Steam and Water Analysis System (SWAS)

An Overview

For over seven decades, Forbes Marshall has been building steam engineering and control instrumentation solutions
that work for process industries. Today we have evolved into a leader in process efficiency and energy conservation
through technology tie-ups and focused investments in manufacturing and research. Our joint ventures with the
world's leading names enable us to deliver quality solutions in more than 20 countries. Forbes Marshall is unique in
having extensive expertise in both steam and control instrumentation. The dual expertise has allowed us to engineer
industry specific systems that focus on energy efficiency and utilities management for diverse sectors such as textiles,
food processing, paper, power, mining, oil and gas, and chemicals.
Our teams consist some of the finest engineers and talent. These highly trained professionals have developed
innovative solutions to better process efficiencies and help save thousands of dollars for our clients. Our business
practices and processes have combined into a singular philosophy of being trusted partners who provide innovative
solutions. It's a philosophy we are proud to live up to.
We have long standing partnerships with some of the best names in the control instrumentation industry such as
Spirax, Arca, Codel, Krohne and Shinkawa, to develop, design and supply innovative solutions for measurement and
monitoring of process parameters. With a combination of specialist knowledge and the latest technology, we provide
products and solutions to achieve optimum efficiency. Our products are a unique combination of hardware and
software that make them reliable and accurate.
Today in power plants, high pressure boilers and steam turbines are under constant attack from erosive and corrosive
elements such as Silica, Sodium, Dissolved Oxygen, Calcium, Chloride and Phosphates. Without accurate measurement
and monitoring, the plant may suffer heavy mechanical damages that can be caused due to imbalance of turbines,
reduced efficiency, deposition on turbine blades, corrosion of steam pipe work and so on.
Our Steam and Water Analysis System (SWAS) is designed to keep you in power. SWAS assures the safety of your
boiler and turbines, by taking along and analsing up to a dozen samples from all the water and steam circuits. In
today's supercritical power plants, sample conditions as high as 600 Degree C and 300 bars are quite common. The
Forbes Marshall SWAS can easily take care of these samples. To protect your equipment our SWAS works in two
stages:
1. Sample Conditioning
2. Sample Analysis

1. Sample Conditioning
The first section of any SWAS is the Sample Conditioning section or the Wet Panel

Enclosed type
Wet Panel

Open frame-free
standing Wet Rack

Here the sample is first cooled in Sample Coolers, de-pressurised in pressure regulators and then fed to various
analyzers while keeping the flow characteristic constant by means of a back pressure regulating device. There are
several safety equipment provided in wet panels, so that the operators feel safe while working with these systems.

The schematic diagram here shows how this happens:

LINE - 1
BOILER FEED WATER
SAMPLE INLET

OTHERS

27

FM

01a

01a

BLOWDOWN HEADER
COOLING WATER OUTLET HEADER
COOLING WATER INLET HEADER

5a

5a
4
02

9
DRAIN
6

12
10

T1

TS
15

11

15

P1

AL

13
PS

14

Description

01a
01b
02
04
05a
06
08
09
10
11
12
13
14
15
16
17
22
23
27

Ht Sample Isolation Valve (globe Type)

Lt Sample Isolation Valve (needle Type)
Sample Cooler
(refer Sample Cooler Sizing)
Coolant Flow Indicator
Coolant Isolation Valve
Sample Filter
Pressure Regulator
Sample Relief Valve
Temperature Gauge
Pressure Gauge
Temperature Switch
Pressure Switch
Solenoid Valve
Regulating Valve
Rotameter
Tundish (for Grab Sampling Facility)
Back Pressure Regulator
Three Way Ball Valve
Bulkhead Union (1/2"nb S/w X 1/4" Od)

*
Ce
Ct
Phe
Pht
Doe
Dot
Hz
Si
Na

Any Of Analyser Given Below

Cond. Cell With Flow Through Chamber
Single Conductivity Transmitter
Ph Electrode
Ph Transmitter
Dissolved Oxygen Sensor
Dissolved Oxygen Transmitter
Hydrazine Analyzer
Silica Analyzer (multichannel)
Sodium Analyzer (multichannel)

16

22

16

23

17

Item No.

19

CE

WASTE DRAIN HDR

DRY PANEL
CT

NA

WASTE DRAIN HDR

DENOTES COOLING WATER LINE

DENOTES SAMPLE LINE

NOTE :
1. SAMPLE TUBING : 1/4" OD, 16 SWG, ASTM A 213, TP-316, SEAMLESS TUBE
2. BLOWDOWN HEADER (DEFAULT) : 2" NB, ASTM A106, GR.B, SCH-80, PIPE FLANGED TO 2" NB, ANSI B16.5, CLASS 300 R/F
3. COOLING WATER HEADERS (DEFAULT) : 2"NB, ASTM A106, GR.B, SCH.40, PIPE FLANGED TO 2"NB, ANSI B16.5 CLASS 150R/F
4. WASTE DRAIN HEADER (DEFAULT) : 2"NB, ASTM A106,GR.B, SCH. 40 C.S,PIPE FLANGED TO 2"NB, ANSI B16.5, CLASS 150 R/F
5. COOLING WATER PIPING : 3/4"NB, SS304 PIPING
6. SAMPLE INLET CONNECTIONS : BULKHEAD UNION FOR SR.NO.27

Some important components of Sampling Systems (Wet Rack)

Sample Cooler
Forbes Marshall Sample Coolers are coil-in-shell type
contra-flow heat exchangers. Validated by a premier
institute like IIT, we are one of the few sample cooler
manufacturers in the world offering a guaranteed
performance. With in-house test set-up for
performance testing, world-class manufacturing and
welding facilities, we offer one of the most trusted
sample coolers in the power sector. Various options
of coil materials such as Stainless Steel AISI 316,
Monel 400, and Inconel 625 etc are available.

High Pressure Regulator

Forbes Marshall offers piston type High Pressure Regulators.
These are used in primary conditioning where sample
pressures are higher than 100 Kg/cm. As these are piston
type Pressure Regulators, there is no fear of diaphragm
rupture etc.
For lower pressure / temperature rating, Forbes Marshall
offers spring loaded diaphragm type Pressure Regulator. To
offer safety against a remote possibility of diaphragm
rupture, an in-built safety valve is a regular feature.

Back Pressure Regulator

Forbes Marshall offers Back Pressure Regulators (BPR)
to avoid low flow (or fluctuating flow) conditions to
analyzers in case of grab sample valve operations. In
the absence of such a device, the sample would flow
to the grab sample line when the grab sample valve is
opened. This can create low flow alarm conditions in
samples going to analyzers.
A Pressure Regulator and Back Pressure Regulator
combination provides very stable pressure and flow
conditions, thereby ensuring reliable, efficient and
accurate analysis.

Sight Glass
Forbes Marshall offers Sample Flow Indicator (Sight
Glass) to view the sample flow inside the sample line.
A rotating wheel indicates presence of cooling water.
The sight glass is made of high grade stainless steel.

Sample Filters
Forbes Marshall also manufactures filters required to
ensure particle-free samples. Particles of size up to 40
microns size can be filtered out. Forged stainless steel
body and hexagonal cap help easy cleaning of the
filter element.

Pressure Relief Valves

Forbes Marshall Pressure Relief Valves comes fitted
with Sample Cooler. A Pressure Relief Valve is
important as it protects the Sample Cooler in case the
coil fails. This is also important for human safety as the
pressurized cooler may burst due to full sample
pressure under coil failure conditions.

High Temperature Isolation Valves

These valves are easy to operate and can be used for
most high pressure and temperature applications.
The unique plug/seat geometry and stuffing box
design allow these valves to operate for extended
periods of time without gland leakage and passing.
Valves are designed for PN 500 (Class 2500) and are
offered for all ratings upto PN 500 and Class 2500.
Body seat integral stellite is hard faced by a special
Automatic welding process. Unique non-rotating
single piece spindle plug design guarantees long seat
life as grinding between plug and seat is eliminated.

Cooling Water Isolation Valve

Cooling Water Isolation Valve is a ball valve. Its
stainless steel body makes it corrosion resistant and
light weight. A long handle makes it easy to operate.
Ball valve type design ensures full flow at open
condition.

Cation Column
The duplex type Cation Conductivity Column is a field
proven Forbes Marshall design. Cation conductivity
measurements are considered to be more reliable
than ordinary conductivity measurements, as this
method ensures elimination of masking effects of
desired chemicals used in treating the water. This
provides a more realistic picture of dissolved
impurities in the sample. The Forbes Marshall Cation
Column is easy to operate, regenerate and maintain.

Significance and importance of boiler parameters

T0C

AK

SiO2 Cond

CI2

TH

Cond

+
pH Na

SiO2

Na

TOC

pH
MAKE-UP

SiO2 Na

pH

Na+

O2

Na+

O2

Cond

Cond N2H4

Cond

TOC

Na+

CONDENSER
POLISHING PLANT

O2

DE-AERATOR

Cond

FEED PUMP
COOLING
TOWER

O2

RE-HEATER
FEED PUMP

H2

SiO2

Cond N2H4

GENERATOR
HP TURBINES

O2

SUPER
HEATERS

SiO2

SiO2

PO4 pH
Na+

HP
HEATERS

ECONOMIZER

SiO2

SiO2

Cond

DRUM

Thermal Power Plant Steam and Water in-line Analytics

CONTAINMENT BUILDING
DEMNERALIZATION PLANT

Cond SiO2 Na

H2

DE-AERATOR

O2

WATER SUPPLY

AK

TH

Cond SiO2 Na

Cond

pH

SiO2 N2H4

O2

O2

pH

PO4

PRIMARY
LOOP:PWR

O2
Cond

O2

Cond

SiO2

Na+

pH

N2H4

H2

O2

pH

H2
O2

Turb

Na+
CONDENSOR

Cond

PRESSURIZER

TH

TOC

HP TURBINES

SiO2
Cond

Na+

SiO2

RE-HEATER

LP TURBINES

GENERATOR

H2

O2

Nuclear cycle measurement

H2

RECTOR CORE

COOLING
TOWER

SECONDARY
LOOP:PWR

CONDENSATE POLISHING PLANT

pH

CI

STEAM GENERATOR

Cond

Cond

H2

REACTOR COOLANT PUMP

FEED PUMP

MAKE-UP

TOC

O2
WASTE GAS DECAY TANKS

TOC Cond Na

O2

pH

CI

pH Analyzer
pH : The steam which goes to the turbines has to be ultra pure. The pH value of the feed water gives direct indication of
alkalinity or acidity of this water. The ultra pure water has pH value of 7. In a steam circuit; it is a normal practice to keep
the pH value of feed water at slightly alkaline levels. This helps in preventing the corrosion of pipe work and other
equipment. Typically dedicated pH analyzers are recommended at following locations in a steam circuit: high pressure
heaters, DM make-up mater, condensate extraction pump discharge.

Features:

Dedicated pH analyzer in each line ensure that

pH is maintained in a specified band

Two wire Aquamon Smartpro series plus

model is the simplest pH and ORP transmitter.
These analyzers are directly loop powered by
+24V DC supply from DCS and PLC

Also direct 110-230 V AC powered Aquamon

4000 transmitter is available if alarm contacts
are required along with 4-20 mA output. For
pH measurement both low and high pH alarm
contacts can be used to control dosing for
chemicals. Separate PT-100 sensor input can
be used for temperature compensation for pH
measurement.

Conductivity Analyzer

Conductivity : Conductivity is an important parameter for detecting any contamination of steam in the boiler
circuit. Conductivity of pure water is almost zero (1-2 Siemens). Ingress of any kind of dissolved impurity will
raise conductivity instantly. Thus conductivity is an important parameter for the detection of leakages.
Typical points in the steam circuit where conductivity should be monitored are: superheated steam, drum water,
high pressure heaters, low pressure heaters, condenser, plant effluent, D.M. plant, make-up water to D.M. plant.

Features:

Like pH Analyzers, Aquamon smart pro series is

also available for conductivity measurement. This
is loop powered through 24VDC power supply.
Both 24V DC loop powered and AC powered
options are available for this measurement

These conductivity transmitters can be used with

cells with different cell constant. PT-100
temperature sensor in conductivity cell helps to
get a compensated reading for conductivity
measurement

Silica : The presence of Silica in the steam and water circuits of a power generation plant is associated with a
number of problems both in the super heater and turbine sections.
The solubility of silica in steam increases with pressure. Hence there are chances of silica carryover. The presence of
silica in steam can lead to deposition in superheated tubes and on the turbine blades which may lead to loss of
efficiency and turbine blade failure. For proper working of turbines, continuous monitoring of silica is highly
recommended.
Similarly, the monitoring of anion and mixed bed ion exchanges safeguards and optimizes the operation of the
demineralization plant.
Thus the typical points in steam circuits where silica analysis is required are Low Level Silica Measurement in: high
pressure and low pressure turbines, steam, drum (saturated) steam, CEP discharge, make-up water, D M makeup
water and high level Silica measurement in drum water.

Features:
Predictive diagnostic tools, including Hach's
proprietary Prognosys technology.
PROGNOSYS is now available to provide
confidence in instrument readings.
PROGNOSYS will monitor and display the
reliability of instrument measurement values
and identify when upcoming maintenance
tasks are due in an easy-to-read color display.
Grab Sample In and Out features allow quick
analysis of a grab sample poured into the
analyzer, and facilitate easily taking a sample
out of the analyzer to verify in a lab test.
The industry's only pressurised reagent
delivery system eliminates the frequent
maintenance associated with pumps.
5.7 color screen with intuitive user interface
and predictive diagnostics
90 days of continuous runtime.

Dissolved Oxygen : At elevated temperature, dissolved oxygen causes corrosion which may cause puncturing and
failure of piping and components respectively. Dissolved oxygen also promotes electrolytic action between
dissimilar metals causing corrosion and leakage at joints and gaskets. Mechanical deaeration and chemicals
scavenger additives are used to remove the dissolved oxygen. An analytical check of process efficiency, therefore, is
essential. Dissolved oxygen monitoring is imperative in power stations using neutral or combined operating
conditions (pH 7.0-7.5 or 8.0-8.5). The typical points in steam circuit where dissolved oxygen monitoring is required
are deaerator inlet and outlet.

Features:

Measurement in ppb range

Better response time 1- 40 ppb :< 30 sec.

Built-in temperature sensor for

temperature easy compensation

Sensors can be directly connected to the

transmitter through a detachable cable for
an easy maintenance

Out put with HART / RS-485 / PROFIBUS-DP

available optionally.

Hydrazine : Hydrazine is used as oxygen scavenger. So it also maintains feed water alkalinity to prevent acidic
corrosion. It prevents frothing in the boiler and minimizes deposits on metal surfaces. Hydrazine also helps in
maintaining a protective magnetite layer over steel surfaces. Under dosing of hydrazine leads to increased corrosion and
overdosing represents a costly waste. Therefore hydrazine monitoring is extremely important. The typical points in a
steam circuit where hydrazine monitoring is required are: re-heaters, economizer inlet and L.P. heaters.

Features:

A response time lower than 60 seconds

Reference electrode with pre-pressurized gel

electrolyte which facilitates maintenance.

Provision for grab sample analysis- A feature very

useful for PLANT CHEMIST

No moving parts such as pumps or valves that are

used to force gases, making the analyzer the most
reliable one.

Out put with HART / RS-485 / PROFIBUS-DP

available optionally.

Sodium :The presence of Sodium signals contamination with potentially corrosive anions, e.g. chlorides, sulfates etc.
Under conditions of high pressure and temperature, neutral sodium salts exhibit considerable steam solubility. NaCl and
NaOH, in particular, are known to be associated with Stress Corrosion Cracking of boiler and superheater tubes. The
ubiquitous character of sodium in the environment makes it a useful indication to reveal possible Leak conditions
within the circuit, particularly in the condenser section where the measurement of sodium detects cooling-water leaks
with a much higher sensitivity than conductivity measurements. The typical points in a steam circuit where sodium
monitoring is required are. D.M. plant make up water, condensate pump discharge, condenser, drum (saturated)
steam.

Features:

Unmatched accuracy with 0.01 ppb detection

unit

Provision of grab Sampling , a feature very useful

for plant chemists

Wide range of measurement from 0 to

10,000ppb. Freely programmable

Use of non-hazardous chemicals for automatic

reactivation of electrodes

Fast Response. Even in multichannel

measurement auto-adapted rinsing sequence to
reach accuracy in a minimized cycle time ( possible
10 minutes)

A reproducibility <1.5% of reading or <0.02

ppb, whichever is greater within 10C

An accuracy <5% of the reading or <0.1 ppb,

whichever is greater

Users can choose the freely programmable

FULLY AUTOMATIC CALIBRATION SEQUENCE
as an option

Chiller

Chilled Package
Chilled water is required when the cooling
water available at site is incapable of cooling
the sample to the temperature required by the
analyzers.
If cooling water temperature exceeds 400 Deg
C, the sample temperature would exceeds
450 Deg C , which is higher than the
temperature required by the analyzers. To
bring down the temperature of the sample,
chilled water is required.
A Chiller Package is also required when a
sample is to be cooled at 25 Deg C. Forbes
Marshall manufactures these in our factory and
are the only SWAS manufacturers having this
capability.

Lab Sampling Module

Forbes Marshall offers the Lab Sampling Module for
laboratory analysis of steam in process boilers which is
designed as per international standards. Its small and
compact size and light weight design makes it
suitable for continuous lab sample collection. It is easy
to operate and can be fitted easily on site.
Wherever there is a Boiler, a Lab Sampling Module is
required.

Photo Gallery

Photo Gallery

Forbes Marshall is the only SWAS manufacturer with a unique expertise in both Steam
Engineering & Control Instrumentation

All power majors deal with us

Alstom

Lanco Group

Siemens

Jindal Group

Doosan

Essar Group

AES Power Machines

Tata Group

ABB

Reliance Industries Ltd.

Power Machine

Reliance Energy Ltd.

BHEL

Larsen & Toubro

NTPC

Thermax

Yokogawa

Bechtel

Honeywell Automation

and many more...

Presence in all continents

Everything about steam and water analysis

Doc#CIG/0414/200/V1.R1

Forbes Marshall Pvt. Ltd.

A-34/35, MIDC, Industrial Estate, H Block, Pimpri, Pune - 411 018. India.
Tel.: 91(0)20 - 27442020 Fax: 91(0)20 - 27442040 E-mail: [email protected]
Plot no. B-85, Chakan MIDC Phase-II, Chakan (CT), Sawardari, Taluka Khed, District Pune 410 501