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HAZZARD
O.R.USRETE,
M.Sc.(che.),b.a.(eNg.LIT.),B.ED.
SR.CHE.MAHAJECO,KTPS,KORA
DI,
NAGPUR,MAHARASTRA,INDIA.
MOB: +91-9423628363
ACTIVITIES OF CHEMISTRY
C H E M IS T R Y
C O A L & O IL
M A IN P L A N T
C H E M IS T R Y
P U R C H A S E ,S T O R E
E N V IR O N M E N T S P E C IA L L A B ,
L W T P O P E R A T IO N
USE OF WATER
AS COOLING WATER FOR CONDENSER (RAW WATER)
AS COOLING WATER UNIT AUXILIARIES (CLF WATER)
DM WATER AS MAKE UP WATER
DRINKING WATER (FILTERED CLARIFIED WATER)
LP/HP WATER
DISSOLVED SOLIDS
CALCIUM SALTS
MAGNESIUM SALT
SODIUM SALTS
IRON,
MANGANESE,
FLUORIDE SALTS
GASES
CHEMICALS
USE
ACTIVATED
CARBON
ALUM, FeCl3
COAGULANT
LIME
pH ADJUSTMENT, SOFTENING
HYDRAZINE
AMMONIA
pH ADJUSTMENT
TSP
HCl ACID
NaOH
RAW WATER
INLET
Chemical Feeding
CLARIFIER
No.1
CLARIFIER
No.2
CLARIFIER
No.3
Chemical
Feeding
Gravity Filters
CLARIFIED
WATER
STORAGE
TANKS
STAGE 1
To DM Plants
CLARIFIED
WATER
STORAGE
TANKS
SATGE 2
PRE-TREATMENT PLANT
pH
TURBI
DITY/ K
DRINKING
WATER
6.5-7.5
< 10NTU
CLARIFIED
WATER
6.5-7.5
< 20 NTU
FILTERD WATER
6.5-7.5
< 5 NTU
DEMINERALISED
WATER
6.5-7.0
K= 0.2-0.1
SILICA
20-10 PPB
DEMINERALIZATION
S.CATION
ACF
TO DM TAN
W.ANION S.ANION
W.CATION
DEGESSER
MIXED BED
FUNCTION OF VESSELS
ACF- Removes turbidity & Residual Chlorine
CATION Removes cationic part e.g. Na+ ,Ca++
DEGASER - Removes CO2
ANION Removes Anionic Part e.g. Cl-, SO4MIXED BED Removes slip over cationic &
anionic part
Note:- From ACF outlet to DM Water Storage Tank is
MSRL. D.M. Storage tank is Araldite / Epoxy coated.
PARAMETERS OF WATERS
Parameters
pH
Silica
ACF
6.5
7.5
--
<2.0
NTU
Nil
--
Anion
6.5
8.0
<10
Nil
Nil
<200
ppb
Mixed Bed
6.5-7.0 <0.2
Nil
Nil
< 20
ppb
CHEMICAL CONTROL OF
STEAM WATER CYCLE
AMMONIA DOSING
1. By dosing ammonia solution (Alkaline) pH of steam
water circuit is maintained around 9.0 pH , so that
corrosion is minimum .
2. During acid cleaning alkali boil out ( precommissioning ) of water circuit ( upto drum) ; a
protective magnetite layer is formed which protects the
parent metal from further attack . This magnetite layer is
only stable at pH 8.0 10.0. Hence, we have to
maintain pH 9.0.
Ammonia is dosed to maintain steam water circuit pH 9.0
HYDRAZINE DOSING
Dissolved Oxygen (D.O) is very detrimental to
steam water circuit.
-D.O also causes electrolytic corrosion by facilitating
electrolytic action between dissimilar metals.
Hence, D.O is to be removed completely before the
water is allowed to boiler circuit. Hydrazine is added
to remove D.O
N2H4 + O2 2H2O + N2
Some excess hydrazine (called as Residual Hydrazine) is
maintained at feed sample (ECO Inlet) 10-20ppb.
This excess hydrazine is converted to ammonia at boiler
drum pressure and temperature. 3N2H4 4NH3 + N2
PHOSPHATE DOSING
HP DOSING SYSTEM : TRI SODIUM PHOSPHATE /
DISODIUM PHOSPHATE /
Na3PO4 + H2O <=> NaOH +Na2HPO4
Na2HPO4 + H2O <=> NaOH +NaH2PO4
SLUDGE REMOVAL
PHOSPHATE HIDEOUT
Solubility of phosphate increases with temperature
but after 1200C to 2200C, this solubility decreases
and after 2200C solubility decrease is very rapid. So
at boiler drum temp 3500C, the solubility of
phosphate becomes very low. It hides out in the form
of a complex salt and leaves free NaOH. This hidden
out phosphate is not alkaline rather slight acidic. So
when this hidden out phosphate comes, pH of boiler
water goes down and PO4 concentration goes up.
Which is very much detrimental to boiler water circuit.
SILICA:
As long as silica is in the boiler water, it
creates no problem (of course very high silica
concentration in boiler water will lead to tube
scaling). However, when it goes along with
steam, it is deposited at the low-pressure area
of turbine (HP/LP/IP), which will create
vibration problem Pressure restriction inside
the turbine.
8.2
3.8
1.9
0.9
0.7
0.52
0.48
150
155
160
165
170
175
180
0.4
0.37
0.30
0.27 (200MW)
0.25
0.22
0.18(500MW)
CHLORIDE
Monitoring of chloride is necessary because chloride
contributes to the following:
- Corrosion fatigue, stress corrosion cracking, and pitting
in LP turbines,
- Corrosion, hydrogen damage, and pitting in boilers, and
- The synergistic effect on corrosion in the presence of
oxygen and copper oxide, i.e. the total effect of all three
is greater than would be expected by simply adding the
effects together.
SODIUM
SODIUM IS MONITORED BECAUSE:
- Sodium is present in the steam in corrosive forms of NaCl and
NaOH and are two major corrodents of the turbine,
- Can lead to stress corrosion cracking of turbine blades and
stainless steel superheater tubes, and
- Sodium hydroxide has in the past caused gouging-type failures
of boiler tubes.
b)AVT ( R )
OXYGENATED TREATMENT
Measurement Locations
Usage
Frequency
Cation Conductivity
CP Discharge
On-line
Cation Conductivity
Cation Conductivity
On-line
Cation Conductivity
Blowdown or Downcomer
On-line
pH (Drum Boilers)
Blowdown or Downcomer
On-line
Dissolved Oxygen
On-line
Sodium
CP Discharge
On-line
Sodium
On-line
COND
FEED
BOILER
STEAM
COND
FEED
BOILER
STEAM
pH
8.8-9.0
8.8-9.0
9.2-9.4
8.8-9.0
9.0-9.2
9.0-9.2
9.1-9.4
9.0-9.2
KH us/cm
,0.3
<0.3
<0.3
<0.2
<0.2
N2H4 ppm
NH3 ppm
0.01-0.02
0.5
<0.02
<0.02
Fe ppm
0.01
Cu ppm
0.005
Na ppb
1.0(Max)
1-2
<0.02
<0.01
<0.01
0.01
0.01
0.01
0.01
0.01
0.005
0.005
0.005
0.005
0.005
Cl ppb
TDS
(mg/l)
1.0 (Max)
2-4
Silica ppm
D.O. ppb
0.01-0.02
0.5
PO4 ppm
0.3
1000
40
<0.2
0.1
<0.01
500
40
15
5
10
S,H.
PO4,SiO2,K
HP/IP
DRUM
L.P.
Turbine
SiO2,K,NH3
R.H.
PO4
K,KH,N2H4,SiO2,D.O.
Condensor
K,KH,SiO2,NH3
D.A.
CEP
BFP
H.P.H.
DEPOSITS
L.P.H.
N2H4
CPU
NH3
CORROSION
NH3,K,KH,SiO2,N
IMPURITY INGRESS
PRIMARY WATER
CONDENSOR LEAKAGE
O.R.USRETE,
M.Sc.(che.),b.a.(eNg.LIT.),B.ED.
SR.CHE.MAHAJECO,KTPS,KORA
DI,
NAGPUR,MAHARASTRA,INDIA.
MOB: +91-9423628363
CONDENSOR LEAKAGE
DETECTION ,ITS EFFECT ON
UNIT OPERATION & CPU
SOURCES OF CONTAMINATION
1. CONTAMINATION FROM WATER TREATMENT
PLANT
2. USE OF IMPURE WATER FOR DOSING SYSTEM
3. USE OF IMPURE DOSING CHEMICALS
4. PRESENCE OF PLASTIC POLYMERS or,
HALOGENETED SOLVENTS
5. RESIDUES FROM CHEMICAL CLEANING
OPERATION
6. CONDENSOR TUBE LEAKAGE / SWEATING.
DETECTION OF CONDENSOR
LEAKAGE
IF LEAKGE IS MINOR
1. ON-LINE SODIUM ANALYSER
2. AFTER CATION CONDUCTIVITY
3. TOTAL HARDNESS OF CONDENSATE
SAMPLE
4. HIGH BOILER SILICA & CONDENSATE
SILCA
5. SILICA WILL BE IN INCREASING TREND
FROM CONDENSATE LPHS-FEED.
IF LEAKAGE IS MORE
1. CONDUCTIVITY OF CONDENSATE /
FEED WILL BE VERY HIGH BUT pH
WILL BE LOW.
2) DO OF CONDENSER WILL BE VERY
HIGH
3) HOT WELL MAKE WILL BE LOW AS
WELL AS LEVEL WILL BE HIGH
4) DEAERATOR LEVEL WILL GO HIGH
5) BOILER WATER WILL pH BE LOW
BUT CONDUCTIVITY IS HIGH.
2)
CPU DESCRIPTION
KORBA 500MW CPU HAVING PROVISION TO
UTILIZE 100% FOR CONDENSATE
TREATMENT
AUTO BYPASS ALLOW BYPASSING OF CPU AT
SET PRESSURE
THE RATIO OF CATION TO ANION IS 1.5 : 1.0
CONCEP PROCESS FOR RESIN SEPERATION
From CEP
B
Y
P
A
S
S
SG
SG
CPU-A
CPU-B
To deareator
From CEP
CPU
SERVICE
FT
bypass
valve
DPT
SG
Service Vessel
CE
To dereator
RT
ARU
CRU
Alkali Met.
Heater
Drain
REGERATION SYSTEM
Drain
Booster pump
Acid
Met.
From DMW Tank
NOs OF VESSELS
02
SIZE OF VESSEL
2850 MM(dia) x 2185 MM
DESIGN FLOW/VESSEL 675 M3/HR
B) RESIN DETAILS
CATION ANION
TYPE OF RESINS
IR-252 IRA-900
QUANTITY
4.25 M3 2.8 M3
DEPTH
0.72 mts 0.475 mts
REGENERANT
408 kgs 358.4 kgs
REGEN.CONCENTRATION 4%
4%
TEMP.LIMIT
120 oC 60 oC
PROCESS
A) SERVICE
SERVICE MODE INITIATED FROM LOCAL CONTROL PANEL
IN SEMIAUTO MODE
THE EXHAUTION OF BED IS INDICATED BY HIGH
COND. ALARM
B)REGENERATION
THE EXHAUSTED RESIN IS TRANSFERRED HYDRAULICALLY
TO REGENERATION SYSTEM
REGENERATION INVOLVE 49 STEPS FOR CLEANING,
SEPARATION AND RGENERATION
THE SEPERATION UTILIZES CONCEP PROCESS-TO ENSURE COMPLETE SEPERATION
-INCLUSION OF RIU DURING TRANSFER OF RESIN
PERFORMANCE OF CPU
BOILER 0.4
SiO2
0.3
PPM
0.2
0.1
0
0
8 10 12 14 16 18 20
RUN TIME
Cl , PPB
600
400
200
0
4
12
16
17
18
19
20
21
22