Corrosion can be broadly classified into two.

Dry Corrosion
Metals have a tendency to return back to their natural state of metal oxides. These metal oxides form a thin layer over them and it prevents further
corrosion attack.

Wet Corrosion
Every metals have a specific potential when placed in an electrolyte. When two metals of different potential are placed in an electrolyte, it forms an
electro-chemical cell. This results in flow of electrons to and from the metals. Even different parts of a single metal can have different potentials in
certain conditions. This also may set up an electro-chemical cell or galvanic cell or corrosion cell.
Whatever be the case a cell means there is an anode and cathode, in which anode loses electrons and deteriorates with time. While at the cathode two
conditions are there:

If electrolyte is acidic, hydrogen gas is released.

If electrolyte is alkaline, polarizing layer of hydrogen is formed, which prevents further corrosion.

Another thing to be noted is that when there is dissolved oxygen in the electrolyte, the polarizing layer of hydrogen is reacted with oxygen to form
water. So no more protection for the metal.
The variation in rate of corrosion with alkalinity at different dissolved oxygen content is shown below.

Influence of Alkalinity on Corrosion Rates of Carbon Steel with Varying Dissolved Oxygen Contents

Where,
1.

High Dissolved Oxygen

2.
3.

Medium Dissolved Oxygen

Low Dissolved Oxygen

4.
Nil Dissolved Oxygen
The graph clearly explains the effect of high dissolved oxygen content and alkalinity of boiler water in rate of corrosion.

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Posted in: Boilers, MEO Examination Study Materials | Tagged: alkalinity and boiler corrosion, alkalinity and dissolved oxygen, dissolved oxygen, dissolved oxygen and rate of boiler
corrosion, how alkalinity prevents boiler corrosion, marine boiler corrosion

Open up Auxiliary Boiler for Inspection

May 8, 2014 10:42 am | Leave a Comment | Frozee

Procedure
Boiler is a pressurized vessel. Incorrect opening procedure could lead to personnel injury as well as equipment damage.

Change over boiler fuel oil to diesel oil.

Make sure all diesel engines are stopped or changed over to diesel oil.
Electric fuel oil heaters can be put in use if fitted on board.
Shut main steam stop valve and put off feed water pump.
Carry out scum blow down to remove floating oil, sludge, etc.
Carry out bottom blow down after scum blow down, otherwise oil carry over may occur.
Boiler blow down to be carried out in steps to avoid thermal stresses. Excessive stresses may lead to cracking.
Sudden cooling down and drop in pressure may cause stresses in boiler. So reduction of pressure must be gradual.
Make sure nobody is standing near ship side blow down valve.
Gradually reduce boiler pressure in steps, 5bar>4.5bar>4bar and so on. This helps in gradual reduction in boiler temperature also.
Safety gear to be used by the personnel operating blow down valves.
When boiler pressure reaches 1bar, open up the vent.
Now if the ship is loaded and having high draft, it may not be possible to drain boiler water completely. In such case arrangements to be made for transferring
remaining boiler water to bilges.

Once the boiler is fully depressurized, slack top manhole door first, make sure no pressure is inside, support the door with chain block, and slowly remove it and
secure.
Now open bottom manhole door slowly. This procedure is to be followed.
Now open remaining mud boxes.
Water washing and inspection of boiler can now be carried out after ventilating sufficiently.

Internal corrosion takes place due to poor quality of feed water or inadequate boiler water treatment. Boiler water may contain dissolved air or gases
such as oxygen and carbon dioxide.

Oxidation and Pitting Corrosion

Oxygen in water causes oxidation of steel, resulting in oxidation corrosion.
4Fe + 3O2 > 2Fe2O3
This is general corrosion, which causes pitting. In order to prevent this:

Use mechanical deaerators to remove dissolved gases from feed water

Use vacuum condenser and keep hot well closed
Use closed circuit system
Dose chemicals such as HYDRAZINE (It reacts with oxygen and releases nitrogen and water)

N2H4 +O2 -> N2 + 2H2O

Carbon dioxide dissolved in water forms carbonic acid.
CO2 + H2O > H2CO3
Chlorides in feed water forms hydrochloric acid.
MgCl2 +2H2O > Mg(OH)2 + 2HCl
Fe + 2HCl >

FeCl2 + H2

In order to counteract the acidic corrosion, alkaline compounds such as sodium hydroxides are added to boiler water.
MgCl2 + 2NaOH >

Mg(OH)2 + 2NaCl

Corrosion Due to Scale Formation

Scale formations results in heavy pitting corrosion. Phosphate treatment in boiler water reduces this type of corrosion.
CaSO4, MgSO4, CaCO3 are scale forming compounds

In order to control the corrosion, tri sodium phosphate, Na3(PO4)2, is dosed.

3CaSO4 + Na3(PO4)2 >

Ca3(PO4)2 + 3Na2SO4

By adding boiler coagulant chemicals, these products from non-sticky sludge and are washed away while regular bottom blow down.