You are on page 1of 51

1

Open Recirculating Cooling


Water for Power Plant

Indonesia Customer Seminar


June 13 & 14 2012
Jakarta Indonesia

Overview
Pushing

the Limits

Mechanical,

Scale

Operational & Chemical Survey

Inhibitor Technology Overview

PC-2040T

Features
Performance
Comparison with other technology
Advantages & Benefit

Cooling System of Power Plant vs Other

Its
BIG !!!!

Open RCW System for Power Plant


Large

systems

HV: 1,800 45,000 m3


RR: 20 200 x 103 m3/hr

Surface,

well, reclaimed make


up waters, sea water

Regulated

to zero discharge

systems
1.2

25 cycles of concentration

Maximizing

utilization!

water and chemical

Challenge: Pushing the Limits


far can we stress our water system
increase the cycle, low etc - without too much
risk?

How

low a treatment level heavy metal,


phosphate, chlorine; etc - will perform?

How

Tech
Risks

Pushing
the Limit
TOC

SHE

Challenge: Pushing the Limits

Treatment
Program
Potential
Risks
System
Survey

Monitoring
& Control

Lowest
TOC

Survey: Mechanical, Operational & Chemical

1. System Survey
2. MakeUp Analysis

Optimizer

Configure

Direct Connect
Cross Over Cable

ISP
Wireless
Modem
Dial Up

3D Web

Dial Up

Download
Excel

Vantage

PSR

Import

3D Data Log

Service Report

Exciter &
Stator Coolers

Hydrogen /Air Coolers

Cooling Source

Condenser

3-5% of
main flow

Circulating Water
Booster Pumps

Circulating
Water
Pumps

Lube Oil
Coolers

Boiler Feed
Pump
Turbine
Condenser

Bearing
Cooling
Water
Coolers

Typical condenser flow:


Fossil = 80 m3/hr/ MW capacity
Nuclear = 123 m3/hr MW capacity
CCGT= 61 o5r 164 m3/hr/MW

Typical Power Plant Circulating


Water Cooling System

Survey: Cooling Tower


Tower

Type

Cross Flow
Counter Flow
Fill

Type

Splash bar
High efficiency
Structure:

Wood, PVC, Cement

Fill Type, Fouling Tendency & Performance

Fill Fouling Issues

Loss of cooling efficiency

High cooling water supply


temperature

Tower capacity derating

Cooling tower failure

Expensive tower fill


replacement

Health-related concerns due


to microbial fouling

Impact of Cooling Tower Performance

Survey: Typical HXs in RCW Power Plant


Service

Flow

Temp

Comments and Concerns

Main Condenser

2.0-2.7 m/s
Continuous

50 C
skin temp

Largest HX, focus of program, but not


severe duty!
Tube leaks contaminate FW.

BFP Turbine
Condenser
(if present)

2.0-2.7 m/s
Continuous

50 C
skin temp

Can be hotter than main condenser.


Typically not a problem area.
Can have older copper alloy tubes.

0.15-2.0 m/s
Throttled

65 C
skin temp

Flow throttled to maintain minimum H2


temp. Tend to silt up in winter.
Often most severe duty in plant.
Unit must de-rate if H2 temp too high.

Lube Oil Coolers

0.15-2.0 m/s
Throttled

40-65 C
skin temp

Flow throttled to maintain minimum lube


oil temp. Can silt up in the winter.
Often very severe duty.
Unit must de-rate if lube oil temp too high.

Exciter Cooling

0.3-2.0 m/s
Throttled

50-65 C
skin temp

May have redundant HX in parallel.


May silt up when throttled.

Bearing /Auxiliary/
Service HX

1-2.7 m/s
Throttled

20 43 C
skin temp

Normally not a problem. Low heat duty.


RCW flow on tube side.
Plate type of exchangers in newer plants.

Combustion Turbine
Cooling

(0.3-2.0 m/s)
Throttled

>65 C
skin temp

CT cooling can be a problem area.


Small tube diameters, high temperatures.

H2 /Air Coolers
(Rotor & Stator)

Surface Condenser

Water-side velocity

: 1.5-2.4 m/s

Vacuum

: 4-10 kPaa

U Value

: 3-5 kW/m2 0C

Sat steam temperature : 30-55 0C

Condenser tube length : 6 15 m

1. Often Key to Efficiency in Plant Operations


2. Condenser leak: boiler water contamination

15

Impact of Condenser Fouling

16

Impact of Condenser Tube Failure


Condenser Tube Failure
pH
9 - 10
8,5 - 9
8 - 8.5
< 8.0

Abnormal Boiler Cycle Chemistry

Boiler Tube Failure

Plant Shutdown

Hydrogen /Air and Lube Oil Coolers


Hydrogen/Air Cooler
Horizontal coolers in modern
combined cycle plant
Vertical coolers in traditional
generator
Hydrogen for >600 MW (high heat
capacity & low density)
Must derate if air or H2 is too hot
Lube Oil Cooler
Modern lube oil system with
reservoir, pumps, filters, PFE
Older plants use shell & tube HX,
typically vertical
Must derate if lube oil is too hot
Throttle flow if lube oil too cold

Aux/Service Cooling Heat Exchangers

Open cooling water


generally on tube side

Relatively low
temperatures and heat
flux.

The intercooler between closed


system and open system

Either shell & tube or plate type


heat exchangers

Can be large if handle main HX


with closed system

Survey: Metallurgy
Copper alloys
- May prohibit or limit use of ammonia for
condensate corrosion control
- Especially for admiralty tubes

Titanium
- Extremely brittle with very thin walls
- Leaks common (especially during initial
commissioning and startup)
- ANY mechanical impingement can cause leaks

Stainless Steel
- Subject to chloride stress corrosion
- Must ensure cooling water chloride level
remains within limits
- Under-deposit corrosion, MIC issues

Ammonia
Grooving

Under Deposit
Corrosion / MIC

Pitting / MIC

Survey: Make-Up Water Chemistry

Make-up water quality


Source: river, sea water, brackish, deep well, recycle
Chemical Properties-Makeup Water
Calcium *
Magnesium *
Manganese
Ammonia
M-Alkalinity *
Silica
Aluminum
Fluoride
Chloride *
Sulfate *
O-phosphate
Copper
Conductivity *
Zinc
Iron
Turbidity

Value
50
18
0,02
0
100
15
0,1
0
35
19
0,1
0
300
0
0,1
2

Variability is important !

Units
ppm Ca as CaCO3
ppm Mg as CaCO3
ppm Mn
ppm NH3
ppm as CaCO3
ppm SiO2
ppm Al
ppm F
ppm Cl
ppm SO4
ppm PO4
ppm Cu
uS/cm
ppm Zinc as Zn
ppm as Fe
NTU

Potential Problems in Open Cooling Water

There are basically four interrelated problems in the


operation of a cooling water
system as depicted by the
Cooling Water Treatment
Triangle below.
Each problem affects and is
affected by the other
problems.

Pushing the Limits: Technical Risks


Silt Fouling

CaCO3 Scale

Steel Corrosion &


Iron Fouling

CaSO4 Scale

Silica Scale

Microbio Fouling

Ca3PO4 Scale

Copper Corrosion

24

Nalco Advanced Technology in Cooling Water


PSO Scale/
Corrosion
Inhibitor
Stabilized
Bromine

Non PO4
Corrosion
Inhibitor

Silica
Inhibitor

High
Stress
Polymer
(HSP)
High
Resistant
Azoles

25

What Do You Need?


Super Duper
Medicine?

Good Doctor
Good Doctor

Good Doctor?

This is not the


best time

to learn
about a
problem!

26

Is The Best
Water Doctor

Identify Potential Issues & Technical Risks

1. System Survey
2. MakeUp Analysis

Optimizer

Configure

Direct Connect
Cross Over Cable

ISP
Wireless
Modem
Dial Up

3D Web

Dial Up

Download
Excel

Vantage

PSR

Import

3D Data Log

Service Report

29

30

3DT Optimizer Simulation & Program Design

Vary Temperature

HX
Temperature
& Velocity

Make Up
Water
Chemistry

Vary Cycle

System
Design
Optimizer

Vary pH

Vary Treatment
Contaminants

System
Metallurgy

31

3DT
Simulation
& Program Design
3DTOptimizer
Optimizer
for Diagnostic

Technical Risks

Safe Operating Window

32

Nalco Advanced Technology in Cooling Water


PSO Scale/
Corrosion
Inhibitor
Stabilized
Bromine

Non PO4
Corrosion
Inhibitor

Silica
Inhibitor

High
Stress
Polymer
(HSP)
High
Resistant
Azoles

Total Operating Cost Simulation

Monitoring & Control: 3D TRASAR Controller

1. System Survey
2. MakeUp Analysis

Optimizer

Configure

Direct Connect
Cross Over Cable

ISP
Wireless
Modem
Dial Up

3D Web

Dial Up

Download
Excel

Vantage

PSR

Import

3D Data Log

Service Report

35

3D TRASAR Stress Management


for Cooling Water System

Automation control of
Corrosion inhibitor TRASAR
Scale inhibitor- Tagged Polymer
Biocide Bio reporter & ORP

On line measurement:

Conductivity
pH
ORP
Corrosion rate

Full communication capability


(digital/analog/ethernet/scada/
modem)

3D TRASAR Scale Control

Trasar & Tagged Polymer

37

Case History: 3DTRASAR Scale Control

Coal fired power plant in Nevada

Nalco 3D Trasar and silica inhibitor


technology allow the plant increase the
cycle from 4.5 to 7.0 (+250 ppm SiO2 in the
recirculating water)

Water saving 281,000,000 gallons/year


(+ 9,000 people consumption per year)

US$ 47,500/yr saving of water pumping &


chemical cost

Date

10/26/03

10/21/03

10/16/03

10/11/03

10/6/03

10/1/03

9/26/03

9/21/03

9/16/03

9/11/03

9/6/03

9/1/03

8/27/03

8/22/03

8/17/03

8/12/03

8/7/03

8/2/03

7/28/03

7/23/03

7/18/03

7/13/03

7/8/03

7/3/03

6/28/03

6/23/03

6/18/03

6/13/03

6/8/03

6/3/03

5/29/03

5/24/03

5/19/03

5/14/03

5/9/03

5/4/03

4/29/03

4/24/03

4/19/03

4/14/03

4/9/03

4/4/03

3/30/03

3/25/03

3/20/03

mpy

3D TRASAR Corrosion Control


Corrosion Rates

3.0

XLP-170/N-23263 Manual Control

2.5

N-23263 Trasar Control/ XLP-170 Slaved

2.0

N-73292 Tagged Control/ N-73284 Trasar Control

1.5

1.0

0.5

0.0

39

Case History: 3D TRASAR Corrosion Control


450 MW Coal Fired Plant operate as ZLD facitlity
CaSO4 and Ca3PO4 deposition Problem
Switch to Nalco 3D TRASAR with PSO program

3D TRASAR Bio Control

Bio Reporter & ORP

Waste Money

41

Case History: 3D TRASAR Bio Control

250 MW Combined Cycle

Need to reduce bleach consumption related to the


environment and copper corrosion

3D Trasar Bio Control technology saving 75% of


bleach consumption and keep the condenser
performance

Nalco 3D TRASAR + Nalco 360 Services:

1. System Survey
2. MakeUp Analysis

Optimizer

Configure

Direct Connect
Cross Over Cable

ISP
Wireless
Modem
Dial Up

3D Web

Dial Up

Download
Excel

Vantage

PSR

Import

3D Data Log

Service Report

3D TRASAR Reports the Data You Need


the Way You Need It, When You Need It

Nalco 360 TM
Nalco 360 Service provides
peace of mind that your water
system is being monitored by
a team of Nalco Experts, 24 hours
a day, 7 days a week.

Nalco 360 TM

Nalco 360
Expert Center

3D TRASAR
controller

Web
connection

Performance
reviews

Immediate alarm
response

Nalco Sales
Engineer

Automated Reporting

Nalco 3D TRASAR + Nalco 360TM


Monitoring & Controlling Your System 24/7

47

Case History: 3D TRASAR + 360 TM

520 MW Combined Cycle Power Plant

Cooling water operate at 3-3.5 cycles

Nalco with 3D Trasar + 360 TM that


monitoring for 24/7 successfully running
the system at cycle 5.

Challenge: Pushing the Limits


far can we stress our water system
increase the cycle, low etc - without too much
risk?

How

low a treatment level heavy metal,


phosphate, chlorine; etc - will perform?

How

Power Plant RCW: Pushing the Limit !


It

is possible and practical

Understanding of the system & its


variability
Identify the technical risks
Best chemical treatment program
Proper implementation
(automation;etc)
24/7 monitoring & control
Best

Technology

Best

Water Doctor !

Is The Best
Water Doctor

Nalco Will Not Only Help You on:


Improve

Efficiency

Enhance

Meet

Reliability

Environment, Health &


Safety Standard

But We Will Also Provide you ..

A Peace of Mind

You might also like