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Refer EPRI Technical report: 1004188, Cycle chemistry guidelines for fossil
plants- Phosphate Continuum and Caustic Treatment, Jan-2004.
Core Monitoring Parameters for All Units Operating
on Phosphate Treatments in AVT (R) feed water
(Drum units with a reducing agent and with mixed
metallurgy in feed water system)
Refer EPRI Technical report: 1004188, Cycle chemistry guidelines for fossil
plants- Phosphate Treatment, Jan-2004.
Potential - pH diagram for carbon
steel at 350C and 165 kg/cm2
Boiler water treatment by Tri sodium
phosphate in 200 / 500 MW boilers
Addition of TSP either by itself or in conjunction with
NaOH provide the pH necessary to minimise the
corrosion of carbon steel tubes.
TSP also provide the sufficient chemical buffering
capacity to cope with small system upset e.g. a small
condenser leaks.
Phosphate also has the ability to significantly curtail the
incidents of caustic embrittlement.
It is economical and easy to handle.
It requires a need to get tighter control.
Black, thin internal magnetite protective layer
Internal deposit layer showing cracks
helps in wick boiling phenomena
Porous internal deposit layer in
water wall tube
Non uniform thick internal deposit
layer in water wall tube
Whitish, thick, adherent internal
deposit in water wall tube
Factors influencing deposit in tubes
Number of startups / shutdown
Ingress of raw water from Condenser leakages
or seepages.
Change in Feed / makeup water quality
Crud formation due to corrosion at LP side and
transfer to the Boiler.
Boiler water chemistry deviations
Preservation of boilers during idle period
Boiler cycle metallurgy
Values of Thermal Conductivities
Material W/mC at Room temp.
Air 0.024
Carbon Steel 45
Boiler Scale 2.32
Cu-Ni 70:30 30
Cu-Ni 70:10 44
Copper 90
Titanium 16
Aluminium 0.04
Stainless steel 15
Steam 0.038
Red Brick 0.81-0.7
Water 0.55
Overheating of tube due to internal
oxide/deposition
Increase in metal temperature due
to internal scale
T T
E H
M I
P C
E K
R N
A E
T S
U S
R
E
H + Fe3C = Fe + CH4
Cementite (Methane gas)
Remedial Measures
Periodic Post operational acid cleaning of
boilers to remove the existing internal
oxide layer and formation of protective
magnetite layer.
Control the ingress of impurities i.e.
cooling water through condenser, which
will reduce the phenomena of salt
concentration by wick boiling.
Recommendations
To control such failures, attempts have been
made in NTPC and worldwide to use condensate
polishing units (CPU)
Maintain the boiler water chemistry parameters
suggested by manufacturers to reduce the internal
corrosion.
Control of cooling water ingress from condenser.
Follow the guidelines of Boiler preservation
during shutdown.
Periodic chemical cleaning of water wall in
boilers.
DM water washing of super heater tubes.
maintain the parameters during startups and
shutdown of boiler.
THANK YOU
VERY MUCH