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Executive Summary
Boiler System: Found the problem of Hydrogen damage issue. The root-cause was come from condenser in-leakage issue from cooling part.
Solution Review the chemical treatment program to effective control corrosion in system with Nalcos product. Implement @T ORP on BFW to monitor the . Cooling System: High chloride issue in cooling system anytime. Induce to face the stress corrosion cracking (SCC) on SS304 condenser tube. Solution Review the chemical treatment program to effective microbial and also control chloride in system with Nalcos product. Implement 3DTRASAR for cooling system. Implement the condenser performance monitoring to ensure the treatment program.
General Information
MB (Demin
Condensate Return
MU)
Cooling tower
DEAERATOR
Shaft speed
Variable Loading
(Operating range 40-50 MW)
HP Boiler
LP Boiler
Boiler System 1 unit CFB Boiler HP = 70 bar, 130 tons/hr Consisting of Economizer, Boiler, Superheater #1 and #2 Deaerator 2 bar, 115-118 C, DO<10 ppb 1 Steam Turbine, 30 MW LP heater: CS Surface condenser Tubes: SS 304 Sheet: carbon steel coated with epoxy Design back pressure = 8,0 kPaa (46,23 mm Hg absolute)
Important Issue
Boiler System The plant experience with 2 (two) tube failures in December 2011. The failures were occurred in the water wall tubes about 5 m above the burner as showing in the picture below
Hydrogen Damage
The main problem with this failure is that it gets spread across the water wall tubes in totally an unpredictable way. Hence to find out the regions affected in the water wall by condenser leakage, exhaustive special probe ultrasonic testing is required.
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12
Confirmation
Yes
Remark
Deposit in steam drum (Boiler inspection May & Sep 2011) Heavy deposition in sampling tube (Sep 2011) Flow disruption only influence by deposition pH of boiler drop to ~8.5 on May 2011 pH of boiler dropped to ~8.4 Hardness in condensate went up to >0.5 ppm Chloride concentration in HP evap. went up >10 ppm
Flow disruption: deposits, DNB, bend/sharp changes in tube direction, locally high heat transfer, etc. Influence of acidic contamination Condenser leak-minor but occurred over an extend period
Yes
Yes Yes
Water treatment plant up set leading to low pH condition Error in chemical cleaning process
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pH 8.5-9.2
11/28/2011
11/30/2011
11/10/2011
11/12/2011
11/14/2011
11/16/2011
11/18/2011
11/20/2011
11/22/2011
11/24/2011
11/26/2011
11/2/2011
11/4/2011
11/6/2011
11/8/2011
SiO2 <20ppb
20 19.5 19 18.5 18 17.5 17 16.5
20.00
15.00 10.00 5.00 0.00 Total Fe <20 ppb
SiO2 <20ppb
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Immediate Solution
Isolate the condenser and plug all the leaking tubes and tubes with high depth wastage. Ensure there is no cooling water in-leakage by checking condensate quality (cation conductivity, hardness, chloride; etc) Selective tube sampling for deposit measurement. Inspection using fiber optic (boroscope) can provide useful information Tube replacement for all tubing with hydrogen damage and/or significant wall loss be replaced Check the efficacy of chemical cleaning
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Chemical cleaning
Proper chemical cleaning method/procedure
Develop specific cycle chemistry targets, action levels and shutdown policies to maintain good HRSG cleanliness.
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Open Cooling Water RR = 6,000 M3/hr, HV = 1,000 M3 5 cell cross flow cooling tower with high efficiency fill Temperature Supply: 34 0C Temperature Return: 42 0C Pipe: carbon steel Condenser DT cooling water (design) = 8 0C Tubes: SS 304 Tubes Sheet: CS with epoxy coating Lube Oil Coolers Served by open cooling water system Tubes: Cu:Ni = 90:10 Tubes Sheet: CS with epoxy coating Air Coolers Served by open cooling water system Tubes: Cu:Ni = 90:10 Sheet: carbon steel coated with epoxy Make-up water : clarified water Source: river water Pretreatment: clarifier filter raw water tank cooling tower
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Important Issue
Cooling Water System There were condenser tube leak event occurred in the surface condenser in year 2011. The tube failure occurred on June 2011, 5 tubes were cracked and leaked cause very high conductivity of condensate and low pH of boiler water (<6.0 for more than 4 hours). This tube failure has forced the plant to have unscheduled shutdown for 2 days. Most of the cracking they found are occurred close to the tube attachment/support, no metal loss happened and branching.
Figure 4: Surface Condenser Tube Failure Fractures The root-cause come from Stress Corrosion Cracking (SCC)
Higher chloride in cooling water will increase potential for stainless corrosion
From above snapshot we found there are issue of SS-304 corrosion that may be the root cause for this issue that make the penalty from unplan shutdown for 2 day around (3Bahtx20kwx1000x24hrx2day = 2.88 MB/time)
Water Quality MU vs CW
Trend of Make up & cooling water quality seem stable, so the problem may be hidden such as - not matching treatment program, - not matching control target
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SOLUTION
To prevent stainless corrosion in condenser and H2 damage in Boiler tube We recommend follow.1. Replace the oxidizing biocide form chloride to bromine base 2. Replace treatment program 3. Use automation system control feeding system to increase system reliability 4. Replace treatment program for more reliability 5. Use automation system to monitor and control feeding system in Boiler system
SOLUTION
1. Replace the oxidizing biocide form chloride to bromine base
To prevent SS-304 corrosion, we recommend to use stabilize bromine for oxidizing biocide that will not increase chloride in water.
SOLUTION
NALCO TREATMENT
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Commercial part
1) Chemical
Product Category or Control Parameter Dosage or Product Number or Control Set Additive Point Control Method Annual Usage Units
303,309.14 Bht/m
Price per Unit Annual Cost
Cooling System
Cycles of Concentration pH Scale Inhibitor Mild Steel Corrosion Inhibitor Oxidizing Biocide Total Treatment Costs H2SO4 3DT104 3DT129 ST-70 7.0 7.6 31 25 0 3D Scale Control Automatic Tag Polymer TRASAR Timer Control 7,190 3,245 2,649 8,675 Kg/Year Kg/Year Kg/Year Kg/Year 6.00 165.00 155.00 198.00 43,138.1 535,448.8 410,643.8 1,717,567.0 2,706,797.7
Boiler System
Oxygen Scavenger Condensate Treatment Internal Treatment Total Treatment Costs Total Cont/Year Eliminox N-356 BT-3000 0.5 Continuous Feed 1.5 Continuous Feed 4 Continuous Feed 562.0 1,685.0 5,616.0 Kg/Year Kg/Year Kg/Year 113.00 246.00 81.00 63,506.0 414,510.0 454,896.0 932,912.0 3,639,709.7
2) Equipment rental -3DTRASAR for CW + 4 pump + Solenoid valve -3DTfB (CONTROLLER & NCSM) Total Treatment Cost
Commercial part
3DTRASAR Value Package
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Workshop grouping