Waterside corrosion

Following the guidelines for water treatment doesnt guarantee that corrosion wont occur. The danger of problems arising increases when a plant is operated outside the prescribed parameters which is often the case during startup and shutdown. It is therefore very important that all parameters are brought within their normal operational ranges as quickly as possible. Problems can also occur during continuous operation, however. Common causes include: contamination of the return condensate creeping condenser leakage malfunctioning deaerator penetration and decomposition of organic materials.

Failure analyses
When damage occurs, it is crucial to establish the cause. With thirty years experience in the field, KEMA has seen almost every type of damage that can possibly occur. So, when called upon to provide assistance, we can assemble a team of specialists to help investigate the background to any incident and, if necessary, get them on site immediately. At KEMA, the emphasis is always on making sure the right conclusions are drawn and on formulating recommendations that will actually prevent recurrence. Because KEMA uses multidisciplinary teams of chemists, materials specialists and corrosion experts, you can be sure that an incident will be considered from all angles and that our advice will be of real practical value.

Total organic carbon (TOC) in process water

Organic components present in an installations water-steam system are liable to break down, leading to the formation of organic acids and thus to corrosion. So, to prevent damage, it is vital to keep the total organic carbon (TOC) concentration in the process water within the limits specified by KEMA. In recent years, the need to avoid turbine failure has increased interest in the measurement of TOC in process water enormously. TOC testing is consequently becoming more and more common in the water-steam circuits of power stations everywhere. KEMA has the expertise to determine the most suitable techniques for TOC reduction in a given situation. It is best to start by gathering data on the various organic components that contribute to the TOC level observed, such as humic acids, fulvine acids, polysaccharides, and organic acids. KEMA has both the know-how and the resources to undertake such work. Tests are carried out using a TOC meter, which measures total carbon (TC) and inorganic carbon (IC) levels; the TOC concentration is then determined by subtracting one from the other.

Fireside corrosion
Corrosion is also possible on the furnace-side of an installation. In the past, when fuel quality was more variable, undesirable flue gas fluctuations were a common cause of corrosion. To address these problems, fuel additives were sometimes used. Nowadays, while primary fuel quality is more consistent, the co-firing of materials such as carpet fragments and poultry litter means that potential side effects such as increased corrosion need to be looked at carefully. KEMA has accordingly developed KEMCOP, a special corrosion probe. Using this ingenious tool, the corrosion situation can be assessed and the side effects of co-firing determined without shutting down your installation.