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Troubleshooting: Boiler Flake formation: Pictures Attached!

Attached herewith are the Photos from Our Boiler Header, What can be the reason for flakes formation? Boiler commissioned 2 months back only 125 TPH @88 kgf/cm2 & 515 using phosphate treatment & oxygen scavenger. The Boiler was at site for nearly one year (Awaiting erection). The area is near sea shore. Could these have contributed to the rusting or is it because of improper storage?

Yogesh Mangal




Dear Yogesh Mangal,

Despite phosphate treatment and use of oxygen scavenger, your boiler has been corroded because of poor quality of feed water used rather than due to improper storage of your boiler near sea shore for long time before erection.

The elaborate information given at along with pictures of corroded boiler that look similar to that of your boiler should be of help to you to know the reasons for corrosion of your boiler, the chemical constituents such as calcium, magnesium, silica etc. in feed water responsible for corrosion, methods that can be used to improve the condition of your boiler and methods that can be used to treat the water to avoid further corrosion.

Good luck,

Dr. R. Jagadiswara Rao
Retired Professor of Geology
Sri Venkateswara University
Tirupati, AP 517502

Dr. R. Jagadiswara Rao, Professor of Geology Retired, Sri Venkateswara University, Tirupati, AP 517502, India


Dear Yogesh,

It is not likely that your boiler has got effected due to prolonged storage in sea- shore environment but more so due to not good quality feed-water.

You need to get your feed-water assessed, and get back to your Boiler makers to suggest feed-water conditioning before it enters the boiler. Then comes your operation, in this also, your water inside the boiler is to be sampled and tested regularly at site. Then have regular boiler water treatment, followed by recommended practices like scum blow-down , bottom drain blow-down done daily, weekly, or as recommended.

On your own, try to recover all spent steam- convert to distilled water for re-use in the boliler, reduce new feed water as far as possible.
The boiler must have passed all certification, and given a certificate. Hence it would be fine to follow the recommended practices .

With wellwishes from VigyanVijay

Er. Ajit Seshadri
The Vigyan Vijay Foundation,

Er. Ajit Seshadri,Head- Environment, The Vigyan Vijay Foundation

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