OGN/OPS/CHEM/002

OPERATION DIVISION
OPERATION GUIDANCE NOTE

Chemical Control of
500MW KWU/BHEL
Generator Stator Primary
Water System

Issue-1
Oct,1994

National Thermal Power Corporation Ltd.

NATIONAL THERMAL POWER CORPORATION

OPERATION DIVISION FORMAL DOCUMENTATION SYSTEM
OPERATION GUIDANCE NOTE OGN/OPS/CHEM/002

Issue No.: 1 October, 1994

CHEMICAL CONTROL OF 500 MW KWU/BHEL

GENERATOR STATOR PRIMARY WATER SYSTEM

Approved for
Implementation by R.V.Shahi
Director (Operation)
Date : 11.10.94.
Enquiries to : Executive Director, Operation Services

CHEMICAL CONTROL OF 500 MW KWU/BHEL

GENERATOR STATOR PRIMARY WATER SYSTEM
CONTENTS
Sl. No.

Description

Page Nos.

1.0

Introduction

2.0

Superseded Documentation

3.0

Sources of Make-up Water

4.0

Electrical Conductivity of Primary Water

5.0

Corrosion of Iron and Copper

6.0

Schedule of monitoring

7.0

Review

Table 1

Recommended Chemical Control Limits

And Monitoring Schedule for 500 MW
KWU/BHEL Generator Stator Primary
Water.

Table 2

Special Nitrogen Gas Impurities

10

Table 3

Specification of Make-up WaterDemineralised

11

Specification of Make-up Water Turbine Condensate.

13

Outline of Analytical Test Methods

For special Pure Grade Nitrogen Gases.

14

Table 4
ILLUSTRATION
Appendix I
Fig. 1 :
Fig. 2 :
Fig. 3 :

Corrosion of Copper in Low Conductivity

Water. Effect of pH and Oxygen.
Simplified Schematic of the Stator
Primary Water System.
M/s Brown Boveris Graph on
Corrosion of Copper

15
16
17

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CHEMICAL CONTROL OF 500 MW KWU/BHEL
GENERATOR STATOR PRIMARY WATER SYSTEM
1.0

INTRODUCTION

1.1

The principal agent of the problem i.e. unprotected mild steel has been
completely excluded from all recent designs of water cooled generators.
This has been replaced by copper and stainless steel. Even then, it is
essential to monitor and control primary water quality.
i)

To maintain the electrical insulation (where it is affected by the

water quality) of the machine

ii)

To prevent corrosion and deposition of corrosion products within the

conductor waterways and the risk of obstructing the cooling water
flow through the bars; and

iii)

To minimise maintenance.

1.2

Table - I shows the recommended monitoring routine and control values. If

the variation from the recommended conditions persist, the causes should
be thoroughly investigated, for which purposes, vertical (facing upward)
sampling point is provided in the system, by the manufacturer of the
machine.

1.3

Corrosion of copper is dependent on pH and dissolved oxygen content of

(PSW) cooling water, as is shown in Figure 3 on Page-17 which is based
on laboratory experimental data. The figure shows that there are two
regimes in which the corrosion rate is minimum.

1.4

i)

Low Oxygen Regime where corrosion is inhibited by formation of

passive layer of cuprous oxide (Cu2O)

ii)

High Oxygen Regime where formation of passive layer of cupric

oxide (CuO) inhibits corrosion. Manufacturer recommends low
oxygen regime for their machine.

In order to ensure that the corrosion rate is minimum, it is essential :

i)

To keep the system tight and stable;

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ii)

To keep the dissolved oxygen content of water within range at all

times. This will avoid sudden changes in passive oxide film, which
on detachement may lead to possible tube blockage.

2.0

SUPERSEDED DOCUMENTS

3.0

SOURCES OF MAKE-UP WATER

3.1

Make-up to stator primary water system can be either;

I)

ii)

3.0

- Nil

Fully demineralised water from the station demineralisation plant

having a maximum direct conductivity of 1.5 S/cm at 25oC and
conductivity after strong acidic cation resin is not more than 0.2
S/cm. The disadvantage associated with use of demineralised
water are :-

a)

High dissolved oxygen content (between 6000.and 8000

g/ltr depending on temperature of water)

b)

Low pH of 7.0 and below (Table-3); or

Turbine condensate taken from the extraction pump discharge. The

advantages associated with the use of turbine condensate are:a)

Low dissolved oxygen content about 50 g/ltr;

b)

Relatively high pH suitable for copper and copper bearing

alloys of the system (pH between 8.8 and 9.0). Table - 4

While using turbine condensate, it is essential to ensure that it is not

contaminated and that it complies with the specified control limits. The
situation is likely to arise when there is condenser leakage and during start
up of the plant when oxides of iron and copper are usually present in
excess of the control limits. It is necessary to provide for an alternative
source of make up such as from station demineralisation plant for use in
case of requirement.

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3.3

Experience and opinion in CEGB, U.K. is that, risk involved due to

ammonia, normally present in turbine condensate to cause stress
corrosion cracking of copper and its alloys within stator primary water
system, is negligible. However, this view is not acceptable to KWU/BHEL
hence, the turbine condensate should be used only after complete
removal of ammonia by passing all make up through CPU/stator water
polishing unit and in conjunction with alkaliser retrofitting for their 500 MW
units.

4.0

ELECTRICAL CONDUCTIVITY OF PRIMARY WATER

4.1

Electrical conductivity is the basic criterion of quality for the stator primary
water and it must always comply with the limit shown in Table - 1. By
maintaining low conductivity and design water flow rate, the risk of flash
over, in a clean water circuit, is eliminated. The upper limit of direct
conductivity in normal operation, as given by KWU/BHEL is as under:I)

1.5 S/cm at 25oC, preferably 0.5 S/cm or below when operating

Without alkaliser system in circuit.

ii)

2.2 S/cm at 25oC with alkaliser system in circuit lower limit being
1.0 S/cm

iii)

The values of conductivity i.e. 1.5 S/cm (with alkaliser system not
in circuit) should not be exceeded during generator commissioning
tests when an over voltage is applied for insulation testing.

4.2

In the absence of any remedial measure, the conductivity of primary water,

will normally, rise slowly because of the impurities e.g. carbon dioxide and
perhaps because of insufficiently good quality of make up water. Control of
conductivity is normally achieved by continuos/intermittent operation of
stator polishing unit and by maintaining inert atmosphere in the system by
use of suitable grade of nitrogen gas as given in 4.6 (see Table-2 for
quality of Nitrogen Gas).

4.3

To assist in evaluating the method of chemical control adopted and in

identifying the source of impurities, the following additional tests are
recommended:i)
To measure conductivity after strongly acidic cation resin in
hydrogen form;

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ii)

In case conductivity in (I) above exceeds limiting value, then

conductivity measurement for water after degassing with nitrogen is
to be done.

These additional tests assist in identifying the source of contamination and

for corrective action that may be needed.
5.0

CORROSION OF IRON AND COPPER

5.1

In general, the amounts of iron and copper is the stator primary water will
depend on the following main factors:i)

Quality and frequency of blowdown;

ii)

Quality and quantity of make up water;

iii)

Concentration of dissolved oxygen gas;

iv)

Quality and pressure of nitrogen gas;

v)

Operation of alkaliser system;

vi)

Operation of stator water polishing unit.

vii)

PSW Cooler leakages (ingress of impurities)

viii)

Presence of Fe ions may increase Cu ions in PSW system.

5.2

As mentioned earlier, the use of mild steel has been displaced by copper
and stainless steel in stator primary water system by manufacturer. Due to
this reason, the quantity of iron in water should be minimum. In case the
quantity is found to be more than normally maintained the reason should
be investigated and corrective measures taken.

5.3

It must be ensured that the storage tanks and pipelines, handling

demineralised water or condensate, as make up to stator primary water
system should be suitably lined. The inspection of lined surfaces should
be carried out at periodic intervals and corrective measures be taken
immediately on detection of any failure of lining.

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5.4

The rate of corrosion is minimum when the stator primary water system is
tight i.e. when neither water is lost from the system nor the make up is
taken into the system. Practically, this is not possible as water is taken out
for manual testing of the constituents and sometimes lost due to leakages.
It is desirable that manual tests are carried out once is every two months,
so that minimum water is taken out from the system. The make up is taken
by operation staff by passing 100% through polishing unit and on
certification of quality by chemist it is jointly recorded. Reason for any
abnormal increase in normal make up is to be investigated and reported.
N2 purging is also simultaneously done when make up is being taken in
the outer circuit of the stator windings. The practice will help in keeping
dissolved oxygen below 100 ppb i.e. before it enters the main circuit.

5.5

Dissolved oxygen in stator primary water is main reason for corrosion.

KWU, manufacturer of the unit has preferred low oxygen regime. In order
to avoid dislodging of passive oxide layer from the surface, leading to the
blockage of bars, it is necessary to regulate the make up water flow in a
manner that dissolved oxygen does not abruptly increase. It is
recommended that a suitable on line dissolved oxygen monitor with
recorder is provided for the system. Till then manual analysis shall be
carried out i.e. once in two months.

5.6

Nitrogen used should have a purity of 99.99% min. and impurities should
not exceed the limits given in Table 2. Although, both the grades of
nitrogen are suitable, Grade 1 is preferred due to its use in critical
equipment. Removal of dissolved oxygen from stator primary water also
depends on nitrogen pressure, which is to be normally maintained at 0.2
kg/cm2 with high pressure alarm set at 0.4 Kg/cm 2 against 0.3 Kg/cm2 as
recommended in the O&M manual for better efficiency and low alarm
setting can be at 0.1 Kg/ cm 2 . Thus in order to ensure that normal
nitrogen pressure is maintained around 0.2 kg/cm 2 it is preferable to install
a pressure switch with setting at 0.1 kg/cm 2 on remote alarm.

5.7

KWU have now established that even with the use of low dissolved
oxygen regime for stator cooling water, copper corrosion of water cooled
windings connot be completely avoided. In isolated cases, the corrosion
products can cause flow restrictions. The severity of the corrosion attack
can be largely reduced by alkalising, low dissolved oxygen water (Fig. 2).
This system then becomes less susceptible to disturbances resulting from
air leakage. M/s. KWU have recommended to operate the generator with

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stator primary water system between pH 8.5 and 9.0 and conductivity
between 1.0 and 2.2 S/cm for improvement in its reliability and
availability. All the 500 MW KWU units are to be fitted with alkaliser units.
5.8

The corrosion products in stator primary water when detached from the
metal surfaces, deposit on the tube ends and also on inlet and outlet
hoses of water cooled generator windings, resulting in flowrate restriction.
In order to get timely indication of flow restriction, it is essential to provide
individual pressure gauges at inlet and outlet of water flowing though
stator windings. Also provision of differential pressure indicator gauge with
suitable alarm setting will ensure proper attention of operation staff for
corrective measure, avoiding long shut down of unit. KWU 500 MW sets
are working on DP- 1 Kg/cm2 where as others around 3 kg/cm 2 across
windings.

5.9

Stator water polishing unit with 2 to 5% polishing is provided in the system

controls conductivity by eliminating electrolytes from the system and
additionally, traps some suspended matter. The unit contains mixed Ion
Exchange Resins of nuclear grade .The exhausted MB resins are
regenerated and put back in SPU. The extent of corrosion can be
assessed by eluting the resins and analysing the eluate when the resins
are getting frequently exhausted. Exhaustion point is touched at 0.8
Sm/cm Conductivity of the effluent.

6.0

SCHEDULE OF MONITORING

6.1

Continuous monitoring of conductivity and dissolved oxygen in stator

primary water is an essential requirement. Proven instruments will be
provided with suitable recorders and recorded measurements will be
analysed for any possible trouble.

6.2

Total iron, total copper and pH will be analysed once in every two (2)
months in normal operation. More frequent analyses may be required
when the unit is being commissioned or when the recommended limits are
violated. Make up should be taken in the system as give in 5.5

6.3

Prior to Synchronisation of the unit, 500 ml. Of water sample will be

filtered through a cellulose nitrate membrane of 0.45 microns pore size
and the stain obtained will be compared against standard stains (which
have been analysed). This will provide a rapid check on suspended oxides
(crud)

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6.4

during cold start up condition. Periodically strainer deposits should be

analysed on XRD for oxides of copper for assessing the loose oxide coat
getting dislodged.
Some details of monitoring are as follows:

7.0

Generator should not run on Hydrogen gas leakages form the Gas
Trap beyond the period as recommended by the manufacturers in
their Operating Manuals. BHEL prescribes 3% Hydrogen leakage as
the limit.

During leakage of Hydrogen in PSW system there are chances of

moisture entering into Hydrogen gas contained in the generator.

DP and Generator temperature rise should be closely monitored.

For that DP gauge across stator winding and outlet pressure gauge
at stator winding outlet should be provided where same are not
installed.

Working in at intermediate Oxygen zone is prohibited. (i.e 100 to

1000 ppb.) (Refer M/s Brown Beveris graph of Corrosion of Copper
Fig.3)

Strainer deposits at the make up tank need periodical check up.

Dissolved Oxygen and conductivity of PSW system should not

frequently vary.

The sampling point for laboratory measurement of Dissolved

Oxygen should be vertically placed in the PSW with a regulating
valve.

REVIEW
The Executive Director, Operation Services will be responsible for
reviewing this document on 2-yearly basis or as necessary.

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Table 1
RECOMMEND CHEMICAL CONTROL LIMITS AND MONITORING SCHEDULE
OF 500 MW/KWU GENERATOR STATOR PRIMARY WATER
S. No. Constituents

Control limits
Without
Alkaliser

With
AlkaLiser

Frequency of
Testing

1.

Direct Conductivity at 25oC

S/cm

Less than
1.5 preferably
below 0.5

Less
Than
2.2

continuous

2.

Dissolved
oxygen

G/ltr

Minimum
< 100

Preferrably
<100

continuous

3.

Total copper

G/kg-

<20

<20

Once in 2
months

4.

Total Iron

g/kg

<20

<20

-do-

5.

pH at 25oC

6.8

8.5
9.0

-do-

Notes :
1.

Continuous monitoring and control of conductivity and dissolved oxygen,

using proven instruments is required to be maintained, within
recommended limits with facility to detect rapid changes even below
recommended maximum in which event, investigation shall be made.

2.

Dissolved oxygen shall be analysed manually alongwith other parameters

once in two months, till the time, reliable and pro on-line instrument for
continuous monitoring is not available.

3.

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Measurements iron is essentially required to test for the presence of any
mild steel in the system, free from mild steel.

4.

If the make up is turbine condensate, it shall be taken in the system

through stator polishing unit, only after ensuring that the after cation
conductivity is within the limit of 0.2 S/cm.

5.

Repeat analyses shall be required in case any limiting value exceeded. In

case, even the repeat test gives violation, investigation shall be carried out
and a separate report shall be furnished including reasons for violation
and remedial measures taken for correction.

6.

Conductivity (S/cm) details, as given by KWU for units provided with

alkaliser units are as under:For main circuit
Minimum setting
Value control

1.0

Alarm

1.0

1.0

1.8

1.8

Alarm

2.2

2.5

Control

2.5

3.0

Operating value
Max. setting value

After Ion-Exchanger

In case PSW System conductivity exceeds the prescribed limit then check
up
a)

Alkali addition rate and concentration

b)

SPU exhaustion point

c)

PSW cooler leakage

d)

Overall Corrosion rate

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Table 2
SPECIAL NITROGEN GAS
(Impurities in ppm)
S. No.

Constituents

Grade I

Grade II

1.

Oxygen

2.0

4.0

2.

Moisture

2.0

4.0

3.

Carbon-dioxide

Nil

0.5

4.

Carbon monoxide

Nil

0.5

5.

Nitrogen Oxides

Nil

0.5

6.

Hydrogen

Nil

1.0

7.

Argon

5.0

10.0

8.

Hydrocarbons

0.2

0.5

9.

Sulphur Compounds

Nil

Nil

10.

Mercury

Nil

Nil

11.

Chlorine

Nil

Nil

Note :

Grade I to be preferred

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Table 3
SPECIFICATION OF MAKE UP WATER
(Demineralised Water)
The water used must not contain any contaminants that might have a harmful effect on
the materials used in the primary water circuit. For this reason, the water must have the
following quality criteria.
Conductivity

10 S/cm invariably 1.5 S/cm

preferably 0.5 S/cm.

PH

68

Dissolved oxygen.

Minimum preferably less than 100 ppb.

Dissolved carbondioxide.

Minimum, permissible conductivity.

Chlorides

After a strong Anion

Other anions

Exchangers 0.2 S/cm

Ammonia

Minimum, test with Nesslers solution as

a reagent shall not cause a colour
change.

Total copper

Less than 20 ppb

Total Iron

Less than 20 ppb

Dissolved solids

The water shall not contain chemicals :

e.g. hydrazine, morpholine, Levoxine,
phos-phate etc.

NOTE :
1.

Conductivity is brought down by nitrogen flushing and passing through the

primary water through polishing unit to less than 1.5 S/cm where alkaliser unit is
not fitted and should not exceed 2.2 S/cm where alkaliser units are provided.

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2.

During make up, purging of primary water shall be ensured to bring down the
dissolved oxygen content to lowest possible value.

3.

Make up shall be taken in less quantities at a time than to take larger make up at
a time. This would ensure that there is no sudden increase in dissolved oxygen
content of the primary water.

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Table 4
SPECIFICATION OF MAKE UP WATER
TURBINE CONDENSATE
(Provided by NTPC & accepted by BHEL)
pH

8.85 9.1

Conductivity S/cm

4.0 to 4.5

Ammonia ppm

0.4 to 0.6

Dissolved oxygen ppb

<100

Chloride ppb

<50

Hydrazine ppb

Not detectable

NOTE:
1.

Before taking in circuit, make up water shall be passed 100% through polishing
unit to ensure removal of ammonia. It shall also be ensured that conductivity after
passing through strongly acidic cation exchanger should not exceed 0.2 S/cm.

2.

Turbine condensate shall be used as make-up to primary water circuit in

conjunction with alkaliser units.

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APPENDIX I
OUTLINE OF ANALYTICAL TEST METHODS FOR
SPECIAL PURE GRADE NITROGEN GASES
Impurities in Special Pure Grade Nitrogen Gases shall be determined using following
methods:1.

Oxygen

Oxygen shall be determined using

oxygen analyser capable of determining
in ppb range. It is essential to install
Diffusion Proof Pressure Regulator
made of stainless steel before and after
the analyser. All connecting tubes shall
also be made of stainless steel.

2.

CO2, CO, HC & H2

3.

NOx, SOx & Cl2

Determinations for these impurities shall

be done using Drager Tubes for
individual constituents. Alternately of
Gas Monitors shall be made.

4.

Moisture

Determination shall be made by using

Moisture Meter. But, determination is not
important, since gas shall be bubbled in
water.

Determination of these impurities shall

be made by using suitable Gas
Chromatograph on TCD & FID modes. It
is better to provide Catalyst Chamber for
determination of CO and CO2 in Gas
Chromatograph for conversion of these
impurities to methane.