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APEC
NALCOWater
An Ecolab Company
2
Introduction
3
Must be protected!
5
Corrosion
Deposition
Steam Purity
Issues/Turbine
Deposits
Importance of Pretreatment
8
Impurities in Water
Air Earth
EPRI Study
Sodium
Stress Corrosion Cracking and
Chloride corrosion on turbine blades
Sulfate
Silica
Deposition on turbine blades resulting
Iron
to efficiency losses.
Copper
TOC
May contribute to corrosion in the
steam turbine
Organic Acids
Turbine Problems Related to Carry
Over and Steam Purity
Rely on
density
difference to
separate
liquid and
vapor phase
Difficulty in Steam Separation at HP’s
Smaller density difference of liquid and vapor
34 barg
129 barg
220 barg
Boiler Pressure vs Mechanical Carry
Over
0.15%
0.11%
0.085%
61 bar 100 bar 143 bar
23
Priming
Misting
Foaming
24
Priming
Lifting of gross amounts of water into the steam due to some
abnormal mechanical or operating condition
Disruption Sudden
Operating High water Sudden Sudden
in boiler severe
the boiler level in reductions increases
water contaminat
> capacity drum in pressure of load
circulation ion
https://www.youtube.com/watch?v=4yW2mKqi8Gc&index=6&list=PL924D2D7822AD04E8
https://www.youtube.com/watch?v=8Lmagejlc1s&index=7&list=PL924D2D7822AD04E8
25
Foaming
Production of a stable frothlike blanket of tiny bubbles on a
boiler water surface.
https://www.youtube.com/watch?v=gBNeIBgVfvk&index=8&list=PL924D2D7822AD04E8
26
2
7
28
Total Carryover
Total Carryover =
Mechanical
Carryover +
Vaporous Carryover
Foaming
▪ Minimize boiler water contamination from upstream side
▪ Control TDS level in BW by means of boiler blowdown
▪ Optimize performance of mechanical steam purification
equipment in the boiler drum
30
BW Contaminants of Concern
Iron TOC
Feedwater Rate
Cycles = ---------------------------
Blowdown Rate
35
• Super concentration of
dissolved solids beneath a
porous deposit through
capillary action
• Capillary channels draw liquid
to the base of the deposit.
• Steam escapes through a
“chimney” through the
successive formation and
release of steam bubble
Key Issue of Impurities in HP Boilers:
No Tolerance for Deposits
HP boiler tubes already
operate at higher temps
Deposit will retard the
heat transfer and further
increase the tube metal
temperature
• High concentration of
agressive ions on the tubes
surface could lead to
localized corrosion
BW Impurities = Boiler Tube Failures
42
Feedwater Treatment
47
Feed Water
Treatment
All Volatile
Reducing
(AVT-R)
All Volatile
Oxidizing
(AVT-O)
All Volatile Treatment (AVT) Concept
Source: EPRI, Cguidelines for Controlling Flow-Accelerated Corrosion in Fossil and Combined Cycle
Plants ,2005
54
AVT vs OT - Comparison
AVT Reducing (R) Control Parameter
Parameter AVT(R)
Volatile pH Adjuster
N1800
▪ 1st : Down stream of CPD
▪ 2nd: Down stream of DA
ReducingAgent
Passivator Eliminox
▪ 1st: Down stream of CPD
▪ 2nd: Down stream of DA
Nalco 1800
▪ Feedback control loop based on FW conductivity/ pH at Economizer
Inlet
▪ Feed forward control loop based on FW flow
• To achieve non-corrosive
boiler water pH levels
Caustic Corrosion
Causes:
▪ Deposition
▪ Free NaOH > 1 ppm
- Na contamination
- Caustic overfeed
Solution
▪ Minimize NaOH
concentration
▪ Na:PO4 = 2.3-2.6
(Congruent PO4)
66
Hydrogen Damage
Causes:
▪ Deposition
▪ Acidic condition
- Condenser in-leakage
- Pretreatment upsets
- Improper cleaning
▪ Inadequate buffer
Solution
▪ Better BFW quality
▪ Control Na:PO4 3:1 to 1 ppm NaOH
▪ Continuum PO4
Phosphate Treatment Evolution
1940’s: Coordinated Phosphate
▪ 3:1 Na:PO4, limited NaOH
Caustic
1960’s: Congruent Phosphate Corrosion
10.0
PC Na/PO4 = 2.8
Na/PO4 = 3.0
pH : 9.0 – 9.7
9.8 Low PC PO4 : 0.3 – 3 ppm Na/PO4 = 2.6
pH at 25 deg C
9.6
PC
9.4
Note:
Minimum PO4
> 0.2 mg/L
9.2
pH : 9.5 – 10.1
9.0 HighPC (L) P
PO4 : 3 - 10ppm
C (H)
8.8
8.6
0 1 2 3 4 5 6 7 8 9 10
m
g
/
L
P
O
4
Phosphate Continuum Control Chart
Phosphate Continuum Control Chart
10.2 TSP + 2 PPM NaOH
9.6
PC
9.4 Note:
NaOH Minimum PO4
> 0.2 mg/L
9.2 Acid Phosphate TSP
Corrosion
9.0
PC (L) PC (H)
8.8
BD
8.6
0 1 2 3 4 5 6 7 8 9 10
mg/L PO4
72
Continuum
EPRI New Cycle Chemistry Guide Line 2004
Oxygenated Treatment
Caustic Treatment (CT)
(OT)
Boiler Internal Treatment
The Benefits and Limitations
Caustic
PC- High AVT- R AV
T- O OT
& C-
P Low
Increase of
• High purity
• Ease of operation
• Better
performance
4 0.4
3.5 0.35
3 0.3
2.5 0.25
uS/cm
ppb
2 0.2
1.5 0.15
1 0.1
0.5 0.05
0 0
OT AVT PC(L) PC(H) CT
1400 28
1200 24
1000 20
800 16
uS/cm
ppb
600 12
400 8
200 4
0 0
OT AVT PC(L) PC(H) CT
Takeaways
Pretreatment is key. The purity of water and steam is
central to ensuring fossil plant component availability and
reliability. You can download and study the EPRI Guideline.
Feedwater treatment centers on the minimization of iron
corrosion products that enters the boiler.
Boiler water internal treatment controls corrosion and helps
ensure steam purity.
Various treatment programs can be adapted depending on
the systems capability.
Control of important parameters is important to ensuring the
expected water treatment results are achieved.