TODAYS TOPIC

COOLING WATER TREATEMENT

CONDENSER LEAK DETECTION
CHLORINATION PLANT
AND
EFFLUENT TREATMENT
BOILER
TURBINE
GENERATOR



CONDENSER
COOLING
WATER
INLET
COOLING
WATER
OUTLET
BOILER FEED PUMP
BASIC THERMAL CYCLE
TYPES OF COOLING SYSTEMS:
1) ONCE THROUGH
2) CLOSED LOOP
3) OPEN RECIRCULATION
OPEN RECIRCULATION
Secondary functions are: -
1. It cools Turbine tube oil in tube
oil cooler.
2. It cools Generator Seal oil Seal
oil cooler.
3. It cools Auxiliary cooling water.
4. It is the source of water to Ash
disposal system.
5. It is the source of water for Fire
system.
Q=UA(T
2
-T
1
)
U=HEAT RATE
A=CONTACT AREA
OF CONDENSER
T2-T1= DIFFERENCE
OF TEMPERATURE
U=2625 Kcal/hr/M
2
/
O
C
A=14376 M
2
T
2
-T
1
=8.5
O
C
Q=320.76 X 10
6
FACTORS AFFECTING
CIRCULATING WATER SYSTEM:
1) CORROSION
2) SCALING
3) MICROBIOLOGICAL
4) FOULING

S
O
L
U
B
I
L
I
T
Y
TEMPERATURE
CaCO
3
CaSO
4
CYCLE OF CONCENTRATION (COC) 1.0 IS IDEAL
COC 1.0
COC 1.1
COC 1.2
COC 2.0
TYPES OF COOLING TOWERS:
1) NATURAL DRAFT
2) FORCED DRAFT
3) INDUCED DRAFT
THE EFFECT OF EVAPORATION


X
Evaporation
Y
X
Make up
M = E + B
M Makeup
E Evaporation
B Blow down
Blow Down
MAKE UP = (X- EVAP.N) + (Y- BLOW DOWN)
BRI EF I NTRODUCTI ON

TS-II CONSISTS OF 7 UNITS OF 210 MW EACH


STEAM EXHAUSTED FROM THE TURBINE IS COOLED
BACK TO WATER IN THE CONDENSER

THE COOLING WATER THAT IS USED TO CONDENSE
THE STEAM IN THE CONDENSER IS HEATED UP AND IS
COOLED DURING EVAPORATION IN THE COOLING
TOWER AND IS RECIRCULATED

EACH UNIT HAS ONE COOLING TOWER

TOTAL EVAPORATION LOSS IS 3300 M3/HR FOR
SEVEN UNITS (PER UNIT 470 M/HR)

AFTER EVAPORATION WATER GETS
CONCENTRATED WITH RESPECT TO SALTS
THEREFORE A PORTION OF WATER IS REMOVED TO
BALANCE THE SYSTEM WHICH IS CALLED
BLOWDOWN

BLOW DOWN IS MADE @ 6000 M3/HR FOR SEVEN
UNITS

MAKE UP FOR EVAPORATION LOSS AND BLOW
DOWN LOSS IS ESSENTIAL


THE MAKE UP WATER IS DRAWN FROM TS-II LAKE,
WHICH IS FED FROM MINES-II BORE WELLS

YEAR

CALCIUM HARDNESS (MAKE UP WATER) PPM
YEAR LOW

DATE

YEAR HIGH

DATE

1990

89

14-11-1990

125

29-10-1990

1991

58

23-08-1991

137

31-07-1991

1992

108

12-02-1992

152

28-09-1992

1993

110

10-06-1993

154

03-12-1993

1994

144

04-01-1994

164

05-03-1994

1995

130

05-07-1995

180

17-02-1995

1996

104

30-12-1996

182

30-08-1996

1997

102

01-01-1997

168

15-03-1997

1998

122

17-03-1998

184

21-12-1998

1999

132

17-08-1999

198

14-10-1999

2000

164

10-11-2000

202

18-10-2000

2001

162

12-02-2001

206

29-05-2001

2002

184

26-04-2002

218

26-08-2002

2003

190

22-04-2003

226

17-07-2003



Calcium Hardness in ppm
0
50
100
150
200
250
1991 1993 1995 1997 1999 2001 2003
Year
p
p
m
YEAR HIGH
MINES-II BORE WELL
WATER
ANALYSIS
B
W
No

pH

Cond


TDS
ppm

M
Alk
ppm

T H
ppm

Ca H
ppm

Cl
H
pp
m


1

6.64

782

508

180

240

140

95

2

7.07

685

445

176

214

126

77

3

6.77

796

517

180

242

138

99

4

6.92

1177

765

156

358

206

154

5

7.13

1274

828

228

384

226

170

6

7.56

1284

835

256

400

234

179

7

6.73

1128

733

230

360

210

143

8

6.74

1030

669

230

310

182

136

9

7.38

992

645

212

314

186

123

10

7.31

747

485

178

220

132

88

11

6.74

665

432

180

188

110

78

12

7.01

659

428

180

182

108

75

13

7.48

1509

981

304

460

276

212

14

6.63

1416

920

288

448

266

182

15

6.90

1268

824

370

428

246

126

16

6.79

1229

799

386

408

232

116

17

7.33

1237

804

378

414

246

120

18

7.15

1192

775

354

428

244

118

19

6.66

1281

832

326

438

258

136

20

6.54

1296

842

236

478

290

116

21

6.86

1317

856

244

486

300

119

22

7.14

925

601

136

300

188

97

23

7.36

903

587

164

284

170

97

24

6.35

1044

679

190

338

200

119

25

7.25

1160

754

280

386

224

137

26

7.01

776

504

214

244

144

92

27

6.57

997

648

310

324

194

98

28

7.52

1100

715

336

366

212

110

29

7.50

1240

806

382

408

244

128

30

7.58

1302

846

380

432

254

141

31

6.99

831

540

196

252

144

108

32

6.76
932

606

196

290

166

117

33

7.50
1000

650

220

308

160

116

34

7.09

1067

693

290

360

212

115

35

6.98

1033

671

204

330

196

126

36

7.87

1166

758

310

330

196

124



FOOT NOTE :


BORE WELLS LESS THAN 200 PPM Ca: 17 No


BORE WELLS MORE THAN 200 PPM Ca: 19 No

DURING INITIAL PERIOD MINES MAKE UP WATER
COULD NOT MEET THE BLOW DOWN FOR THE 1.2 COC

THEREFORE INCREASED TO 1.6 COC

1989 WHEN THE CONDENSER WAS OPENED SCALING
WAS OBSERVED

ORGANOPHOSPHONATE TREATMENT WAS
INTRODUCED IN DECEMBER 1990 WITH A COC 2.0

AS OF NOW THE Ca LEVEL INCREASES TO 226 PPM
AND CYCLE OF CONCENTRATION IS RESTICTED TO 1.33

Cl
Ca
Return water
Cl
Ca
WITH OP TREATMENT
Make up water
No scale tube
Ca scale tube
WITHOUT OP TREATMENT
Without OP treatment
+
Concentration
Temperature
Ca Ca
With OP treatment
Ca
+
Ca
Concentration
Temperature
Ca
OP
Ca
Limitations for OP
pH 9.1 Calcium 300 ppm
What is pH
0.0
7.0
14.0
Acidic Neutral Basic
Citric Distilled water Milk of Magnesia
<
>
OP
OP
OP
OP
OP
OP
Ca Ca
H

H C H


O O

OH P C P OH

OH OH OH

HYDROXY ETHYLYDENE
DIPHOSPHONIC ACID ( HEDP)

PHOSPHONOBUTANE TRICARBOXYLIC ACID (PBTC)


OH


H H OH P O H


H C C C C H


C O H C O C O

OH OH OH

POLYMERS SUCH AS MALEIC ACID


H COOH


C


C


H COOH

H COOCH3


C




C


H H
METHYL ACRYLATE
MICROBIOLOGICAL PROBLEMS:
*THEY ENTER THROUGH MAKE UP WATER
*TEMPERATURE
*NUTRIENTS
*LOCATION
*ATMOSPHERE
FOULING:
*DUE TO SUSPENDED SOLIDS
*DUE TO MICROBIOLOGICAL SLIMES
*CORROSION PRODUCTS
CONDENSER LEAK DETECTION
1) CANDLE METHOD
2) BLOTTING PAPER
3) FILLING THE CONDENSER
WITH DM WATER
Crux of the Problem
The High Calcium in Make up Water affects the
System in two ways

1. The Present Chemical (Organophosphonate) treatment
has an inherent limitation /constraint that it is totally
ineffective when Calcium level goes beyond 300 ppm in
return water with the prevailing pH. Therefore, it
necessitates Higher Blow Down than the normal out flow.

2. This Higher Blow Down upsets water balance in the TS-II
Lake resulting in dangerous Low Level.

Points To Ponder
Is it feasible to Pre-Treat High Calcium
Make up water before reaching TS-II Lake ??





Solution to the Problem
YES Pre-Treating such voluminous make up
Water is to be explored in the order of 5000
M3/Hr along with the consequential effluent
sludge



PRETREATMENT OF STROM WATER
FROM MINES-II
Ca LEVEL WITH 220 PPM
DM PLANT
S-I& II & EXP.N
Ca LEVEL 80 PPM
TS-II FORE BAY
Ca LEVEL80 PPM

FOR TS-II
EXPANSION
NEEDS
Ca LEVEL80 PPM
CONCEPT OF PREATMENT OF STORM WATER FROM MINES-II
PRETREATMENT PLANT
* CTO NLC awarded consultancy to IIT Chennai for suitable
pretreatment of 4000 M3/Hr.

In TS-II Chemical department has asked to study the proposal
of IIT Chennai.

TS-II Chemical department thoroughly studied and following
opinions were sent to CTO for further decision.

IIT Chennai submitted report on Lime Soda process for
pretreatment.

It involves investment of Rs11.0 Crores for 2500 M3/Hr and
O&M cost comes to Rs 19.0 Crores per year (Chemical cost 16.0
Crores and recurring cost 3.0 Crores.



Operating cost.

Labor intensive.

Storage and ware housing cost.

Disposal of sludge 48.0 Tones/day/stream is a
major problem, needs compliance to TNPCB
norms
POINTS TO PONDER

CAN WE EXPLORE EFFECTIVE CHEMICAL

FORMULATION TO GO BEYOND 300 PPM

CALCIUM??
A TRIAL STUDY IS PROPOSED FOR DOZING A NEW

FORMULATION (POLYMER BASED WITH PBTC) TO

HOLD 400 PPM CALCIUM

E Excerpts of 400 Ca ppm Scale inhibitor for circulating
water treatment:

With a view to increase the Cycle of Concentration
of circulating water treatment a chemical suitable for with
standing 400 ppm of Calcium from the present 300 ppm
Calcium is thought of, therefore, precious water can be
conserved.

As a part of study vendors were asked to submit
samples to test in the Laboratory in TS-II with
out any commitment on NLC part.
Eight vendors were submitted samples as
Calcium Scale Inhibitor instead of
Organophosphonate or Non Organophosphonate,
to with stand 400 ppm Calcium in the Laboratory
test.
Five vendors passed through the test.

1) M/S Chembond Drewtreat, Mumbai, 2) M/S
Chempure Technologies, Chennai, 3) M/S
Credence, Mumbai, 4) M/S Puja Chemicals,
Surat, 5) M/S Universal Enterprises, Mumbai.


Budgetary offers were asked from vendors
to make trial in the Stage-I in TS-II.

Note was raised to make trial with
400 ppm Calcium Scale Inhibitor in
Stage-I in TS-II on 07-02-2004.

COST COMPARISION OPTIONS

I ELEMENT A) INSTALLATION CAPITAL
B) RUNNING COST
II CHEMICAL TREATMENT

OPTIONS FOREBAY O & M COST

I 19.0 CRORES 6.5 CRORES +POWER 0.75
CONSUMPTION+AMC
0.05 CRORES

II 12.0 CRORES 12.0 CRORES
III OPTION

NLC POWER GENERATION IS SOLELY DEPENDENT
ONLY ON GROUND WATER (FROM MINES)

IT IS SUGGESTED TO INSTALL ANOTHER 10 BORE WELLS TO
MEET 10,000 GPM OF WATER. A TEST BORE WELL HAS BEEN
CONDUCTED IN NORTH WEST (BEHING SWITCH YARD) OF TS-II
FOR DM PLANT PURPOSE WHICH SHOWS A VERY LOW CALCIUM
CONTENT (AROUND 40 PPM).

TO INSTALL ONE BORE WELL IT COSTS AROUND 35 LAKHS,
THEREFORE FOR 10 BORE WELLS IT COMES TO 3.5 CRORES PLUS
PIPING COST AND PUMPING COST COMES TO ANOTHER 1.5
CRORES.

THESE BORE WELLS HAVE TO BE TREATED AS
ESSENTIAL FOR POWER GENERATION AS SUCH BORE
WELLS BEING DRILLED IN MINES FOR MINING
LIGNITE.

III OPTION:

NO OF MINES BORE WELLS UPTO 160 PPM CALCIUM 10 NO

NO OF MINES BORE WELLS 160-200 PPM CALCIUM 7 NO

NO OF BORE WELLS AT TS-II BELOW 100 PPM CALCIUM 7 NO

TOTAL NO OF BOREWELLS AVALIABLITY 24 NO

MAKE UP WATER REQUIREMENT AT 2.0 COC 28,000 30,000 GPM

ADDITIONAL BOREWELLS TO BE ADDED 10 NO
EXCERPTS OF THE MINUTES OF MEETING HELD ON
15-11-2003 IN THE OFFICE OF THE CGM/MINE-I & IA

THE RAISING TREND OF Ca VALUE AND RELATED
PROBLEMS IN MINES-II HAS BEEN EXPLAINED IN
DETAIL

TPS-I AND TPS-I EXP REQUIREMENT 23,200 GPM

EXPECTED MAXIMUM PUMPAGE IS 25,000 GPM
FROM MINE-I

WITH FURTURE REQUIREMENT FOR 125 MW IN B &
C, THERE IS NO SCOPE OF INCREASED WATER FLOW
FROM MINE-I

OPTION OF NOT CONNECTING TUBE WELLS WHERE
HIGH CALCIUM IS TO BE EXPLORED

AVALIABLE OPTIONS

CAPITAL COST O&M COST COC
1. PRESENT OP TREATMENT NIL 0.85 CRORES 1.40



2. POLYMER
TREATMENT NIL 12.0 CRORES 2.0


3. PRE TREATMENT OF MINE-II
STORM WATER 38.0 CRORES 22.0 CRORES
3A. POLYMER TREATMENT
WITH 400 PPM CALCIUM NIL 12.0 CRORES 2.0
4. DRILLING 10 BORE WELLS
IN TS-II 3.5 CRORES 1.5 CRORES
4A. POLYMER TREATMENT
FOR 400 PPM NIL 12.0 CRORES 2.0


5. LIVING WITH MINE-II BORE
WELL WATER OF 250 PPM
CALCIUM PLUS POLYMER
TREATMENT UP TO 500 PPM
CALCIUM NIL 15.0 CRORES 2.0

CONCLUSION



SUBMITDTED FOR ADVICE SELECTIONS FROM THE
ABOVE OPTIONS