Introduction to Advances in Power Plant Chemistry

Objectives and other details of modules

Duration – 90 minutes
Training aids
Power point Presentations
Objective
  At the end of the session participants will be able to:
 Describe advances made in boilers - design & size and chemical
control limits with reference to different types / sizes of boilers for:
●
Feed water
●
Steam water cycle
●
Superheated steam cycle
●
Condensates
 List out online and offline instruments in SWAS and purpose of
these instruments
 Use online and offline instruments for measuring parameters
related to water chemistry

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 Advances in Boiler design and
its implication for water chemistry

●
Double Drum Boiler – early 60s – 50-100MW
●
Single Drum with mud and clean compartment –
Russian design/Skoda-50, 100, 200 MW
●
Single Drum Boiler- BHEL based on CE
design/Alstom/Ansaldo - 210, 250, 500 MW, 600MW
(Chinese)
●
Drum less subcritical Boiler- Stain France - 500MW
●
Supercritical Boiler- BHEL based on Alstom design-
660, 800 MW, MHI, Ansaldo, Toshiba, Babcock – 660
MW

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Chemical Control Limits
in
Different Design Boiler
For
Steam-water Cycle
CHEMICAL CONTROL LIMITS FOR FEED WATER
OF 60,100 & 200 MW

SN Parameter 60 MW 100MW 200 MW

1 pH at 25oC 8.8-9.0 8.8-9.0 8.8-9.0

2 Cation Conductivity, µS/cm 0.3 0.3 0.2

3 Dissolved O2, µg/l, max 7 7 5
4 Silica, µg/l, max 20 20 20
5 Residual N2H4, µg/l 20-30 20-40 10-20
6 Total Fe, µg/l, max 10 10 10
7 Total Cu, µg/l, max 5 5 5
 CHEMICAL CONTROL LIMITS FOR FEED
WATER OF 500 MW AND ABOVE

SN Parameter 500 MW
1 pH at 25oC 9.0 – 9.2
2 Cation Conductivity, µS/cm 0.2
3 Dissolved O2, µg/l, max 5
4 Silica, µg/l, max 10
5 Residual N2H4, µg/l 10 – 20
6 Total Fe, µg/l, max 10
7 Total Cu, µg/l, max 3

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CHEMICAL CONTROL LIMITS OF STEAM-WATER
CYCLE OF 60,100 & 200 MW

SN Parameter 60 MW 100MW 200 MW

1 pH at 25oC 9.2 – 9.7 9.2 – 9.5 9.2 – 9.5

2 Sp. Conductivity, µS/cm, at 30 50 30

25oC, max
3 Silica, mg/l, max 2.5 1.5 0.4
4 Phosphate, mg/l 2–6 2–6 2-4
5 Chloride, mg/l, max 1.6 1.0 1.0

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CHEMICAL CONTROL LIMITS OF STEAM-WATER
CYCLE OF 500 MW & ABOVE

SN Parameter 500 MW
1 pH at 25oC 9.1 – 9.4
2 Sp. Conductivity, µS/cm, at 25oC, max 20
3 Silica, mg/l, max 0.1
4 Phosphate, mg/l 1–2
5 Chloride, mg/l, max 0.5

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CHEMICAL CONTROL LIMITS OF SUPERHEATED
STEAM CYCLE OF 60,100 & 200 MW

SN Parameter 60 MW 100MW 200 MW

1 pH at 25oC 8.8 – 9.0 8.8 – 9.0 8.8 – 9.0

2 Cation Conductivity, 0.35 0.3 0.2

µS/cm, at 25oC, max
3 Silica, µg/l, max 20 20 20
4 Sodium, µg/l, max 10 5 5
5 Ammonia, mg/l, max 0.5 0.5 0.5
6 Iron, µg/l, max 10 10 10
7 Copper, µg/l, max 58.8 5 5

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CHEMICAL CONTROL LIMITS OF SUPERHEATED
STEAM CYCLE OF 500 MW & ABOVE

SN Parameter 500 MW
1 pH at 25oC 9.0 – 9.2
2 Cation Conductivity, µS/cm, at 25oC, max 0.2
3 Silica, µg/l, max 10
4 Sodium, µg/l, max 5
5 Ammonia, mg/l, max 1.0
6 Iron, µg/l, max 10
7 Copper, µg/l, max 3

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CHEMICAL CONTROL LIMITS OF CONDENSATE OF
60,100 & 200 MW

SN Parameter 60 MW 100MW 200 MW

1 pH at 25oC 8.8 – 9.0 8.8 – 9.0 8.8 – 9.0

2 Cation Conductivity, 0.35 0.3 0.3

µS/cm, at 25oC, max
3 Silica, µg/l, max 20 20 20
4 Dissolved O2, µg/l, max 50 40 40
5 Ammonia, mg/l, max 0.5 0.5 0.5
6 Total Iron, µg/l, max 10 10 10
7 Total Copper, µg/l, max 5 5 5

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CHEMICAL CONTROL LIMITS OF CONDENSATE OF
500 MW & ABOVE

SN Parameter 500 MW
1 pH at 25oC 9.0 – 9.2
2 Cation Conductivity, µS/cm, at 25oC, max 0.2
3 Silica, µg/l, max 10
4 Dissolved O2, µg/l, max 40
5 Ammonia, mg/l, max 1.0
6 Total Iron, µg/l, max 10
7 Total Copper, µg/l, max 3
8 Sodium, µg/l, max 5

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CHEMICAL CONTROL LIMITS OF STEAM-WATER CYCLE
FOR POWER PLANT UNITS TREATED CONDENSATE
CPU In/Out)

S.N. PARAMETER 2x500MW 3x500MW 3x500MW

1. Type of CPU provided Deep MB Deep MB Deep MB
(Ammonex) (Consep) (Seprex)
IN/OUT IN/OUT IN/OUT
2. pH at 25oC, max -- 9.2/-- 9.2/--
3. Ammonia, µg/l, max -- 500/-- 500/--
4. --/0.1 --/0.1 --/0.1
Cation Conductivity, µS/cm, at
5. 25oC, max 20/5 20/5 20/5
6. Silica, µg/l 10/1 10/2 10/2
7. Sodium, µg/l 10/1 10/2 10/2
8.
Chloride, µg/l 50/5 50/5 50/5
9.
Iron, µg/l 5/2 5/2 5/2
10.
Copper, µg/l 100/25 100/25 100/25
11.
50/10 50.5/ 50/5
TDS, µg/l

Crud, µg/l
13
CHEMICAL CONTROL LIMITS OF STEAM-WATER CYCLE FOR
COAL/GAS BASED UNITS (100 & 200 MW) PRIMARY STATOR
WATER

SN Parameter 60 MW 100MW 200 MW

1 pH at 25oC 6.8 – 7.0

2 Sp. Conductivity, µS/cm, at Stator is Stator is 1.0

250C, max cooled cooled by
3 Dissolved O2, mg/l, max by H2 H2 1.0 – 4.5
4 Copper, µg/l, max -
5 Iron, µg/l, max -

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 COAL BASED UNITS (500 MW AND ABOVE)
PRIMARY STATOR WATER

SN Parameter 500 MW
1 pH at 25oC 8.5 – 9.0
2 Sp. Conductivity, µS/cm, at 250C, max 2.2
3 Dissolved O2, µg/l, max 10
4 Copper, µg/l, max 20
5 Iron, µg/l, max 20

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CHEMICAL CONTROL LIMITS OF STEAM-WATER CYCLE
FOR GAS/NAPHTHA BASED UNITS FEED WATER

SN Parameter 88MW 111.19M 106MW 144.3MW

(GT)+ W(GT) (GT) (GT)
149MW 109.3M 116.1MW 225MW
(ST) W(ST) (ST) (ST)

1 pH at 25oC 9.2 – 9.7 8.5 – 9.5 9.0 – 9.5 8.5 -9.5

2 Cation Conductivity, 0.2 0.2 0.2 0.2
µS/cm
3 Dissolved O2, µg/l, max 7 7 10 7
4 Silica, µg/l, max 20 20 20 20
5 Residual N2H4, µg/l, - 10 - 10
max
6 Total Fe, µg/l, max 20 20 20 30
7 Total Cu, µg/l, max 3 3 5 20

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CHEMICAL CONTROL LIMITS OF STEAM-WATER CYCLE
FOR GAS/NAPHTHA BASED UNITS BOILER WATER (HP
DRUM)

SN Parameter 88MW 111.19M 106MW 131

(GT)+ W(GT) (GT) MW(GT)
149MW 109.3MW 116.1MW 225MW
(ST) (ST) (ST) (ST)

1 pH at 25oC 9.8 – 10.2 9.2 – 10.3 9.5 – 10.5 9.0 – 9.8

2 Sp. Conductivity, µS/cm, 50 100 150 150
at 25oC, max
3 Silica, mg/l, max 4.0 2.0 2.0 2.0
4 Phosphate, mg/l, max 6 3 – 10 1 – 10 2-6
5 TDS, mg/l, max 100 100 100 100
6 Chloride, mg/l, max 10 10 10 10
7 Total Iron, mg/l, max 0.5 0.5 0.5 0.5
8 Total Copper, mg/l, max 0.1 0.1 0.1 0.1

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GAS/NAPHTHA BASED UNITS BOILER WATER
(LP DRUM)

SN Parameter 88MW 111.19M 106MW 131

(GT)+ W(GT) (GT) MW(GT)
149MW 109.3MW 116.1MW 225MW
(ST) (ST) (ST) (ST)

1 pH at 25oC 9.8 – 10.2 9.2 – 10.3 9.5 – 10.5 9.0 – 10.5

2 Sp. Conductivity, µS/cm, 50 100 150 150
at 25oC, max
3 Silica, mg/l, max 4.0 2.0 5.0 2.0
4 Phosphate, mg/l, max 6 3 – 10 10 – 20 15
5 TDS, mg/l, max 100 100 100 100
6 Chloride, mg/l, max 10 10 10 10

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CHEMICAL CONTROL LIMITS OF STEAM-WATER CYCLE FOR
GAS/NAPHTHA BASED UNITS MAIN STEAM

SN Parameter 3x88MW 4x111.19 4x106 3x144.3

(GT)+ MW(GT) MW (GT) MW(GT)
1x149 +2x109.3 +2x116.1 +1x225
MW (ST) MW(ST) MW (ST) MW (ST)

1 pH at 25oC 9.2 – 9.7 8.5 – 9.5 8.8 – 9.2 8.8 – 9.2

2 Cation Conductivity, 0.2 0.2 0.2 0.2
µS/cm, at 25oC, max
3 Silica, µg/l, max 20 20 20 20
4 Sodium, µg/l 10 - 10 10
5 Ammonia, mg/l, max - - - -
6 Iron, µg/l, max 20 - - 20
7 Copper, µg/l, max 3 - - 20
8 Chloride, µg/l, max - - - 3

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GAS/NAPHTHA BASED UNITS CONDENSATE

SN Parameter 3x88MW 4x111.19 4x106 3x144.3

(GT)+ MW(GT) MW (GT) MW(GT)
1x149 +2x109.3 +2x116.1 +1x225
MW (ST) MW(ST) MW (ST) MW (ST)

1 pH at 25oC 9.2 – 9.7 8.5 – 9.2 8.8 – 9.2 8.5 – 9.5

2 Cation Conductivity, 0.2 0.2 0.2 0.2
µS/cm, at 25oC, max
3 Silica, µg/l, max 20 20 20 20
4 Dissolved O2, µg/l, max 100 20 20 25
 SWAS

Online Instruments in SWAS

●
Silica Analyzer

●
Phosphate Analyzer

●
pH meter

●
Conductivity meter

●
ACC Conductivity meter

●
Hydrazine Analyzer

●
Ammonia Analyzer

●
Dissolved Oxygen Analyzer 21
 SWAS

OFF Line Instruments in SWAS

●
pH meter
●
Conductivity meter
●
Turbidity meter
●
Double
●
Double bean spectrophoto meter to analyze:
●
Silica
●
Ammonia
●
Hydrazine
●
Phosphate
●
Iron
●
Copper
22