F. Open Cooling Water System

8/10/2019 F. Open Cooling Water System

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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



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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


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


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


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

47

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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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 ..

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F. Open Cooling Water System