CHEMICAL MANAGEMENT DEPARTMENT

HRSG CHEMICAL CONTROL FOR STEAM-WATER

Document Code: HEI-IMS-CHEM-SOP07 Page: 1 of 17

HRSG CHEMICAL CONTROL FOR STAM-WATER

(Clause 8.1, 8.5 of ISO 9001:2015, 6.1, 8.1 of ISO 14001:2015 & ISO
45001:2018)

Lead OPS Plant Plant

Chemist Manager Manager Manager
Issued for HEI HEI QATPL HEI
00 Jan 2019
Implementation Muhammad Mehdi
Ashar Muhammad
Akhtar Hassan
Ishfaq Khan Janhanzeb
Bhatti

Rev Issue Date Description Prepared by Checked by Checked by Approved by

 CHEMICAL MANAGEMENT DEPARTMENT

HRSG CHEMICAL CONTROL FOR STEAM-WATER

Document Code: HEI-IMS-CHEM-SOP07 Page: 2 of 17

1.0 DOCUMENT HISTORY

2.0 PURPOSE

3.0 SCOPE

4.0 RESPONSIBILITIES

5.0 PROCEDURE

5.0 RELATED DOCUMENTS

 CHEMICAL MANAGEMENT DEPARTMENT

HRSG CHEMICAL CONTROL FOR STEAM-WATER

Document Code: HEI-IMS-CHEM-SOP07 Page: 3 of 17

DOCUMENT HISTORY
REV. # DATE PAGE # SECTION DCR# NATURE OF AMENDMENT

* All changes made in the document are notified in the Document History. For details of
amendments, please refer to relevant DCR (Doc. Change Request).

1. PURPOSE
 CHEMICAL MANAGEMENT DEPARTMENT

HRSG CHEMICAL CONTROL FOR STEAM-WATER

Document Code: HEI-IMS-CHEM-SOP07 Page: 4 of 17

The purpose of this document is to:

1.1 Provide instructions, determines pre-requisites, identifies precautions, details

the sequential steps and assigns responsibilities for chemical control for
maintaining the quality of HRSG steam/water

1.2 Define safe practices to handle the chemicals properly while using them.

2. SCOPE

The primary objective of water treatment program is the long-term reliability and
health of all materials in the steam/water cycle. This requires that water and steam purity be
constantly monitored and controlled to prevent corrosion and deposition. Corrosion and
deposition are often related; corrosion in one area of the steam/water cycle often results in
deposition further downstream in the process. An accumulation of deposits can, conversely,
promote corrosion of the underlying metal.

Chemical control limits are of little value without frequent and accurate monitoring to ensure
compliance. Online and manual testing is very essential if the plant is to be protected from
damage caused by chemistry excursions

2.1 Pre-requisites for chemical solution preparation and dosing.

 All online and laboratory equipment are working properly.

 Water sample is coming through all sampling points.
 Proper chemical solutions of ammonia, Oxygen scavenger and Tri-sodium
phosphate has been prepared and reasonable stock is available.
 Wear all necessary personal protective equipments (PPEs) like; Gloves,
safety shoes, Face shield, Gas mask, safety helmet with chin, Goggles, ear
muff etc.

3. RESPONSIBILITIES

3.1. Plant Manager

Plant Manager ensures that the proper procedures, as detailed below, are
followed for controlling the quality of steam and water in HRSGs.

3.2. Lead Chemist

It is the responsibility of Lead Chemist to ensure that the proper procedures

are developed and followed for controlling the quality of steam and water in
HRSGs. Ensures proper actions should be taken according to the system
requirements if some abnormalities are observed during plant operations.

Maintaining records of log sheets and daily reports.

Ensuring that solution preparation is carried out correctly and according to
procedure.
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HRSG CHEMICAL CONTROL FOR STEAM-WATER

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3.3. Assistant Chemist

Responsible for proper testing and reporting the parameters as per described
log sheet according to the procedure.
Assistant Chemist will ensure that proper actions are taken as per instruction
provided in this procedure.

3.4. Department heads

It is the responsibility of each Maintenance Department Head to manage the

maintenance of tanks, pumps, valves and other equipment as per PM
schedule.

4. PROCEDURE

4.1 Requirements for Testing and Treating of the Steam/Water Cycle

The aim of the treatment of the steam/water cycle is to:

a) Minimize corrosion and deposits in the boiler/feed/steam circuits.

b) Avoid deposition on turbine blades

This will be achieved by the following:

c) Using demineralized water

d) Increasing the PH with selective chemical treatment
e) Reducing Oxygen/Carbon Dioxide contents.

Chemical treatment will involve dosing as per the following regime:

f) Hydrazine as feed water oxygen scavenger (when required)

g) Trisodium Phosphate for boiler water dosing
h) Ammonia as volatile alkalization agent for steam and condensate

Recommended Values for Normal Operations

Parameter Feedwater Boiler Water Superheated Steam

LP IP HP LP IP HP
CC μs/cm <0.2 < 0.2 < 0.2 < 0.2
9.2-
pH 9.3-9.6 9.0-9.3 9.0-10.0 9.0-9.3 9.0-9.3 9.0-9.3
11.2
Sp. Cond µS/cm 15 15 <500 < 80 5 5 5
Phosphate mg/kg - <6 <2
N2H4 mg/kg 0.02
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HRSG CHEMICAL CONTROL FOR STEAM-WATER

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SiO2 mg/kg < 0.1 < 0.1 < 2.6 < 0.2 <0.02 <0.02 <0.02
Oxygen μg/kg <7
Iron μg/kg 10 < 20 < 20 < 20
Na & K μg/kg 1025 < 10 < 10 < 10

CC is Conductivity after a Cation exchange resin

This is a very important on-line meter and measures the purity of the water in the steam
water cycle. The cation resin acts by removing alkalizing agents like ammonia and at the
same time converts any contaminant into its corresponding acid thereby increasing its
sensitivity. Levels of less than 0.5 micro-siemens/cm indicate a good level of purity.

pH-value

A pH of greater than 9.0 will minimize the corrosion-rate of mild steel in the feed/boiler/steam
circuits. Feed water/steam is kept at 9.0 to 9.6 by the addition of Ammonia. Trisodium
Phosphate is added to boiler drums to keep the pH at 9.0-10.0.
The phosphate level in the boiler water should be 2-6 mg/kg. pH and phosphate levels are
measured on a daily basis by the laboratory.

Oxygen

Oxygen in the feed water will cause corrosion of the steel. Oxygen is removed by the de-
aerator. Oxygen levels should be less than 7 μg/l. Should the oxygen level exceed 7 μg/kg
then a chemical oxygen scavenger, Hydrazine, should be added. Oxygen meters are
installed on-line in the condensate and feed.

Silica

Silica has volatility depending on temperature and pressure. If this carries over from the
boiler it can be deposited on turbine blades leading to loss of efficiency. Silica can enter the
system through the demin plant.
Silica is measured on-line from the demin plant and lab analysis is carried out on boiler
water and steam. Levels of Silica in the boiler is set to ensure that the steam silica is less
than 0.02mg/kg

Chemical Parameters And Action Limits

 Normal Values Design values consistent with long term running

 Action level 1 There is a potential for the accumulation of

contaminants and corrosion. Return to normal levels
within 1 week. Maximum exposure is 336 cumulative
hours per year, excluding start-up conditions.

 Action level 2 The accumulation of contaminants and/or corrosion will

occur. Return to normal levels within 24 hours. Maximum
exposure is 48 cumulative hours per year, excluding start-up
conditions.
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HRSG CHEMICAL CONTROL FOR STEAM-WATER

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 Immediate Shutdown There is clear evidence of rapid damage or severe

restrictions of operation by insufficient water quality.

The parameters to be supervised are set out below in the following tables.
All parameters can be higher during start-up.

Condensate

Parameter Units Normal Value Action Action Immediate shutdown

1 2
Cat μS/c <0.2 0.2-0.5 0.5-1.0 >1.0
Conductivity m
Sp. Conductivity μS/c 5 5-10 10-15 > 15
m
pH 9.0-9.4 NA NA NA
Silica μg/kg <20 NA NA NA
Iron μg/kg <20 NA NA NA
Copper μg/kg <3 NA NA NA
Chloride μg/kg <70 <100 <250 <500

Feedwater (after feedwater pump)

Parameter Units Normal Action 1 Action2 Immediate shutdown

Value
Sp. μS/cm 15-20 NA NA NA
Conductivity
pH 9.0-9.6 NA NA NA
Silica μg/kg <20 NA NA NA
Iron μg/kg <10 NA NA NA
Copper μg/kg <2 NA NA NA
Oxygen μg/kg <7 NA NA NA

pH and ammonia concentration as well as specific conductivity must be basically in direct

correlation.

During normal operation hydrazine is not injected. This is because hydrazine, in an oxygen
free environment, favors Flow Assisted Corrosion in low temperature areas such as LP
boilers and HP, LP economizers. Hydrazine is only injected if the oxygen in feedwater is
above 10ppb.

Boiler Water (HP, IP and LP)

Parameter Units Normal Action 1 Action2 Immediate

Value shutdown
Specific Conductivity (LP μS/cm <15 15-40 >40 NA
Drum)
pH (LP Drum) 9.0-10.0 <9.0, NA <8.0
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HRSG CHEMICAL CONTROL FOR STEAM-WATER

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>10.0
Silica (LP Drum) mg/kg <0.1 NA NA NA

Specific Conductivity (IP μS/cm <80 80-100 >100 NA

Drum)
pH (IP Drum) 9.2-11.2 <9.0, NA <8.0
>11.0
Silica (IP Drum) mg/kg < 2.6 NA NA NA
Phosphate (IP Drum) mg/kg 2-6* >10 >20 NA
Specific Conductivity (HP μS/cm <80 80-100 >100 NA
Drum)
pH (HP Drum) 9.0-10.0 <9.0, NA <8.0
>10.0
Silica (HP Drum) mg/kg < 0.2 NA NA NA
Phosphate (HP Drum) mg/kg 2-3* >10 >20 NA

*The coordinated pH-phosphate relationship in the boiler water should be maintained

according to the phosphate plot shown in the HRSG O & M document.

Steam (LP, IP and HP saturated and superheated steam)

Parameter Units Normal Action 1 Action Immediate shutdown

Value 2
Cat Conductivity μS/cm <0.2 0.2-0.5 0.5-1.0 >1.0
Sp. Conductivity μS/cm 5-10 NA NA NA
pH 9.0-9.3 NA NA NA
Silica μg/kg <20 >20 NA NA
Iron μg/kg <20 NA NA NA
Copper μg/kg <3 NA NA NA
Sodium+Potassiu μg/kg <10 10-20 20-40 >40
m

Make-up Water

Parameter Units Normal Value Action 1 Action 2 Immediate shutdown

Sp. Conductivity
μS/cm <0.3 NA NA NA
Demin Outlet
Sp. Conductivity
μS/cm <1.0 1.0-1.5 >1.5
Storage tank

Silica as SiO2 μg/kg <20 20-50 50-200 >200

4.2 Measurement and Control Of Chemical Parameters

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HRSG CHEMICAL CONTROL FOR STEAM-WATER

Document Code: HEI-IMS-CHEM-SOP07 Page: 9 of 17

The most important chemical parameters of the steam/water cycle are measured on-line and
indicated at sampling room. Signals are also sent to the main control room to the DCS.
Sampling points are also provided to check the meters and to monitor other parameters.
The instruments and sampling points for the steam/water cycle are all grouped together in a
central monitoring station.

On-Line Measurement

The following on-line monitoring is installed for each boiler.

Condensate Pump Discharge

Cation Conductivity Range 0-1 μS/cm Limit > 0.2

Oxygen Range 0-20 μg/kg Limit > 7

Feedwater

Cation Conductivity Range 0-1 μS/cm Limit >0.2

Oxygen Range 0-7 μg/kg Limit > 7

HP, IP and LP Boiler Drum

Specific Conductivity Range 0-100 μS/cm Limit < 80, >5

HP, IP and LP Sat Steam/Superheated steam

Cation Conductivity Range 0-1 μS/cm Limit < 0.2

Daily Chemical Analysis

Please refer Appendix 1

Recording

A daily sheet (CHEM-SOP-007 LS) had been drawn up to record all the instrument results
and also lab analysis.
Please refer Appendix 1

Corrective Action Guide

Condensate

SYMPTOMS CAUSE ACTIONS

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HRSG CHEMICAL CONTROL FOR STEAM-WATER

Document Code: HEI-IMS-CHEM-SOP07 Page: 10 of 17

Establish full bore flow,

Bad sample or pH meter
PH <9.0
Out of calibration
Sample is not
representative
Ammonia injection low
recalibrate pH meter,
resample
Establish good sample flow
& resample
Increase pump stroke/check
tank strength

Sample is not
Resample
representative
PH >9.6
or
Recalibrate pH meter,
pH meter out of calibration
Decrease pump
Ammonia injection high
stroke/check tank strength

Sample is not
Specific Conductivity >11 representative
/test
Ammonia injection high
Tube leak from condenser
Repeat sample/test. Cross
check against pH
Decrease pump
stroke/check tank strength
Analyze cond/boiler for
chloride. Take action as per
boiler water corrective action

Sample is not
Cation Conductivity >0.5 representative
/test
Exhausted resin column
Incorrect demin quality
Tube leak from condenser
Repeat sample/test
Change/regenerate column
Check chemistry parameters
Analyze cond/boiler for
chloride. Take action as per
boiler water corrective action

Sample is not
Silica >0.02 representative Repeat sample/test
/test
Incorrect demin quality Check chemistry parameters
Analyze cond/boiler for
Tube leak from condenser chloride. Take action as per
boiler water corrective action

Feedwater

SYMPTONS CAUSE ACTIONS

 CHEMICAL MANAGEMENT DEPARTMENT

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pH <9.0 Sample is not Recalibrate pH meter,

representative resample
or pH meter out of
calibration
Ammonia injection low Increase pump stroke/check
tank strength

pH >9.6 Sample is not Recalibrate pH meter,

representative resample
or pH meter out of
calibration
Ammonia injection high Decrease pump
stroke/check tank strength
Open CBD

Specific Conductivity Sample is not Repeat sample/test

>11μS/cm representative
/test
Incorrect demin quality Check chemistry parameters
Tube leak from condenser Analyse condensate/boiler
for chloride. Take action as
per boiler water corrective
action
Open CBD

Cation Conductivity Sample is not Repeat sample/test

>0.5 μS/cm
Silica >0.02 mg/kg
Oxygen >0.007 mg/kg
representative
/test
Exhausted resin column Change/regenerate column
Incorrect demin quality Check chemistry parameters
Tube leak from condenser Analyse condensate/boiler
for chloride. Take action as
per boiler water corrective
action
Sample is not Repeat sample/test
representative
/test
Incorrect demin quality Check chemistry parameters
Tube leak from condenser Analyse condensate/boiler
for chloride. Take action as
per boiler water corrective
action
Sample is not Check analyser
representative maintenance/ sample flow
/test
Air leakage in condenser or Check circuits for air leak &
vacuum system vacuum system. Start
hydrazine pump.
Hydrazine pump problem Check pump/increase stroke
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HRSG CHEMICAL CONTROL FOR STEAM-WATER

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Increase in demin water Start hydrazine pump

make up
HRSG start up or load Start hydrazine if not on.
change Refer to boiler water
corrective action guide
Drum Water
SYMPTONS CAUSE ACTIONS
pH <9.0 Sample is not Set flow correctly in the
representative sample point.
Recalibrate pH meter,
pH meter out of calibration resample
Trisodium phosphate Increase pump
injection low in IP and HP stroke/check tank strength
drums
Tube leak from condenser Increase phosphate
injection
Check condensate chloride
level
pH >10 Sample is not Set flow correctly in the
representative sample point.
Recalibrate pH meter,
pH meter out of calibration resample
Trisodium phosphate Decrease pump
injection high stroke/check tank strength
Formation of free hydroxide Increase phosphate
injection
Specific Conductivity > 50 Sample is not Set flow correctly in the
representative sample point.
Recalibrate conductivity
Conductivity meter out of meter,
calibration resample
Trisodium phosphate Decrease pump
injection high stroke/check tank strength
Open CBD
Tube leak from condenser Check sodium to phosphate
ratio
Check condensate chloride
level
Open CBD
Specific Conductivity Sample is not Set flow correctly in the
<6 μS/cm representative sample point.
Recalibrate conductivity
Conductivity meter out of meter,
calibration resample
Phosphate <2.0 mg/kg Sample is not Repeat sample/test
representative Cross check with pH
/test
Trisodium phosphate Increase pump
injection low stroke/check tank strength
 CHEMICAL MANAGEMENT DEPARTMENT
HRSG CHEMICAL CONTROL FOR STEAM-WATER
Document Code: HEI-IMS-CHEM-SOP07
Phosphate >6.0 mg/kg
Silica > 0.5 mg/kg for HP
>0.5 mg/kg for LP
Saturated and Superheated Steam
SYMPTOMS
Cationic Conductivity
>0.5 μS/cm
Na + K >0.010 mg/kg
Silica >0.020mg/kg
Page: 13 of 17
Sample is not Repeat sample/test
representative Cross check with pH
/test
Trisodium phosphate Decrease pump
injection high stroke/check tank strength
Open CBD
Bad sample/test Repeat sample/test
Silica level high Open CBD
Incorrect demin quality Check chemistry
parameters
Tube leak from condenser Increase phosphate
injection
Other tests must show Refer to action guide for
serious deviation boiler
CAUSE ACTIONS
Sample is not Release air in column outlet
representative -air lock flow.
Test with lab conductivity If same value, calibrate on
meter line meter.
Exhausted resin column Change/regenerate column
HRSG drum level high Take corrective action
High Ammonia Confirm by test and if
confirmed reduce ammonia
dosing.
Sample is not Repeat sample/test
representative
/test
HRSG drum level high Take corrective action
High level of Sodium in Blow down drum, follow
boiler corrective Chemistry guide
Problem with Cross check against
desuperheating condensate
Check for tube leak
Sample is not Repeat sample/test
representative
/test
HRSG drum level high Take corrective action
High Silica in boiler Blow down boiler, follow
corrective Chemistry guide
Problem with de- Cross check against
superheating condensate
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HRSG CHEMICAL CONTROL FOR STEAM-WATER

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Check for tube leak

Check DM water quality For high DM silica,
regenerate Mixed Bed.

Appendix 1
QUAID E AZAM THERMAL POWER PLANT
CHEMICAL LABORATORY
PROCESS CONTROL – STEAM / WATER CIRCUIT

TEST SCHEDULE THINGS TO BE MONITERED

Four
ITEM Once Monthl
Tests Time
Daily y
Daily
pH X
DM Water Conductivity X
Silica X
pH X Online DO, Online Specific
conductivity
Condensate Conductivity X Online after cation conductivity
Chloride X
Silica X
pH X Online DO, Online Specific
conductivity
Conductivity X Online after cation conductivity
Feed Water
Hydrazine X
Oxygen X
Iron X
pH X Online after cation conductivity
HP, IP and LP Conductivity X Steam flow rate
Steam Silica X
Sodium X
pH X Online pH,Coductivity,Drum
pressure,
Conductivity X CBD status.
HP and IP
Phosphate X
Drum
Silica X
Chloride X
Sodium X
pH X Online pH,Coductivity,Drum
pressure,
Conductivity X CBD status.
LP Drum
Silica X
Chloride X
Iron X
Chemical - - - - Tank level, Pump stroke, Dis.press.
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HRSG CHEMICAL CONTROL FOR STEAM-WATER

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for NH3, N2H4 &Na3PO4

Dosing System
NOTE: The Above test frequency holds good when all the parameters are within the limit.
If there is any Off-Spec. tests to be done frequently till compliance is achieved.
During the plant start-up testing will be frequent till normalcy is reached.
 CHEMICAL MANAGEMENT DEPARTMNET

HRSG STEAM/WATER ANALYSIS

LOG SHEET
Document Code: HEI-IMS-CHEM-FRM02

 
 
Date: HRSG-1 HRSG-2
TIME/LIMITS
SAMPLE  Parameters
8 14 20 4   8 14 20 4
pH 6.3-7                  
MAKEUP WATER Cond. Max 1 µS/cm                  
SiO2 Max 100 ppb                  
pH 9.0-9.4                  
Cond. Max 5.0 µS/cm                  
CONDENSATE Cat Cond. Max 0.2 µS/cm                  
PUMP OUTLET
T.Hardness Nil                  
SiO2 Max 200 ppb                  
Inlet of
Cat Cond. Max 0.2 µS/cm
Economizer                  
pH 9.0-9.3                  
Cond. Max 15.0 µS/cm                  
LP DRUM WATER SiO2 Max. 100 ppb                  
T.Hardness Nil                  
Chloride Max. 700 ppb                  
pH 9.3-9.6                  
Cond. Max 15.0 µS/cm                  
Cat Cond. Max 0.2 µS/cm                  
BOILER FEED
N2H4 Max. 20 ppb                  
PUMP
Iron Max. 10 ppb                  
Copper Max. 3 ppb                  
DO Max. 7 ppb                  
pH 9.2-11.0                  
Cond. Max 500 µS/cm                  
T.Hardness Nil                  
IP DRUM WATER SiO2 Max. 2600 ppb                  
Chloride Max. 70 ppb                  
Sodium Max. 1.25 ppm                  
PO4 Max. 6 ppm                  
HP DRUM pH 9.0-10.0                  
WATER Cond. Max 80 µS/cm                  
 CHEMICAL MANAGEMENT DEPARTMNET

HRSG STEAM/WATER ANALYSIS

LOG SHEET
Document Code: HEI-IMS-CHEM-FRM02

T. Hardness Nil                  
SiO2 Max. 200 ppb                  
Chloride Max. 70 ppb                  
Sodium Max. 1.25 ppm                  
PO4 Max. 1.8 ppm                  
LP Saturated
Cat Cond. Max 0.2 µS/cm
Steam                  
Reheat Steam Cat Cond. Max 0.2 µS/cm                  
pH 9.0-9.3                  
Cond. Max 5.0 µS/cm                  
Cat Cond. Max 0.2 µS/cm                  
LP SUPER
SiO2 Max. 20 ppb                  
HEATED STEAM
Na Max. 10 ppm                  
Fe Max. 20 ppb                  
Cu Max. 3 ppb                  
IP Saturated
Cat Cond. Max 0.2 µS/cm
Steam                  
pH 9.0-9.3                  
Cond. Max 5.0 µS/cm                  
Cat Cond. Max 0.2 µS/cm                  
IP SUPER HEATED
SiO2 Max. 20 ppb                  
STEAM
Na Max. 10 ppm                  
Fe Max. 20 ppb                  
Cu Max. 3 ppb                  
HP Saturated
Cat Cond. Max 0.2 µS/cm
Steam                  
pH 9.0-9.3                  
Cond. Max 5.0 µS/cm                  
Cat Cond. Max 0.2 µS/cm                  
HP SUPER
SiO2 Max. 20 ppb                  
HEATED STEAM
Na Max. 10 ppm                  
Fe Max. 20 ppb                  
Cu Max. 3 ppb                  
 
Shift   Morning Shift   Night Shift
Name    
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