Introduction to Advances in Power Plant Chemistry

Objectives and other details of modules

Duration 90 minutes
Training aids
Power point Presentations
Objective
Attheendofthesessionparticipantswillbeableto:
Describe advances made in boilers - design & size and chemical
control limits with reference to different types / sizes of boilers for:

Feed water

Steam water cycle

Superheated steam cycle

Condensates
List out online and offline instruments in SWAS and purpose of
these instruments
Use online and offline instruments for measuring parameters
related to water chemistry

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 Advances in Boiler design and
its implication for water chemistry

Double Drum Boiler early 60s 50-100MW

Single Drum with mud and clean compartment
Russian design/Skoda-50, 100, 200 MW

Single Drum Boiler- BHEL based on CE
design/Alstom/Ansaldo - 210, 250, 500 MW, 600MW
(Chinese)

Drum less subcritical Boiler- Stain France - 500MW

Supercritical Boiler- BHEL based on Alstom design-
660, 800 MW, MHI, Ansaldo, Toshiba, Babcock 660
MW

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Chemical Control Limits
in
Different Design Boiler
For
Steam-water Cycle
CHEMICAL CONTROL LIMITS FOR FEED WATER
OF 60,100 & 200 MW

SN Parameter 60 MW 100MW 200 MW

1 pH at 25oC 8.8-9.0 8.8-9.0 8.8-9.0

2 Cation Conductivity, S/cm 0.3 0.3 0.2

3 Dissolved O2, g/l, max 7 7 5
4 Silica, g/l, max 20 20 20
5 Residual N2H4, g/l 20-30 20-40 10-20
6 Total Fe, g/l, max 10 10 10
7 Total Cu, g/l, max 5 5 5
 CHEMICAL CONTROL LIMITS FOR FEED
WATER OF 500 MW AND ABOVE

SN Parameter 500 MW
1 pH at 25oC 9.0 9.2
2 Cation Conductivity, S/cm 0.2
3 Dissolved O2, g/l, max 5
4 Silica, g/l, max 10
5 Residual N2H4, g/l 10 20
6 Total Fe, g/l, max 10
7 Total Cu, g/l, max 3

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CHEMICAL CONTROL LIMITS OF STEAM-WATER
CYCLE OF 60,100 & 200 MW

SN Parameter 60 MW 100MW 200 MW

1 pH at 25oC 9.2 9.7 9.2 9.5 9.2 9.5

2 Sp. Conductivity, S/cm, at 30 50 30

25oC, max
3 Silica, mg/l, max 2.5 1.5 0.4
4 Phosphate, mg/l 26 26 2-4
5 Chloride, mg/l, max 1.6 1.0 1.0

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CHEMICAL CONTROL LIMITS OF STEAM-WATER
CYCLE OF 500 MW & ABOVE

SN Parameter 500 MW
1 pH at 25oC 9.1 9.4
2 Sp. Conductivity, S/cm, at 25oC, max 20
3 Silica, mg/l, max 0.1
4 Phosphate, mg/l 12
5 Chloride, mg/l, max 0.5

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CHEMICAL CONTROL LIMITS OF SUPERHEATED
STEAM CYCLE OF 60,100 & 200 MW

SN Parameter 60 MW 100MW 200 MW

1 pH at 25oC 8.8 9.0 8.8 9.0 8.8 9.0

2 Cation Conductivity, 0.35 0.3 0.2

S/cm, at 25oC, max
3 Silica, g/l, max 20 20 20
4 Sodium, g/l, max 10 5 5
5 Ammonia, mg/l, max 0.5 0.5 0.5
6 Iron, g/l, max 10 10 10
7 Copper, g/l, max 58.8 5 5

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CHEMICAL CONTROL LIMITS OF SUPERHEATED
STEAM CYCLE OF 500 MW & ABOVE

SN Parameter 500 MW
1 pH at 25oC 9.0 9.2
2 Cation Conductivity, S/cm, at 25oC, max 0.2
3 Silica, g/l, max 10
4 Sodium, g/l, max 5
5 Ammonia, mg/l, max 1.0
6 Iron, g/l, max 10
7 Copper, g/l, max 3

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CHEMICAL CONTROL LIMITS OF CONDENSATE OF
60,100 & 200 MW

SN Parameter 60 MW 100MW 200 MW

1 pH at 25oC 8.8 9.0 8.8 9.0 8.8 9.0

2 Cation Conductivity, 0.35 0.3 0.3

S/cm, at 25oC, max
3 Silica, g/l, max 20 20 20
4 Dissolved O2, g/l, max 50 40 40
5 Ammonia, mg/l, max 0.5 0.5 0.5
6 Total Iron, g/l, max 10 10 10
7 Total Copper, g/l, max 5 5 5

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CHEMICAL CONTROL LIMITS OF CONDENSATE OF
500 MW & ABOVE

SN Parameter 500 MW
1 pH at 25oC 9.0 9.2
2 Cation Conductivity, S/cm, at 25oC, max 0.2
3 Silica, g/l, max 10
4 Dissolved O2, g/l, max 40
5 Ammonia, mg/l, max 1.0
6 Total Iron, g/l, max 10
7 Total Copper, g/l, max 3
8 Sodium, g/l, max 5

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CHEMICAL CONTROL LIMITS OF STEAM-WATER CYCLE
FOR POWER PLANT UNITS TREATED CONDENSATE
CPU In/Out)

S.N. PARAMETER 2x500MW 3x500MW 3x500MW

1. Type of CPU provided Deep MB Deep MB Deep MB
(Ammonex) (Consep) (Seprex)
IN/OUT IN/OUT IN/OUT
2. pH at 25oC, max -- 9.2/-- 9.2/--
3. Ammonia, g/l, max -- 500/-- 500/--
4. --/0.1 --/0.1 --/0.1
Cation Conductivity, S/cm, at
5. 25oC, max 20/5 20/5 20/5
6. Silica, g/l 10/1 10/2 10/2
7. Sodium, g/l 10/1 10/2 10/2
8.
Chloride, g/l 50/5 50/5 50/5
9.
Iron, g/l 5/2 5/2 5/2
10.
Copper, g/l 100/25 100/25 100/25
11.
50/10 50.5/ 50/5
TDS, g/l

Crud, g/l
13
CHEMICAL CONTROL LIMITS OF STEAM-WATER CYCLE FOR
COAL/GAS BASED UNITS (100 & 200 MW) PRIMARY STATOR
WATER

SN Parameter 60 MW 100MW 200 MW

1 pH at 25oC 6.8 7.0

2 Sp. Conductivity, S/cm, at Stator is Stator is 1.0

250C, max cooled cooled by
3 Dissolved O2, mg/l, max by H2 H2 1.0 4.5
4 Copper, g/l, max -
5 Iron, g/l, max -

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 COAL BASED UNITS (500 MW AND ABOVE)
PRIMARY STATOR WATER

SN Parameter 500 MW
1 pH at 25oC 8.5 9.0
2 Sp. Conductivity, S/cm, at 250C, max 2.2
3 Dissolved O2, g/l, max 10
4 Copper, g/l, max 20
5 Iron, g/l, max 20

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CHEMICAL CONTROL LIMITS OF STEAM-WATER CYCLE
FOR GAS/NAPHTHA BASED UNITS FEED WATER

SN Parameter 88MW 111.19M 106MW 144.3MW

(GT)+ W(GT) (GT) (GT)
149MW 109.3M 116.1MW 225MW
(ST) W(ST) (ST) (ST)

1 pH at 25oC 9.2 9.7 8.5 9.5 9.0 9.5 8.5 -9.5

2 Cation Conductivity, 0.2 0.2 0.2 0.2
S/cm
3 Dissolved O2, g/l, max 7 7 10 7
4 Silica, g/l, max 20 20 20 20
5 Residual N2H4, g/l, - 10 - 10
max
6 Total Fe, g/l, max 20 20 20 30
7 Total Cu, g/l, max 3 3 5 20

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CHEMICAL CONTROL LIMITS OF STEAM-WATER CYCLE
FOR GAS/NAPHTHA BASED UNITS BOILER WATER (HP
DRUM)

SN Parameter 88MW 111.19M 106MW 131

(GT)+ W(GT) (GT) MW(GT)
149MW 109.3MW 116.1MW 225MW
(ST) (ST) (ST) (ST)

1 pH at 25oC 9.8 10.2 9.2 10.3 9.5 10.5 9.0 9.8

2 Sp. Conductivity, S/cm, 50 100 150 150
at 25oC, max
3 Silica, mg/l, max 4.0 2.0 2.0 2.0
4 Phosphate, mg/l, max 6 3 10 1 10 2-6
5 TDS, mg/l, max 100 100 100 100
6 Chloride, mg/l, max 10 10 10 10
7 Total Iron, mg/l, max 0.5 0.5 0.5 0.5
8 Total Copper, mg/l, max 0.1 0.1 0.1 0.1

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GAS/NAPHTHA BASED UNITS BOILER WATER
(LP DRUM)

SN Parameter 88MW 111.19M 106MW 131

(GT)+ W(GT) (GT) MW(GT)
149MW 109.3MW 116.1MW 225MW
(ST) (ST) (ST) (ST)

1 pH at 25oC 9.8 10.2 9.2 10.3 9.5 10.5 9.0 10.5

2 Sp. Conductivity, S/cm, 50 100 150 150
at 25oC, max
3 Silica, mg/l, max 4.0 2.0 5.0 2.0
4 Phosphate, mg/l, max 6 3 10 10 20 15
5 TDS, mg/l, max 100 100 100 100
6 Chloride, mg/l, max 10 10 10 10

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CHEMICAL CONTROL LIMITS OF STEAM-WATER CYCLE FOR
GAS/NAPHTHA BASED UNITS MAIN STEAM

SN Parameter 3x88MW 4x111.19 4x106 3x144.3

(GT)+ MW(GT) MW (GT) MW(GT)
1x149 +2x109.3 +2x116.1 +1x225
MW (ST) MW(ST) MW (ST) MW (ST)

1 pH at 25oC 9.2 9.7 8.5 9.5 8.8 9.2 8.8 9.2

2 Cation Conductivity, 0.2 0.2 0.2 0.2
S/cm, at 25oC, max
3 Silica, g/l, max 20 20 20 20
4 Sodium, g/l 10 - 10 10
5 Ammonia, mg/l, max - - - -
6 Iron, g/l, max 20 - - 20
7 Copper, g/l, max 3 - - 20
8 Chloride, g/l, max - - - 3

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GAS/NAPHTHA BASED UNITS CONDENSATE

SN Parameter 3x88MW 4x111.19 4x106 3x144.3

(GT)+ MW(GT) MW (GT) MW(GT)
1x149 +2x109.3 +2x116.1 +1x225
MW (ST) MW(ST) MW (ST) MW (ST)

1 pH at 25oC 9.2 9.7 8.5 9.2 8.8 9.2 8.5 9.5

2 Cation Conductivity, 0.2 0.2 0.2 0.2
S/cm, at 25oC, max
3 Silica, g/l, max 20 20 20 20
4 Dissolved O2, g/l, max 100 20 20 25
 SWAS

Online Instruments in SWAS

Silica Analyzer

Phosphate Analyzer

pH meter

Conductivity meter

ACC Conductivity meter

Hydrazine Analyzer

Ammonia Analyzer

Dissolved Oxygen Analyzer 21
 SWAS

OFF Line Instruments in SWAS

pH meter

Conductivity meter

Turbidity meter

Double

Double bean spectrophoto meter to analyze:

Silica

Ammonia

Hydrazine

Phosphate

Iron

Copper
22