Introduction to Advances in Power Plant Chemistry

Introduction to Advances in Power Plant Chemistry

Objectives and other details of modules Duration 90 minutes Training aids Power point Presentations Objective At the end of the session participants will be able to: Describe advances made in boilers - design & size and chemical control limits with reference to different types / sizes of boilers for: Feed water Steam water cycle Superheated steam cycle Condensates List out online and offline instruments in SWAS and purpose of these instruments Use online and offline instruments for measuring parameters related to water chemistry 11/27/13 Fußzeilentext 2

Advances in Boiler design and its implication for water chemistry Double Drum Boiler early 60s 50-100MW Single Drum with mud and clean compartment Russian design/skoda-50, 100, 200 MW Single Drum Boiler- BHEL based on CE design/alstom/ansaldo - 210, 250, 500 MW, 600MW (Chinese) Drum less subcritical Boiler- Stain France - 500MW Supercritical Boiler- BHEL based on Alstom design- 660, 800 MW, MHI, Ansaldo, Toshiba, Babcock 660 MW 11/27/13 Fußzeilentext 3

Chemical Control Limits in Different Design Boiler For Steam-water Cycle

CHEMICAL CONTROL LIMITS FOR FEED WATER OF 60,100 & 200 MW SN Parameter 60 MW 100MW 200 MW 1 ph at 25oC 8.8-9.0 8.8-9.0 8.8-9.0 2 Cation Conductivity, µs/cm 0.3 0.3 0.2 3 Dissolved O2, µg/l, max 7 7 5 4 Silica, µg/l, max 20 20 20 5 Residual N2H4, µg/l 20-30 20-40 10-20 6 Total Fe, µg/l, max 10 10 10 7 Total Cu, µg/l, max 5 5 5

CHEMICAL CONTROL LIMITS FOR FEED WATER OF 500 MW AND ABOVE SN Parameter 500 MW 1 ph at 25oC 9.0 9.2 2 Cation Conductivity, µs/cm 0.2 3 Dissolved O2, µg/l, max 5 4 Silica, µg/l, max 10 5 Residual N2H4, µg/l 10 20 6 Total Fe, µg/l, max 10 7 Total Cu, µg/l, max 3 11/27/13 Fußzeilentext 6

CHEMICAL CONTROL LIMITS OF STEAM-WATER CYCLE OF 60,100 & 200 MW SN Parameter 60 MW 100MW 200 MW 1 ph at 25oC 9.2 9.7 9.2 9.5 9.2 9.5 2 Sp. Conductivity, µs/cm, at 25oC, max 30 50 30 3 Silica, mg/l, max 2.5 1.5 0.4 4 Phosphate, mg/l 2 6 2 6 2-4 5 Chloride, mg/l, max 1.6 1.0 1.0 11/27/13 Fußzeilentext 7

CHEMICAL CONTROL LIMITS OF STEAM-WATER CYCLE OF 500 MW & ABOVE SN Parameter 500 MW 1 ph at 25oC 9.1 9.4 2 Sp. Conductivity, µs/cm, at 25oC, max 20 3 Silica, mg/l, max 0.1 4 Phosphate, mg/l 1 2 5 Chloride, mg/l, max 0.5 11/27/13 Fußzeilentext 8

CHEMICAL CONTROL LIMITS OF SUPERHEATED STEAM CYCLE OF 60,100 & 200 MW SN Parameter 60 MW 100MW 200 MW 1 ph at 25oC 8.8 9.0 8.8 9.0 8.8 9.0 2 Cation Conductivity, µs/cm, at 25oC, max 0.35 0.3 0.2 3 Silica, µg/l, max 20 20 20 4 Sodium, µg/l, max 10 5 5 5 Ammonia, mg/l, max 0.5 0.5 0.5 6 Iron, µg/l, max 10 10 10 7 Copper, µg/l, max 58.8 5 5 11/27/13 Fußzeilentext 9

CHEMICAL CONTROL LIMITS OF SUPERHEATED STEAM CYCLE OF 500 MW & ABOVE SN Parameter 500 MW 1 ph at 25oC 9.0 9.2 2 Cation Conductivity, µs/cm, at 25oC, max 0.2 3 Silica, µg/l, max 10 4 Sodium, µg/l, max 5 5 Ammonia, mg/l, max 1.0 6 Iron, µg/l, max 10 7 Copper, µg/l, max 3 11/27/13 Fußzeilentext 10

CHEMICAL CONTROL LIMITS OF CONDENSATE OF 60,100 & 200 MW SN Parameter 60 MW 100MW 200 MW 1 ph at 25oC 8.8 9.0 8.8 9.0 8.8 9.0 2 Cation Conductivity, µs/cm, at 25oC, max 0.35 0.3 0.3 3 Silica, µg/l, max 20 20 20 4 Dissolved O2, µg/l, max 50 40 40 5 Ammonia, mg/l, max 0.5 0.5 0.5 6 Total Iron, µg/l, max 10 10 10 7 Total Copper, µg/l, max 5 5 5 11/27/13 Fußzeilentext 11

CHEMICAL CONTROL LIMITS OF CONDENSATE OF 500 MW & ABOVE SN Parameter 500 MW 1 ph at 25oC 9.0 9.2 2 Cation Conductivity, µs/cm, at 25oC, max 0.2 3 Silica, µg/l, max 10 4 Dissolved O2, µg/l, max 40 5 Ammonia, mg/l, max 1.0 6 Total Iron, µg/l, max 10 7 Total Copper, µg/l, max 3 8 Sodium, µg/l, max 5 11/27/13 Fußzeilentext 12

CHEMICAL CONTROL LIMITS OF STEAM-WATER CYCLE FOR POWER PLANT UNITS TREATED CONDENSATE CPU In/Out) S.N. PARAMETER 2x500MW 3x500MW 3x500MW 1. Type of CPU provided Deep MB Deep MB Deep MB (Ammonex) (Consep) (Seprex) IN/OUT IN/OUT IN/OUT 2. ph at 25oC, max -- 9.2/-- 9.2/-- 3. 4. 5. 6. 7. 8. 9. 10. 11. Ammonia, µg/l, max Cation Conductivity, µs/cm, at 25oC, max Silica, µg/l Sodium, µg/l Chloride, µg/l Iron, µg/l Copper, µg/l TDS, µg/l -- --/0.1 20/5 10/1 10/1 50/5 5/2 100/25 50/10 500/-- --/0.1 20/5 10/2 10/2 50/5 5/2 100/25 50.5/ 500/-- --/0.1 20/5 10/2 10/2 50/5 5/2 100/25 50/5 Crud, µg/l 13

CHEMICAL CONTROL LIMITS OF STEAM-WATER CYCLE FOR COAL/GAS BASED UNITS (100 & 200 MW) PRIMARY STATOR WATER SN Parameter 60 MW 100MW 200 MW 1 ph at 25oC 2 Sp. Conductivity, µs/cm, at 250C, max Stator is cooled by H2 Stator is cooled by H2 6.8 7.0 3 Dissolved O2, mg/l, max 1.0 4.5 4 Copper, µg/l, max - 5 Iron, µg/l, max - 1.0 11/27/13 Fußzeilentext 14

COAL BASED UNITS (500 MW AND ABOVE) PRIMARY STATOR WATER SN Parameter 500 MW 1 ph at 25oC 8.5 9.0 2 Sp. Conductivity, µs/cm, at 250C, max 2.2 3 Dissolved O2, µg/l, max 10 4 Copper, µg/l, max 20 5 Iron, µg/l, max 20 11/27/13 Fußzeilentext 15

CHEMICAL CONTROL LIMITS OF STEAM-WATER CYCLE FOR GAS/NAPHTHA BASED UNITS FEED WATER SN Parameter 88MW (GT)+ 149MW (ST) 111.19M W(GT) 109.3M W(ST) 106MW (GT) 116.1MW (ST) 144.3MW (GT) 225MW (ST) 1 ph at 25oC 9.2 9.7 8.5 9.5 9.0 9.5 8.5-9.5 2 Cation Conductivity, µs/cm 0.2 0.2 0.2 0.2 3 Dissolved O2, µg/l, max 7 7 10 7 4 Silica, µg/l, max 20 20 20 20 5 Residual N2H4, µg/l, max - 10-10 6 Total Fe, µg/l, max 20 20 20 30 7 Total Cu, µg/l, max 3 3 5 20 11/27/13 Fußzeilentext 16

CHEMICAL CONTROL LIMITS OF STEAM-WATER CYCLE FOR GAS/NAPHTHA BASED UNITS BOILER WATER (HP DRUM) SN Parameter 88MW (GT)+ 149MW (ST) 111.19M W(GT) 109.3MW (ST) 106MW (GT) 116.1MW (ST) 131 MW(GT) 225MW (ST) 1 ph at 25oC 9.8 10.2 9.2 10.3 9.5 10.5 9.0 9.8 2 Sp. Conductivity, µs/cm, at 25oC, max 50 100 150 150 3 Silica, mg/l, max 4.0 2.0 2.0 2.0 4 Phosphate, mg/l, max 6 3 10 1 10 2-6 5 TDS, mg/l, max 100 100 100 100 6 Chloride, mg/l, max 10 10 10 10 7 Total Iron, mg/l, max 0.5 0.5 0.5 0.5 8 Total Copper, mg/l, max 0.1 0.1 0.1 0.1 11/27/13 Fußzeilentext 17

GAS/NAPHTHA BASED UNITS BOILER WATER (LP DRUM) SN Parameter 88MW (GT)+ 149MW (ST) 111.19M W(GT) 109.3MW (ST) 106MW (GT) 116.1MW (ST) 131 MW(GT) 225MW (ST) 1 ph at 25oC 9.8 10.2 9.2 10.3 9.5 10.5 9.0 10.5 2 Sp. Conductivity, µs/cm, at 25oC, max 50 100 150 150 3 Silica, mg/l, max 4.0 2.0 5.0 2.0 4 Phosphate, mg/l, max 6 3 10 10 20 15 5 TDS, mg/l, max 100 100 100 100 6 Chloride, mg/l, max 10 10 10 10 11/27/13 Fußzeilentext 18

CHEMICAL CONTROL LIMITS OF STEAM-WATER CYCLE FOR GAS/NAPHTHA BASED UNITS MAIN STEAM SN Parameter 3x88MW (GT)+ 1x149 MW (ST) 4x111.19 MW(GT) +2x109.3 MW(ST) 4x106 MW (GT) +2x116.1 MW (ST) 3x144.3 MW(GT) +1x225 MW (ST) 1 ph at 25oC 9.2 9.7 8.5 9.5 8.8 9.2 8.8 9.2 2 Cation Conductivity, µs/cm, at 25oC, max 0.2 0.2 0.2 0.2 3 Silica, µg/l, max 20 20 20 20 4 Sodium, µg/l 10-10 10 5 Ammonia, mg/l, max - - - - 6 Iron, µg/l, max 20 - - 20 7 Copper, µg/l, max 3 - - 20 8 Chloride, µg/l, max - - - 3 11/27/13 Fußzeilentext 19

GAS/NAPHTHA BASED UNITS CONDENSATE SN Parameter 3x88MW (GT)+ 1x149 MW (ST) 4x111.19 MW(GT) +2x109.3 MW(ST) 4x106 MW (GT) +2x116.1 MW (ST) 3x144.3 MW(GT) +1x225 MW (ST) 1 ph at 25oC 9.2 9.7 8.5 9.2 8.8 9.2 8.5 9.5 2 Cation Conductivity, µs/cm, at 25oC, max 0.2 0.2 0.2 0.2 3 Silica, µg/l, max 20 20 20 20 4 Dissolved O2, µg/l, max 100 20 20 25

SWAS Online Instruments in SWAS Silica Analyzer Phosphate Analyzer ph meter Conductivity meter ACC Conductivity meter Hydrazine Analyzer Ammonia Analyzer Dissolved Oxygen Analyzer 21

SWAS OFF Line Instruments in SWAS ph meter Conductivity meter Turbidity meter Double Double bean spectrophoto meter to analyze: Silica Ammonia Hydrazine Phosphate Iron Copper 22