Boiler Water Chemistry

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Boiler Water Chemistry

Best Practices - A key to success in


Super Critical Boilers

By: Team NTPC


Nov 21, 2013 1
PRESENTATION OUTLINE

 NTPC Overview

 OT – Introduction

 Oxygen Dosing System Details

 Operation and Control

 AVT v/s OT – Data Comparison

 AVT v/s OT - Benefits

 Results and Conclusion

Nov 21, 2013 2


Our Vision

“To be the world’s


largest and best
power producer,
powering India’s
growth”

Nov 21, 2013 3


Planning for Accelerated Growth

Today 2032
~41 GW* ~ 128 GW

Coal Gas Nuclear Hydro Renewables

Capacity under construction: ~20 GW


* 10 MW Solar PV Projects
Nov 21, 2013 4
NTPC’s Growth Journey
1975 1982 1997 2004 2010 2013
Listed on • Became a
• GOI further
First 200 MW Became a Indian Stock Maharatna
NTPC divested
unit Navratna Exchanges Company
incorporated 9.5%
commissioned Company (GoI holding • GOI divested
equity
89.5%) 5% equity

41794*

*10 MW
20249 Solar PV

11333

Nov 21, 2013 5


Pan India Presence
No. of Capacity
Share
plants MW
NTPC Owned
KOLDAM
KOLDAM
(800
(800 MW)
MW)
Coal 16 32,355 77.42%
LOHARINAG
LOHARINAG PALA
PALA
(600 MW)
DADRI (600 MW)
DADRI Gas/Liquid fuel 7 3955 9.46%
(817 MW)
FARIDABAD
FARIDABAD
(430
(430 MW)
MW) TAPOVAN
TAPOVAN VISHNUGAD
VISHNUGAD
Solar 2 10 0.02 %
BTPS NCTPP
NCTPP (520
(520 MW)
MW)
(705
(705 MW)
MW)(2,310
(1,820 MW)
MW)
TANDA
Sub-Total 25 36,320 86.9%
IGSTPP
IGSTPP (440 MW)
UNCHAHAR
(1,500
(1,500 MW)
MW) UNCHAHAR
AURAIYA(1,050
AURAIYA (1,050 MW)
MW) KAHALGAON
KAHALGAON BONGAIGAON
BONGAIGAON
Owned by JVs
(652 MW) NABINAGAR
NABINAGAR(2,340 MW)
ANTA
ANTA (750
(750 MW)
MW)
(413 MW)
(1,000 MW)
(1,000 MW)
RIHAND
Coal 6 3534 8.46%
SINGRAULI RIHAND
SINGRAULI (3,000
(3,000 MW)
(2,000 MW) MW)BARH
BARH
3,300
3,300 MW
FARAKKA
FARAKKA
MW (2,100
(2,100 MW)
MW)
Gas 1 1940 4.64%
VINDHYACHAL
GANDHAR (4,260
(4,260 MW)
MW)
(648
(648 MW)
MW) Sub-Total 7 5474 13.1%
KORBA ROURKELA DURGAPUR
ROURKELA
(120
(120 MW)
MW) (120
(120 MW)
MW)
KAWAS
KAWAS (2,600
(2,600 MW)
MW)
(645
(645 MW)
MW) MAUDA
MAUDA
BHILAI
BHILAI
574
TALCHER KANIHA
(3,000
(3,000 MW)
Total 32 41,794 100%
(1,000
(1,000 MW)
MW) 574 MW
MW MW)
SIPAT
SIPAT
2,980
2,980 MW
MW TALCHER
TALCHER Thermal
Thermal
(460 MW)

RGPPL RAMAGUNDAM
RAMAGUNDAM
(2,600
(2,600 MW)
MW) SIMHADRI
(1480
(1480 MW)
MW) SIMHADRI
(2,000
(2,000 MW)
MW)

COAL POWER STATION


ONGOING HYDRO POWER PROJECTS
GAS POWER STATIONS
VALLUR
VALLUR
(1,500
(1,500 MW)
MW) ONGOING THERMAL PROJECTS
KAYAMKULAM
KAYAMKULAM
Note: Capacity
(350includes
(350 MW)
MW) capacity under construction; Map not to scale

Nov 21, 2013 6


Sustainable Power Development

Implementing high efficiency technology

Hydro, Renewable & Nuclear Energy forays


 1499 MW hydro capacity under construction
 Developing Wind and Solar capacities – 1000 MW by 2017
 Anushakti Vidhyut Nigam Ltd. - JV company formed with NPCIL for nuclear
power development - NTPC(49% ) & NPCIL( 51%) – 14 GW by 20

Nov 21, 2013 7


Research & Technology Development

Focus Areas
Efficiency & Availability Improvement
and Cost Reduction

Renewables and Alternate Energy

Climate Change and Environment

Scientific Support to Stations

 ECBC (Energy Conservation Building Code) compliant


building
 ISO/NABL 17025 Certified Labs, CBB certification
Investment of more than 1% of PAT for R&D Activities and
Nov 21, 2013 Climate Change studies 8
OXYGENATED TREATMENT (OT)

 Oxygenated treatment – Feed water treatment or


conditioning.
 Injection of High purity oxygen gas at CPU &
Deaerator outlet
 Conversion of Fe3O4 (Magnetite) to hydrated FeOOH
and Fe2O3 (Hematite).
 Hydrated FeOOH and/or Fe2O3 block the pores in the
magnetite layer and forms a more adherent protective
layer and reduces the migration of iron
 Prevents flow accelerated corrosion (FAC).

Nov 21, 2013 9


FEED WATER SPECIFICATION

Normal Operation
During
S.N Parameter Units Alkaline
Oxygenated Start up
water
Treatment
Treatment
1 pH Min 9.0 8-8.5 Min 9.0

2 ACC, ms/cm ms/cm Max 0.2 <0.15 Max 0.5

3 DO ppb <5 30-150 Max 100


4 Iron ppb <2 <2 < 20
5 Sodium ppb <2 <2 < 10
6 Silica ppb <10 < 10 < 30
7 Turbidity NTU <2 <2 <5

Nov 21, 2013 10


STEAM PARAMETERS LIMITS

Action 1 Action 2 Action 3


Immediate
Parameter Normal (2 weeks (2 days per (8 hours shut down
per year) year) per year)
ACC, ms/cm
<0.15 >0.2 >0.3 >0.6 >2

Silica, ppb
10 >10 >30 >40 >50

Sodium, ppb <3 >3 >6 >12 >24

Chloride, ppb <3 >3 >6 >12 >24

Nov 21, 2013 11


STEAM WATER ANALYSIS SYSTEM (SWAS)

Online Monitors:

S.No System Type of measurement


1 Make up DM water SP.COND., CATION
CONDUCTIVITY (ACC)
2 CEP discharge pH, ACC, Na, DO, SP.COND.,

3 CPU Outlet pH, ACC, Na, SILICA, SP.COND.,

4 Deaerator outlet DO

5 Feed water at economizer pH, ACC, COND., SILICA


inlet

Nov 21, 2013 12


STEAM WATER ANALYSIS SYSTEM (SWAS)
contd….

S.No System Type of measurement


6 Separator outlet steam ACC, SP.COND., SILICA

7 Main steam pH, ACC, Na, SILICA, SP.COND.,

8 Water separation storage Cation conductivity (ACC)


tank of boiler

9 Reheated steam Cation conductivity (ACC)

Nov 21, 2013 13


STARTUP, OPERATION AND SHUTDOWN

 Stop oxygen feed at least one hour before shutdown


 Increase ammonia feed rate to achieve a pH > 9.0
 Open Deaerator vents
Nov 21, 2013 14
CRUD LOAD DURING START UP
Normal Running condition

During shut down


Ammonia vaporise to upper layer

During shut down


Dissolution of iron in low pH water Water wall tube
deposits from
feed iron
transport

Crud load during start up


Nov 21, 2013 15
BOILER PROTECTIVE LAYER
AVT OT

Migration of Fe2+ to fluid boundary layer FeOOH/Fe2O3 block pores lowering Fe2+ migration

Nov 21, 2013 16


OXYGEN DOSING SYSTEM

The piping material is of SS 316

 Pressure Regulating Valve

 Flow Control Valves

 Gas Cylinders

 Motorised Valves

Nov 21, 2013 17


OPERATION AND CONTROL

 Five gas cylinders charge at once at regulated pressure 42 ksc

 The safety valve operates, if gas pressure is >50ksc.

 Four dosing lines - two each at D/A and CPU outlet

 Dosing line with one Motorised (MOV) and one Flow control
valve (FCV)

 The MOV is fully opened and gas flow is controlled by FCV.

Nov 21, 2013 18


OXYGEN DOSING OPERATION

The injection control is


automatically adjusted by
Condensate water flow and
Feed DO.

Nov 21, 2013 19


CONVERSION TO OT - ACTIVITIES

Pre OT Activities
 Instruments Installation – DO
meter, ACC
 Install Sampling lines – ACC,
pH, K at each CPU Vessel
PORTABLE D.O. METER
 Replacement of De-aerator
O/L sample line by Feed
water line to analyzer for
round the clock monitoring of
Feed DO.

Nov 21, 2013 20


PORTABLE A.C.C. METER
OT CONVERSION - ACTIVITIES
CPU Availability
 100% CPU availability
 Formal training to Shift –Chemist regarding CPU operation.

Training Session
 The training session for operators regarding OT &
 Actions to be taken during start-up, shut-down and in normal
operation.

Database
 Recording and observing parameters for three months before
start comprising Feed & CEP DO
 Monitoring of ACC of cycle chemistry under AVT condition to
ensure the readiness of boilers for conversion to OT.

Nov 21, 2013 21


ACC (uS/cm)
Dissolved Oxygen (ppb)
11
-1 11
2

0.00
0.05
0.10
0.15
0.20
13 - 20 -1
2-
-1 1 2

0.00
5.00
10.00
15.00
20.00
25.00
2 18 201
2
20 - 2 0 -1
-1 12 2-
2 25 201
2 9 - 20
-1 12 -1 2
2 2-
2
01 - 20 0

Nov 21, 2013


01
.0 12 -0 12
1 1-
08 .2 0
.0 13 08 201
1 -0 3
15 .2 0 1-
.0 13
1 15 201
3
21 .2 0 -0
.0 13 1-
1 22 201
28 .2 0 -0 3
.0 13 1-
1 2
04 .2 0 29 01
.0 13 -0 3
2 1-

Day(s)
11 .2 0 05 20
.0 13

Day(s)
2 -0 13
2-
18 .2 0
.0 13 12 201
2 -0 3
25 .2 0 2-
.0 13
2 19 201
02 .2 0 -0 3
.0 13 2-
3 2 0
U#2, Feed Water D.O. in AVT

04 .2 0 26
.0 13 -0 13

U#2, Feed and MS ACC value in AVT


3 2-
08 .2 0 05 201
.0 13 -0 3
3. 3-
20 20
13 13

Feed Water
Main Steam
Feed Water

ACC (uS/cm) Dissolved Oxygen (ppb)


04 01
-1 .01

0.00
0.05
0.10
0.15
0.20

2-
0.00
5.00
10.00
15.00
20.00
25.00

20 .2
08
-1 12
10 0
2- .01 13
13 20 12 .2 0
-1 1 2
2 .01 13
25 - 20 19 .2 0
-1 12
2 .01 13
01 - 20 24 .2 01
.0 12
1 .01 3
10 .2 0 31 .2 0
.0 13 .01 13
1.
19 2 01 06 .2 01
.0
1 3 .02 3
24 .2 0 08 .2 0
.0 13
1 .02 13
31 .2 0 10 .2 0
.0 13
1 .02 13
04 .2 01
Day(s)

.0 13 .2 01
Day(s)

2 3 .02 3
09 .2 0 15 .2 0
.0 13
2 .02 13
13 .2 01
.0 19 .2 01
2 3 .02 3
18 .2 0
.0 13 20 .2 0
2 .02 13
U#3, Feed Water D.O. in AVT

25 .2 0
.0 13 25 .2 0
2
U#3, Feed and MS ACC value in AVT

.02 13
26 .2 0
.0 13 26 .2 01
2. .02 3
DO/ACC DATA TREND BEFORE OT

20 .2
13 01
3
Feed Water
Main Steam
Feed Water

22
COMMISSIONING ACTIVITIES.
Instrument Checking
 Calibration of all pressure gauges and transmitters
 Checking of following for protection of FCV.
• Pressure regulating valve & set at 42ksc
• Pressure safety valve & set at 50ksc.

Valve Operation
 Checking of all MOVs and FCVs for local and remote
operation.

Leak Detection Test


 Pressurizing of dosing lines
 Checking for any gas leakage at every weld-joint.
Nov 21, 2013 23
GAS FLOW MEASUREMENT & FCV SETTING

BALLOON

 Most important activity as


dosing of oxygen gas with in
limit is dependent on FCV
setting.
 Measurement of gas flow
using Balloons (spherical and
cylindrical) and a connector

Nov 21, 2013 24


CONVERSION TO OT - GUIDELINES

 Based on DO data of different units, decision to start OT first in


one unit.

 Steady rate of passivation, [target value of DO is set max. 80


ppb (range 30 -150 ppb)].

 Initially operation at 9.0 to 9.2 pH and then slowly and steadily


convert to lower value by monitoring Feed ACC.

 Afterwards operate DO level at 80 -110 ppb range.

Nov 21, 2013 25


CONVERSION TO OT – Case study
Case study 1:
 Oxygen dosing started
 The D/A vents fully closed and oxygen dosed at CPU O/L.
 Feed DO started increasing from 6.8 ppb to 20 ppb within 10hrs
 After two days, Feed DO attained 20-40 ppb range only
 Additionally the dosing carried out at D/A O/L as minor passing
was observed from D/A vent.
 After that, DO increased to 65-80 ppb.
 The target value achieved within 5days of start of OT.
 In the second phase, operation started at DO level of 80-110
ppb.

Nov 21, 2013 26


CONVERSION TO OT – Case Study

U#3 Feed Water D. O. in initial month (March, 2013)


120.00
b)

100.00
en(pp

80.00
vedOxyg

60.00
isslo

40.00
D

20.00

0.00

13 13 13 13 13 13 13 13 13 13 13 13
3.
20 .20 .20 3.
20
3.
20 .20 .20 3.
20
3.
20 .20 .20 4.
20
2.0 4.03 5.03 5.0 7.0 8.03 1.03 4.0 5.0 6.03 5.03 1.0
0 0 0 0 0 0 1 1 1 1 2 0
Days

U#3 Fe e d Wate r D. O. tre nd upto July, 2013


140.00

120.00
DisslovedOxygen(ppb)

100.00

80.00

60.00

40.00

20.00

0.00
3 3 3 3 3 3 3 3 3 3 3 3 3 3
01 01 01 01 01 01 01 01 01 01 01 01 01 01
3.2 3.2 3.2 3.2 3.2 3.2 4.2 4.2 5.2 5.2 5.2 5.2 6.2 7.2
.0 .0 .0 .0 .0 .0 .0 .0 .0 .0 .0 .0 .0 .0
02 05 07 11 15 18 01 29 11 18 20 27 17 08
Days

Nov 21, 2013 27


CONVERSION TO OT – Case Study
Case study 2:

 Oxygen dosing started

 The D/A vents fully closed

 Oxygen dosed at CPU O/L & D/A outlet simultaneously

 Feed DO started increasing from 9.2 ppb to 40 ppb within 48


hrs

 After three days, Feed DO attained 50 ppb range

 The target value achieved within 5days of start of OT.

 In the second phase, operation started at DO level of 80-110


ppb.

Nov 21, 2013 28


CONVERSION TO OT – Case Study
U#2 Feed Water D. O. trend in March, 2013

100.0

80.0
p
en(pb)

60.0
v xy
edO g

40.0
Disslo

20.0

0.0

-13 -13 -13 -13 -13 -13 -13 -13 -13


ar ar ar ar ar ar ar ar ar
-M -M -M -M -M -M -M -M -M
15 17 19 21 23 25 27 29 31
Days

U#2 Feed Water D. O. trend upto 29th July, 2013


120.00

100.00
DisslovedOxygen(ppb)

80.00

60.00

40.00

20.00

0.00

13 13 13 13 13 13 13 13 13 13
20 20 20 20 20 20 20 20 20 20
03. 03. 03. 04. 04. 05. 05. 05. 06. 06.
. . . . . . . . . .
15 16 25 15 29 13 20 27 17 27
Days

Nov 21, 2013 29


AVT v/s OT – DATA COMPARISON

Feed and Main Steam ACC


 The Feed and MS A.C.C. values of OT - almost stable (0.09-
0.10 μS/cm)
 Values are less in comparison to AVT (0.2 μS/cm)

U#3, Avg ACC value U#2, Avg ACC value

0.20
0.20

0.15
A C C (u S / c m )

0.15

A C C (u S/c m )
0.10 Feed Water 0.10
Feed Water
0.05 Main Steam Main Steam
0.05

0.00
0.00
'13

'1 3
r' 1 3
r' 1 3
3
2

3
b'1
c' 1

y '1

3
3

3
2

3
J an

J un

3
Ap

r' 1
Ma

c '1

n '1

y'1
r '1

n '1
b'1
Fe

Ma
De

Ma

Ap

Ma
De

Ja

Ju
Fe
Month Month

Nov 21, 2013 30


AVT V/S OT – DATA COMPARISON

Feed and Main Steam Iron values


 Rise in Feed and MS iron values of OT at the start (3-4 ppb)
and decrease afterwards (2-3 ppb)
 Values lesser in comparison to AVT (more than 5 ppb).
U#2, Avg Iron value U#3, Avg Iron value

8
8
7 7
6 6
I r o n (p p b )

Iro n (p p b )
5 5
4 Feed Water 4
3 Feed Water
3
2 Main steam Main steam
2
1
1
0
0
'13
'13

r' 1 3

'1 3
'13

r' 1 3
2

3
3
c' 1

g '1
y '1

3
3
3

3
3
2

3
3
J an

J un

J ul
F eb

l' 1
r'1
c '1

n '1

r '1

n '1
Ap

g '1
y'1
b '1
Ma

Ma
De

Au

Ju
Ma

Ap

Ma
De

Ja

Ju
Fe

Au
Month Month

Nov 21, 2013 31


BENEFITS of OT over AVT
50% increase in CPU load
 AVT - 240000 M3 load
 OT - 360000 M3 load
Environmental benefits and Safety
 Increase in CPU loading results decrease in regeneration
frequency.
 Reduction in spent regenerant waste. Environmental benefit.
 Reduction in Ammonia consumption by 64%
Reduction in DM Makeup (Cyclic)
 Cyclic make up reduction ( less than 1%)
AVT- D/A vents open; OT - close/throttle the vent
Nov 21, 2013 32
BENEFITS of OT over AVT
Reduction of chemical cost :

Consumption (Ltr) Cost (in Rs)


Chemical AVT OT AVT OT

Ammonia 1100 400 39600 14400

Oxygen (No. of Cyl.) -- 15 -- 1950

Total Cost ( in Rs) 39600 16350

MONTHLY SAVINGS (in Rs): 39600-16350 = 23250/-

(monthly average values of chemicals consumed is taken, and current price is considered)

Nov 21, 2013 33


BENEFITS of OT over AVT
CPU- Regeneration
Reduction in monthly consumption of HCl & NaOH as CPU
loading is increased by 50%.

CONSUMPTION (Ltr) Cost (in Rs)


Chemical
AVT OT AVT OT
ACID (HCl) 31 MT 20 MT 48050/- 31000/-

ALKALI (NaOH) 8 MT 5 MT 210224/- 131390/-

TOTAL COST (in Rs) 258274/- 162390/-

Total monthly savings (in Rs.) = 23250.00 + 95884.00 = Rs. 119134/-.

* Cost of HCl is taken as Rs.1550/MT and Alkali as Rs. 26278/mt. thus monthly savings of
Rs. 95884/-

Nov 21, 2013 34


RESULTS AND CONCLUSIONS

 The judicious and efficient CPU operation helps to maintain


stringent Feed -water quality.

 Increase in the Feed DO range to 80-110ppb, and maintaining


ACC in the range of 0.09-0.11 S/cm.

 Stabilization of steam water cycle chemistry - evident from the


analytical parameters & CPU cleaning process (hematite layer
conversion)

 Success factor of conversion to OT will be more promising after


physical inspection of boiler components

Nov 21, 2013 35


TRANSFORMING LIVES

Nov 21, 2013 36

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