Kaushik Chaudhuri

CESC Limited

Global distribution of Water

% Distribution
2% 1%

Ocean
Ice
Fresh water
97%

Use of Fresh Water

Fresh Water Distribution
3%
10%

5%
Evaporation

12%

Power Plants
70%

Irrigation
Industries
Domestic

Sources of Raw Water for Power

Plants

Ocean

River

Dam

Lake

Canal

Raw water contains

Suspended solids

Dissolved solids

Dissolved gases

Organics

Industrial effluents

Types of Water used in a Power

Plant

Raw

Clarified

De-mineralized

Points of Use
Raw Water
 Mainly Condenser cooling (once through)
 Washing/Cleaning

Points of Use
Clarified Water
 Condenser cooling
 Auxiliary cooling (Turbine Lub oil cooler, Vacuum pump

cooler, DMCW HEX etc)

 Service water system (Cleaning, washing, gardening, Ash
handling system, dust suppression, water fogging, ESP
hopper cooling, Air washery , Sludge conveying, Intake
pump gland cooling)
 Hydrant/Mulsifier system
 Drinking water (after proper chlorination)

Points of Use
De-mineralized Water










Boiler makeup through RFW tank

Condenser emergency makeup
DMCW system makeup
Stator coolant makeup
Oil Centrifuge sealing
Chemical preparation
Laboratory
Boiler cold filling
Deaerator cold filling

Raw Water Treatment

Typical impurities in River Water (like Ganga)

1. Non-ionic & undissolved impurities (Suspended Solids)

e.g. mud,dirt,slime,clay and other suspended matter,organic
matters etc.
2. Ionic & Dissolved impurities (Dissolved Solids)
e.g. Salts of calcium, magnesium, sodium etc.
Fulvic , Humic acids,Tannins,Lignins as organics.
3. Gaseous impurities (Dissolved Gases)
e.g. Oxygen , carbon dioxide, hydrogen sulphide,

Pre-treatment of Raw Water

1. Clarification
a) Coagulation
b) Flocculation
c) Sedimentation
2. Filtration
3. Chlorination

RAW WATER TREATMENT PLANT

RAW WATER CIRCUIT

Clarification Process

Flash Mixture Tank

Flocculation Tank/Clariflocculator

Inclined Surface Settler

Effect : Lowering of Turbidity (NTU)

Filtration

Pressurized Sand Filter

or

Gravity Sand Filter
Effect : Further lowering of Turbidity (NTU)

FILTRATION
Clarified Water (Turbidity: 2 NTU)
Sand
Pebbles
Gravels
Filtered Water (Turbidity: 0.2 NTU)

CLARIFICATION

Al2(SO4)3

Al(OH)3 + H2SO4

Fe2(S04)3

Fe(OH)3 + H2SO4

Chemical reactions in water is as follows.

Coagulation Mechanism : Lowering of ZETA POTENTIAL.

POTENTIAL
Crabing action as well as reduction of Z P found in PE.It also increases
sludge density and increases efficacy of alum.
Poly electrolyte : Cationic form (0.2
(0.20.5 %. Alum soln. : 2--2---5%
---5% Is
coagulant

generally used as

Jar Test Apparatus

CHLORINATION
Na(OCl)
HOCl

H2O

HOCl
H+ + Ocl-

HOCl as well as Ocl enters into the cells of

bacteria and destroy the protein structures
of living beings

Typical River Water Parameters

pH

COND.
(ms/cm)

TURB.
(NTU)

ALK.
(ppm)

TH.
(ppm)

Ca-H
(ppm)

Mg-H
(ppm)

NaCl
(ppm)

SiO2
(ppm)

7.7-8.3

200-500

50-1200

70-170

55-175

30-100

25-75

12-35

7-14

DM Water Production
RWTP

DGP

WBA

GSF

Degasser

SBA

FWR

SAC

MB

DMSP

ACF

DM
Storage

RWTP

Removes Suspended & Colloidal particles

GSF

Reduces Turbidity

ACF

Removes Oil, grease, colour, odour, Chlorine

SAC

Removes Cations like Ca,Mg,Na

Degasser

Removes CO2

WBA

Removes strong acids like Chloride, Sulphates

SBA

Removes weak acids like Silica, carbonates

MB

Final polishing

Some Facts about DM Water Production

Regeneration Requirement (sample)

SAC : Requires about 1 Te of HCL (33% bulk conc), resins are regenerated using
5% HCL

WBA & SBA : Require approx 400 Kg of NaOH (46.5% bulk conc), 4% NaOH
for SBA & 2% for WBA

MB : Requires 260 Kg of HCL & 170 Kg of NaOH

Regeneration waste goes to Neutralizing Pit where it is neutralized before
discharging

High Pressure Boiler Water Treatment

Methods

Co-ordinated Phosphate Ph control

Congruent control

All volatile treatment

Coordinated Phosphate -Ph control

method.
In this method only TSP solution is used.
PO4 content : 10 ppm
pH :

9.8---10.0

Congruent control Method

In this process TSP & DSP

are mixed 4:1 ratio
externally and dosed to
boiler. Na:PO4=2.66:1

All Volatile Treatment (AVT)

Hydrazine Hydrate : 40100 ppb

(in Economizer inlet water)

Ammonia : 1.5---2.00 ppm

(in Main Steam sample)

Advantage : Zero blowdown

AVT Control of Power Cycle Water

Drum Water
Parameters
PH

9 9.5

Conductivity (ms/cm)

5 - 15

Silica (ppm)
Chloride (ppm)

Range

0.2 (max)
0.13

AVT Control of Power Cycle Water

Main Steam
Parameters
PH
Conductivity (ms/cm)
Silica (ppm)
Ammonia (ppm)

Range
9.3 9.7
6 - 15
0.02 (max)
1.4 2.5

AVT Control of Power Cycle Water

Economizer Inlet
Water Parameters
PH
Conductivity (ms/cm)
Hydrazine (ppb)

Range
9.3 9.7
6 - 15
40 - 200

AVT Control of Power Cycle Water

CEP Discharge Water
Parameters
PH
Conductivity (ms/cm)
Silica (ppm)
Ammonia (ppm)

Range
9.3 9.7
6 - 15
0.02 (max)
1.4 2.5

AVT Control of Power Cycle Water

Deaerator Water
Parameters
PH
Conductivity (ms/cm)

Range
9.3 9.7
6 - 15

Chemical Control of Stator Coolant Water

Stator Coolant Water
Parameters
PH

Range
6 7.5

Conductivity (ms/cm)

2 (max)

Chemical Control of Closed Circulating

Condenser Cooling Water
Forebay/CW Water
Parameters
PH
Turbidity (NTU)
M- Alkalinity

Range
8.5 8.7
< 20
150 - 200

Ca - Hardness

< 650

Chloride (ppm)

500

Corrosion Limits
Type of Water

Control

Power Cycle

Iron < 10 ppb

DMCW

Iron < 50 ppb

Stator Coolant

Copper < 80 ppb

Cooling Tower

< 4 MPY

Problems faced with closed loop

Condenser cooling water

Scaling

Corrosion

Biofouling

Scaling
Scale is a dense coating of predominantly inorganic
material formed from the precipitation of water-soluble
constituents. Some common scales are

Calcium phosphate

Magnesium salts

Calcium Carbonate

Silica

Calcium Carbonate deposition in

tube

Corrosion
Corrosion is the mechanism by which metals are reverted back to their natural
oxidized state

Some common types of Corrosion

1. General Corrosion
2. Galvanic Corrosion
3. Localized Pitting Corrosion
General Corrosion
The metal loss is uniform from the surface. It is often combined with high-velocity fluid
erosion, with or without abrasives.

 Galvanic Corrosion :-Occurs when two different metals are in the same system. Can
occur when two different metals are in contact. The more active metal corrodes rapidly.

Localized Pitting Corrosion :- exists when only small area of the metal corrodes.
Pitting may perforate the metal in short time. The main source for pitting attack is
dissolved oxygen.

Bio-fouling
 Biofouling or Biological fouling is the deposition &

growth of micro-organisms on wet surface.

 Biofouling severely impede heat exchange in
Condenser, HEX and Cooling tower

Bio-fouling in BBGS Unit-3 CT

Bio-fouling in BBGS Unit-3 CT

Bio-fouling in BBGS Unit-3 CT

Microbiological Growth

Mainly three kinds of troublesome micro-organisms found in Cooling tower water

Algae , Fungi , Bacteria
Classifications of Bacteria
Planktonic:
Free-floating bacteria in bulk water.
Sessile:
Bacteria attached to surfaces.Over 95% of bacteria in a cooling system are sessile and live in
Biofilms.

Biofilms can generally be described as a physically coordinated community of

bacteria and other microorganisms, embedded in a protective glycocaylx with
entrained organic and inorganic debris attached to a surface.

MIC (Microbiologically influenced corrosion)

o Corrosion caused or promoted by micro-organisms.
o MIC does not involve direct attack of bacteria on metal. Rather,

MIC refers to corrosion that is induced or accelerated by the

presence of products of microbiological metabolism.

o The most commonly seen cases of MIC are caused by Sulphate-

reducing bacteria (SRB).

o Other bacteria can also cause MIC to occur - Acid-producing

bacteria (APB).

o Anaerobic bacteria, specially Sulfate Reducing Bacteria (SRB) and

Acid Producing Bacteria (APB) can accumulate under-deposits.

Metabolic reactions of these bacteria produce acids, dropping the
pH low enough to cause serious localized or pitting attack.

Outer surface of the Fire Water & Service water line at

Turbine house

The common types of bacteria can form gelatinous masses in pipes. they adsorb suspended
matter and form a physical obstacle to the water flow. In addition, they create local
conditions favorable to the growth of ferruginous and sulfate reducing bacteria.

Inside
the Fire
water
pipe at
Turbine
house

Forbay

Controls Microbiological growth by reducing nutrient food source

CW bus
Condenser
Vent

Air for
backwash

Chemical Management of Closed Circulating

Condenser Cooling Water

Dosing of Sulphuric acid

Dosing of antiscalant & corrosion inhibitor
(Organophosphonate)

Dosing of Bio-dispersant

Dosing of Oxidizing Biocide (Sodium
hypochlorite/ClO2)

Shock dosing of Non-oxidizing Biocide followed
by Blowdown

In Forebay
Ca(HCO3)2 + H2SO4 = CaSO4 +CO2 + 2H2O
NaClO2 + Cl2 + HCl  ClO2 + NaCl + NaoH
For Recirculated water
Ca(HCO3)2 + NaOH = CaCO3 + NaHCO3+ H2O
CaSO4+ 2NaHCO3 = CaCO3 +Na2SO4+H2O+CO2

Oxidizing Biocides
Bacteria

Fungi

Algae

PH range

Chlorine (Cl2)

Excellent

Good

Good

5-8

Chlorine-dioxide (ClO2)

Excellent

Good

Good

insensitive

Bromine

Excellent

Good

Poor

5 - 10

Ozone

Excellent

Good

Good

7-9

Chlorine is the most popular oxidizing Biocide

When chlorine is added to water, the initial chemical reaction creates a mixture of
hypochlorous acid (HOCl) and hydrochloric acid (HCl):
Cl2 + H2O HCl + HOCl

HOCl is the actual oxidant that attacks the microorganism. As pH increases, HOCl
starts to dissociate into hypochlorite (OCl-):
HOCl H+ + OCl
OCl- is also an oxidant, but a much weaker one than HOCl. Together these chlorine
species are known as free chlorine. At a pH of 5.5, the HOCl concentration in the solution is
near 100%. As the pH of the solution increases to 8.5, the HOCl concentration drops to near
10% and the OCl- concentration is now 90%.

Chlorine Dissociation Curve

Non-oxidizing Biocides
Non-oxidizing Biocides are Organic Biocides, normally
slow acting and are applied periodically in high
concentration for maximum efficacy

Measurements & Implications

Langelier Saturation Index (LSI)

Corrosion rate (CR)

Oxidation Reduction Potential (ORP)

Total Bacterial Count (TBC)

Sulphate Reducing Bacteria (SRB)

Langelier Saturation Index

It is used to predict the calcium carbonate stability of water

LSI = pH - pHs
Where:

pH is the measured water pH

pHs is the pH at saturation in calcite or calcium carbonate and is

defined as:

pHs = (9.3 + A + B) - (C + D)
Where:

A = (Log10 [TDS] - 1) / 10
B = -13.12 x Log10 (oC + 273) + 34.55
C = Log10 [Ca2+ as CaCO3] - 0.4
D = Log10 [alkalinity as CaCO3]

Corrosion Rate
Corrosion Rate (MPY) =
22.3 X Difference of weight of coupon in gm X 1000

------------------------------------------------------------------------Surface area of the coupon (sq inch) X Density (gm/cc) X no.

of days exposed

Corrosion Rack

Total Bacterial Count

Before Shock Dozing

After Shock Dozing

Sulphate Reducing Bacteria

Day 4 sample

Day 2 sample

Day 5 sample