Importance of Cycle water chemistry &

(SWAS) monitoring
reliability in thermal power plant cycle.

By Sudhanshu Dash
Chemcal Operation
Thermal Power Cycle water And Steam Flow
Introduction:-
Now a days a very competitive business and technology advancement
it is very need to improvement efficient and cost effective production
of electric power from fossils fuel. In conventional designs in which
steam is produced and expanded in a turbine, the ability to provide
water at higher purity levels than previously possible enabled
designers to increase the operating temperatures and pressures of
fossil units. These improvements were accompanied by increasingly
tighter chemistry limits and a need for reliable monitoring approaches
that could be used for surveillance and control purposes. This need
shifted the emphasis on chemistry monitoring from infrequent
collection and analysis of grab samples to reliance on analysers that
provided semi-continuous or real time monitoring of the chemistry
parameters of interest.
Monitoring Requirements and Choice of Cycle
Chemistry
To maintain boilers & turbines at a high
level of availability and efficiency, we need
to prevent

• Corrosion in feed, boiler and steam

path.

• Scale & Deposit formation on heat

transfer surfaces

• Deposition & Corrosion in turbines.

• And finally proper feed water

treatment
Choice of Cycle Chemistry & types of Feed Water Treatment.

As per Electric power Research institute(EPRI ) and current guidelines there are
3 types of feed water treatment and four types of boiler water treatment and
Effective cycle chemistry programs require proper selection of treatments
consistent with unit
Characteristics.
Feed water Treatment:-
1. Reducing all-volatile treatment, AVT(R), in which the feed water must be dosed
with reducing agent to minimize corrosion of copper alloy components (HEL
using this treatment)

2. Oxidizing all-volatile treatment, AVT(O), in which no reducing agent is added or

needed since there are no copper alloys in the feed water system

3. Oxygenated treatment, OT, in which the feed water is dosed with oxygen; OT
can only be used in cycles where the feed water meets necessary purity criteria,
employs condensate polishing and no copper alloys are present following the
condensate pump discharge.
Choice of Cycle Chemistry & types of Feed Water
treatment.
Boiler Water Treatment:-
• All-volatile treatment [1], AVT, in which the feed water treatment is either AVT(R) or
AVT(O) as appropriate and no further chemical treatment is applied within the boiler.

• Phosphate Continuum Treatment [2], PC, in which a drum boiler is dosed principally
with trisodium phosphate (TSP); dosing of the boiler water with sodium hydroxide is also
allowed as a supplement to TSP when needed for pH control. Low and high level TSP
dosage variants of PC, termed PC(L) and PC(H), respectively may be considered
depending on the characteristics and needs of the unit.

• Caustic Treatment [2], CT, in which a drum boiler is dosed with sodium hydroxide.

• Oxygenated Treatment [3], OT, in which the feed water dosed with oxygen as needed
for OT is used in the boiler without further treatment; OT may be used in cycles with
once-through or drum type boilers, however, with the latter feed water oxygen dosing
must be more carefully controlled so as to avoid possible corrosion in the boiler.
Types of Parameter Monitoring in Cycle Chemistry
In thermal power plant we are monitoring the significance
chemistry parameter in two ways one is offline and another is
online analysers. So in cycle water chemistry as per EPRI guidelines
and IS guidelines it is divided into two general categories
i:e-
1.Those parameters which all thermal/fossil plants should have for
optimum chemistry control –Core parameters

2. Those parameters which are regarded as diagnostic parameters

that may be monitored as needed for troubleshooting or during
Commissioning-Diagnostic parameter
Types of Parameter Monitoring in Cycle Chemistry
Core Monitoring Parameter As per EPRI and Monitoring In Haldia
Energy Limited (Online Monitoring In SWAS)
Parameter Monitoring Points
Cation Conductivity Condensate Pump Discharge,
Economizer Inlet, Reheat , Main Steam, Saturated
Steam Boiler Water
Specific Conductivity Condensate Pump Discharge,
Economizer Inlet, Reheat , Main Steam, Saturated
Steam Boiler Water

pH Condensate Pump Discharge,

Economizer Inlet, Reheat , Main Steam, Saturated
Steam Boiler Water

Dissolved Oxygen Condensate Pump Discharge, Economizer

Inlet,Deartor Out let
Sodium Condensate Pump Discharge, Saturated Steam
,Main Steam
Types of Parameter Monitoring in Cycle Chemistry
Diagnostic Monitoring Parameter and Monitoring In Haldia Energy
Limited
In customizing the cycle chemistry programs, the organization may elect
to monitor one or more of the diagnostic parameters with on-line
analysers
The Diagnostic Parameters are
1.Ammonia-Check in main steam and Feed water
2.Chloride-Check in MS , Feed , CEP , Boiler water ,SS and RH
3.Hydrazine- Feed Water, Online also check
4.Phosphate- Boiler water ,HEL have no Phosphate treatment
5.Silica-Check in MS , Feed , CEP , Boiler water ,SS and RH (Online
Monitoring Required )
6.Iron & Copper-BD ,Feed,CEP
7.Total Organic Carbon-BD
8.Alaknity -BD
Haldia Energy Limited SWAS cycle chemistry
Introduction to Steam and water Analysis System (SWAS) in HEL
Haldia Energy Limited (300 MW * 2) is Sub –critical Drum type natural circulation
boiler and having AVT (R) feed water treatment option. As like thermal power
plant HEL also have SWAS monitoring system in both units .I have discussed its
importance and parameters monitoring one by one. It is very essential to know
and aware about all operation engineers for better reliable operation of thermal
power plant for longer and stable the plant
SWAS System Detail
1.Primary Sample point –Sample coming from different sample point location.
2.Primary cooler for cooling the sample.
3.Secondary Cooler for maintain sample temp.
4.Wet Panels-Where Grab sample collected and Online analysers are installed for
analysis.
5.Dry Panels-Where online value readings are shown.
6.Sample flow ,Pressure and temp. control for best results.
7.Cation Column Resin for Cationic Conductivity.
DRY PANEL
WET PANEL
Online parameters Monitoring in HEL and their
Standard Limit:-
pH 9.0-9.4
Sp. Conductivity μs/cm < 15
Boiler Drum water Cation Conductivity μs/cm < 1.5
Chloride ppb < 100
Silica as SiO2 @ 180 kg/cm2 ppb < 200
Cation Conductivity μs/cm <0.3
Main Steam
Silica as SiO2 ppb < 15
pH 9.2 -9.6
Sp. Conductivity μs/cm < 15
CEP O/L Cation Conductivity µs/cm <0.3
Dissolved Oxygen ppb < 30
Sodium ppb <5
pH 9.2 -9.6
Sp. Conductivity μs/cm < 15
Dissolved Oxygen ppb <7
Feed Water
Cation Conductivity µs/cm <0.3
Hydrazine hydrate ppb 10 ̴ 30
Iron ppb <10
Online parameters Monitoring in HEL and their
Standard Limit:-
pH 6.5 - 7.2
Stator water Specific Conductivity µs/cm < 0.5

Dissolved Oxygen ppb > 2000

pH 8.5-9.0
CCW
Specific conductivity µs/cm < 10

pH 9.2 -9.6
Saturated steam Cation Conductivity µs/cm <0.3

Sodium ppb <5

HRH Cation Conductivity μs/cm < 0.3

Condenser leak detector Cation Conductivity < 0.3

μs/cm
Details of online/Core Parameter Monitoring in Cycle Chemistry
pH
In cycle water chemistry, pH is Core Monitoring/online monitoring Parameter .As
such, pH should continuously be monitored on-line to check the acceptability of
the water chemistry, there by ensuring that corrosion rates are kept at low
levels.
In thermal plant steam-water cycles pH may also be monitored for one or more
of the following
reasons:
• To facilitate the correlation between two or more water chemistry parameter
(e.g., pH, conductivity, ammonia correlation).
• To provide a feedback signal for automated process control.
• To warn of in-leakage of contaminants.
• To warn of condensate polisher malfunction.
• To troubleshoot or verify the accuracy of other on-line pH monitors.
• To check the pH of water streams not routinely monitored continuously by on-
line monitors.
Details of online/Core Parameter Monitoring in Cycle Chemistry

Relationship Between Ammonia, Sp. Conductivity and pH in the Absence of

carbon Dioxide.
Details of online/Core Parameter Monitoring in Cycle Chemistry
Conductivity/Cation Conductivity
Conductivity, more specifically cation conductivity is an important Core Monitoring
parameter . As such, cation conductivity is continually monitored on-line to indicate the
ionic concentration in the solution being monitored and to warn of contaminant in-leakage.
Three types of conductivity measurements are discussed:
• Specific conductivity
• Cation (acid) conductivity
• Degassed cation conductivity
These three types of conductivity are also monitored for one or more of the following reasons:
• To facilitate the correlation of a water chemistry parameter (e.g., pH, conductivity, ammonia
correlation).
• To check the accuracy of water chemistry control (such as ammonia or pH).
• To warn of condensate polisher malfunction.
• To provide feedback signal for automated process control.
• To facilitate demineralizer system operation and/or regeneration.
• To monitor for the intrusion of volatile contaminates (e.g., CO2 or volatile organics).
• To monitor the laboratory pure water system.
• To determine the concentration of ions in solution.
Details of online/Core Parameter Monitoring in Cycle Chemistry

Chloride concentration Vs Cation Conductivity

Details of online/Core Parameter Monitoring in Cycle Chemistry

Sodium
Sodium is a SWAS Core/Online Monitoring Parameter .As such, it should be monitored
continuously on-line to check the acceptability of water chemistry, thereby ensuring that
corrosion rates are kept at low levels.

Significance of Monitoring
Sodium may also be monitored for one or more of the following reasons:
• To warn of in-leakage of contaminants.
• To warn of boiler water carryover.
• To identify cooling water in-leakage at the main steam condenser.
• To warn of condensate polisher malfunction.
Details of online/Core Parameter Monitoring in Cycle Chemistry
Dissolved Oxygen
Dissolved oxygen (DO) is an online/ Core Monitoring Parameter . As such, the reason for
continuous on-line monitoring of DO is to check the acceptability of water chemistry,
thereby ensuring that dissolved oxygen is maintained at acceptable levels—with lower
levels in feed water for cycles employing reducing all volatile treatment-reducing (AVT (R))
and somewhat higher levels when using oxidizing all volatile treatment-oxidizing (AVT(O))
or oxygenated treatment (OT).

Significance of Monitoring
1.To check the accuracy of water chemistry control, so ensuring that corrosion rates
are kept at acceptable low levels.
2.To facilitate the correlation of a water chemistry parameter with plant operating
variables, with an aim to optimizing operations (e.g., condenser air removal or
deaerator operations).
3.To monitor for condensate pump seal leakage.
4.During and following changes in feed water treatment.
Details of online/Core Parameter Monitoring in Cycle Chemistry
Silica
While silica is both online and offline parameter for thermal plants.
it is widely monitored for diagnostic and troubleshooting purposes. It is included as a
Core Monitoring Parameter for combined cycle plants . Elevated silica concentrations
in steam can lead to silica deposition in the low pressure turbine so it is desirable to
control the silica content of boiler water. Silica content is also the primary indication of
anion resin exhaustion in both makeup and condensate polishing equipment: under
most conditions, an increase in silica content at the anion resin outlet will occur prior to
a change in either pH or conductivity. Silica is most frequently monitored in the plant
for the following reasons:

Significance of Monitoring
1.To warn of in-leakage of contaminants.
2.To facilitate the correlation of a water chemistry parameter with plant operating
variables, with an aim to optimizing operations.
3.To check the accuracy of water chemistry control (for silica), so ensuring that carry-
over and deposit rates are kept at acceptable low levels.
Details of online/Core Parameter Monitoring in Cycle Chemistry
Ammonia
Ammonia is offline parameter in Cycle Chemistry ,it is commonly checked, usually as
a grab sample at a location such as the economizer inlet. Ammonia is one of several
alkaline chemicals that may be added to increase the pH of boiler feed water in order
to control corrosion of carbon-steel and other ferrous alloys in the steam/water cycle.
When system metallurgy contains copper alloys, accurate determination of ammonia
content is necessary to minimize formation of the copper/amine complex which leads
to rapid localized corrosion.

Significance of Monitoring
1.Check the accuracy of water chemistry control, so ensuring that corrosion rates are
kept at acceptable low levels.
2.Facilitate the correlation of ammonia with other chemistry parameters (i.e., pH and
specific
conductivity).
Details of online/Core Parameter Monitoring in Cycle Chemistry
Chloride
Chloride is offline monitoring parameter recommended as a troubleshooting tool and for
commissioning purposes. Now a days chloride monitoring requirement with cation
conductivity as the Core Parameter, partially due to the difficulty of on-line
measurement of low level anions including chloride. Elevated chloride concentrations in
the boiler can lead to corrosive conditions which can damage the water wall tubes.
Carryover can degrade steam purity, lead to build-up on turbine components and
promote corrosion mechanisms. Minimizing this carryover is an additional reason to
control the chloride content of boiler water. Chloride is most frequently monitored in the
plant for the following reasons:
Significance of Monitoring
1.To warn of in-leakage of contaminants (primarily condenser cooling water ingress).
2.To facilitate the correlation with other chemistry parameters (i.e., cation conductivity).
3.To check the accuracy of water chemistry control (for chloride), so ensuring that
carryover and deposit rates are kept at acceptable low levels.
4.To warn of condensate polisher malfunction.
5.To warn of make-up demineralizer malfunction
Details of online/Core Parameter Monitoring in Cycle Chemistry
Hydrazine
Hydrazine is a reducing agent that is frequently used in boiler feed water treatment to
promote oxygen removal. Hydrazine reacts with oxygen to form water and nitrogen and,
under certain conditions (e.g. temperatures > 270°C (518°F)), it can also decompose to
form ammonia and nitrogen. Hydrazine is also instrumental in promoting magnetite
(Fe3O4) formation which provides an iron oxide surface that consumes dissolved oxygen.
Reducing agents such as hydrazine are critical in mixed metallurgy systems (systems
containing copper alloys) to prevent copper corrosion due to amines in the presence of
dissolved oxygen.

it is often monitored in mixed metallurgy feed water cycles using reducing All Volatile
Treatment—AVT(R). This chemical treatment scheme refers to the feed water treatment
and is not influenced by further addition of phosphate or caustic in the boiler drum. The
prescribed location for this sample point is the DE aerator inlet, although many plants
sample the economizer inlet as well. Proper control of hydrazine as a reducing agent is
necessary to protect the copper alloys in the mixed metallurgy system from oxygen
attack. Overfeeding hydrazine can lead to excess ammonia in the system, which can
also be damaging to the copper alloys. Hydrazine federate can be indirectly controlled
by measurement of the oxidation reduction potential (ORP) of the system.
Details of online/Core Parameter Monitoring in Cycle Chemistry
Hydrazine
Significance of Monitoring

Hydrazine is continually monitored on-line/Offline in the plant for the following

reasons, listed in order of importance:

1.To check the accuracy of water chemistry control, so ensuring that corrosion rates
are kept at acceptably low levels.

2.To evaluation of other chemistry parameters (i.e., ORP and dissolved oxygen).

3. To provide feedback stimulus for automated process control.

Details of online/Core Parameter Monitoring in Cycle Chemistry
Iron & Copper
Iron and copper are not online /core parameter but it is suggested that samples be
taken and analysed periodically to measure corrosion product levels in the steam-
water cycle. Performance of corrosion product monitoring campaigns is a useful means
of verifying that the levels of corrosion product transport are consistent with those
which can be attained when the feed water treatment has been properly selected and
optimized. Transport of feed water corrosion products can cause problems in both
fossil and nuclear power plants. Iron and copper corrosion products are of primary
concern because of their relative abundance in power plant cycles. In thermal power
plants, transported corrosion products can form deposits on water-wall tubes under
high heat flux conditions, providing a site for concentration of impurities and potentially
leading to tube failures by caustic gouging, hydrogen damage, and low cycle corrosion
fatigue
Details of online/Core Parameter Monitoring in Cycle Chemistry
Iron & Copper
Significance of Monitoring
1.To facilitate the correlation of a water chemistry parameter with plant operating
variables.

2.To check the accuracy of water chemistry control (such as reducing agent, oxygen,
ammonia or pH), so ensuring that corrosion rates are kept at acceptable low levels.
 Stator Water System

In HEL SWAS panel apart from the cycle water chemistry parameter
we are provision for checking online parameter for Stator water pH
and Conductivity. As before Discuss about the work and indication
of pH and Conductivity same in Stator water system for minimise
the corrosion of stator coil and indication of ingress of impurities
and the standard limit discuss earlier .I am not going the detailed
about Stator chemistry ,Next ppt I will covered the Stator water
Chemistry.
Online parameters Monitoring performance and
Record by HEL water Chemistry team.
As we are part of chemistry team ,we are very careful about our cycle water chemistry
performance .So we are regularly monitoring and maintenance the SWAS parameter
and record keeping to evaluation the plant reliability run due to proper water
chemistry maintain
Action Taken BY HEL Chemistry Team
1.Every Two Hours SWAS online parameter Monitoring and w.r.t offline every 4 hours in our
Chemical Lab.

2.Proper Record keeping for performance evolution.

3.Various improvements taken for cation conductivity improvement such as proper

regeneration of resin, Calibration of sensor ,Frequently replace the resin etc.

4.Online Instrument regularly calibration by E & I Team.

5.Sample Temperature and flow maintain .

Online parameters Monitoring performance and
Record by HEL water Chemistry team.
Record Log Sheet and Case Studies
THANK YOU