)
External (Full Vacuum, Half Vacuum)
Corrosion Allowance
Vessel (1/8, 1/16, etc.)
Connection neck (1/8, 1/16, etc.)
Design Temperature
Heater (deg F) (300 deg F if not specified)
Storage Tank (deg F) (300 deg F if not specified)
Post Weld Heat Treatment (PWHT)
If specified, one stage PWHT is assumed
If not specified, NO PWHT will be included

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Mechanical Design Parameters

Internal Material
Spray nozzles: 316 SS (no exceptions)
Trays (if spray-tray): 430 SS unless otherwise specified
Internal bolting: Stainless steel
Traybox (Parallel Downflow): Carbon Steel
Traybox (Counterflow): 300 Series SS
Misc material outside tray box: Carbon Steel
Scrubber: Carbon Steel
Atomizing Valve: Type 304 SS
Vent Condenser: 300 Series SS

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Mechanical Design Parameters

Accessories

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Relief Valve

Water Inlet Control Valve

Vacuum Breaker

Level Controller

Vent Valve/Vent Orifice

Steam Control valve

Thermometer

Overflow Control Valve

Pressure Gauge

Sample Cooler

Level Switch

Transmitters (Level, Pressure, Temp)

Gauge Glass

Dissolved Oxygen (DO) test kit

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Parameters for Deaerator Selection

Operation Process Conditions
Space Limitation
Preference
Existing Deaerator Replacement (minimal piping changes)
Experience with Specific Types
Budgetary Concern

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Parameters for Deaerator Selection

Spray Scrubber Type - only applies where the load is more
or less steady and over a limited range

Atomizing Type - good for low head room and marine

applications

Spray Tray Type - most flexible and reliable. Two types, the
Parallel Down Flow and the Counter Flow

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Deaerator Spray Nozzles

Spray Nozzle Design
If 90-95% of the deaeration process takes place when the water
contacts the steam, then the most important part of the process is
the spray pattern put out by the spray nozzle.

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Deaerator Spray Nozzles

Spray Nozzle Design:
Crane Lock-N-Load Spray Nozzle
316 SS construction with non-binding Teflon guide prevents tilting
of the valve disc due to flow impingement.
Auto-adjusts based on load
The spray disc is partnered with a serrated body to ensure a
uniform spray pattern and optimum water break up over ALL load
conditions.
Can be replaced from outside without the need to open and enter
DA tank!
Dramatically cuts down on replacement time, labor and costs

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Parallel Down Flow Deaerator: Unique Water Seal

Proper water distribution at all loads

Improved stage one / preheater

performance

True two-stage performance

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Parameters for Deaerator Selection

Tray Type
More flexible in turn down
Allows wide load swings-10%-100%
More reliable due to fewer moving parts

Parallel Down Flow (PDF)

Can tolerate temp. rise as low as 15-20 deg. F
Acceptable for all applications except when size reaches
1.2-1.5 million PPH because its less cost effective

Counter Flow (CF)

Requires a temp. rise of 30 deg. F or higher
Power Plant operations or applications with a high return
of condensate flow
Usually found in larger applications

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Parameters for Deaerator Selection

Atomizing
Suitable in low head room applications, single tank
Tolerates water containing scale or solids (no baffles)
Minimum temp. rise 50 deg. F
Effective turn down range 10%-100%
Good selection for smaller, packaged units

Spray/Scrubber (re-boiler type)

Good choice for narrower turn down, more steady operation level
Minimum temp. rise 50 deg. F
Effective turn down range 50%-100%
Less expensive alternative
Only use to meet specification or direct replacement

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Parallel Down Flow vs. Counter Flow

Deaerators

Parallel Down Flow

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Counter Flow

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Parallel Down Flow Deaerator

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Parallel Down Flow vs. Counter Flow

Deaerators
Parallel Down Flow

Counter Flow

Utilizes a two-stage cascade stripping process

Usually found in larger applications

Unique Water Seal

Standard for larger utility type power plants.

Co-current steam/water tray contact

Utilizes a two-stage counter flow stripping

process

Versatility (100% make up or mixed condensate)

Will perform equally under all operating
conditions
Ability to handle a high percentage of make-up
water
Ability to handle low temp waters
Minimum temp rise as low as 15 deg. F
Higher turndown capabilities
Able to handle high pressure / flashing
condensate returns
More spilling edge per volume of trays
Better use of tray volume
Greater level of agitation / control
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Counter-current steam/water tray contact

Operating conditions must be rigidly specified at
design
Best utilized when feed water contains a high
percentage of condensate (>50%)
Can only handle high-pressure flashing return
containing O2 not exceeding 15ppb
Not suitable where water temperature falls below
60 degree F
Minimum temp rise is 30 deg. F
Susceptible to tray flooding when steam pressure
fluctuates.
Unable to deaerate condensate from flashing
return lines during start-up and re-starts
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Parallel Down Flow vs. Counter Flow

Deaerators
Tray Comparison
Parallel Down Flow Trays

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Counter Flow Trays

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Parallel Down Flow vs. Counter Flow

Deaerators
Tray Comparison

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Atomizing Deaerators

Enterprise
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Nimitz class aircraft carrier U.S.S. Enterprise has twin

Crane monel atomizing deaerators installed.

Nimitz Class aircraft carrier U.S.S. Ronald Reagan, has

twin Crane atomizing deaerators installed.

Future class aircraft carrier U.S.S Gerald R. Ford,

under construction, will have newly designed twin
Crane atomizing deaerators.

Reagan

Ford
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Counter Flow Deaerators

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ExxonMobil 5.0 M PPH x 2

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ExxonMobil 5.0 M PPH x 2

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Pennsylvania Power & Light 6.2 M PPH

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Questions & Answers

For More Information

Local Contacts:
Frost Engineering Service Co. NW, Snohomish, WA
Mike Matsumoto
(360) 668-0280 O; (206) 396-8851 Cell
mikem@frostnw.com
Crane Environmental, Fallbrook, CA
Rob Haney, Regional Sales Manager
(760) 723-5587 O; (760) 468-3594 Cell
rhaney@cranewater.com