f. open cooling water system
TRANSCRIPT
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Overview
Pushing the LimitsMechanical, Operational & Chemical Survey
Scale Inhibitor Technology Overview
PC-2040T Features
Performance
Comparison with other technology
Advantages & Benefit
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Cooling System of Power Plant vs Other
Its
BIG !!!!
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Open RCW System for Power Plant
Large systems HV: 1,80045,000 m3
RR: 20200 x 103m3/hr
Surface, well, reclaimed makeup waters, sea water
Regulated to zero dischargesystems
1.225 cycles of concentration
Maximizing water and chemicalutilization!
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Challenge: Pushing the Limits
How far can we stress our water systemincrease the cycle, low etc - without too muchrisk?
How low a treatment levelheavy metal,phosphate, chlorine; etc - will perform?
Pushingthe Limit
Tech
Risks
SHETOC
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6
SystemSurvey
PotentialRisks
TreatmentProgram
Monitoring
& Control
LowestTOC
Challenge: Pushing the Limits
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Optimizer3D Web
Configure
Excel
3D Data Log
1. System Survey
2. MakeUp Analysis
Download
Import
PSRVantage
Dial Up
Direct Connect
Cross Over Cable
ISP
WirelessModemDial Up
Service Report
Survey: Mechanical, Operational & Chemical
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Typical Power Plant Circulating
Water Cooling System
Condenser
Cooling SourceExciter &
Stator CoolersHydrogen /Air Coolers
Circulating Water
Booster Pumps
Lube Oil
Coolers
Boiler Feed
PumpTurbine
Condenser
Bearing
CoolingWater
Coolers
Circulating
Water
Pumps
3-5% of
main flow
Typical condenser flow:
Fossil = 80 m3/hr/ MW capacity
Nuclear = 123 m3/hr MW capacity
CCGT= 61 o5r 164 m3/hr/MW
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Survey: Cooling Tower
Tower Type Cross Flow
Counter Flow
Fill Type Splash bar
High efficiency
Structure:
Wood, PVC, Cement
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Fill Type, Fouling Tendency & Performance
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Fill Fouling Issues
Loss of cooling efficiency
High cooling water supplytemperature
Tower capacity derating
Cooling tower failure
Expensive tower fillreplacement
Health-related concerns dueto microbial fouling
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Impact of Cooling Tower Performance
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Survey: Typical HXs in RCW Power Plant
Service Flow Temp Comments and Concerns
Main Condenser 2.0-2.7 m/s
Continuous
50 C
skin temp
Largest HX, focus of program, but notsevere duty!
Tube leaks contaminate FW.
BFP Turbine
Condenser
(if present)
2.0-2.7 m/s
Continuous
50 C
skin temp
Can be hotter than main condenser.
Typically not a problem area.
Can have older copper alloy tubes.
H2/Air Coolers
(Rotor & Stator)
0.15-2.0 m/s
Throttled
65 C
skin temp
Flow throttled to maintain minimum H2temp. Tend to silt up in winter.
Often most severe duty in plant.
Unit must de-rate if H2temp too high.
Lube Oil Coolers 0.15-2.0 m/s
Throttled
40-65 C
skin temp
Flow throttled to maintain minimum lubeoil temp. Can silt up in the winter.
Often very severe duty.
Unit must de-rate if lube oil temp too high.
Exciter Cooling 0.3-2.0 m/s
Throttled
50-65 C
skin temp
May have redundant HX in parallel.
May silt up when throttled.
Bearing /Auxiliary/
Service HX
1-2.7 m/s
Throttled
2043 C
skin temp
Normally not a problem. Low heat duty.
RCW flow on tube side.
Plate type of exchangers in newer plants.
Combustion Turbine
Cooling
(0.3-2.0 m/s)
Throttled
>65 C
skin temp
CT cooling can be a problem area.
Small tube diameters, high temperatures.
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Surface Condenser
Water-side velocity : 1.5-2.4 m/s
Vacuum : 4-10 kPaa
U Value : 3-5 kW/m2 0C
Sat steam temperature : 30-55 0C
Condenser tube length : 615 m
1. Often Key to Efficiency in Plant Operations
2.Condenser leak: boiler water contamination
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Impact of Condenser Fouling
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Impact of Condenser Tube Failure
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pH
9 - 10
8,5 - 98 - 8.5
< 8.0
Condenser Tube Failure
Abnormal Boiler Cycle Chemistry
Boiler Tube Failure
Plant Shutdown
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Hydrogen /Air and Lube Oil Coolers
Horizontal coolers in moderncombined cycle plant
Vertical coolers in traditionalgenerator
Hydrogen for >600 MW (high heatcapacity & low density)
Must derate if air or H2is too hot
Hydrogen/Air Cooler
Modern lube oil system with
reservoir, pumps, filters, PFE Older plants use shell & tube HX,
typically vertical Must derate if lube oil is too hot Throttle flow if lube oil too cold
Lube Oil Cooler
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Aux/Service Cooling Heat Exchangers
Open cooling watergenerally on tube side
Relatively lowtemperatures and heatflux.
The intercooler between closedsystem and open system
Either shell & tube or plate typeheat exchangers
Can be large if handle main HX
with closed system
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Survey: Metallurgy
Copper alloys
- May prohibit or limit use of ammonia forcondensate corrosion control
- Especially for admiralty tubes
Titanium
- Extremely brittle with very thin walls- Leaks common (especially during initial
commissioning and startup)
- ANY mechanical impingement can cause leaks
Stainless Steel
- Subject to chloride stress corrosion- Must ensure cooling water chloride level
remains within limits- Under-deposit corrosion, MIC issues
Ammonia
Grooving
Under Deposit
Corrosion / MIC
Pitting / MIC
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Survey: Make-Up Water Chemistry
Make-up water quality Source: river, sea water, brackish, deep well, recycle
Variability is important !
Chemical Properties-Makeup Water Value Units
Calcium * 50 ppm Ca as CaCO3
Magnesium * 18 ppm Mg as CaCO3
Manganese 0,02 ppm Mn
Ammonia 0 ppm NH3
M-Alkalinity * 100 ppm as CaCO3
Silica 15 ppm SiO2Aluminum 0,1 ppm Al
Fluoride 0 ppm F
Chloride * 35 ppm Cl
Sulfate * 19 ppm SO4
O-phosphate 0,1 ppm PO4
Copper 0 ppm Cu
Conductivity * 300 uS/cm
Zinc 0 ppm Zinc as ZnIron 0,1 ppm as Fe
Turbidity 2 NTU
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Potential Problems in Open Cooling Water
There are basically four inter-related problems in theoperation of a cooling water
system as depicted by theCooling Water Treatment
Trianglebelow.
Each problem affects and isaffected by the otherproblems.
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CaCO3Scale
CaSO4Scale
Ca3PO4Scale
Steel Corrosion &Iron Fouling
Microbio Fouling
Silica Scale
Silt Fouling
Copper Corrosion
Pushing the Limits: Technical Risks
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Nalco Advanced Technology in Cooling Water
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PSO Scale/CorrosionInhibitor
Non PO4Corrosion
Inhibitor
HighStress
Polymer
(HSP)
HighResistant
Azoles
SilicaInhibitor
StabilizedBromine
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What Do You Need?
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Good Doctor
Good Doctor
Super DuperMedicine?
Good Doctor?
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This is not thebest time
to learn
about aproblem!
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Is The BestWater Doctor
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Optimizer3D WebConfigure
Excel
3D Data Log
1. System Survey
2. MakeUp Analysis
Download
Import
PSRVantage
Dial Up
Direct Connect
Cross Over Cable
ISP
WirelessModemDial Up
Service Report
Identify Potential Issues & Technical Risks
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3DT Optimizer Simulation & Program Design
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HXTemperature
& Velocity
SystemDesign
SystemMetallurgy
Contaminants
Make UpWaterChemistry
Optimizer
Vary Cycle
Vary pHVary Treatment
Vary Temperature
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3DT Optimizer for Diagnostic
3
Technical Risks
Safe Operating Window
3DT Optimizer Simulation & Program Design
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Nalco Advanced Technology in Cooling Water
PSO Scale/CorrosionInhibitor
Non PO4Corrosion
Inhibitor
HighStress
Polymer
(HSP)
HighResistant
Azoles
SilicaInhibitor
StabilizedBromine
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Total Operating Cost Simulation
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Optimizer 3D WebConfigure
Excel
3D Data Log
1. System Survey
2. MakeUp Analysis
Download
Import
PSRVantage
Dial Up
Direct Connect
Cross Over Cable
ISP
WirelessModemDial Up
Service Report
Monitoring & Control: 3D TRASAR Controller
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Automation control of Corrosion inhibitorTRASAR
Scale inhibitor- Tagged Polymer
BiocideBio reporter & ORP
On line measurement: Conductivity
pH
ORP
Corrosion rate
Full communication capability(digital/analog/ethernet/scada/modem)
3D TRASAR Stress Managementfor Cooling Water System
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Trasar & Tagged Polymer
3D TRASAR Scale Control
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Case History: 3DTRASAR Scale Control
Coal fired power plant in Nevada
Nalco 3D Trasar and silica inhibitortechnology allow the plant increase thecycle from 4.5 to 7.0 (+250 ppm SiO2in the
recirculating water)
Water saving 281,000,000 gallons/year(+ 9,000 people consumption per year)
US$ 47,500/yr saving of water pumping &chemical cost
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Corrosion Rates
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3/20/03
3/25/03
3/30/03
4/4/03
4/9/03
4/14/03
4/19/03
4/24/03
4/29/03
5/4/03
5/9/03
5/14/03
5/19/03
5/24/03
5/29/03
6/3/03
6/8/03
6/13/03
6/18/03
6/23/03
6/28/03
7/3/03
7/8/03
7/13/03
7/18/03
7/23/03
7/28/03
8/2/03
8/7/03
8/12/03
8/17/03
8/22/03
8/27/03
9/1/03
9/6/03
9/11/03
9/16/03
9/21/03
9/26/03
10/1/03
10/6/03
10/11/03
10/16/03
10/21/03
10/26/03
Date
mpy
XLP-170/N-23263 Manual Control
N-23263 Trasar Control/ XLP-170 Slaved
N-73292 Tagged Control/ N-73284 Trasar Control
3D TRASAR Corrosion Control
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Case History: 3D TRASAR Corrosion Control
450 MW Coal Fired Plant operate as ZLD facitlity CaSO4and Ca3PO4deposition Problem Switch to Nalco 3D TRASAR with PSO program
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Waste Money
Bio Reporter & ORP
3D TRASAR Bio Control
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250 MW Combined Cycle
Need to reduce bleach consumption related to theenvironment and copper corrosion
3D Trasar Bio Control technology saving 75% of
bleach consumption and keep the condenserperformance
Case History: 3D TRASAR Bio Control
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Optimizer 3D WebConfigure
Excel
3D Data Log
1. System Survey
2. MakeUp Analysis
Download
Import
PSRVantage
Dial Up
Direct ConnectCross Over Cable
ISP
WirelessModemDial Up
Service Report
Nalco 3D TRASAR + Nalco 360 Services:
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3D TRASAR Reports the Data You Needthe Way You Need It, When You Need It
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Nalco 360 TM
Nalco 360 Service providespeace of mindthat your watersystem is being monitored bya team of Nalco Experts, 24 hoursa day, 7 days a week.
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+
3D TRASARcontroller
Webconnection
Nalco SalesEngineer
Immediate alarmresponse
Nalco 360Expert Center
Performancereviews
Automated Reporting
+
Nalco 360 TM
TM
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Nalco 3D TRASAR + Nalco 360TMMonitoring & Controlling Your System 24/7
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C Hi 3D TRASAR 360 TM
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520 MW Combined Cycle Power Plant
Cooling water operate at 3-3.5 cycles
Nalco with 3D Trasar + 360 TMthat
monitoring for 24/7 successfully runningthe system at cycle 5.
Case History: 3D TRASAR + 360 TM
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Challenge: Pushing the Limits
How far can we stress our water systemincrease the cycle, low etc - without too muchrisk?
How low a treatment levelheavy metal,phosphate, chlorine; etc - will perform?
C
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It is possible and practical Understanding of the system & its
variability
Identify the technical risks
Best chemical treatment program
Proper implementation(automation;etc)
24/7 monitoring & control
Best Technology
Best Water Doctor !
Power Plant RCW: Pushing the Limit !
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Is The BestWater Doctor
N l Will N t O l H l Y
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Improve Efficiency
Enhance Reliability
Meet Environment, Health &Safety Standard
Nalco Will Not Only Help You on:
B t W Will Al P id
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A Peace of Mind
But We Will Also Provide you ..