1

Open Recirculating Cooling

Water for Power Plant

Indonesia Customer Seminar

June 13 & 14 2012
Jakarta Indonesia
Overview
 Pushing the Limits
 Mechanical, Operational & Chemical Survey

 Scale Inhibitor Technology Overview

 PC-2040T
 Features
 Performance
 Comparison with other technology
 Advantages & Benefit
Cooling System of Power Plant vs Other

It’s
BIG !!!!
Open RCW System for Power Plant
 Large systems
 HV: 1,800 – 45,000 m3
 RR: 20 – 200 x 103 m3/hr

 Surface,
well, reclaimed make
up waters, sea water
 Regulated to zero discharge
systems
 1.2 – 25 cycles of concentration
 Maximizing water and chemical
utilization!
Challenge: Pushing the Limits
 How far can we stress our water system –
increase the cycle, low etc - without too much
risk?
 Howlow a treatment level – heavy metal,
phosphate, chlorine; etc - will perform?
Tech
Risks

Pushing
the Limit

TOC SHE
 6

Challenge: Pushing the Limits

Lowest
Monitoring TOC
& Control
Treatment
Program
Potential
Risks

System
Survey
Survey: Mechanical, Operational & Chemical

1. System Survey
2. MakeUp Analysis

ISP
Wireless 3D Web
Direct Connect Modem
Optimizer Configure
Cross Over Cable Dial Up
Dial Up

Download

Excel Vantage PSR

Import

3D Data Log
Service Report
 Exciter &
Cooling Source
Stator Coolers
Hydrogen /Air Coolers

Condenser Circulating
3-5% of Water
main flow Circulating Water Pumps
Booster Pumps

Lube Oil
Coolers

Boiler Feed Bearing Typical condenser flow:

Pump Cooling Fossil = 80 m3/hr/ MW capacity
Turbine Water
Condenser Coolers Nuclear = 123 m3/hr MW capacity
CCGT= 61 o5r 164 m3/hr/MW

Typical Power Plant Circulating

Water Cooling System
Survey: Cooling Tower
 Tower Type
 Cross Flow
 Counter Flow

 Fill Type
 Splash bar
 High efficiency

 Structure:
 Wood, PVC, Cement
Fill Type, Fouling Tendency & Performance
Fill Fouling Issues
• Loss of cooling efficiency
• High cooling water supply
temperature
• Tower capacity derating
• Cooling tower failure
• Expensive tower fill
replacement
• Health-related concerns due
to microbial fouling
Impact of Cooling Tower Performance
Survey: Typical HX’s in RCW Power Plant
Service Flow Temp Comments and Concerns
Main Condenser 2.0-2.7 m/s 50 C • Largest HX, focus of program, but not
Continuous skin temp severe duty!
• Tube leaks contaminate FW.

BFP Turbine 2.0-2.7 m/s 50 C • Can be hotter than main condenser.

Condenser Continuous skin temp • Typically not a problem area.
(if present) • Can have older copper alloy tubes.

0.15-2.0 m/s 65 C • Flow throttled to maintain minimum H2

H2 /Air Coolers temp. Tend to silt up in winter.
Throttled skin temp
(Rotor & Stator) • Often most severe duty in plant.
• Unit must de-rate if H2 temp too high.
Lube Oil Coolers 0.15-2.0 m/s 40-65 C • Flow throttled to maintain minimum lube
Throttled skin temp oil temp. Can silt up in the winter.
• Often very severe duty.
• Unit must de-rate if lube oil temp too high.
Exciter Cooling 0.3-2.0 m/s 50-65 C • May have redundant HX in parallel.
Throttled skin temp • May silt up when throttled.

Bearing /Auxiliary/ 1-2.7 m/s 20 – 43 C • Normally not a problem. Low heat duty.
Service HX Throttled skin temp • RCW flow on tube side.
• Plate type of exchangers in newer plants.
Combustion Turbine (0.3-2.0 m/s) >65 C • CT cooling can be a problem area.
Cooling Throttled skin temp • Small tube diameters, high temperatures.
Surface Condenser
 Water-side velocity : 1.5-2.4 m/s
 Vacuum : 4-10 kPaa
 U Value : 3-5 kW/m2 0C
 Sat’ steam temperature : 30-55 0C
 Condenser tube length : 6 – 15 m

1. Often Key to Efficiency in Plant Operations

2. Condenser leak: boiler water contamination

 15

Impact of Condenser Fouling

 16

Impact of Condenser Tube Failure

• Condenser Tube Failure

pH
9 - 10
8,5 - 9 • Abnormal Boiler Cycle Chemistry
8 - 8.5
< 8.0

•Boiler Tube Failure

•Plant Shutdown
Hydrogen /Air and Lube Oil Coolers
Hydrogen/Air Cooler

• Horizontal coolers in modern

combined cycle plant
• Vertical coolers in traditional
generator
• Hydrogen for >600 MW (high heat
capacity & low density)
• Must derate if air or H2 is too hot

Lube Oil Cooler

• Modern lube oil system with
reservoir, pumps, filters, PFE
• Older plants use shell & tube HX,
typically vertical
• Must derate if lube oil is too hot
• Throttle flow if lube oil too cold
Aux/Service Cooling Heat Exchangers

 The intercooler between closed

system and open system
 Either shell & tube or plate type
heat exchangers
 Can be large if handle main HX
with closed system

 Open cooling water

generally on tube side
 Relatively low
temperatures and heat
flux.
Survey: Metallurgy
 Copper alloys
- May prohibit or limit use of ammonia for
condensate corrosion control
- Especially for admiralty tubes

 Titanium Ammonia
- Extremely brittle with very thin walls Grooving
- Leaks common (especially during initial
commissioning and startup)
- ANY mechanical impingement can cause leaks

 Stainless Steel Under Deposit

- Subject to chloride stress corrosion Corrosion / MIC
- Must ensure cooling water chloride level
remains within limits
- Under-deposit corrosion, MIC issues
Pitting / MIC
Survey: Make-Up Water Chemistry
 Make-up water quality
 Source: river, sea water, brackish, deep well, recycle
Chemical Properties-Makeup Water Value Units
Calcium * 50 ppm Ca as CaCO3
Magnesium * 18 ppm Mg as CaCO3
Manganese 0,02 ppm Mn
Ammonia 0 ppm NH3
M-Alkalinity * 100 ppm as CaCO3
Silica 15 ppm SiO2
Aluminum 0,1 ppm Al
Fluoride 0 ppm F
Chloride * 35 ppm Cl
Sulfate * 19 ppm SO4
O-phosphate 0,1 ppm PO4
Copper 0 ppm Cu
Conductivity * 300 uS/cm
Zinc 0 ppm Zinc as Zn
Iron 0,1 ppm as Fe
Turbidity 2 NTU

 Variability is important !
Potential Problems in Open Cooling Water

There are basically four inter-

related problems in the
operation of a cooling water
system as depicted by the
Cooling Water Treatment
Triangle below.

Each problem affects and is

affected by the other
problems.
Pushing the Limits: Technical Risks

CaCO3 Scale Silt Fouling Microbio Fouling

Steel Corrosion &

CaSO4 Scale Iron Fouling

Silica Scale Ca3PO4 Scale Copper Corrosion

 24

Nalco Advanced Technology in Cooling Water

PSO Scale/
Corrosion
Inhibitor

Non PO4
Stabilized
Corrosion
Bromine
Inhibitor

High
Silica Stress
Inhibitor Polymer
(HSP®)
High
Resistant
Azoles
 25

What Do You Need?

Super Duper
Medicine?

Good Doctor

Good Doctor
Good Doctor?
 …to learn
This is not the
about a
best time…
problem!

26
Is The Best
Water Doctor ……
Identify Potential Issues & Technical Risks

1. System Survey
2. MakeUp Analysis

ISP
Wireless 3D Web
Direct Connect Modem
Optimizer Configure
Cross Over Cable Dial Up
Dial Up

Download

Excel Vantage PSR

Import

3D Data Log
Service Report
29
 30

3DT Optimizer® Simulation & Program Design

HX
Temperature Vary Cycle
Vary Temperature & Velocity

Make Up
System
Water
Design
Chemistry

Optimizer

Vary Treatment Vary pH

System
Contaminants
Metallurgy
 31

3DT
3DTOptimizer®
Optimizer®Simulation & Program Design
for Diagnostic

Technical Risks

Safe Operating Window

 32

Nalco Advanced Technology in Cooling Water

PSO Scale/
Corrosion
Inhibitor

Non PO4
Stabilized
Corrosion
Bromine
Inhibitor

High
Silica Stress
Inhibitor Polymer
(HSP®)
High
Resistant
Azoles
Total Operating Cost Simulation
Monitoring & Control: 3D TRASAR® Controller

1. System Survey
2. MakeUp Analysis

ISP
Wireless 3D Web
Direct Connect Modem
Optimizer Configure
Cross Over Cable Dial Up
Dial Up

Download

Excel Vantage PSR

Import

3D Data Log
Service Report
 35

3D TRASAR® Stress Management

for Cooling Water System

 Automation control of
 Corrosion inhibitor – TRASAR
 Scale inhibitor- Tagged Polymer
 Biocide – Bio reporter & ORP

 On line measurement:
 Conductivity
 pH
 ORP
 Corrosion rate

 Full communication capability

(digital/analog/ethernet/scada/
modem)
3D TRASAR® Scale Control

Trasar & Tagged Polymer

 37

Case History: 3DTRASAR® Scale Control

 Coal fired power plant in Nevada

 Nalco 3D Trasar® and silica inhibitor
technology allow the plant increase the
cycle from 4.5 to 7.0 (+250 ppm SiO2 in the
recirculating water)
 Water saving 281,000,000 gallons/year
(+ 9,000 people consumption per year)
 US$ 47,500/yr saving of water pumping &
chemical cost
 mpy

0.0
0.5
1.0
1.5
2.0
2.5
3.0
3/20/03
3/25/03
3/30/03
4/4/03
4/9/03
4/14/03
4/19/03
4/24/03
4/29/03
5/4/03
5/9/03
5/14/03
5/19/03
5/24/03
XLP-170/N-23263 Manual Control

5/29/03
6/3/03
6/8/03
6/13/03
6/18/03
6/23/03
6/28/03
7/3/03
7/8/03

Date
7/13/03
Corrosion Rates

7/18/03
7/23/03
7/28/03
8/2/03
3D TRASAR® Corrosion Control

8/7/03
8/12/03
8/17/03
8/22/03
8/27/03
9/1/03
9/6/03
N-23263 Trasar Control/ XLP-170 Slaved

9/11/03
9/16/03
9/21/03
9/26/03
10/1/03
10/6/03
10/11/03
N-73292 Tagged Control/ N-73284 Trasar Control

10/16/03
10/21/03
10/26/03
 39

Case History: 3D TRASAR® Corrosion Control

 450 MW Coal Fired Plant operate as ZLD facitlity

 CaSO4 and Ca3PO4 deposition Problem
 Switch to Nalco 3D TRASAR® with PSO program
3D TRASAR® Bio Control

Bio Reporter & ORP

Waste Money
 41

Case History: 3D TRASAR® Bio Control

 250 MW Combined Cycle

 Need to reduce bleach consumption related to the
environment and copper corrosion
 3D Trasar® Bio Control technology saving 75% of
bleach consumption and keep the condenser
performance
Nalco 3D TRASAR® + Nalco 360 Services:

1. System Survey
2. MakeUp Analysis

ISP
Wireless 3D Web
Direct Connect Modem
Optimizer Configure
Cross Over Cable Dial Up
Dial Up

Download

Excel Vantage PSR

Import

3D Data Log
Service Report
3D TRASAR® Reports the Data You Need
the Way You Need It, When You Need It
Nalco 360 TM
Nalco 360™ Service provides
peace of mind that your water
system is being monitored by
a team of Nalco Experts, 24 hours
a day, 7 days a week.
Nalco 360 TM

Nalco 360
3D TRASAR Expert Center
controller
+
Performance
Web reviews Immediate alarm
connection response

+
Nalco Sales Automated Reporting
Engineer
Nalco 3D TRASAR® + Nalco 360TM
Monitoring & Controlling Your System 24/7
 47

Case History: 3D TRASAR® + 360 TM

 520 MW Combined Cycle Power Plant

 Cooling water operate at 3-3.5 cycles
 Nalco with 3D Trasar® + 360 TM that
monitoring for 24/7 successfully running
the system at cycle 5.
Challenge: Pushing the Limits
 How far can we stress our water system –
increase the cycle, low etc - without too much
risk?
 Howlow a treatment level – heavy metal,
phosphate, chlorine; etc - will perform?
Power Plant RCW: Pushing the Limit !

It is possible and practical

 Understanding of the system & its
variability
 Identify the technical risks
 Best chemical treatment program
 Proper implementation
(automation;etc)
 24/7 monitoring & control

Best Technology
Best Water Doctor !
Is The Best
Water Doctor ……
Nalco Will Not Only Help You on:

 Improve Efficiency

 Enhance Reliability

 MeetEnvironment, Health &

Safety Standard
But We Will Also Provide you ……..

A Peace of Mind