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Power Plant Operator
Chemistry Training.
Prepared By : -
Syed Aqeel Ahmed
M.Tech, Chemical, MBA, G.M.
Stagger In-Charge
Chemistry & Environment
Hub Power Station, Pakistan,
Hub Power Service Ltd,
Hub Power Company Ltd.
At the end of the respective training course, the participants will
be able to:
• Understand the basics of Water Quality Control to avoid the scale
corrosion and biological growth in the Power plant system, and to
operate the mentioned at max performance.
• Understand the troubleshooting events to the plant chemistry system.
Main Objective
External Water Treatment
• It is the removal of impurities from water out side the (
Condenser ) in power plant because raw water taken
from open sea that contain a large number of impurities
with respect to surrounding , so it is very necessary to
make cleaned and purify the water before it entrance
to wards (Condenser/boiler)
Sea Water Impurities.
Electro chlorination Plant
Basic Concept
Product
NaOCL By Products
Electrolyser
Current Electrolysis
Sea Water
NaCl H2O
Manual dosing regime, in absence of
Electro chlorination Plant
• Each cane contain 30 kgs of 15%
NaO’Cl concentration.
• Dosing half cane every after six
hour in each bay.
External Water Treatment
 Practically all surface water contain small
amount of mud, clay ,silt ,decayed, vegetation,
Micro Organisms etc.
To obtain required quantity of water
various techniques are applied Such as
Clarification ,Filtration ,Evaporation ,Softening,
Desalination (MED, MSF & RO ) , Ion
Exchange.
Thermal Desalination, MED
 Multi-Effect distillation (MED) is a
water desalination process that distill
sea water by flashing a portion of the
water into steam in multiple stages.
The strict control of operation
parameters plays vital role for
availability of MED.
Anti scalant chemical Belgard-EV is
being used to maintain 4 ~ 6 ppm in
feed water.
Demineralization
 Removal of all kind of ion from water by ion exchange is
called demineralization. Any salt dissolved in water
consist of two types of ions, +Ve ion called cat ion and
-Ve ion's called anion . In demineralization process cat
ion and anion present in water are removed one after
other by organic ion exchange resin
The organic resin's are of two types
 Strong Cat ion resin R-HSO3 Sulphonic group
 Strong anion resin R-NH3OH Amino group
Cat ion Exchangers
Strong Cat ion
 A regenerated strong cat ion resins has
sulphonic functional group (-HSO3) and
removes cat ions, from water as given
below.
 2RSO3.H + CaSO4 (RSO3)2 Ca+H2SO4
 2RSO3.H + CaCl2 Strong Acid
 2RSO3.H + Ca(NO3)2
 2RSO3.H + Ca(HCO3)2
(RSO3)2 Ca+2HCl
(RSO3)2 Ca+2HNO3
(RSO3)2 Ca+2H2CO3 Weak Acid
 The water at the outlet of strong cat ion exchanger cat
ion strong acids ( HCl , H2SO4 , & HNO3 )
Anion Exchanger
Strong anion
 This filter remove anion of both weak acids and strong acids.
(RNH3)2CO3 +2H2O
(RNH3)2SiO3 +2H2O
RNH3Cl +H2O
(RNH3)2SO4 +2H2O
 2RNH3.OH + H2CO3
 2RNH3.OH + H2SiO3
 2RNH3.OH + HCl
 2RNH3.OH + H2SO4
 Alkali Treatment
 NaOH is used passed through the filter.This filter is stopped for
regeneration when SiO2 content increasing trend.
Mix Bed Filter
 The filter bed contain strong cat ion The cat ion and
anion resin are so intimately mixed that water following
through the bed may be considered to have comes
across a large number of small strong cat ion and
strong anion beds. The water at the outlet of mix bed is
of higher quality purity and its conductivity may be low
as 0.05 µS/cm.
Increase in silica content of effluent water
of the mixed bed is a signal of exhaustion of strong
anion resin and increase of conductivity means
exhaustion of cat ion resin.
REGENERATION OF CATION & ANION EXCHANGER.
When all the H ion of the cation exchanger and when all the
hydroxyl OH ion of the anion resin are consumed in
removing cation & anions from the water, the resin will no
more remove cation & anion from water, then it is said to
have exhausted.
The cation’s exhausted resin are replaced by H ion of the
acid (HCl) the exhausted anion resin is regenerated with
sodium hydroxide (NaOH) to make it useful once again.
RSO3. Ca + 2HCl → RSO3. H + CaCl2
RNH3. Cl + NaOH → RNH3. OH + NaCl.
SPECIFIC CONDUCTIVITY
Tomaintain conductivity levels within
acceptable limits.
Tofacilitate the correlation of a water chemistry
parameter (e.g.,pH, conductivity, ammonia correlation).
Tocheck the accuracy of water chemistrycontrol (such
as ammonia orpH).
Towarn of condenser tube leakage/seepage.
Towarn of condensate polishermalfunction.
Conductivity: Meter
Measuring the conductivity is an
accurate way to determine salinity.
Conductivity of ions is measured using the
following two units…
Freshwater = micro Siemens (µS)
Saltwater = milli Siemens (mS)
Troubleshooting High Purity Conductivity Measurements
Symptom Possible Cause—Corrective Action
Grab sample conductivity reads
higher than on-line sample
 Grab sample is exposed to air too long, allowing significant
absorption of CO2.—Seal grab sample better or measure from
flowing sample.
 Grab sample sensor and/or container are contaminated.—
Rinse longer.
 Portable instrument has inadequate temperature compensation.—
Use on-line instrument type as portable.
Grab sample conductivity reads
lower than on-line sample
 Portable instrument has inadequate temperature compensation—
Use on-line instrument type as portable.
Conductivity reads high or off-scale  DI Resin beads or fines are trapped between sensor electrodes—
Clean sensor.
 Instrument has inadequate temperature compensation.—Check
setting, replace instrument.
Conductivity reads low or cycles
down and up
 In makeup water, gas bubbles form in the sensor due to pressure drop,
temperature rise and/or CO2 release. When bubbles are large enough,
they dislodge and new ones begin to form. Repetition of this causes
cycling.—Increase flowrate and/or relocate sensor into more turbulent
flow to carry away bubbles.
 In makeup water system, sensor is located in or after a “deadleg” which
is very slowly rinsed after regeneration.—Revise piping.
 Cable between instrument and sensor is too long— limit length to
system specifications.
 Instrument has inadequate temperature compensation.—Check
setting, replace instrument.
SIGNIFICANCE OF pH MONITORING
• Tomaintain pH levels within acceptablelimits.
• Corrosion of metals and alloys is a functionof pH.
• AlkalinepHvalues increasethestabilityof the oxide
film and reduceoxidesolubilityinwater.
• Tofacilitate the correlation between two or more water
chemistry parameter (e.g., pH, conductivity, ammonia
correlation).
• Toprovide a feedback signal forautomated
chemical dosing and processcontrol.
• Towarn of in-leakage ofcontaminants.
• Towarn of condensate polishermalfunction
Measuring pH
Using a meter
“Calibrate the probe and meter according to the
manufacturer’s directions. Use of two buffers (pH 7
and 9) for calibration is recommended.”
Internal Water
Treatment
 The term internal water treatment describe
the reaction induced with in the boiler
system to render the water less harmful to
system operation .
The main features of internal
water treatment are summarized on the
next slides.
Internal Water Treatment
Prevention scale by
1) Ether precipitating chelating the hardness in water
2) Maintaining the sufficient alkalinity for appropriate
chemical reaction.
3) Sludge conditioning to keep the suspended particle in
non adhering state.
4) Maintaining total dissolve solid with in limit.
Prevention of Corrosion.
In Boiler by
1) Scavenging oxygen formulation of protective film .
2) Maintaining sufficient alkalinity neutralizing CO2
formulation of protective film.
Oxygen Scavenger
An oxygen scavenger is a chemical which
remove dissolve O2 in H2O by a reduction reaction and
there by inhibits to corrosion cause by the O2.
Hydrazine
Hydrazine ( N2H4 ) can economically remove
small amount of dissolved oxygen . In addition it acts to
produce nitrogen and water thereby leaving the TDS
level of water un effected.
 N2H4 + O2 N2 + 2H2O
Theoretically 1ppm of hydrazine is required to
react with 1ppm dissolved “ O2 “ but actually 1.5 to 2.0
ppm of N2H4 are required per 1ppm “ O2”
Hydrazine also react with Fe2O3 in the boiler
water to form a passive magnitide film on the boiler
internal surface preventing form the corrosion.
 N2H4 + 6Fe2O3 4Fe3O4 + N2 + 2H2O
Hydrazine
Thermal decomposition of hydrazine
takes place above 270 °C.
N2H4 NH3 + N2
Treatment for Condensate line
 Neutralizing Amines
Volatile or
neutralizing amines are employed
as corrosion inhibitors to prevent
Co2 corrosion . They neutralize
carbonic acid and raise
condensate pH . Volatile amine
are
1) Ammonia NH3
2) Cyclohexyl amine C6H11NH2
3) Morph line C4H4ONH
Neutralizing Amines
These amine are injected to
the feed water .The amine added to the
feed water volatizes together with the
steam generated in the boiler with the
condensation of steam . The amine
neutralizes Co2 to raise pH of condensate
and thereby inhibits corrosion .
NH3 + H2O
C6H11NH2 + CO2+ H2O
C4H8ONH +CO2 + H2O
NH4+HCO3
C6H11NH3+HCO3
C4H8ONH2+HCO3
Filming Amines
These represent an effective
economical approach to condensate
system corrosion control.
The purpose of filming amines in
the formation of an adherent mono
molecular film providing protection from O2
and Co2 corrosion . First the film is build up
then only the amount of amines is required
to maintain the film .
Typical Filming Amines
1) Octa decyl amine
2) Hexa decyle amine
CH3(CH2)16 CH2NH2
CH3(CH2)14CH2CH2
3) Di Octa decyle amine CH3 (CH2)16(CH2)2NH2
The general formula for filming amine is
R-NH2 where R= Alkyl group ( C10 – C12 ) the
corrosion inhibits . The effect of filming amines
on the steel material increases proportionally
with the increased number of carbon atoms.
The amines when feed in the boiler ,
also volatize with steam and condense to form
an organic film in condensate line .
AFTER CATION COLUMN CONDUCTIVITY(ACCC
Themeasurement wasadopted for
monitoring the power plantsteam
/ water cycle asit candetect low levels
of anion contaminantssuch as
chlorides, sulphates, and organic acids
(parts per billion) on acontinuous
basis,while at the sametime the
measurement is very simple and easy
to maintain.
REACTIVE SILICA
Tomaintain silica levels within acceptablelimits.
Towarn of in-leakageofcontaminants.
To facilitate the correlation of a water chemistry parameter
with plant operating variables, with an aim to optimizing
operations.
To check the accuracy of water chemistry control (for silica),
so ensuring that carry-over and deposit rates are kept at
acceptablelowlevels.
Towarn of condensatepolishermalfunction.
HYDRAZINE
Hydrazine is monitored in mixedmetallurgyfeedwater cyclesusing reducingAll VolatileTreatment
-AVT(R).Itis monitoredintheplantforthefollowing reasons:
Tomaintain hydrazine levelswithin acceptable limits.
Toevaluation of other chemistryparameters (i.e., ORP
anddissolvedoxygen).
Toprovidefeedbackstimulusforautomated
processcontrol.
CHLORIDE
Elevatedchlorideconcentrationsintheboiler canlead tocorrosiveconditions
which candamage thewater walltubes.
Towarn of in-leakage of contaminants(primarily condenser
coolingwater ingress).
Tofacilitate the correlation with other chemistry
parameters (i.e., cationconductivity).
Tocheckthe accuracyof water chemistry control (for chloride), so
ensuring that carryover and deposit rates are kept at acceptable
lowlevels.
Towarn of condensatepolishermalfunction.
Towarn of make-updemineralizermalfunction.
PHOSPHATE
Phosphateisa CoreMonitoring Parameterforboilers with Phosphate
Treatment.It ismonitoredintheplantforthefollowing reasons:
To maintain phosphate levels withinacceptable limits.
To checktheaccuracyof water chemistry control(suchas
thesodium-to-phosphatemolar ratio).
To facilitatethecorrelation ofphosphate
contentwith plant operatingvariables.
To warn of in-leakageofcontaminants.
AMMONIA
Ammonia is monitored to:
Checktheaccuracyof water chemistrycontrol,so
ensuringthat corrosionratesarekeptat
acceptable lowlevels.
Facilitatethecorrelationof ammonia with
otherchemistry parameters(i.e.,pHand
specific conductivity).
SODIUM
Sodiumis aCoreMonitoringParameter.It should bemonitored
continuously on-line to checkthe acceptabilityof water chemistry,
therebyensuring that corrosionratesarekeptat low levels.
Tomaintain sodium levels within acceptablelimits.
Towarn of in-leakage ofcontaminants.
Towarn of boiler watercarryover.
Toidentify cooling water in-leakage at the mainsteam
condenser.
Towarn of condensate polishermalfunction.
DISSOLVE OXYGEN
Tomaintain dissolved oxygen levelswithin
acceptable limits.
Tocheckthe accuracyof water chemistrycontrol,
so ensuring that corrosion rates are kept at
acceptable low levels.
Tofacilitate the correlation of a water chemistry
parameter with plant operating variables, withan
aim to optimizing operations (e.g., condenser air
removal or de-aeratoroperations).
IRON AND COPPER
Iron and copper areanalyzed periodically tomeasure corrosion
product levels in the steam-water cycle.Corrosion product
monitoring in the plant is conducted primarily for thefollowing
reasons:
Tofacilitate the correlation of a water
chemistry parameter with plantoperating
variables.
Tocheckthe accuracyof water chemistry
control (such as reducing agent, oxygen,
ammonia or pH),so ensuring thatcorrosion
rates arekeptat acceptable lowlevels.
CONDENSER LEAKAGE
A potential major source of ingress of
impurity into the boiler water system is from
leakage of cooling water into the main
condenser steam space (because steam
space is maintained by vacuum) which is
called condenser leakage.
DETECTION OF CONDENSER LEAKAGE
Online sodium increases (normal < 2 ppb). After
cation conductivity increases (normal <0.2
µS/cm.
Chloride ion will go on increasing and can not be
controlled with out operation of CBD.
Condensate, Feed train and in Boiler Drum, Total
Hardness may also appear and increase after
approximate 5 ppm Chloride ion, (in sea water
cooled condenser).
PREVENTIVE/REMEDIAL ACTION
1. Open CBD10 0 %, makeup will go high. (Heat as well as
DM water loss).
2. Increaset he concent rat ion of Sodum Hydroxide and free
alkalinity in boiler.
3. Limit/close as for as possible the boiler de-
superheater spray water to prevent contamination of
the system.
4. Isolate one pat h of condenser, and see the results
and vice versa.
5. Put CPU into service if available.
LEAK LOCATION
If the leak is in minor in nature:
In running units, isolate one half the condenser
at a time and monitor the chemical parameter s
and find out which half is leaking. Isolate the
leaky half por tion. Plug or repair the leak .
Normalize and comeback to full load.
LOCATING THE SPECIFIC LEAK
• First is path detection
• Flood test
• Candle Test
• Dye test
• Foam Test
CONDENSATE POLISHING UNIT
Condensate polishing is employed to
purify the return steam condensate in
order to meet the quality requirements of
high pressure thermal cycles and
minimize consumption of make-up
water.
BENEFITS OF USING CONDENSATE POLISHING UNITS.
• Improvement in the quality of condensate and cycle clean-up.
• Reduce blow down and mak up requirement,
• Improvement in Boiler water quality for Drum type Boilers.
• Quick start-up and as a result full load condition are reached
early giving economics.
8H
FI
PI
FIA
*
* LL * LL
L
* LL
* L * L *
*
TEMPPRESS
CTRL
WATER TANK
VENT
TO ROOF
O.C.E C.E
MAKE-UP
( DEMIN )
STATOR WATER SYSTEM
SWS1.DRW
FI
FSA
PA
PC
FA
TI
TR
DP
QSA
PI
*
FLOW INDICATION
FLOW ALARM
FLOW ALARM EMERG
PRESS INDICATION
PRESS ALARM
PRESS CONTROLLER
DIFF PRESSURE
TEMP INDICATION
TEMP RECORDER
ACTION
CONDUCTIVITY MONITOR
ALARM OR INDIC TO CCR
CENTRIFUGAL
PUMPS
STOP CHECK
VALVES
QSI CONDUCTIVITY INDIC
RESIN
BED
FSAFSA
FI
FSA
QIA
*
DP
TR
TR
TA
FA
TI TR TR
*TA
TSA
TSA
QIAY
TR
DV
DV
TI
PI
PA
CTRLFI
DP
DP
PC
PCPI
TI
TR
TR
TA
FIA
PA PA
TSA ***
*
LA
PI QAI
LA
PI
H2 INLET VALVE
H2 OUTLET VALVE
AIR INLET TO STATOR WATER TANK FROM SLMS
1 2
1
2
SAMPLE INLET TO SLMS
SAMPLE OUTLET FROM SLMS
DRAIN VALVE # 2
EXISTING DRAIN VALVE # 1
AIR OUTLET VALVE #1
AIR OUTLET VALVE # 2
O2
DO2 SENSOR TO SLMS
FROM SLMS
35
33
31
32
34
18
17
Chemical waste water control
(without boiler washing water).
Chemical waste water control by WWTP by using HCl &
NaoH maintain water PH from 6 to 9
• Chemical washing wastes arising from operation and maintenance activities
will be collected via an installed drains network and transferred to the Waste
Water Treatment Plant. The treated effluent, suitable for disposal, will be let into
the CW outlet.
Boiler washing Chemical waste water
control
• Boiler washing Chemical waste water also control by WWTP with
clarification unit by using NaoH & coagulant & separated sludge
collect in sludge bed & then dump into the control waste.
WASTE WATER TREATMENT
Task of Chemical Drain in Retention Basin, Boiler & GAH
Wash Water Effluent from Storage Pond to maintain and
eliminate:
a) Suspended solids
• Metals
b) Coloids – substances of:
• variable size
• variable charge
Methods of pretretment:
Direct separation – sedimentation, filtration, ultrafiltration or
microfiltration
Coagulation and separation – ultrafiltration, nanofiltration or reverse
osmosis
Clarification (coagulation + flocculation -sedimantation) – acid, neutral and
alcalic
ClaRification of feed water
Clarification is composed of:
• coagulation - elemination of particle charge
• flocculation - formation of flakes and their sedimentation
• sedimentation (filtration) – separation of the flakes
Clarification depends upon pH value of the water – different techiques:
• Acidic clarification
• Neutral clarification
• Alkaline clarification
Acidic clarification (pH < 7)
Fe3+(coagulant) + 3 HCO3
- = Fe(OH)3 + 3 CO2 at pH 5.5 – 7.0
Neutral clarification (pH= 6 -8)
Clarification agent: coagulant + NaOH = neutral flakes
Alkaline clarification (pH >10)
Fe3+(coagulant) + 3 HCO3
- = Fe(OH)3 + 3 CO2
2 CO2 + Ca(OH)2 = Ca(HCO3)2+ Ca(OH)2 = 2 CaCO3 + 2 H2O
ClaRification of feed water
Floculation
• Speed of floculation – concentration of sediment x imput of energy (mixing) x tim
• Two stages of floculation
- perikinetics phase (Brown motion of particles)
- ortokinetics phase (mixing or other agitation)
Sedimentation
• Separation of flake in sediment cloud
Filtration
• One – component sand filters
• Multi-component sand filters
Gas Air Heater
Water Wash Water
Economiser
Wash Water
Wash Down
Sump
Storage
Pond
Clarifier Tank
Sludge Beds Sump
Retension Basin
Demin Effluant Aux. Blr. Drains
Demin Basin
Sump
Ph Adjustment Tank
Discharge To Sea
Coagulent
Recirculation If Ph Not in limits
Chemical Injection Balance
Mixer
Mixer
Ph Feedback
Caustic
Caustic
Pumps
Pumps
Pumps
Waste water System
Simplified Drawing
LS
FROM NaOH STORAGE TANK
OIL SEPERATION
& OIL YARD DRAIN
CHEMICAL DRAIN
AUX BOILER
DRAIN
REGENERATI
ON
DEMIN BASIN SUMP RETENTION BASIN+ PUMPS
No 1 NaOH
DOSING
TANK
COAGULANT
DOSING TANK
No 2 NaOH
DOSING
TANK
HCL
DOSING
TANK
P.H. ADJUSTMENT
TANK
SLUDGE DRYING BEDS
SUPERNATAN SUMP
& PUMPS
OPENGULLEY
STORAGE POND
& PUMPS
CLARIFICATION
PACKAGE UNIT
EFFLUENT PUMPS
LS LS
FROM HCL STORAGE TANK
LS
WASTE WATER TREATMENT PLANT
10% Ferric
Chloride
pH controlled
LS LS
GAS AIR
HEATER
WASHING
WATER
No 1 WASHDOWN
SUMP & SUMP PUMPS
PUMP
CONTROLS
LS LS
GAS AIR
HEATER
WASHING
WATER
No 2 WASHDOWN
SUMP & SUMP PUMPS
PUMP
CONTROLS
PUMP
CONTROLS
L
LS LS
& SUMP PUMPS
PUMP
CONTROLS
LS P
P
PUMP
CONTROLS
L L
L
LSLS
PUMP
CONTROLS
PUMP
CONTROLS
8
4
6
Hub Power Station
27
7
8
19
42
3
5
13a 13a
14
20
20
29
29
13
13
13 13
12 12 12 12
1
1c
11
9a
45
10
15
38 22
26
24
23
23a
2
17
3737
30
31
18
RISING STATION CHEMICAL
WATER
DRAINS LAYOUT
16 16 1616
1b
21
21
21
21
21a
32
33
29a29a
36
46
34
1a
44
39
47
9
RS1
0
Building Sources
1-T.G building # 12.
2-Chemical store building # 18.
3-Hydrogen building # 11
4-Stack building # 14..
5-Control/D.G building # 30.
6-Demin drain basin. building # 5.
7-Aux.-boiler building # 10.
8-Chlorination building # 1.
..
7
RS-09
RS0
8
RS-21 RS-20 RS-19 RS-18
Cond Pit Cond Pit Cond Pit Cond Pit
RS-17
RS-16 RS-15 RS-14 RS-13
Foul Water Foul Water Foul Water Foul Water
RS-22
Note: Rising station #13 to #16 & #18 to #21
are not the chemical water drain but discharge is connected
with RS #10. The layout is provided just for taking an idea.
Shift C Shahid Ansari
8
4
6
Hub Power Station
27
7
8
19
42
3
5
13a 13a
14
20
20
29
29
13
13
13 13
12 12 12 12
1
1c
11
9a
45
10
15
38 22
26
24
23
23a
2
17
3737
30
31
18
RISING STATION
OILYWATER
DRAINS LAYOUT
16 16 1616
1b
21
21
21
21
21a
32
33
29a
29a
36
46
34
1a
44
39
47
9
Building Sources
1-T.G building # 12.
2-Transformers building #16.
3-Workshop building # 24.
4-F.O metering building # 32...
5-Control/D.G building # 30.
6-Boilers. building # 13..
7-Aux.-boiler building # 10.
8-F.O transfer building #19..
9-Unit F.O pump building # 20.
10-F.O Service tanks building # 28..
7
RS-06
RS-17
RS-22
RS
07
RS-05
RS-01 RS-02 RS-03 RS-04
4MKC 3MKC 1MKC2MKC
4BAT
4BBT 3BBT
3BAT 2BAT
2BBT6BCT 5BCT
1BAT
1BBT
Shift C Shahid Ansari
8
4
6
Hub Power Station
27
7
8
19
42
3
5
13a 13a
14
20
20
29
29
13
13
13 13
12 12 12 12
1
1c
11
9a45
10
15
38 22
26
24
23
23a
2
17
3737
30
31
18
RISING STATION SEWAGE
WATER
DRAINS LAYOUT
16 16 1616
1b
21
21
21
21
21a
32
33
29a29a
36
46
34
1a
44
39
47
9
RS-11
RS-12
Building Sources
1-T.G building # 12.
2-Switch yard building # 23.
3-Workshop building # 24.
4-Admin building # 26.
5-Control building # 30.
6-Aux. Elec. building # 37.
7-Re-boiler building # 38.
7
RS-22
RS-17
Shift C Shahid Ansari
World Bank Guidelines - Reporting of Releases
Parameter Limit & Sample Point
BOD No limit quoted Sewage plant discharge .
pH Between 6 and 9 Waste water plant final discharge.
Suspended solids 30mg/l discharge - taken as difference
across the cooling water inlet and outlet
Cooling water intake and effluent of
WWTP effluent discharge,
Sewage plant discharge.
Temperature Max. 3°C increase across Inlet and Outfall
Cooling water intake and Outfall
Temperature at Hubco Marina.
Oil & Grease 20mg/l Waste water plant discharge
Chlorine 0.2mg/l Ave 0.5mg/l MAX. Outgoing Cooling water
at discharge plume (b)
T.D.S <10% Increase across Cooling water Inlet and
Outfall Cooling water intake and outfall.
Thank you.

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Power Plant Operator Chemistry Training

  • 1. Power Plant Operator Chemistry Training. Prepared By : - Syed Aqeel Ahmed M.Tech, Chemical, MBA, G.M. Stagger In-Charge Chemistry & Environment Hub Power Station, Pakistan, Hub Power Service Ltd, Hub Power Company Ltd.
  • 2. At the end of the respective training course, the participants will be able to: • Understand the basics of Water Quality Control to avoid the scale corrosion and biological growth in the Power plant system, and to operate the mentioned at max performance. • Understand the troubleshooting events to the plant chemistry system. Main Objective
  • 3. External Water Treatment • It is the removal of impurities from water out side the ( Condenser ) in power plant because raw water taken from open sea that contain a large number of impurities with respect to surrounding , so it is very necessary to make cleaned and purify the water before it entrance to wards (Condenser/boiler)
  • 6. Basic Concept Product NaOCL By Products Electrolyser Current Electrolysis Sea Water NaCl H2O
  • 7. Manual dosing regime, in absence of Electro chlorination Plant • Each cane contain 30 kgs of 15% NaO’Cl concentration. • Dosing half cane every after six hour in each bay.
  • 8. External Water Treatment  Practically all surface water contain small amount of mud, clay ,silt ,decayed, vegetation, Micro Organisms etc. To obtain required quantity of water various techniques are applied Such as Clarification ,Filtration ,Evaporation ,Softening, Desalination (MED, MSF & RO ) , Ion Exchange.
  • 9. Thermal Desalination, MED  Multi-Effect distillation (MED) is a water desalination process that distill sea water by flashing a portion of the water into steam in multiple stages. The strict control of operation parameters plays vital role for availability of MED. Anti scalant chemical Belgard-EV is being used to maintain 4 ~ 6 ppm in feed water.
  • 10. Demineralization  Removal of all kind of ion from water by ion exchange is called demineralization. Any salt dissolved in water consist of two types of ions, +Ve ion called cat ion and -Ve ion's called anion . In demineralization process cat ion and anion present in water are removed one after other by organic ion exchange resin The organic resin's are of two types  Strong Cat ion resin R-HSO3 Sulphonic group  Strong anion resin R-NH3OH Amino group
  • 11. Cat ion Exchangers Strong Cat ion  A regenerated strong cat ion resins has sulphonic functional group (-HSO3) and removes cat ions, from water as given below.  2RSO3.H + CaSO4 (RSO3)2 Ca+H2SO4  2RSO3.H + CaCl2 Strong Acid  2RSO3.H + Ca(NO3)2  2RSO3.H + Ca(HCO3)2 (RSO3)2 Ca+2HCl (RSO3)2 Ca+2HNO3 (RSO3)2 Ca+2H2CO3 Weak Acid  The water at the outlet of strong cat ion exchanger cat ion strong acids ( HCl , H2SO4 , & HNO3 )
  • 12. Anion Exchanger Strong anion  This filter remove anion of both weak acids and strong acids. (RNH3)2CO3 +2H2O (RNH3)2SiO3 +2H2O RNH3Cl +H2O (RNH3)2SO4 +2H2O  2RNH3.OH + H2CO3  2RNH3.OH + H2SiO3  2RNH3.OH + HCl  2RNH3.OH + H2SO4  Alkali Treatment  NaOH is used passed through the filter.This filter is stopped for regeneration when SiO2 content increasing trend.
  • 13. Mix Bed Filter  The filter bed contain strong cat ion The cat ion and anion resin are so intimately mixed that water following through the bed may be considered to have comes across a large number of small strong cat ion and strong anion beds. The water at the outlet of mix bed is of higher quality purity and its conductivity may be low as 0.05 µS/cm. Increase in silica content of effluent water of the mixed bed is a signal of exhaustion of strong anion resin and increase of conductivity means exhaustion of cat ion resin.
  • 14. REGENERATION OF CATION & ANION EXCHANGER. When all the H ion of the cation exchanger and when all the hydroxyl OH ion of the anion resin are consumed in removing cation & anions from the water, the resin will no more remove cation & anion from water, then it is said to have exhausted. The cation’s exhausted resin are replaced by H ion of the acid (HCl) the exhausted anion resin is regenerated with sodium hydroxide (NaOH) to make it useful once again. RSO3. Ca + 2HCl → RSO3. H + CaCl2 RNH3. Cl + NaOH → RNH3. OH + NaCl.
  • 15. SPECIFIC CONDUCTIVITY Tomaintain conductivity levels within acceptable limits. Tofacilitate the correlation of a water chemistry parameter (e.g.,pH, conductivity, ammonia correlation). Tocheck the accuracy of water chemistrycontrol (such as ammonia orpH). Towarn of condenser tube leakage/seepage. Towarn of condensate polishermalfunction.
  • 16. Conductivity: Meter Measuring the conductivity is an accurate way to determine salinity. Conductivity of ions is measured using the following two units… Freshwater = micro Siemens (µS) Saltwater = milli Siemens (mS)
  • 17. Troubleshooting High Purity Conductivity Measurements Symptom Possible Cause—Corrective Action Grab sample conductivity reads higher than on-line sample  Grab sample is exposed to air too long, allowing significant absorption of CO2.—Seal grab sample better or measure from flowing sample.  Grab sample sensor and/or container are contaminated.— Rinse longer.  Portable instrument has inadequate temperature compensation.— Use on-line instrument type as portable. Grab sample conductivity reads lower than on-line sample  Portable instrument has inadequate temperature compensation— Use on-line instrument type as portable. Conductivity reads high or off-scale  DI Resin beads or fines are trapped between sensor electrodes— Clean sensor.  Instrument has inadequate temperature compensation.—Check setting, replace instrument. Conductivity reads low or cycles down and up  In makeup water, gas bubbles form in the sensor due to pressure drop, temperature rise and/or CO2 release. When bubbles are large enough, they dislodge and new ones begin to form. Repetition of this causes cycling.—Increase flowrate and/or relocate sensor into more turbulent flow to carry away bubbles.  In makeup water system, sensor is located in or after a “deadleg” which is very slowly rinsed after regeneration.—Revise piping.  Cable between instrument and sensor is too long— limit length to system specifications.  Instrument has inadequate temperature compensation.—Check setting, replace instrument.
  • 18. SIGNIFICANCE OF pH MONITORING • Tomaintain pH levels within acceptablelimits. • Corrosion of metals and alloys is a functionof pH. • AlkalinepHvalues increasethestabilityof the oxide film and reduceoxidesolubilityinwater. • Tofacilitate the correlation between two or more water chemistry parameter (e.g., pH, conductivity, ammonia correlation). • Toprovide a feedback signal forautomated chemical dosing and processcontrol. • Towarn of in-leakage ofcontaminants. • Towarn of condensate polishermalfunction
  • 19. Measuring pH Using a meter “Calibrate the probe and meter according to the manufacturer’s directions. Use of two buffers (pH 7 and 9) for calibration is recommended.”
  • 20. Internal Water Treatment  The term internal water treatment describe the reaction induced with in the boiler system to render the water less harmful to system operation . The main features of internal water treatment are summarized on the next slides.
  • 21. Internal Water Treatment Prevention scale by 1) Ether precipitating chelating the hardness in water 2) Maintaining the sufficient alkalinity for appropriate chemical reaction. 3) Sludge conditioning to keep the suspended particle in non adhering state. 4) Maintaining total dissolve solid with in limit. Prevention of Corrosion. In Boiler by 1) Scavenging oxygen formulation of protective film . 2) Maintaining sufficient alkalinity neutralizing CO2 formulation of protective film.
  • 22. Oxygen Scavenger An oxygen scavenger is a chemical which remove dissolve O2 in H2O by a reduction reaction and there by inhibits to corrosion cause by the O2.
  • 23. Hydrazine Hydrazine ( N2H4 ) can economically remove small amount of dissolved oxygen . In addition it acts to produce nitrogen and water thereby leaving the TDS level of water un effected.  N2H4 + O2 N2 + 2H2O Theoretically 1ppm of hydrazine is required to react with 1ppm dissolved “ O2 “ but actually 1.5 to 2.0 ppm of N2H4 are required per 1ppm “ O2” Hydrazine also react with Fe2O3 in the boiler water to form a passive magnitide film on the boiler internal surface preventing form the corrosion.  N2H4 + 6Fe2O3 4Fe3O4 + N2 + 2H2O
  • 24. Hydrazine Thermal decomposition of hydrazine takes place above 270 °C. N2H4 NH3 + N2
  • 25. Treatment for Condensate line  Neutralizing Amines Volatile or neutralizing amines are employed as corrosion inhibitors to prevent Co2 corrosion . They neutralize carbonic acid and raise condensate pH . Volatile amine are 1) Ammonia NH3 2) Cyclohexyl amine C6H11NH2 3) Morph line C4H4ONH
  • 26. Neutralizing Amines These amine are injected to the feed water .The amine added to the feed water volatizes together with the steam generated in the boiler with the condensation of steam . The amine neutralizes Co2 to raise pH of condensate and thereby inhibits corrosion . NH3 + H2O C6H11NH2 + CO2+ H2O C4H8ONH +CO2 + H2O NH4+HCO3 C6H11NH3+HCO3 C4H8ONH2+HCO3
  • 27. Filming Amines These represent an effective economical approach to condensate system corrosion control. The purpose of filming amines in the formation of an adherent mono molecular film providing protection from O2 and Co2 corrosion . First the film is build up then only the amount of amines is required to maintain the film .
  • 28. Typical Filming Amines 1) Octa decyl amine 2) Hexa decyle amine CH3(CH2)16 CH2NH2 CH3(CH2)14CH2CH2 3) Di Octa decyle amine CH3 (CH2)16(CH2)2NH2 The general formula for filming amine is R-NH2 where R= Alkyl group ( C10 – C12 ) the corrosion inhibits . The effect of filming amines on the steel material increases proportionally with the increased number of carbon atoms. The amines when feed in the boiler , also volatize with steam and condense to form an organic film in condensate line .
  • 29. AFTER CATION COLUMN CONDUCTIVITY(ACCC Themeasurement wasadopted for monitoring the power plantsteam / water cycle asit candetect low levels of anion contaminantssuch as chlorides, sulphates, and organic acids (parts per billion) on acontinuous basis,while at the sametime the measurement is very simple and easy to maintain.
  • 30. REACTIVE SILICA Tomaintain silica levels within acceptablelimits. Towarn of in-leakageofcontaminants. To facilitate the correlation of a water chemistry parameter with plant operating variables, with an aim to optimizing operations. To check the accuracy of water chemistry control (for silica), so ensuring that carry-over and deposit rates are kept at acceptablelowlevels. Towarn of condensatepolishermalfunction.
  • 31. HYDRAZINE Hydrazine is monitored in mixedmetallurgyfeedwater cyclesusing reducingAll VolatileTreatment -AVT(R).Itis monitoredintheplantforthefollowing reasons: Tomaintain hydrazine levelswithin acceptable limits. Toevaluation of other chemistryparameters (i.e., ORP anddissolvedoxygen). Toprovidefeedbackstimulusforautomated processcontrol.
  • 32. CHLORIDE Elevatedchlorideconcentrationsintheboiler canlead tocorrosiveconditions which candamage thewater walltubes. Towarn of in-leakage of contaminants(primarily condenser coolingwater ingress). Tofacilitate the correlation with other chemistry parameters (i.e., cationconductivity). Tocheckthe accuracyof water chemistry control (for chloride), so ensuring that carryover and deposit rates are kept at acceptable lowlevels. Towarn of condensatepolishermalfunction. Towarn of make-updemineralizermalfunction.
  • 33. PHOSPHATE Phosphateisa CoreMonitoring Parameterforboilers with Phosphate Treatment.It ismonitoredintheplantforthefollowing reasons: To maintain phosphate levels withinacceptable limits. To checktheaccuracyof water chemistry control(suchas thesodium-to-phosphatemolar ratio). To facilitatethecorrelation ofphosphate contentwith plant operatingvariables. To warn of in-leakageofcontaminants.
  • 34. AMMONIA Ammonia is monitored to: Checktheaccuracyof water chemistrycontrol,so ensuringthat corrosionratesarekeptat acceptable lowlevels. Facilitatethecorrelationof ammonia with otherchemistry parameters(i.e.,pHand specific conductivity).
  • 35. SODIUM Sodiumis aCoreMonitoringParameter.It should bemonitored continuously on-line to checkthe acceptabilityof water chemistry, therebyensuring that corrosionratesarekeptat low levels. Tomaintain sodium levels within acceptablelimits. Towarn of in-leakage ofcontaminants. Towarn of boiler watercarryover. Toidentify cooling water in-leakage at the mainsteam condenser. Towarn of condensate polishermalfunction.
  • 36. DISSOLVE OXYGEN Tomaintain dissolved oxygen levelswithin acceptable limits. Tocheckthe accuracyof water chemistrycontrol, so ensuring that corrosion rates are kept at acceptable low levels. Tofacilitate the correlation of a water chemistry parameter with plant operating variables, withan aim to optimizing operations (e.g., condenser air removal or de-aeratoroperations).
  • 37. IRON AND COPPER Iron and copper areanalyzed periodically tomeasure corrosion product levels in the steam-water cycle.Corrosion product monitoring in the plant is conducted primarily for thefollowing reasons: Tofacilitate the correlation of a water chemistry parameter with plantoperating variables. Tocheckthe accuracyof water chemistry control (such as reducing agent, oxygen, ammonia or pH),so ensuring thatcorrosion rates arekeptat acceptable lowlevels.
  • 38. CONDENSER LEAKAGE A potential major source of ingress of impurity into the boiler water system is from leakage of cooling water into the main condenser steam space (because steam space is maintained by vacuum) which is called condenser leakage.
  • 39. DETECTION OF CONDENSER LEAKAGE Online sodium increases (normal < 2 ppb). After cation conductivity increases (normal <0.2 µS/cm. Chloride ion will go on increasing and can not be controlled with out operation of CBD. Condensate, Feed train and in Boiler Drum, Total Hardness may also appear and increase after approximate 5 ppm Chloride ion, (in sea water cooled condenser).
  • 40. PREVENTIVE/REMEDIAL ACTION 1. Open CBD10 0 %, makeup will go high. (Heat as well as DM water loss). 2. Increaset he concent rat ion of Sodum Hydroxide and free alkalinity in boiler. 3. Limit/close as for as possible the boiler de- superheater spray water to prevent contamination of the system. 4. Isolate one pat h of condenser, and see the results and vice versa. 5. Put CPU into service if available.
  • 41. LEAK LOCATION If the leak is in minor in nature: In running units, isolate one half the condenser at a time and monitor the chemical parameter s and find out which half is leaking. Isolate the leaky half por tion. Plug or repair the leak . Normalize and comeback to full load.
  • 42. LOCATING THE SPECIFIC LEAK • First is path detection • Flood test • Candle Test • Dye test • Foam Test
  • 43. CONDENSATE POLISHING UNIT Condensate polishing is employed to purify the return steam condensate in order to meet the quality requirements of high pressure thermal cycles and minimize consumption of make-up water.
  • 44. BENEFITS OF USING CONDENSATE POLISHING UNITS. • Improvement in the quality of condensate and cycle clean-up. • Reduce blow down and mak up requirement, • Improvement in Boiler water quality for Drum type Boilers. • Quick start-up and as a result full load condition are reached early giving economics.
  • 45. 8H FI PI FIA * * LL * LL L * LL * L * L * * TEMPPRESS CTRL WATER TANK VENT TO ROOF O.C.E C.E MAKE-UP ( DEMIN ) STATOR WATER SYSTEM SWS1.DRW FI FSA PA PC FA TI TR DP QSA PI * FLOW INDICATION FLOW ALARM FLOW ALARM EMERG PRESS INDICATION PRESS ALARM PRESS CONTROLLER DIFF PRESSURE TEMP INDICATION TEMP RECORDER ACTION CONDUCTIVITY MONITOR ALARM OR INDIC TO CCR CENTRIFUGAL PUMPS STOP CHECK VALVES QSI CONDUCTIVITY INDIC RESIN BED FSAFSA FI FSA QIA * DP TR TR TA FA TI TR TR *TA TSA TSA QIAY TR DV DV TI PI PA CTRLFI DP DP PC PCPI TI TR TR TA FIA PA PA TSA *** * LA PI QAI LA PI H2 INLET VALVE H2 OUTLET VALVE AIR INLET TO STATOR WATER TANK FROM SLMS 1 2 1 2 SAMPLE INLET TO SLMS SAMPLE OUTLET FROM SLMS DRAIN VALVE # 2 EXISTING DRAIN VALVE # 1 AIR OUTLET VALVE #1 AIR OUTLET VALVE # 2 O2 DO2 SENSOR TO SLMS FROM SLMS 35 33 31 32 34 18 17
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  • 52. Chemical waste water control (without boiler washing water). Chemical waste water control by WWTP by using HCl & NaoH maintain water PH from 6 to 9 • Chemical washing wastes arising from operation and maintenance activities will be collected via an installed drains network and transferred to the Waste Water Treatment Plant. The treated effluent, suitable for disposal, will be let into the CW outlet.
  • 53. Boiler washing Chemical waste water control • Boiler washing Chemical waste water also control by WWTP with clarification unit by using NaoH & coagulant & separated sludge collect in sludge bed & then dump into the control waste.
  • 54. WASTE WATER TREATMENT Task of Chemical Drain in Retention Basin, Boiler & GAH Wash Water Effluent from Storage Pond to maintain and eliminate: a) Suspended solids • Metals b) Coloids – substances of: • variable size • variable charge Methods of pretretment: Direct separation – sedimentation, filtration, ultrafiltration or microfiltration Coagulation and separation – ultrafiltration, nanofiltration or reverse osmosis Clarification (coagulation + flocculation -sedimantation) – acid, neutral and alcalic
  • 55. ClaRification of feed water Clarification is composed of: • coagulation - elemination of particle charge • flocculation - formation of flakes and their sedimentation • sedimentation (filtration) – separation of the flakes Clarification depends upon pH value of the water – different techiques: • Acidic clarification • Neutral clarification • Alkaline clarification Acidic clarification (pH < 7) Fe3+(coagulant) + 3 HCO3 - = Fe(OH)3 + 3 CO2 at pH 5.5 – 7.0 Neutral clarification (pH= 6 -8) Clarification agent: coagulant + NaOH = neutral flakes Alkaline clarification (pH >10) Fe3+(coagulant) + 3 HCO3 - = Fe(OH)3 + 3 CO2 2 CO2 + Ca(OH)2 = Ca(HCO3)2+ Ca(OH)2 = 2 CaCO3 + 2 H2O
  • 56. ClaRification of feed water Floculation • Speed of floculation – concentration of sediment x imput of energy (mixing) x tim • Two stages of floculation - perikinetics phase (Brown motion of particles) - ortokinetics phase (mixing or other agitation) Sedimentation • Separation of flake in sediment cloud Filtration • One – component sand filters • Multi-component sand filters
  • 57. Gas Air Heater Water Wash Water Economiser Wash Water Wash Down Sump Storage Pond Clarifier Tank Sludge Beds Sump Retension Basin Demin Effluant Aux. Blr. Drains Demin Basin Sump Ph Adjustment Tank Discharge To Sea Coagulent Recirculation If Ph Not in limits Chemical Injection Balance Mixer Mixer Ph Feedback Caustic Caustic Pumps Pumps Pumps Waste water System Simplified Drawing
  • 58. LS FROM NaOH STORAGE TANK OIL SEPERATION & OIL YARD DRAIN CHEMICAL DRAIN AUX BOILER DRAIN REGENERATI ON DEMIN BASIN SUMP RETENTION BASIN+ PUMPS No 1 NaOH DOSING TANK COAGULANT DOSING TANK No 2 NaOH DOSING TANK HCL DOSING TANK P.H. ADJUSTMENT TANK SLUDGE DRYING BEDS SUPERNATAN SUMP & PUMPS OPENGULLEY STORAGE POND & PUMPS CLARIFICATION PACKAGE UNIT EFFLUENT PUMPS LS LS FROM HCL STORAGE TANK LS WASTE WATER TREATMENT PLANT 10% Ferric Chloride pH controlled LS LS GAS AIR HEATER WASHING WATER No 1 WASHDOWN SUMP & SUMP PUMPS PUMP CONTROLS LS LS GAS AIR HEATER WASHING WATER No 2 WASHDOWN SUMP & SUMP PUMPS PUMP CONTROLS PUMP CONTROLS L LS LS & SUMP PUMPS PUMP CONTROLS LS P P PUMP CONTROLS L L L LSLS PUMP CONTROLS PUMP CONTROLS
  • 59. 8 4 6 Hub Power Station 27 7 8 19 42 3 5 13a 13a 14 20 20 29 29 13 13 13 13 12 12 12 12 1 1c 11 9a 45 10 15 38 22 26 24 23 23a 2 17 3737 30 31 18 RISING STATION CHEMICAL WATER DRAINS LAYOUT 16 16 1616 1b 21 21 21 21 21a 32 33 29a29a 36 46 34 1a 44 39 47 9 RS1 0 Building Sources 1-T.G building # 12. 2-Chemical store building # 18. 3-Hydrogen building # 11 4-Stack building # 14.. 5-Control/D.G building # 30. 6-Demin drain basin. building # 5. 7-Aux.-boiler building # 10. 8-Chlorination building # 1. .. 7 RS-09 RS0 8 RS-21 RS-20 RS-19 RS-18 Cond Pit Cond Pit Cond Pit Cond Pit RS-17 RS-16 RS-15 RS-14 RS-13 Foul Water Foul Water Foul Water Foul Water RS-22 Note: Rising station #13 to #16 & #18 to #21 are not the chemical water drain but discharge is connected with RS #10. The layout is provided just for taking an idea. Shift C Shahid Ansari
  • 60. 8 4 6 Hub Power Station 27 7 8 19 42 3 5 13a 13a 14 20 20 29 29 13 13 13 13 12 12 12 12 1 1c 11 9a 45 10 15 38 22 26 24 23 23a 2 17 3737 30 31 18 RISING STATION OILYWATER DRAINS LAYOUT 16 16 1616 1b 21 21 21 21 21a 32 33 29a 29a 36 46 34 1a 44 39 47 9 Building Sources 1-T.G building # 12. 2-Transformers building #16. 3-Workshop building # 24. 4-F.O metering building # 32... 5-Control/D.G building # 30. 6-Boilers. building # 13.. 7-Aux.-boiler building # 10. 8-F.O transfer building #19.. 9-Unit F.O pump building # 20. 10-F.O Service tanks building # 28.. 7 RS-06 RS-17 RS-22 RS 07 RS-05 RS-01 RS-02 RS-03 RS-04 4MKC 3MKC 1MKC2MKC 4BAT 4BBT 3BBT 3BAT 2BAT 2BBT6BCT 5BCT 1BAT 1BBT Shift C Shahid Ansari
  • 61. 8 4 6 Hub Power Station 27 7 8 19 42 3 5 13a 13a 14 20 20 29 29 13 13 13 13 12 12 12 12 1 1c 11 9a45 10 15 38 22 26 24 23 23a 2 17 3737 30 31 18 RISING STATION SEWAGE WATER DRAINS LAYOUT 16 16 1616 1b 21 21 21 21 21a 32 33 29a29a 36 46 34 1a 44 39 47 9 RS-11 RS-12 Building Sources 1-T.G building # 12. 2-Switch yard building # 23. 3-Workshop building # 24. 4-Admin building # 26. 5-Control building # 30. 6-Aux. Elec. building # 37. 7-Re-boiler building # 38. 7 RS-22 RS-17 Shift C Shahid Ansari
  • 62. World Bank Guidelines - Reporting of Releases Parameter Limit & Sample Point BOD No limit quoted Sewage plant discharge . pH Between 6 and 9 Waste water plant final discharge. Suspended solids 30mg/l discharge - taken as difference across the cooling water inlet and outlet Cooling water intake and effluent of WWTP effluent discharge, Sewage plant discharge. Temperature Max. 3°C increase across Inlet and Outfall Cooling water intake and Outfall Temperature at Hubco Marina. Oil & Grease 20mg/l Waste water plant discharge Chlorine 0.2mg/l Ave 0.5mg/l MAX. Outgoing Cooling water at discharge plume (b) T.D.S <10% Increase across Cooling water Inlet and Outfall Cooling water intake and outfall.