PRETREATMENT

POST TREATMENT OF
WATER

Presentation by
R.N.BHENDEKAR
Senior Chemist,CSTPS
MAHAGENCO
 Steam

Spinning turbine
blades and
generator
Boiling water
 540oC

Generator

HPT IPT LPT

340oC
feeder
From

CEP

Grid
A
P
Boiler H HP
LP Heaters

DA
Heater
ESP
Mill FD FAN

BFP
3
11/2 ID Fan 3
5/
PA FAN
 JUNG SE JUNG

CHEMIST
Vs
CORROSION
WATER TREATMENT PLANT
WINGS.....
PTP PLANT--- TO REMOVE S.Ṣ
POST T.P.-------TO REMOVE D.S. & PREPARE DMW
SOFT WATER
SWAS LAB------BOILER FEED WATER CYCLE
ENVIRONMENT CELL---STACK + ETP WATER
COAL CELL--- QUALITY & QUANTITY.
CPU ---------------MINIMISES CONTAMINATION.FE,CL,TH

GEN.LAB ----BATTLE FIELD

CONSUMPTION OF WATER & COAL:

WATER COAL

210 MW = 26000 M3/Day 3500 MT

500 MW = 34000 M3/Day 8000 MT

660 MW = 60000 M3/Day 11000 MT

Typical range of specific water consumption
figures of different power plants
Power plant type Range M3/MW

Gas based power plants 1.7-2.0

Total dry ash handling power plants 3.0-3.5

200 MW coal based thermal power plants with once trough system 3.0-3.5

200 MW coal based thermal power plants 4.5-5.0

500 MW coal based super thermal power plants 4.0-4.5

200 MW coal based power plants with ash water recycling 3.5-4.0

500 MW coal based super thermal power plants with ash water
3.5
recycling

110 MW coal based old power plants 70.-8.0

Source: The Bulletin on Energy Efficiency

RECYCLED

 MOEF NOTIFICATION
 ZERO DISCHARGE
 SEARCH NEW ALTERNATIVES
 SEWAGE WATER FOR COOLING
 Objectives of water chemistry

1)Reduce corrosion of metals

2) Prevent formation of deposits
3) Produce good quality steam
{ without carryover of boiler water Solids }
Water is a like blood
Of
Thermal power plant.
Water Cycle of Thermal Power
Plant
IS IT WATER
COLOURLESS ???
 WATER IS COLOURLESS ???
 CHEMISTS POINT OF VIEW,
 IT IS HAVING COLOURS(PARAMETERS),
 DRINKING
 FEED
 BOILER SYSTEM
 EFFLUENTS
THE BASIS FOR CYCLE CHEMISTRY
1. To form the proper protective passive layer.
2. To protect this passive protective layer during operation.
3. To protect this passive protective layer during shutdown.

All boiler tube and turbine blade failures influenced by cycle

water chemistry have the breakdown of the passive protective
layer as part of the failure mechanism.
If you protect your protective layer 24/7 seven days a week
365 days a year, you will not have boiler or turbine blade
failures due to cycle chemistry.

LOSS= --------
 INDIAN STANDARD DRINKING WATER
SPECIFICATION  ( BIS  10500 : 1991 )
Permissible
Sl. Limit in the
Requirement (Desirab
No Substance or Characteristic absence of
le Limit)
. Alternate
source
Essential characteristics
1. Colour, ( Hazen units, Max ) 5 25
2. Odour Unobjectonable Unobjectionabl
e
3. Taste Agreeable Agreeable
4. Turbidity ( NTU, Max) 5 10
5. pH Value 6.5 to 8.5 No
Relaxsation
6. Total Hardness (as CaCo3) 300 600
mg/lit.,Max
7. Iron (as Fe) mg/lit,Max 0.3 1.0
8. Chlorides (as Cl) mg/lit,Max. 250 1000
9. Residual,free 0.2 --
chlorine,mg/lit,Min
Desirable Characteristics
10. Dissolved solids mg/lit,Max 500 2000
11. Calcium (as Ca) mg/lit,Max 75 200
12. Copper (as Cu) mg/lit,Max 0.05 1.5
13 Manganese (as Mn)mg/lit,Max 0.10 0.3
14 Sulfate (as SO4) mg/lit,Max 200 400
15 Nitrate (as NO3) mg/lit,Max 45 100
16 Fluoride (as F) mg/lit,Max 1.9 1.5
17 Phenolic 0.001 0.002
Compounds (
as C 6 H5OH)mg/lit, Max.
18 Mercury (as Hg)mg/lit,Max 0.001 No relaxation
19 Cadmiun (as Cd)mg/lit,Max 0.01 No relaxation
20 Selenium (as Se)mg/lit,Max 0.01 No relaxation
21 Arsenic (as As) mg/lit,Max 0.05 No relaxation
22 Cyanide (as CN) mg/lit,Max 0.05 No relaxation
23 Lead (as Pb) mg/lit,Max 0.05 No relaxation
 Minerals & other contents in Raw Water
Sr.No Constituents Unit Raw Water
1 pH 7.5 to 8.5
o
2 Temp C 2 to 30
3 TSS ppm 36
4 TDS ppm 450
5 Calcium ppm as CaCO3 100
6 Magnesium ppm as CaCO3 50
7 Sodium ppm as CaCO3 150
8 Potassium ppm as CaCO3 7
9 Iron ppm as CaCO3 0.5
Total Cation 307.5
10 M Alkalinity ppm as CaCO3 140
11 P Alkalinity ppm as CaCO3 0
12 Chlorides ppm as CaCO3 90
13 Sulphates ppm as CaCO3 70
14 Fluorides ppm as CaCO3 1
15 Phosphate ppm as CaCO3 0
16 Nitrate ppm as CaCO3 6
Total Anion 307
17 Silica ppm as CaCO3 25
18 Colloidal Silica ppm 2
19 Organic as KmNO4 ppm 3
20 NH3 ppm 0
21 BOD ppm 12
22 COD ppm 30
Industrial Water Charges & Cess :

Water Charges Cess

July - Nov. = Rs. 5.35 /M M3 20 %

Dec – March = Rs. 10.70 /M M3 20 %
April – June = Rs. 16.05 /M M3 20 %

Domestic Water = Rs. 0.44 / M3

 Specific Consumption and Cost

Cost
Raw Water = 3.5 Lit./KWH Rs. 0.018 / KWH

DM Water = 0.042 Lit./KWH Rs. 0.0135 / KWH

Cooling Water = < 2.0 Lit./KWH Rs. 0.011 / KWH

Coal = 0.8 Kg/KWH Rs. 2.00 / KWH

 ROLE OF CHEMIST:

 Water Treatment.

 On load / off load corrosion.

 Sampling and Analysis of fuel.

 Maintain the effectiveness of heat transfer surface.

 Maintain high level of steam purity.

 Condenser and cooling water problem.

 Maintain corrosion rate minimum.

 Sampling and Analysis of Lubricating oils.

 Atmospheric Pollution and effluent control.

 Safety.
 I…
H A
AL
K
TO
AI
H
L
JA
COST QUALITY AVAILIBILITY

CORROSION

Cl, SO4, TDS, Fe

DISSOLVED GASES

PROBLEMS
SCALING FOULING

Ca, Mg, Fe Fe, MUD, SS,

SiO2, Al.., MICROBIAL,
ORGANICS
 Water RA
River IN
W
AT
E R

Sources of water

UN
GR DER
O
WA UND
SE A TE
RS
WA
T ER
 Impurities
in Water

ORGANICS Suspended
Form

Dissolved
Colloidal
form
form
 :

Ground water--------- High dissolved solids

Less suspended solids

River Water -----------Conains Impurities in the form of

Floating Solids,Suspended Solids,

Dissloved solids,Colloids,Dissolved

Liquids / Gases.
 :

Raw Water Charecteristics Classified As---

Physical Charecteristics--- Colour,Odour,Temp.Turbidity

Biological Charecteristics---Viruses,Algae,Fungi,Plant Tissues

Chemical Charecteristics---- Organic Carbohydrates,Fats,

Grease,Pesticides,Phenols

Inorganic-Alkalinity,Acidity,

Chlorides,Sulphour,DO,H2S,CO2
 :

Floating Solids ------Removed at River Intake by applying

Screens..25 mm & 6mm.

Suspended+Organic Matter---Removed in PTP

Dissloved Solid--------Removed in PO.TP.

 Need of ( Pre)-Treatment Plant:

 Sources are natural.

 Journey from Mountain, Hill, Rocks and Surfaces.
 Always get contaminated with floating solids, suspended
solids, dissolved solids, colloids and dissolved gases etc.
 Water is not suitable for power generation and domestic
purposes.
 May affects health of human being and metallurgy.
 This needs treatment to lower down level of impurities
(ppm/ppb).
 Level of impurities are removed in PTP & load of Post
Treatment Plant are minimized.
ORGANIC IMPURITIES IN WATERS

Insoluble Organic Matter: Debris of vegetable and animal origin

Micro-organisms
Oily material
Humic matter Soluble Organic Matter: Humic matter
Fatty acids
Nitrogenous matter Proteins, peptides, & Amino acids
Saccharides & Sugars
Dissolved Organic gases (such as Methane)
Soluble extracts of Vegetable and animal matter
Synthetic Organic Compounds
 Contaminants or impurities in water
Physical Impurities:
Color, Tastes and odors, Suspended solids, Turbidity, Temperature
Chemical Impurities:
pH, Acidity, Alkalinity, Hardness, TDS, Fluorides, Chlorides, Sulphates, Nitrates,
Phosphates,
Toxic chemicals- may be inorganic Like Zn,Cu,Pb,As, Cd, Cr(VI), Hg etc
Various organic compounds Like pesticides, Carbon Tetra Chloride, Vinyl Chloride,
Cyanide, Phenol, Chlorinated hydrocarbons etc.
Dissolve Oxygen.(8- 10 mg/L) D.O makes the water taste good. Surface water
contain more D.O due to more surface contact. Depletion of D.O. indicated
utilization by Organic or inorganic compounds i.e. contamination from domestic
and industrial wastes.
Bacteriological Impurities:
Virus, Bacteria Protozoa, helminthic worms.
 Water Impurities and its effect

Impurity Effect
Total Hardness Scale formation
(Calcium + Magnesium)

M-Alkalinity Corrosion - Low Alk.

Scale / Deposition - High Alk.

Chlorides Corrosion / SCC of SS

Suspended Solids Deposition

Sulphate Corrosion / Scale formation

SiO2 Scale
Contd.
Impurity Effect

SiO2 Scale

Organic Matters Fouling

Iron and Magnesium Deposition

Micro-Organisms Fouling / Corrosion

Ammonia Nitrifying bacteria / fouling
 Measurements of Acidity & Alkilinity (pH)

Acidity of a solution >

measured by concentration
of hydrogen ions (H+).

pH ranges: 0 (very _______) to

14 (very ________).

Change in just one unit of

scale = tenfold change in
H+ concentration.

If concentration of H+ = OH
- … neutral.

Images: pH scale, Edward Stevens, Wiki From the Virtual Cell Biology Classroom on ScienceProfOnline.com
STANDARD FOR CHEMICAL CONTROL

SL ITEM pH TURBI SILICA

NO DESCRIPTION DITY

1 DRINKING WATER 7.5-8.5 < 10NTU 15-25 PPM

2 CLARIFIED 6.8-8.5 < 20 NTU 15-25 PPM

WATER

3 FILTERD WATER 7.5-8.5 < 5 NTU 15-25 PPM

4 DEMINERALISED 6.5-7.0 < 1 NTU < 2.0 PPB

WATER
BOILER TUBE FAILURES (22 PRIMARY MECHANISMS)

•Stress Rupture
1. Short Term Overheating
2. High Temperature Creep
3. Dissimilar Metal Welds
•Fatigue
1. Vibration
2. Thermal
3. Corrosion
•Waterside Corrosion
1. Caustic Corrosion
2. Hydrogen Damage
3. Pitting
•Erosion
1. Fly Ash
2. Falling Slag
3. Soot Blower
4. Coal particle
•Fire side corrosion
1. Low Temperature
2. Water wall
3. Coal Ash
4. Oil Ash
 Total Water Management in thermal power station

1. Treatment of water for boiler feed

2. Treatment of water for condenser cooling

3. Treatment of wastewater for disposal or recovery of water for reuse.

Dissolved solids

 Calcium bicarbonate , Ca(HCO3)2

 Magnesium bicarbonate , Mg(HCO3)2

 Sodium bicarbonate , NaHCO3

 Ferrous bicarbonate , Fe(HCO3)2

 Manganous bicarbonate , Mn(HCO3)2

 Calcium chloride , CaCl2

 Magnesium chloride , MgCl2

 Sodium chloride , NaCl

OPERATION OF DIFFERENT UNITS AND ITS
PURPOSES
 One Day Reservoirs: Stand by storage & pretreatment of
suspended matter.
 Cascade Aerator: Removes unwanted gases and increase the level
of dissolved oxygen.
 Chlorination: Addition of chlorine gas to kill germs, algae and
micro organism.
 Chemical Addition: Coagulation.
 Flash Mixing: Ensure mixing of coagulant with bulk of water.
 Flocculation: Growth of floc size to permit settling under gravity.
 Settling: Clarification of water.
 Filtration: To strain micro-flocs.
One Day Reservoir
Raw water

Aeration
Exposing Water to Atmospheric air thereby
oxidizing some of the dissolved salts.
During aeration, two impurities viz. Ferrous
Bicarbonate and Manganous
Bicarbonate are oxidized as follows;
Fe(HCO3) + O2 -- FeO(OH) + CO2 + H2O
Mn(HCO3) + O2 -- MnO2(OH) + CO2 + H2O
Raw water
Raw water

Dosing
- Cl2 (disinfection, to
control bacteria,
virus & org. mat)
- Lime(pH adjustment,
softening)
- alium(coagulant)
 AERATION

 While dissolving oxygen in water is most often the goal, aeration also
includes removal of undesirable gases, such as CO2 and methane from
water, sometimes referred to as degasification.

 By far the greatest use for aeration equipment is in the field of

biochemical oxidation of organic wastes, domestic or industrial. But,
aeration is also used extensively for oxidation of inorganic impurities
such as iron, manganese, and hydrogen sulfide, and for removal or
oxidation of volatile impurities causing odour or bad taste.
PURPOSE

 IRON-MANGANSE REMOVAL...
4Fe(HCO3)2 + O2 + H 2O 4Fe(OH)3 + 8CO2
Ferrous
Oxygen Water Ferric Carbon
Bicarbonate
Hydroxide Dioxide

2Mn(HCO3)2 + O2 2MnO2 + 4CO2- + 2H2O

Manganese Manganese Carbon
Oxygen Water
Bicarbonate Dioxide Dioxide
COAGULATION
DISINFECTANT
CHLORINE
OZONE
Jar Test For Chemical Dosing
FINE PARTICLES , --VE CHARGE, REMAIN SUSPENDED

+ Al +
+

CHARGE NEUTRALISATION BY Al3+, COAGULATION

Raw water

Flash mixer
 Removal of organic matter

 Organic matter can either be in colloidal or dissolved form or

both. Here again, removal of organics by proper pre-
treatment is the most logical and economical way.
 Pre-chlorination of water oxidizes dissolved organic matter
and colloidal organic is best removed by proper coagulation
and clarification. Ion exchange resins resistant to fouling by
organics present in water should be used. Any residual
organic matter can be removed by Nano-filtration (NF)
membranes. UF membranes are not very effective.
RGF COMPONANTS

 SAND
 ACTIVATED CHARCOAL
 GRAVELS
 PEBBLES
 B/W OF RGF
 CHEMICALS USED IN TREATMENT
SL.N CHEMICALS USE
O
1 ACTIVATED TASTE,ODOUR & DECHLORINATION
CARBON
2 ALUM, FeCl3 COAGULANT
3 LIME pH ADJUSTMENT, SOFTENING
4 Cl2, O3, Na(OCl)Cl DISINFECTION, TO CONTROL BACTERIA,
VIRUS & ORG. MAT
5 HYDRAZINE OXYGEN SCAVENGER, MAGENTITE
LAYER
6 AMMONIA pH ADJUSTMENT
7 TSP TO TREAT BOILER WATER
8 HCl ACID REGENERANT OF CATION RESIN
9 NaOH REGENERANT OF ANION RESIN
 CHEMICALS USED IN TREATMENT

SL.NO CHEMICALS USES

1 ACTIVATED TASTE,ODOUR & DECHLORINATION

CARBON
2 ALUM. COAGULANT
3 LIME pH ADJUSTMENT.
4 Cl2, O3, CLO2. DISINFECTION, TO CONTROL BACTERIA,
VIRUS & ORG. MAT
 Lower dosage requirement
 No requirement for any neutralizing agent (soda, lime)
 Shorter flocculation time
 Smaller amount of sludge
 Reduced number of back washing steps
 Higher quality of the treated water.
 PAC works satisfactorily over a pH range of 5.0 to 8.0.
 GF Bed
Clarified Sand filters
water
FW DW
sump sump

Clari-
flocculator Cl2 Post-
chlorination
DW
Cl2 FW pump
House pumps s

Filtered
water
To Township for
DM water
DM PLANT drinking water
for Plant
purpose Turbidity & Free Cl2
 ULTRAFILTRATION
Ultra-filtration (UF), a pressure activated process
and employs a semi permeable membrane with
asymmetric structure and can be effectively
employed for removal of non-reactive silica.
 Removes colloidal silicates, aluminium and organics
humic, fulvic acids)
 Reduce silica deposition on turbine blades
 Reduce corrosion potential of high molecular weight
organics
 Reduce turbine maintenance down time
 Reduced boiler feed chemicals
 Fewer make-up water upsets means more on-line
time
 Less power purchased from other utilities
 Post Treatment Plant

Demineralization Plant (DM

Plant).
Non Demineralization Plant
(Softening Plant).
What is DM water ?
NEED FOR DEMINERALISATION:

Raw water contains various dissolved salts & suspended solids. For
use as feed in boiler these are to be removed as they may get
deposited on heat transfer zones thereby restricting heat
transfer & may lead to corrosion,overheating.
 ION
EXCHANGE
 More than 100 years it was recognized that
some natural solids could exhibit ion
exchange properties.
 The first examples are Rocks and Solids.
 In 1935 synthetic ion exchange materials
were prepared using polymers then
available.
 In 1944 first polystyrene based resins were
produced and still this is the major ion
exchange polymer used.
Resin
 H+
H+ OH-
OH-
SO3- SO3-
- SO3- R N+ R N+
H+ 4 4 OH-
H+ SO3- SO3- OH- R N+
4
- SO3-
H+ R N+ -
4
R N+
4
OH-
H+
OH R -N+
4
CATION RESIN
ANION RESIN
The main characteristic of Ion Exchange resins are

 In soluble in water but permeated by water

 An ability to exchange ions with those in solution.

 To allow water to flow through the bed and offer

low resistance and should act as filter medium.

RH+NaCl RNa+HCl

ROH+HCl RCl+H2O
 MAKE IN INDIA

INDIGINIOUS RESIN---RS 300/LIT

IMPORATED RESIN---RS 600/LIT

 GENERAL ORDER OF ION SELECTIVITY IN WATER BELOW 1000 MG/L TDS
Cations Anions
Fe3+ CrO42-*
Al3+ SO42-*
Pb2+ SO32-*
Ba2+ HPO42-*
Sr2+ NO3-
Cd2+ NO2-
Zn2+ Br-
Cu2+ Cl-
Fe2+ CNHCO3-
Mn2+ H3SiO3-
Ca2+ OHF
Mg2+
K+
NH4+
Na+
H+
Li +

Notes: Changes in position may occur between products of different manufacture or having
slightly different skeletons or exchange groups. In general, selectivity is affected by:
(a) Ionic valence: 3 > 2 > 1.
(b) Atomic number: Ba > Sr > Ca > Mg in Group UA.
(c) Hydrated ionic radius: the larger the radius, the lower the selectivity and exchange capacity.
Processes …..

FW water

ACF WAC SAC

Degasser

WBA SBA MB

CST
Processes …..

FW water

ACF WAC SAC

Degasser

WBA SBA MB

CST

ACF
acts on principle of adsorption which is a surface active phenomenon
It removes residual turbidity (<2 NTU) of water to its 1/10 level.
It removes organic molecules to control colour and odour.
It removes free residual chlorine present in filtered water(0.5 ppm Nil)
Degasser
Processes …..

FW water

ACF WAC SAC

Degasser

WBA SBA MB

CST

WAC resin is capable to exchange cations of alkalinity producing salts only

ie, for carbonate hardness removal purpose.
2 R-COOH + Ca(HCO3)2  (RCOO)2Ca2+ 2 H2CO3
WAC resin can exchange ions only in neutral to alkaline pH range.
WAC results efficient TDS reduction in high carbonate hardness water.
Efficient regeneration takes place even with very dilute acid solution.
Processes …..

FW water

ACF WAC SAC

Degasser

WBA SBA MB

CST

SAC resin works over wide pH range & is capable to

exchange any type of cations present in salts as
sulphonic acid group is strongly acidic.
2 R-SO3-H+ + CaCl2  (RSO3)2Ca2+ 2 (H+ + Cl- )
 FMA/EMA/ NA
SLIP///REGENERATION

 BACKWASH----TO LOOSEN RESIN BED

 ALKALI / ACID—UNIFORM DISTRIBUTION

 SLOW RINSE—REMOVE XTRA ACID/ ALKALI

 AIR SCORING—MAKE FREE RESIN

 FAST RINSE----GET IN SERVICE

Processes …..

FW water

ACF WAC SAC

Degasser

WBA SBA MB

CST

Water from the ex-cation contains carbonic acid which is very weak acid
and difficult to be removed by strongly basic anion resin and causing
hindrance to remove silicate ions from the bed.
The ex-cation water is trickled in fine streams from top of a tall tower
packed with rasching rings, and compressed air is passed from the
bottom
Carbonic acid break into CO^ and water. carbon dioxide escapes into the
Processes …..

FW water

ACF WAC SAC

Degasser

WBA SBA MB

CST

Weak anion resins derive their functionality from primary

(RNH2),secondary(R-NHR’)& tertiary amine (R3N)groups.
The weak weak-base anion resins remove free minerals
acidity(FMA) such as HCl & H2SO4 but doesn’t remove
weakly ionized acids such silicic acid and bicarbonates
Processes …..

FW water

ACF WAC SAC

Degasser

WBA SBA MB

CST

The Strong base anion resins derived their

functionality from quaternary ammonium
exchange sites.These are capable of exchanging
anions like Cl-,HCO3-,Silica.
Processes …..

FW water

ACF WAC SAC

Degasser

WBA SBA MB

CST

ex-anion water is fed to the mixed bed exchanger containing both cationic
resin and anionic resin.
This bed not only takes care of sodium slip from cation but also silica slip
from anion exchanger very effectively
The final output from the mixed bed is an extira-ordinarily pure water having
less than 0.2/Mho conductivity, H 7.0 and silica content less than 0.02
ppm.
REGENRATION

 CATION DONE BY ACID HCL

 ANION BY ALKALI NAOH

 REGENERATION

 BACKWASH----TO LOOSEN RESIN BED

 ALKALI / ACID—UNIFORM DISTRIBUTION

 SLOW RINSE—REMOVE XTRA ACID ALKALI

 AIR SCORING—MAKE FREE RESIN

 FAST RINSE----GET IN SERVICE

 REGENERATION PROCESS

SAC SAC

R2-Ca2+ R2Mg2+ R-H+ R-H+

HCl R-Na+ R-K+ TO R-H+ R-H+

DRAIN
R3-Fe+3 R3-Al+3 NaCl,CaCl2 etc. R-H+ R-H+

WBA SBA SBA+

WBA
R-Cl
R-OH-
TO R2-SO4 R2-SiO2
R-OH- R-
DRAIN R-NO3 R2-SiO2 OH-
R-Cl
NaOH
R2-SiO2 R-OH-
R-OH- R-
 PARAMETER OF VARIOUS…..

Parameters pH Conducti Turbidity Residual Silica

vity Chlorine

ACF 7.5— 200— <2.0 Nil 10---25

8.5 400 NTU PPM
Micromh
os/cm
Anion 6.5 – <10 Nil Nil <200
8.0 PPB

Mixed Bed 6.5-7.0 <0.2 Nil Nil < 20

PPB
Mixed Bed Resin:
Outlet of SAC and SBA passed through Mixed
bed resin to ensure there is no cation and anion
present in D M water.

Storage Tank:
Outlet of mixed bed resin collected in storage
tank from where make up can be given to CST.

BREATHERS…..
Alkali and Acid Storage Tank /fumes
absorbers/mopping
Resin Transfer Vessel
PREVENTION……

PROTECTION OF ION EXCHANGE VESSELS

FROM CORROSION BY APPLYING COATING
EPOXY PAINT
RUBBER LINING
ANTI CORROSIVE COATING
TYPES OF DM PLANTS

WAC DGT WBA

SAC DGT WBA SBA

SAC DGT WBA SBA MB

WAC SAC DGT WBA SBA MB

SPECIFIC CONSUMPTION

 D.M.WATER----------< 0.020 Lit/KWH

 SOFT WATER-------- < 2.0 Lit/KWH

 ASH WATER----------< 1.5 Lit/KWH

 RAW WATER---------< 3.5 Lit/KWH

 Soften Water Plant

 There is 1 stream with 7 No. of Softeners.

 Flow of each softener is 250 M3/Hr.
 Each softener contains Strong Acid Cation Resin.

Type of Cut-off
Vessel Removes Regenerant
Exchanger parameter
If Hardness
Strong
appears or
Acid Brine
Softener water pass Hardness
Cation Solution
cross 6500
(Na-form)
M3/vessel
 Types of circulation at
NDCT

 Once Through circulation.

 Closed circulation.

 Open circulation.
The following four problems are normally associated with cooling water systems.

1. CORROSION
Manufacturing of common metals used in cooling systems, such as mild steel,carbon
steel,SS involves removing oxygen from the natural ore. Cooling water systems are an
ideal environment for the reversion of the metal to the original oxide state. This
reversion process is called corrosion.
2. SCALE
Minerals such as calcium carbonate, calcium phosphate, and magnesium silicate are
relatively insoluble in water and can precipitate out of the water to form scale deposits
when exposed to conditions commonly found in cooling water systems.
3. FOULING
The deposition of suspended material in heat exchange equipment is called fouling.
Foulants can come from external sources such as dust around a cooling tower or
internal sources such as by-products of corrosion.
4. BIOLOGICAL CONTAMINATION
Cooling water systems provide an ideal environment for microbial organisms to grow,
multiply, and cause deposit problems in heat exchange equipment. Microbial growth can
strongly influence corrosion, fouling, and scale formation, if not controlled properly.
 Corrective actions

 Restoration water chemistry

 Removal of unit from service , if pH falls below 8

 Condenser leakage { powerful concentration mechanism inside a

boiler ; in-leakage of even few ppm of contaminants can cause
severe damage }

 Water-side deposition control

 Inadvertent release of water treatment regeneration chemicals

SWAS LAB
BOILER DRUM – PH / CONDUCTIVITY / SILICA/PO4/TH/CL/
MAIN STEAM
ECONOMISER ------ DO / RESI.HYDRAZINE
CONDENSER -------DO
CST
CHEMICALS USED
HYDRAZINE,AMMONIA,TSP
 S,H. HP/IP L.P.
PO4,SiO2,K

DRUM Turbine
SiO2,K,NH3
R.H.

PO4

K,KH,N2H4,SiO2,D.O. Condensor
K,KH,SiO2,NH3
D.A.

CEP

BFP
L.P.H. CPU

H.P.H. N2H4 NH3 NH3,K,KH,SiO2,Na

 CAUSTIC GOUGING

 Caustic gouging is caused by localized concentration of

sodium hydroxide (NaOH) to high pH levels, which
solubilizes the protective magnetite layer of the tubing
steel and leads to rapid dissolution of the underlying tube
metal
 Typical reactions of caustic with iron oxide and iron are
Fe3O4 + 4NaOH  2NaFeO2 + Na2FeO2 + 2H2O

2NaOH + Fe  Na2FeO2 + H2

2Fe2O3 + N2H4 + 2NH4OH  Fe3O4 + NH4FeO2 + 2H2O

 Pitting corrosion
General description :

oxygen … chemical agent { plus moisture }

Idle boiler affected more than the running boiler

…protective magnetite attacked

4 Fe3O4 + O2 6 Fe2O3

Unprotected metal attacked

2 Fe + H2O + O2 Fe2O3 + H2

Corrosion product carried to other parts of the boiler; gets deposited

on the high heat zones

 HYDROGEN DAMAGE

 Atomic hydrogen can diffuse into steel and react with iron carbide

 Fe3C + 4 H 3 Fe + CH4

 Methane , being a bigger molecule , can not diffuse ; but accumulate

at grain boundaries

 Stresses at grain boundaries produce intergranular micro-cracks

[making tube brittle ]

 Thick-walled burst occurs { large , rectangular section of the wall

blown out with a big hole }

[ brick structure without mortar ]

 Caustic corrosion

 Alkali-producing chemicals dosed in boiler water to

maintain the optimum pH

Na3PO4 + H2O Na2HPO4 + NaOH

 Corrosive action of sufficiently concentrated alkali on

boiler tubes leads to corrosion

Fe3O4 + 4 NaOH 2 NaFeO2 + Na2FeO2 + 2H2O

{ black magnetite eaten away }

Fe + 2 NaOH Na2FeO2 + H2

{ parent metal attacked }

 Boiler water treatment
 Trisodium phosphate provides the needed alkalinity in boiler systems as follows :

Na3PO4 + H2O NaOH + Na2HPO4

 Absorption of contaminants :

10Ca2+ + 6PO43-- + 2OH-- 3Ca3(PO4).Ca(OH)2

calcium hydroxyapetite

3 Mg2+ + 2SiO32- + 2OH-- + H2O 3MgO.2SiO2.2H2O

serpentine

 Calcium hydroxyapetite and serpentine exist as soft sludges and much easier to
remove ; typically settle in the drum and removed by blowdown
 Feed water chemistry
 Condensate plus make-up water

 Virtually all impurities carried into the boiler through the feedwater

 Condensate : Corrosion in the pre-boiler section ; subsequent transport to the

economizer, boiler and subsequent deposition high heat zones

 Make-up water : Though less prevalent can carry hardness salts and silica
 Quantity of deposit and unit cleanliness

Quantity of deposit Surface cleanliness

 Less than 15 mg /sq.cm. Clean surface
 15 to 40 mg / sq.cm. Moderately dirty
 more than 40 mg /sq.cm. Dirty

 Chemical cleaning should be done whenever deposits

are more than 40 mg / sq.cm .
 once in 4 years as a mandatory maintenance practice

( guidelines only / not a rule or code ) BIS : 10391

 Alkali boil-out
 Method 1  Method 2
Na2CO3 Na3PO4 1000 ppm
Na3PO4 8000 Na2HPO4 500 ppm
ppm
NaOH Unit fired & alkali boil-out
Unit fired & alkali boil-out carried out at 40 kg / sq.cm
carried out at 20 kg / sq. cm
or 20 % MCR , whichever is
less
 Water technology

Why passivation ?

Magnetite , Ferric oxide ,

{ Fe3O4 } { Fe2O3 }

Colour black brownish red

Binding tightly binds flakes off easily

nature to base metal from base metal

w.r.to protects the does not protect

corrosion base metal the base metal

{significance}
 Research & Development

Passivation

 Anti – corrosion measures

 Hydarzine and ammonnia

 Magnetite layer formed

--- must be continuous and adherent

 magnetite layer adherence to the metal poor below 250 o

C [ Only temporary protection ]

 High temperature passivation very much adherent &

resistant to corrosion

 6 Fe2O3 + N2H4 4 Fe3O4 + N2 + 4 H2O

 CONSTRAINTS

LDO---RS 55000/KL

FO-----RS 38000/KL
 O N
S I
O S
R R
CO
I D
VO
A
T
N
A

TO
L
P
S
N
M
D O
, I
K T
U
N
L
A
T O
S
D
I E
C N
I
A
R
R B
O
R T
F
O N
S F E
G M
G N
N
L
I N O
I N
N
A

G R
T

I T I
E

A I
L V
M
S
O
E N
E
R C
D E
E
L

B Y E
A
F
B X
H
T

O
I

U O T
P
U

S R E
E E
G
E
E G
E N
S
S

A N
S
•U

•U A
•U H
•C H
•C
PRESERVATION OF TUBES
 PROCEDURE
1. Chemical used is hydrazine hydrate.
2. Concentration of hydrazine hydrate - 200 ppm.
3. Ammonia requirement per cycle – 100 litrs.
4. pH maintained – 10 to 11.
5. Time duration per cycle – 3 days.
6. Quantum of the tubes preserved per cycle – 1000 RMT including bends.
AUDIT CARD

WATER AUDIT___IN PROCESS

CORROSION AUDIT…..
 DAILY WATER BALANCE OF WATER TREATMENT PLANT - 500MW
September - 2016
Fire
Drinking Total PTP
PTP Total Fightin
DM PTP Water water Ash
DM/ Soft water Industrial Ash g Total STP ETP PTP
Water water Softenin (M3) Produce PTP Bund ACW
CPU Water required Water Raw Water Water Reco Recov Recov
e (backfl required g Regn (Domest (DM+Softeni Waste Reco Drain
Effluent (backflus for required Water & for GRN very ery ery
ush) for DM (M 3
) ic Water ng+Drinking) (M3
) very (M3)
(M3) h) (M3) Softening by WTP (M3) service (M3) (M3) (M3) (M3)
(M3) Water Backflus (Backflush (M3)
Water (M3) water
h Qty) Qty)
(M3)
708 100 4560
ende 24576 M3 150 / 150 M3 / 150/
M3 / M3 /       425/Hr   M3 /     10/Hr    
meters / day Regn day Hr
day Regen day  
p-16 246 0 246 18800 1500 20300 150 20696 850 21546 10890 1000 33436 150 1500 850 0 0
p-16 243 0 243 20400 900 21300 150 21693 850 22543 11055 1000 34598 150 900 850 0 0
p-16 226 200 426 19400 1200 20600 175 21201 1133 22334 4620 1000 27954 150 1400 1133 0 0
p-16 163 0 163 17750 900 18650 150 18963 850 19813 11220 1000 32033 150 900 850 0 0
p-16 249 0 249 23550 1050 24600 175 25024 850 25874 14520 1000 41394 150 1050 850 0 0
p-16 233 0 233 19550 1050 20600 150 20983 1133 22116 12375 1000 35491 150 1050 1133 0 0
p-16 264 300 564 24900 900 25800 150 26514 850 27364 13530 1000 41894 150 1200 850 0 0
p-16 258 0 258 19500 1200 20700 150 21108 850 21958 5775 1000 28733 150 1200 850 0 0
p-16 249 200 449 24950 900 25850 150 26449 1133 27582 15015 1000 43597 150 1050 1133 0 0
p-16 256 0 256 20650 1350 22000 150 22406 1133 23539 15840 1000 40379 150 1350 1133 0 0
p-16 306 0 306 22400 900 23300 150 23756 567 24323 11220 1000 36543 150 900 567 0 0
p-16 195 0 195 19700 1050 20750 175 21120 850 21970 9735 1000 32705 150 1050 850 0 0
p-16 234 300 534 21770 750 22520 150 23204 850 24054 7920 1000 32974 150 1050 850 0 0
p-16 240 0 240 23100 1050 24150 150 24540 567 25107 11385 1000 37492 150 1050 567 0 0
p-16 248 0 248 18450 900 19350 150 19748 850 20598 15015 1000 36613 150 900 850 0 0
p-16 248 0 248 19250 1350 20600 150 20998 850 21848 7920 1000 30768 150 1350 850 0 0
p-16 224 100 324 19500 1050 20550 225 21099 850 21949 8580 1000 31529 150 1125 850 0 0
p-16 260 200 460 18450 900 19350 150 19960 850 20810 7920 1000 29730 150 1125 850 0 0
p-16 222 0 222 18100 1200 19300 150 19672 567 20239 7920 1000 29159 150 1200 567 0 0
p-16 221 0 221 22600 900 23500 150 23871 567 24438 10560 1000 35998 150 900 567 0 0
p-16 258 0 258 18250 900 19150 200 19608 850 20458 5280 1000 26738 150 900 850 0 0
p-16 355 0 355 22700 900 23600 175 24130 850 24980 6930 1000 32910 150 900 850 0 0
p-16 579 300 879 2250 750 3000 150 4029 567 4596 3630 1000 9226 150 1050 567 0 0
p-16 0 0 0 1500 0 1500 150 1650 0 1650 0 1000 2650 150 0 0 0 0
p-16 661 0 661 3100 0 3100 150 3911 0 3911 1485 1000 6396 150 0 0 0 0
p-16     0     0   0   0     0     0 0 0
p-16     0     0   0   0     0     0 0 0
p-16     0     0   0   0     0     0 0 0
p-16     0     0   0   0     0     0 0 0
p-16     0     0   0   0     0     0 0 0
Total 6638 1600 8238 460570 23550 484120 3975 496333 19267 515600 230340 25000 770940 3750 25100 19267 0 0
 What is Microbial Contamination?
The uncontrolled growth of microorganisms can lead to deposit formation that
contributes to fouling, corrosion, and scale.

 What are Microbial Slimes?

Microbial slimes are masses of microscopic organisms and their waste products.
These slime layers are usually sticky and effective in trapping foulants present in the
bulk water.

 How do Slime Layers Impact Cost of Operation?

Microbial slime, like other fouling materials, reduces the efficiency of heat transfer.
In fact, microbial slime is more insulating than other common deposits. The slime can
trap other deposits, making the problem worse.

 How do Microorganisms Enter a Cooling Water System?

There are two primary modes of entry of microorganisms into cooling water
systems. One is the makeup water in which microorganisms are already present.
Another is via airborne microorganisms that are blown into the cooling tower
MAHARASHTRA STATE ELECTRICITY POWER GENERATION COMPANY LTD. KHAPERKHEDA THERMAL
POWER STATION
WATER TREATMENT PLANT –II (500MW)

Date:
 
SUB: - Boiler light-up programme of Unit # V (500MW).
 
Following programme may, please be carried out during light up:-
 
1) Intimation regarding boiler filling and FST filling through boiler fill pump / feed
pump may please be given to Sr. Chemist (on duty) so as to arrange for chemical
dozing through HP / LP dosing pumps.
2) Before running condensate extraction pumps (CEP) & putting in normal system,
please inform Sr. Chemist (on duty), Arrange for condenser water flushing, if
necessary.
3) Please arrange to bring drum level upto normal light-up level, before light-up.
4) After light-up raise the boiler drum pressure up to 5 Kg / cm2 (after closing vents)
and inform Sr. chemist (on duty) to arrange for chemical dozing to boiler through
phosphate dozing pump (H P pumps).
5) Arrange HBD at 20kg / 30kg cm2, water wall ring header bottom HBD valve. Blow
down may be operated for one minute after killing fire in order to di-sludge, flush out
loose debris, rust, corrosion product from boiler.
6) Operate 20% CBD at boiler drum pressure of 40Kg /cm2 till further intimation
from Sr. Chemist (on duty).
7) Before admitting the steam in the H.P. turbine please obtain clearance for chemical
parameters of saturated / superheated steam i.e. Silica clearance etc. Boiler pressure should be
maintained as per silica curve as permissible.
8) H.P. Heater to be flushed for 4-5 Hrs. and obtain the clearance from Sr. Chemist (on duty)
before taking into service.
9) Boiler drum pressure clearance may be obtained from time to time from Sr. Chemist.
10) Relevant information such as starting of CEP / BFP, rolling of TG Set, Synchronisation
etc. may please be given so that appropriate actions can be taken like running of chemical
dozing pump etc.
 
 
 
Senior Chemist (On Duty)
WTP-II, 500MW
 
 
To: - The Shift In charge, Unit # V (500MW).
 PERMISSIBLE SILICA LIMIT PERMISSIBLE CHLORIDES
AGAINST PRESSURE IN BOILER LIMIT AGAINST PRESSURE IN
WATER BOILER WATER
PRESSURE SILICA PRESSURE CHLORIDES
SN SN
(kg/Cm2) (ppm) (kg/Cm2) (ppm/ppb)
1 120 0.91 1 130 2.0 ppm
2 130 0.77 2 135 1.9 ppm
3 135 0.68 3 140 1.7 ppm
4 140 0.59 4 150 1.6 ppm
5 145 0.5 5 155 1.5 ppm
6 150 0.45 6 165 1.2 ppm
7 155 0.36 7 170 900 ppb
8 160 0.32 8 180 700 ppb
9 165 0.22 9 185 520 ppb
10 170 0.18 10 188 450 ppb
11 175 0.13 11 190 400 ppb
12 180 0.11 12 200 250 ppb
13 >180<204 <0.10 13 204 150 ppb
 CHEMICAL DOSING SYSTEM
AT ETP
 Alum Dosing System:
Tank 1 No. (Capacity 4.2 m3)
Pumps 2 Nos. (Capacity 375 lph.)

 Lime Dosing System:

Tank 1 No. (Capacity 2.42 m3)
Pumps 2 Nos. (Capacity 225 lph.)

 Polyelectrolyte Dosing System:

Tank 1 No. (Capacity 1.62 m3)
Pumps 2 Nos. (Capacity 150 lph.)
TREATED WATER PARAMETERS AT
ETP
 As per / STP
MPCB Norms :
Particular Parameter
pH 6.5 to 8.5
Dissolve Oxygen (D.O.) 5.0 (ppm)
Chemical Oxygen Demand Not to exceed 250.0
(C.O.D.) (ppm)
Biological Oxygen Demand Not to exceed 30.0
(B.O.D.) (ppm)
Suspended Solid (S.S.) Not to exceed 100.0
(ppm)
Mix Liquor Suspended Solid 2000 to 4000 (ppm)
(MLSS)
Mix Liquor Volatile Suspended 1060 to 3000 (ppm)
 Online Effluent Monitoring System (OCEMS)
Connectivity to MPCB / CPCB Server
Particular Parameter

pH 6.5 to 8.5

Chemical Oxygen Demand Not to exceed 250.0

(C.O.D.) (ppm)
Biological Oxygen Demand Not to exceed 30.0
(B.O.D.) (ppm)
Total Suspended Solid (T.S.S.) Not to exceed 100.0
(ppm)
 Coal Transportation
Coal Yard
MGR
Mines
(NCL)
e y or
onv
C

Bunker

Feeder

Mills
 CHEMICALS USED IN TREATMENT
SL.N CHEMICALS USE
O
1 ACTIVATED TASTE,ODOUR & DECHLORINATION
CARBON
2 ALUM, FeCl3 COAGULANT
3 LIME pH ADJUSTMENT, SOFTENING
4 Cl2, O3, Na(OCl)Cl DISINFECTION, TO CONTROL BACTERIA,
VIRUS & ORG. MAT
5 HYDRAZINE OXYGEN SCAVENGER, MAGENTITE
LAYER
6 AMMONIA pH ADJUSTMENT
7 TSP TO TREAT BOILER WATER
8 HCl ACID REGENERANT OF CATION RESIN
9 NaOH REGENERANT OF ANION RESIN
 H. 500MW BOILER
R.
M.S C.R.H H

BCW Pump

FROM F.R.S
BOTTOM RNG HDR WW PANELS & 1 PASS
ST

W.W.
1ST PASS W.W O/L HDRS ROOF I/L HEADER
2ND PASS UPPER C-HDR 2nd PASS LOWER C-HDRS
LTSH I/L HEADER LTSH & O/L HEADER
D.P.I/L HEADER D.P.O/L HEADER
FINAL S.H. R.H.HEADER
2 ND
PASS ROOF O/L HDR(REAR ECONOMISER
 BOILER AIR & FLUE GAS TEMPERATURES MAX-134 ºC
Div Pl SH RH
DRUM PSH

1036ºC
685ºC
1372ºC 1130

LTSH
542ºC

1300-1400
ECO
330ºC

SA-310 ºC APH
A B PA-306 ºC

134 ºC 134 ºC

ESP
 BOILER WATER & STEAM TEMPERATURE

Div Pl SH RH
DRUM
PSH
361 ºC
337-540 ºC

473-540ºC
401-473 ºC 365-401ºC
LTSH

254-321ºC ECO
1300-1400

APH
A B

ESP