Analytical Instruments

STEAM-WATER &
FLUE GAS
Analyzers
12 April 2018 PMI Revision 00 1

Presentation outline
•Monitoring Requirement of analyzers in
thermal plant
•Sampling and Conditioning Circuit
•Measuring principles of Analyzers
•Flue gas and emission Monitoring
Analyzers

IN THERMAL POWER PLANT
THE MAJOR INPUTS ARE WATER & FUEL
THE OUTPUTS (OTHER THAN GENERATED MW,
OF COURSE) ARE EFFLUENT WATER AND FLUE
GASES.
HENCE THE QUALITY CONTROL OF INPUTS AND

OUTPUTS BECOMES ESSENTIAL TO ENSURE SAFE
AND RELIABLE OPERATION, MINIMISE HEAT LOSS
AND CONFORMING TO ENVIRONMENTAL NORMS

POOR QUALITY OF FEEDWATER AND
STEAM RESULTS IN
• CORROSION IN FEED, BOILER AND STEAM
SYSTEM
• SCALE AND DEPOSIT FORMATION ON HEAT
TRANSFER SYSTEM
• DEPOSITION AND CORROSION IN TURBINE DUE
TO CARRY OVER.

CORROSION
– MAY BE DEFINED AS REVERSION OF METAL TO A

MORE STABLE OXIDISED STATE.
– WHEN THE ENVIRONMENT FAVOURS

CONVERSION OF THE METAL TO OXIDE BY
REACTION WITH OXYGEN OR A SOURCE OF
OXYGEN SUCH AS WATER THE CORROSION
OCCURS.
– CORROSION INCLUDES GENERAL CORROSION,

ALKALI CORROSION, STRESS CORROSION,
STRESS CRACKING AND PITTING.

SCALE AND DEPOSIT FORMATION
GENERALLY, THOSE SUBSTANCES ADHERED
ON HEATING SURFACES SUCH AS PIPE WALLS
AND DRUM WALLS ARE CALLED SCALE.
 SCALE IS FORMED WITH SOLUBLE SOLIDS IN

THE WATER GRADUALLY CONCENTRATED TO
SATURATION WITHIN THE BOILER.
 SULPHATES (MOSTLY CONSISTING OF

CALCIUM SULPHATES) AND SILICATES (MOSTLY
CONSISTING OF CALCIUM SILICATES) CAN BE
VERY DETERMENTAL HARD SCALE.

ff
 HINDERS HEAT TRANSFER REDUCING BOILER EFFICIENCY.
 ADHERES ON THE INNER WALL OF WATER PIPE AND
DISTURBS WATER CIRCULATION.
 CAUSES OVERHEATING OF HEAT TRANSFER SURFACE AND
PIPE EXPLOSION.
 BOILER UNDER HIGH TEMPERATURE AND HIGH PESSURE
IS LARGELLY AFFECTED BY SCALE TO A DANGEROUS
EXTENT. THEREFORE CONTENTS OF SULPHATES,
SILICATES AND CARBONATES ARE TO BE LIMITED WITH
RISE IN TEMPERATUE AND PRESSURE.

CARRYOVER
DISSOLVED OR SUSPENDED SOLIDS IN BOILER

WATER AND MOISTURE BROUGHT OUT OF THE
BOILER TOGETHER WITH THE STEAM STREAM
IS CALLED CARRY OVER.
SILICA UNLIKE DISSOLVED SOLIDS OF BOILER
WATER, DISSOLVE IN THE STEAM AND
SOLUBILITY STEEPLY INCREASES AS THE
PRESSURE RISES. SILICA DISSOLVED IN THE
VAPOUR GETS CARIED OVER AND GETS
DEPOSITED ON THE TURBINE BLADES.
CARRYOVER CAUSES THE FOLLOWING:
contd….
PRECIPITATION ADHERES TO THE SH TUBES-
CAUSES DAMAGE TO THE TUBE OR DEGRADED
THERMAL CONDUCTION.
PRECIPITATION ADHERES TO THE VALVE SEAT

OF STEAM VALVE AND TURBINE BLADES
DISTURBING THEIR PROPER FUNCTIONS.
MOISTURE ENTERS THE SUPERHEATER TUBE

RESULTING IN INSUFFICIENT SUPERHEATING.

IMPORTANCE OF CORROSION FREE
OPERATION
FROM THE ABOVE DISCUSSION IT IS CLEAR THAT
IF SAFE, RELIABLE, CORROSION-FREE OPERATION
OF HIGH PRESSURE DRUM BOILERS IS TO BE
ACHIEVED , IT IS NECESSARY TO OPERATE WITH A
BOILER WATER CHEMICAL COMPOSITION THAT
WILL PRODUCE AND MAINTAIN A STABLE
PROTECTIVE OXIDE FILM ON THE TUBE
SURFACE. THIS CAN BE ACHIEVED BY USING A
WATER THAT SIMULTANEOUSLY CONTAINS:
-LOW CONTROLLED LEVELS OF OXIDE.
-VERY LOW LEVELS OF OXYGEN
-LOW LEVELS OF POTENTIAL ACID FORMING
IMPURITIES SUCH AS CL.
BOILER WATER CHEMISTRY CONTROL
THIS IS ACHIEVED THROUGH
- MAKING BOILER WATER ALKALINE WITH

SUITABLE CHEMICAL DOSING.
- BOILER WATER BLOW DOWN TO MAINTAIN

NACL CONCENTRACTION WITHIN A
TARGET VALUE (NAOH TO NACL 1.5:1)
- OPTIMISING ALKALI AND REDUCING

IMPURITIES

STEAM AND WATER ANALYSIS SYSTEM
 FOR THE CLOSE CHEMICAL CONTROL NEEDED

TO PROTECT STEAM/ WATER CIRCUITS OF
POWER PLANT, DETAILED INFORMATION ON THE
PREVAILING CHEMICAL CONDITION IS ESENTIAL.
 EXTENSIVE USE OF ON-LINE INSTRUMENTATION
FOR ALL IMPORTANT CHEMICAL MEASURE-
MENTS HELPS OPERATORS TO
-MONITOR THE CHEMICAL CONDITIONS IN THE
STEAM/ WATER CIRCUIT TO ENSURE THAT
SATISFACTORY CHEMICAL CONTROL IS BEING
MAINTAINED AND ALERT OPERATOS TO
ABNORMAL QUALITY PARAMETERS
CONTD...
-MONITOR THE OPERATION AND
PERFORMANCE OF PLANT INSTALLED TO
FACILITATE CHEMICAL CONTROL, E.G.
THE WATER TREATMENT, CONDENSATE
POLISHING PLANT AND CHEMICAL
DOSING PLANT.
-TO FACILITATE CHEMICAL

INVESTIGATIONS WHEN UNEXPECTED
PROBLEMS ARISE.

MONITORING REQUIREMENT FOR STEAM/
WATER CIRCUIT.
 THE CHEMICAL MONITORING REQUIRED FOR

STEAM/ WATER CIRCUIT WILL VARY ACCORDING
TO THE PARTICULAR TYPE OF PLANT
CONSIDERED. HOWEVER, THE PRINCIPAL
SAMPLING LOCATIONS AND PARAMETERS TO BE
MEASURED ARE AS BELOW:

1.MAKE UP DM WATER CONDUCTIVITY.
(FINAL CHECK ON INPUT

DM WATER)
2. HOTWELL CONDENSATE - CONDUCTIVITY
(BOTH SIDES) (TO ASSIST LOCATION OF
CONDENSER LEAKS)
3. CEP DISCHARGE a)CONDUCTIVITY
b)SODIUM(TO PROVIDE
WARNING OF CONDENSER
LEAKAGE)
c)DO (TO ESTABLISH
ADEQUACY OF OXYGEN
REMOVAL)
4.CONDENSATE POLISHER
a) Cond
b)PH
c)SILICA
d)SODIUM
(PERFORMANCE OF THE
PLANT AND THE NEED FOR
RESIN BED REGENERATION)
5.DEAERATOR OUTLET a) D.O.

(TO ENSURE
SATISFACTORY
PERFORMANCE OF
DEAERATOR)

6) FEEDWATER ECONOMISER COND
. - PH
(FINAL ON QUALITY &
ACCEPTABILITY)
D.O.
HYDRAZINE
(EFFECTIVENESS OF
HYDRAZINE
DOSING)
7) BOILER DRUM .
a)COND.
b)PH
c)SILICA
d)PHOSPHATE
e)CHLORIDE
(TO ENSURE PROPER
BOILER WATER CONDITIONS)
8)BOILER SATURATED
STEAM a)COND.
b)SODIUM
(CRITERIA TO MINIMISE
SALT DEPOSITION IN THE SH IS
MET).
9)BOILER SUPERHEATED STEAM
a) COND
b) PH
c) SODIUM
(CRITERION TO MINIMISE
SALT IN THE RH IS MET)

10)CONDENSER COOLING a) PH
WATER b) COND.

SAMPLING AND SAMPLE CONDITIONING
• IT IS ESSENTIAL TO OBTAIN A SAMPLE FOR

ANALYSIS WHICH IS REPRESENTATIVE OF THE
FLUID IN THE SYSTEM BEING MONITORED.
• THE DESIGN AND LOCATION OF A SAMPLING
DEVICE MUST TAKE ACCOUNT OF THE FLUID
CONDITIONS AT THE SAMPLING POINT (I.E.
WHETHER ONE PHASE FLUID OR TWO PHASE
FLUID IS RPESENT).
• THE FOLLOWING FIG. SHOWS A TYPICAL
ARRANGEMENT OF SAMPLE CONDITIONING
EQUIPMENT FOR USE WITH ON LINE CHEMICAL
MEASURING INSTRUMENTATION. THE SYSTEM
CONSISTS OF:
•PRIMARY SAMPLE COOLING (WHEREVER REQUIRED
IN THE FIELD.
•HIGH PESSURE REDUCTION ( WHEREVER REQUIRED
IN THE FIELD
•SAMPLE FILTERING
•SECONDARY SAMPLE COOLING AND TEMPERATURE
CONTROL.
•PRESSURE REDUCTION AND CONTROL AS REQD.
•FLOW RATE CONTROL AND MEASUREMENT.
( THE CLOSE CONTROL OF THE FINAL SAMPLE IS
VERY IMPORTANT TO GIVE MORE RELIABLE RESULTS
THAN COMPENSATING FOR TEMPERATURE
VARIATION AT THE INSTRUMENT THEMSELVES).
ANALYZERS IN COMMON USE MAY BE BROADLY
GROUPED INTO FOUR GENERAL CATEGORIES:
– A: PHYSICAL PROPERTY ANALYZERS,

– B: ELECTRO-CHEMICAL ANALYZERS,
– C: SPECTRO PHOTOMETRIC ANALYZERS
– D: COMPOSITIONAL ANALYZERS.
A. SIMPLY MONITORS PHYSICAL PROPERTIES OF A PROCESS

B. MEASURE IONIC SPECIES IN A PROCESS STREAM OR REACTION
OF IONS IN THE STREAM WHEN A VOLTAGE OR CURRENT IS
APPLIED.
C. MEASURE INHERENT OPTICAL PROPERTIES OF THE MOLECULES
IN THE PROCESS STREAM.
D. MEASURE ALL OF THE COMPONENTS INDIVIDUALLY IN A GAS OR
LIQUID SYSTEM.
HOWEVER ANALYZERS USED IN TPS, UNDER STEAM AND WATER

ANALYSIS SYSTEM (SWAS ) COME UNDER B AND C.

TYPES OF ANALYSERS – CONTD.
• CONDUCTIVITY, PH,DO,HYDRAZINE, ANALYZERS ARE

TYPICALLY ELECTRO CHEMICAL TYPE ANALYZERS
• SILICA, PHOSPHATE, CHLORIDE WORK ON
COLORIMETRIC PRINCIPLE.
(IN THE COLORIMETRIC ANALYZERS THE SAMPLE TO BE
MEASURED IS MADE TO UNDERGO A CHEMICAL REACTION TO
PRODUCE A COLOURED SOLUTION, THE INTENSITY OF WHICH
CAN BE RELATED TO ITS CONCENTRATION.)

IN BOILER WATER QUALITY CONTROL, SPECIFIC CHEMICALS
ARE INJECTED TO SPECIFIC PLACES FOR THE FOLLOWING
PURPOSE.
PURPOSE CHEMICAL
•DEOXIDATION N2H4 (HYDRAZINE)

(DOSING AT CEP DISCH AND/ OR BFP SUCTION)
•PH ADJUSTMENT NH4OH

(DOSING AT CEP DISCH AND / OR BFP SUCTION)
•CACO3 REMOVAL NA3PO4

(DOSING AT BOILER DRUM WATER)

TYPICAL SPECIFICATIONS FOR SWAS
EQUIPMENT
• PANELS
• SAMPLE COND. PANEL:

• Sample conditioning panel (Wet Section) shall house
– secondary coolers
– Conductivity & pH cells
– bulk head type fittings,
– removable cartridge type filters,
– pressure reducing elements, flow rate control,
– grab sample valve and other sample conditioning
equipments.
• Sample conditioning panel shall be corridor type with
walkway construction with side doors & removable type
plate at the back.

EQPT SPECS. ----CONTD.
• ANALYSER PANEL:
• Analyzer Panel (Dry Section) shall house

– analyzers
– monitors
– Reagents for silica/ phosphate analysers etc.
• The analyser panel shall be free standing & totally

enclosed construction with back doors.

PANELS SPECS. ………CONTD.
• The panels shall be constructed of 2.5mm

thick steel plates except for doors, which
shall be of 2.0 mm thickness. The panel floor
shall be made of 316/ 304 Stainless Steel
Sheet of 5mm thickness with central flat
portion for walk way and slightly sloping
sections towards front and rear side and a
panel drain. The waste water/sample from
panel drain shall be piped to the nearest plant
drain.

SWAS EQPT SPECS.---CONTD.
• Primary Cooler
• Primary cooling of all samples having temperature

in excess of 45 deg C shall be provided through an
individual sample cooler (primary cooler) of
submerged helical coil type of shell and tube design
with removable shell, meeting the intent of ASTMD
1192-1977, to bring down the temperature to
around 45 deg C.
• The sizing of the coolers should consider total

sample flow plus 500 ml / min grab sample & a
fouling factor of 0.2.

• Secondary Cooler
• Each sample stream with the required flow rate shall be

finally cooled from approximately 45 Deg. C to 25 Deg.
C+/-1 Deg. C or to a preset temperature required by the
analyzer through an individual secondary cooler before
passing the sample to the respective measuring cells and
analyzer. The capacity calculation (considering fouling
factor of 0.2) shall be subject to Employer's approval
during detailed engineering.
• The secondary coolers will be of submerged helical coil

type of shell and tube design meeting the intent of
ASTMD 1192-1977.

• CHILLER SYSTEM
• Two (2) 100% capacity water cooled chillers shall be

provided
• Each chiller unit shall be designed with sufficient

refrigeration capacity to ensure each sample stream
temperature to 25 deg. C ± 1 deg. C when all streams
are simultaneously at maximum flow rate and maximum
temperature. The chiller capacity shall have a provision
of 25% spare capacity for future samples.

EQPT SPECS. ---CONTD. - ANALYSERS
Common specification for analysers:
Field proven monitors/ analyzers based on microprocessors with

LCD display and with necessary fault diagnostic features shall be
employed.
CONDUCTIVITY ANALYSER:
Type For Hotwell, Two removable
Type of Cells.
For Others, Continuous Flow
Through Type
Accuracy <= +/- 1 %
Response Time <= 1 Sec
(90 % of Full Scale)
Range 0-1,0-10,0-100 micro-
Mho/cm(freely programmable)
for Specific Conductivity.
0-1 micro-mho/cm log scale for
Cation conductivity
Temperature Comp. Automatic/
pH ANALYSER:
Type Flow Through Type
Accuracy <= +/- 1 %
Range 6-11 pH
freely programmable
Temperature Comp. Automatic

PHOSPHATE ANALYSER:
Type Colourimetric
Accuracy <= +/- 5 % of reading
Response Time <= 6 min

Range 0-10 ppm

freely programmable

HYDRAZINE ANALYSER:
Type Automatic Continuous

Electrochemical Type
Accuracy <= +/- 5 %
Response Time <= 3 Min.
Range 0-50, 0-100 ppb freely
programmable
Sample shut off solenoid valve to be provided.

SILICA ANALYSER:
Type Continuous Colorimetric

Type - Multi stream

Response Time <= 15 min( including sample
(90 % of Full Scale) switching)
Range 0-50, 0-100 ,0-500 ppb freely

programmable
Sample shut off solenoid valve to be provided.

SODIUM ANALYSER:
Type Continuous Flow through

Type – Multi stream

Response Time <= 4 Min
Range 0-1,0-10, 0-200 ppb
(freely programmable)

DISSOLVED OXYGEN ANALYSER:
Type Continuous Flow through

Type
Response Time <= 30 secs.

Range 0-20, 0-200 ppb

(freely programmable)

EQUIPMENT SPECS. ---CONTD.
Other important general requirements
• Multi-Stream analysers shall have at least two streams as spare.

• All the analysers/ cells shall have open Corrosion resistant drain to
waste header.
• All chemicals reagents required for 12 months operation is to be
supplied in phased manner depending on shelf life in addition to that
indicated under Mandatory Spares.
• Analysers/ monitors/ cells shall be suitable for operating under the
conditions specified.
• Dual cation exchange column shall be provided for cation
conductivity.

FLUE GAS ANALYSERS

Combustion Efficiency
• Optimizing a boiler’s efficiency is important to minimize the
fuel consumption and the excess to the environment.
• The combustion efficiency can be estimated by measuring the
content of carbon dioxide and the temperature of the excess
gas. The efficiency may be calculated by the formula:
• ηc = 100 - (0.95 + 37.2 / CO2%) (tsmoke- 20) / 100 (1)
• where
• ηc = combustion efficiency
• CO2% = % volume CO2 in the excess gas
• tsmoke = temperature in the excess gas (oC)
• The optimal content of carbon dioxide - CO2 - is approximately
10% for natural gas fuel and approximately 13% for light oils.

Stoichiometric Combustion
• Stoichiometric or Theoretical Combustion is the ideal combustion
process during which a fuel is burned completely. A complete
combustion is a process which burns all the carbon (C) to (CO2), all
hydrogen (H) to (H2O) and all sulfur (S) to (SO2). If there are unburned
components in the exhaust gas such as C, H2, CO the combustion
process is uncompleted.
• Mostly depends on:
• Air-Fuel Ratio
• Excess Air
• Air-Fuel Ratio
• Air-Fuel Ratio is frequently used in the analysis of the combustion
process. It is usually expressed on a mass basis, i.e.
AF=(mass of Air)/(mass of Fuel)
• Excess Air
• Excess Air is defined as the amount of air in excess of the
stoichiometric amount. It is common to use more air than the
stoichiometric amount in the combustion chamber. It increases the
chances of complete combustion. Excess air can also be used to
control the temperature of combustion chamber.
Efficient combustion
• Stable and efficient combustion conditions require correct
mixtures of fuels and oxygen.
• To understand the basics of efficient boiler operation, the
combustion process must be understood.
• Stable combustion conditions requires the right amounts of

fuels and oxygen. The combustion products are heat energy,
carbon dioxide, water vapor, nitrogen, and other gases
(excluding oxygen). In theory there is a specific amount of
oxygen needed to completely burn a given amount of fuel. In
practice, burning conditions are never ideal.
• Therefore, more air than ideal must be supplied to burn all fuel
completely. The amount of air more than the theoretical
requirement is referred to as excess air.

Typical values of excess air for some common fuels
are shown in the table below:
• Fuel Excess of Air (%)

•
Anthracite 40
• Coke oven gas 5 – 10
• Natural Gas 5 – 10
• Coal, pulverized 15 – 20
• Coal, stoker 20 – 30
• Oil (No. 2 and No. 6) 10 to 20
• Semi anthracite, hand firing 70 to 100
• Semi anthracite, with stoker 40 to 70
• Semi anthracite, with traveling 30 to 60
• grate

Stoichiometric Combustion
• To determine the excess air at which the
combustion system will operate we have to start
with the stoichiometric air-fuel ratio, known as the
perfect, correct or ideal fuel ratio, the stoichiometric
combustion. During stoichiometric combustion there
are a chemically correct mixing proportion between
the air and the fuel. During the stoichiometric
combustion process no fuel or air are left over.
• Process heating equipment almost never run

stoichiometric. Even so-called "on-ratio"
combustion, used in boilers and high temperature
process furnaces, incorporates a modest amount of
excess air, 10 to 20% more than needed to burn
the fuel completely.

Requirement of ‘Excess Air’
• If insufficient amount of air is supplied to the burner,
unburned fuel, soot, smoke, and carbon monoxide are
exhausted from the boiler. The results are:
• heat transfer surface fouling,
• pollution,
• lower combustion efficiency,
• flame instability and a potential for explosion.
To avoid inefficient and unsafe conditions, boilers normally

operate at an excess air level. This excess air level also
provides protection from insufficient oxygen conditions
caused by variations in fuel composition and "operating
slops" in the fuel-air control system.

FLUE GAS ANALYSIS
TWO MAJOR OBJECTIVES OF FLUE GAS ANALYSIS
ARE:
•TO ENSURE COMPLETE COMBUSTION.

(i.e COMPLETE CONVERSION OF FUEL TO HEAT)
•ENVIRONMENTAL CONSIDERATIONS
(i.e REDUCTION OF POLLUTANTS FROM FLUE GAS)

COMPLETE COMBUSTION
•IT IS IMPORTANT TO MAINTAIN THE AIR-FUEL
RATIO AT ITS MOST ECONOMIC LEVEL, IN SUCH A
WAY THAT COMPLETE COMBUSTION IS ENSURED
WITH MINIMUM AMOUNT OF EXCESS AIR.
•AS CAN BE SEEN FROM THE CURVE DEPICTING THE
EXCESS OXYGEN, CARBON MONOXIDE (CO) LEVEL,
AND UNBURNT CARBON, THERE EXISTS A
‘STOICHIOMETRIC POINT’ WHERE CO LEVEL IS
MINIMUM.
•THUS MEASUREMENT OF ‘OXYGEN’ AND ‘CO’ LEVELS
IN THE FLUE GAS GIVES A GOOD FEEL OF THE
COMBUSTION PROCESS.
•HENCE, BOTH ‘CO’ AND ‘O2’ ARE MEASURED IN
POWER PLANTS TO ENSURE PROPER COMBUSTION
AT THE MOST ECONOMIC MODE.
O2 MEASUREMENT
TYPICALLY O2 IS MEASURED AT TWO LOCATIONS IN THE
FLUE GAS PATH:
• AT PLATEN SUPERHEATER ZONE.

• AT ECONOMISER OUTLET.
THE MEASUREMENT AT PLATEN SH ZONE IS CLOSE TO COMBUSTION

PROCESS AND GIVES A FEEL OF THE SAME. HOWEVER, ONE
ARGUMENT MAY BE THERE THAT THE COMBUSTION PROCESS IS NOT
COMPLETE AT THAT ZONE AND THE GAS MIXTURE IS NOT
HOMOGENOUS.
HENCE, ANOTHER MEASUREMENT IS DONE DOWN THE PATH AT

ECONOMISER OUTLET. THESE TWO MEASUREMENTS TOGETHER GIVE
AN INDICATION OF THE COMBUSTION PROCESS.
AS AN OVERSHOOT, AN ADDITIONAL INFORMATION MAY BE GATHERED
FROM THESE TWO MEASUREMENTS I.E. AIR LEAKAGE (INGRESS) IN THE
FLUE GAS PATH.

SH ZONE MEASUREMENT
•THE O2 MEASUREMENT AT SH ZONE IS DONE USING NON-
HEATED TYPE ZIRCONIA PROBE. THIS IS BASED ON NERNST
EQUATION WHEREIN,
EMF a T LOGN P1/P2
WHERE,
P1 = PARTIAL PRESSURE OF OXYGEN IN REFERENCE GAS.
P2 = PARTIAL PRESSURE OF OXYGEN IN SAMPLE GAS.
T = ABSOLUTE TEMPERATURE.
• ZINCONIA CELL OPERATES ON THE ABOVE PRINCIPLE IN THE
TEMPERATURE RANGE OF 650 DEG.C – 1200 DEG.C. THE
TEMPERATURE AT THE ZONE IS ALSO MEASURED AND THE
OXYGEN CONCENTRATION IS CALCULATED FROM THE ABOVE
EQUATION.

ECONOMISER OUTLET ZONE
MEASUREMENT.
IN THIS CASE ALSO, ZINCONIA CELL IS USED.

THE ONLY DIFFERENCE IS THAT THE
TEMPERATURE BEING LESS THEN 600 DEG. C
AT THIS ZONE, A HEATED TYPE ZINCONIA
PROBE IS USED. THE TEMPERATURE IS
MAINTAINED AT AROUND 700 DEG.C USING
SUITABLE HEATER WITH CONTROLLER. IN THIS
CASE, AS THE TEMPERATURE IS CONSTANT,
THE EMF BECOMES PROPORTIONAL TO P1/P2
IN THE ABOVE NERNST EQUATION.

CO MEASUREMENT
TYPICALLY CO IS BEING MEASURED USING IN-SITU TYPE
ANALYSER AT STACK. THIS MEASUREMENT IS USED IN THE
COMBUSTION CONTROL LOOP TO OPTIMISE COMBUSTION
PROCESS.
ANALYSER USES PRINCIPLE OF SPECIFIC RADIATION ABSORPTION,

TYPICALLY IN INFRA-RED SPECTUM. IT USES A RADIATION SOURCE
AND A RECEIVER UNIT ACROSS THE DUCT. USING THE RATIO OF
THE MEASURING & REFERENCE SIGNALS ALONGWITH PATH
LENGTH AND TEMPERATURE, THE CO IN FLUE GAS IS
CALCULATED.
THE OPTICS ARE PROTECTED FROM GETTING

CONTAMINATED WITH DUST USING SUITABLE AIR
CURTAINS/ BLOWERS.

ENVIRONMENTAL MONITORING
IT IS IMPERATIVE THAT THE STATUTORY
NORMS STIPULATED BY CENTRAL & STATE
POLLUTION CONTROL BOARDS WITH
RESPECT TO EMISSIONS ARE MET.
• THE MAJOR COMPONENTS FOR WHICH

REQUIREMENTS ARE STIPULATED ARE:
• DUST OR SUSPENDED PARTICULATE

MATTER (SPM)
• SULPHUR DIOXIDE (SO2)
• OXIDES OF NITROGEN (NOX)

DUST/ SPM MEASUREMENT
• THIS IS AN IMPORTANT MEASUREMENT AS IT NOT ONLY
GIVES A MEASURE OF ENVIRONMENTAL POLLUTION BUT
ALSO HELPS IN INDIRECTLY ASSESSING THE
PERFORMANCE OF THE ELECTROSTATIC PRECIPITATORS
(ESP)
• THE DUST/ SPM ANALYSER USUALLY WORKS ON OPACITY

PRINCIPLE I.E. VISIBLE LIGHT IS TRANSMITTED ACROSS
THE DUCT AND THE REFLECTED LIGHT IS RECEIVED. BY
COMPARING THE TRANSMITTED AND REFLECTED
(DOUBLE BEAM PRINCIPLE) INTENSITIES, THE DUST
CONCENTRATION IN THE FLUE GAS IS CALCULATED. IN
ORDER TO PREVENT THE OPTICS (LENS ETC.) FROM
GETTING CONTAMINATED, SUITABLE AIR CURTAINS/
BLOWERS ARE EMPLOYED.

SULPHUR DIOXIDE
•AS THIS GAS IS ONE OF MAIN GASEOUS POLLUTANTS EMITTED DURING
THE COMBUSTION OF SULPHUR-BEARING FUEL, CONTINOUS ON-LINE
MEASUREMENT OF THE SAME IS ENVISAGED IN THERMAL POWER
PLANTS. HIGHER LEVELS OF SO2 MAY CAUSE ACID RAIN.
•TYPICALLY IN NTPC, EXTRACTIVE TYPE (I.E. SAMPLING TYPE) ANALYSER
IS EMPLOYED. THESE ANALYSERS ALSO GENERALLY OPERATE ON
SPECIFIC RADIATION ABSORPTION PRINCIPLE (IN UV OR IR SPECTRUM).
TYPICALLY THEY CONSIST OF A SAMPLE CELL AND A REFERENCE CELL
AND THE RATIO/ DIFFERENTIAL OF THE IR/UV INTENSITIES OF REFERENCE
AND SAMPLE (MEASURING) CELL GIVES A MEASURE OF THE COMPONENT
I.E. SO2.
•FOR CONDITIONING OF THE SAMPLE BEFORE IT REACHES THE
ANALYSER, SUITABLE CONDITIONING SYSTEM COMPRISING REFRIGERANT
TYPE OF COOLER, FILTERS, ANTI-CONDENSATION EQUIPMENT VIZ. HEAT
TRACING ETC. IS PROVIDED.

OXIDES OF NITROGEN (NOX)
•THESE OXIDES HAVE GAINED IMPORTANCE DURING THE PAST
DECADE AS ONE OF THE MAJOR ATMOSPHERIC POLLUTANTS, WHICH
MAY CAUSE ACID RAIN.
•FOR NOX MEASUREMENT ALSO, SAMPLING TYPE ANALYSER IS

EMPLOYED IN NTPC, OPERATING ON UV/ IR ABSORPTION OR
CHEMILUMINISCENCE.
SPECIFIC RADIATION ABSORPTION

•IN UV/ IR TYPE ANALYSER, AS DESCRIBED FOR SO2 ANALYSER, THE
RATIO/ DIFFERENTIAL BETWEEN SAMPLE & REFERENCE INTENSITIES
IS MEASURED AND THE NOX LEVEL OBTAINED.
•CONTD……...

• IN ADDITION TO THE SAMPLE CONDITIONING EQUIPMENT, A ‘NO2
TO NO CONVERTER’ IS EMPLOYED BEFORE ROUTING THE SAMPLE
TO THE ANALYSER, TO GET THE TOTAL OXIDES OF NITROGEN.
• COMMON SAMPLE CONDITIONING EQUIPMENT MAY BE EMPLOYED
FOR BOTH SO2 & NOX, AND THE CONDITIONED SAMPLE ROUTED
TO BOTH ANALYSER MODULES.
CHEMILUMINISCENCE TYPE
• IN CHEMILUMINISCENCE TYPE OF ANALYSER, THE EMISSION OF

LIGHT RESULTING FROM CHEMICAL REACTION WITH OZONE IS
MEASURED PHOTOMETRICALLY AND THE AMOUNT OF NO IS
DERIVED. TO OBTAIN BOTH OXIDES OF NITROGEN I.E. NO2 & NO, A
CONVERTER AS ABOVE IS INTRODUCED BEFORE ROUTING THE
SAMPLE TO THE ANALYSER.

TYPICAL FEATURES/ PARAMETERS FOR
SPECIFICATION OF ANALYZERS
- TYPE / PRINCIPLE
- ACCURACY
- RESPONSE TIME (90% OF FULL SCALE)
- STABILITY OVER TIME
- RANGE
- TEMP. COMPENSATION
- OPTICS PROTECTION
- SAMPLE CONDITIONING REQUIREMENTS
- CALIBRATION REQUIREMENTS ETC.

TYPICAL SPECIFICATIONS OF
FLUE GAS ANALYSIS INSTRUMENTS
• Common Requirements
• Output signals
• Analog :4-20 mA DC galvanically isolated. If analyser
provides superimposed HART signal on 4-20 mA DC
output, It shall also be connected to PC based station.
• Binary: 2 NO + 2 NC for high alarm
• Zero & span Adjustment : To be provided with range
selection facility.
• Ambient temp.: 50°C
• Indication : Digital Alphanumeric Display. Diplay of
reading in engineering units shall be provided.
• Enclosure Type/MaterialWeather & Dust proof (IP 55) : Die
cast Aluminium/SS
• Type of Electronics: Microprocessor based with self
diagnostic.

TYPICAL SPECIFICATIONS OF
FLUE GAS ANALYSIS INSTRUMENTS
• Common reqts - contd.
• Digital Signal transmission :RS 485 Port Modbus Protocol / Ethernet

TCP/IP protocol for communication with plant control system.
• Calibration : Auto & Manual (from Remote)
• Power Supply : To be arranged by Contractor subject to Employer’s

approval.
• Others : All interconnection tubing and cabling between probe and

analyser / analyser panel and cabling from analyser/ analyser panel to
local junction box are to be provided. All the calibration gases required
for one year continuous operation shall be provided. The calibration gas
container material shall not contaminate the calibration gas.

Sox/ Nox analyser specs
• Type of Instrument : Sampling type
• Principle of Measurement :Radiation absorption
• Measurement Range: 0-300 ppm/ 0-1000ppm Selectable
• Accuracy : +/- 1% of F.S.
• Linearity : +/- 1% of F.S.
• Repeatibility: < 0.5% of Span
• Response time(upto 90% of full scale)” < 5 secs
• a)Temperature Drift+/- 1% / 10 deg.C
• b)Zero Drift< 1% span/weekc)
• Span Drift< 1% measured value/week
• Operating Temperature Range : 0-300 deg.C
• Accessories : Purging system (Auto Scavenging facility)
• Compensation for temperature.: Yes
• Location: On chimney

Oxygen Analyser (HT) specs
• Type of Instrument : Non-heated in-situ dry type
• Principle of Measurement :Partial-pressure using Zirconium
Oxide Cell
• Measurement Range: 0.01% to 10% oxygen
• Accuracy : +/-1% of F.S. or 0.5 % O2, whichever is more
• Operating Temperature Range : 600-1600 deg.C Accessories :
Purging system and amplifier, XMTR etc.
• Compensation for temperature.: Yes With R/B type
thermocouples (to be finalised during detailed Engineering)
required.
• Location: SH Zone

Oxygen Analyser (LT) specs
• Type of Instrument : Heated in-situ dry type
• Principle of Measurement :Partial-pressure using Zirconium
Oxide Cell
• Measurement Range: 0.01% to 10% oxygen
• Accuracy : +/-1% of F.S. or 0.5 % O2, whichever is more
• Operating Temperature Range : 0-450 deg.C Accessories :
Purging system and amplifier, XMTR etc.
• Compensation for temperature.: Automatic temperature
control of heating circuit through thermostat
• Location: AH outlet

•
CO Analyser specs
Type of Instrument : In-situ type
• Principle of Measurement :IR absorption
• Measurement Range: 0-200, 0-1000 ppm,
programmable.
• Accuracy : +/- 5% of F.S.
Accessories : Purging system to be provided with
heavy duty blowers and shutter mechanism for
automatic isolation of lens during purge air failure .
• Compensation for temperature.: Automatic
• Location: Chimney

Dust/ SPM Analyzer specs
• Type of Instrument : In-Situ dry type visible light
(through LED) stack
• Principle of Measurement : Transmission and absorption
• Measurement Range: 0 to 999mg/m2, programmable.
• Accuracy : +/-2% of F.S.
Accessories : Purging system to be provided with
heavy duty blowers and shutter mechanism for
automatic isolation of lens during purge air failure .
• Compensation for temperature.: Automatic
• Location: Chimney

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STEAM-WATER &

12 April 2018 PMI Revision 00 1

12 April 2018 PMI Revision 00 2

HENCE THE QUALITY CONTROL OF INPUTS AND

12 April 2018 PMI Revision 00 3

12 April 2018 PMI Revision 00 4

– MAY BE DEFINED AS REVERSION OF METAL TO A

– WHEN THE ENVIRONMENT FAVOURS

– CORROSION INCLUDES GENERAL CORROSION,

12 April 2018 PMI Revision 00 5

 SCALE IS FORMED WITH SOLUBLE SOLIDS IN

 SULPHATES (MOSTLY CONSISTING OF

12 April 2018 PMI Revision 00 6

12 April 2018 PMI Revision 00 7

DISSOLVED OR SUSPENDED SOLIDS IN BOILER

PRECIPITATION ADHERES TO THE VALVE SEAT

MOISTURE ENTERS THE SUPERHEATER TUBE

12 April 2018 PMI Revision 00 9

THIS IS ACHIEVED THROUGH

- MAKING BOILER WATER ALKALINE WITH

- BOILER WATER BLOW DOWN TO MAINTAIN

- OPTIMISING ALKALI AND REDUCING

12 April 2018 PMI Revision 00 11

 FOR THE CLOSE CHEMICAL CONTROL NEEDED

-TO FACILITATE CHEMICAL

12 April 2018 PMI Revision 00 13

 THE CHEMICAL MONITORING REQUIRED FOR

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(FINAL CHECK ON INPUT

5.DEAERATOR OUTLET a) D.O.

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9)BOILER SUPERHEATED STEAM

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12 April 2018 PMI Revision 00 19

• IT IS ESSENTIAL TO OBTAIN A SAMPLE FOR

– A: PHYSICAL PROPERTY ANALYZERS,

A. SIMPLY MONITORS PHYSICAL PROPERTIES OF A PROCESS

HOWEVER ANALYZERS USED IN TPS, UNDER STEAM AND WATER

12 April 2018 PMI Revision 00 23

• CONDUCTIVITY, PH,DO,HYDRAZINE, ANALYZERS ARE

12 April 2018 PMI Revision 00 24

•DEOXIDATION N2H4 (HYDRAZINE)

•PH ADJUSTMENT NH4OH

•CACO3 REMOVAL NA3PO4

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• SAMPLE COND. PANEL:

12 April 2018 PMI Revision 00 26

• Analyzer Panel (Dry Section) shall house

• The analyser panel shall be free standing & totally

12 April 2018 PMI Revision 00 27

• The panels shall be constructed of 2.5mm

12 April 2018 PMI Revision 00 28

• Primary cooling of all samples having temperature

• The sizing of the coolers should consider total

12 April 2018 PMI Revision 00 29

• Each sample stream with the required flow rate shall be

• The secondary coolers will be of submerged helical coil

12 April 2018 PMI Revision 00 30

• Two (2) 100% capacity water cooled chillers shall be

• Each chiller unit shall be designed with sufficient

12 April 2018 PMI Revision 00 31

Field proven monitors/ analyzers based on microprocessors with

Type Flow Through Type

Accuracy <= +/- 1 %