Common damages and defects – awareness is the key to mitigating risks

Regular monitoring and maintenance can help the ship crew detect the problem areas and issues early before they cause structural damage to the system.

Challenges affecting Boiler Water Systems

There are three key challenges associated with Boiler Water Systems – corrosion, scaling/deposition, and carryover. These need to be guarded against to ensure proper and efficient functioning of the equipment.

Corrosion

Corrosion describes loss of metal resulting from chemical oxidation of the metal in the presence of electrolytes in the surrounding environment. The multitude of causes; improper pH control, contaminated feedwater, and incorrect operating temperature can all cause corrosion in the Boiler Water System over time.

Scaling/deposition

Mineral scaling such as calcium and magnesium can restrict boiler water circulation, increasing drag, accelerating deposition, and potentially causing overheating. Over time, deposits and scaling can lead to localized overpressure and premature equipment failure, including ruptured pipes.

Carryover

Boiler carryover occurs when water and steam are carried over from the boiler drum into the system piping. This typically happens when there is a surge in steam demand, improper boiler level control, or excess dissolved solids or organic matter in the boiler water.

Summary of operational pain points that crews should be aware of:

Corrosion and scaling/deposits reduce heat exchange and performance of the Boiler Water System while increasing fuel consumption, costs, and emissions.

Defects can lead to a higher required boiler temperature endangering the boiler structure while also reducing efficiency.

Deposits restrict boiler water circulation, potentially leading to overheating and premature failure of equipment.

Carryover of contaminants in boiler steam can infect connected systems again reducing overall efficiency.

Challenges affecting Engine Cooling Water Systems

The same challenges of corrosion and scaling/deposition are found in Engine Cooling Water Systems, with the addition of biofouling. It is crucial to safeguard against all three issues to ensure efficient equipment performance over time.

Corrosion

Corrosion describes loss of metal resulting from chemical oxidation of the metal in the presence of electrolytes in the surrounding environment. Seawater in the Engine Cooling Water System can lead to corrosion of equipment components.

Scaling/deposition

The accumulation of scale, rust and sludge can lead to blockages and ‘clogging’ in heat exchangers, reducing efficiency and causing equipment malfunction. Scaling/ deposition results in poor heat transfer of metal surfaces thereby increasing cooling water temperature leading to an overheated engine.

Biofouling

Biofouling refers to the gradual build-up of marine microorganisms and macro-organisms within the Engine Cooling Water System. This can lead to increased friction and reduced water circulation causing the engine to overheat. Biofouling also impacts heat transfer efficiency and can trigger corrosion leading to metal loss.

Summary of operational pain points that crews should be aware of:

These problems, either individually or combined, can lead to financial losses due to vessel downtime, repair costs, as well as increased fuel consumption and emissions.