Training Manual for SWSS[1].pdf

Embed Size (px)

Citation preview

  • 8/22/2019 Training Manual for SWSS[1].pdf

    1/35

    TRAINING MANUAL FOR

    STEAM AND WATER SAMPLING SYSTEM

    EROOM TECHNOLOGY CO., LTD.

  • 8/22/2019 Training Manual for SWSS[1].pdf

    2/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 2 -

    CONTENTS

    1. SWSS General

    2. Basic Cycle Chemistry of Drum-type Units

    2.1 Steam Generator (Boiler) Conditioning

    2.2 Feedwater Cycle Condit ioning

    3. Sample Points and Analysis Selection

    3.1 Feedwater Pump Inlet (Sample #1, 8)

    3.2 LP Drum Water (Sample #2, 9)

    3.3 LP Superheated Steam (Sample #3, 10)

    3.4 LP Saturated Steam (Sample #4,11)

    3.5 HP Drum Water (Sample #5, 12)

    3.6 HP Saturated Steam (Sample #6, 13)

    3.7 HP Superheated Steam (Sample #7, 14)

    3.8 Condensate extraction pump discharge (Sample #15)

    3.9 Condensate pol isher outlet (Sample #16)

    3.10 Aux. cooling water (Sample #17)

    4. Sample Obtaining and Transport

    4.1 Sample Obtaining

    4.2 Sample Transport

  • 8/22/2019 Training Manual for SWSS[1].pdf

    3/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 3 -

    5. Sample Condit ioning

    5.1 Pressure control

    5.2 Flow control

    5.3 Temperature control

    5.4 Other sampling system components

    5.5 Instrumentation and control

    6. Sample Analysis

    6.1 Precautions for grab sampling

    6.2 Precautions for on-line analysis

    6.3 Analysis definition, methods and applications

    7. References

  • 8/22/2019 Training Manual for SWSS[1].pdf

    4/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 4 -

    1 SWSS General

    1.1 Purpose of SWSS

    To transport and condition samples without altering the constituents in the

    samples.

    To provide information on cycle chemistry to help assure the performance

    determination of significant components and of the steam cycle in general.

    1.2 Parameters to be controlled : Velocity (flow), temperature and pressure

    1.3 Components constituting Sampling System :

    pipes (tubes), Primary and secondary coolers, pressure reducing valves,

    pressure and flow regulators, isolation valves, blowdown valves, resin

    columns, control systems, analyzers and instruments.

  • 8/22/2019 Training Manual for SWSS[1].pdf

    5/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 5 -

    2 Basic Cycle Chemistry of Drum-type Units

    2.1 Steam Generator (Boiler) Conditioning

    2.1.1 Problems that could be caused by inappropriate steam generator

    chemistry

    (1) Deposition of solids on inside boiler tube walls.

    - Corrosion products from condensate and feedwater systems,

    and hardness constituents (Ca and Mg) in boiler water.

    - form scales on high heat flux area of S/G

    - reduces heat transfer and results in overheating and failure of

    tubes.

    (2) Corrosion of S/G material which causes

    - material loss

    - heat transfer resistance by resultant oxides resulting in tube

    failure due to overheating and caustic attack

    (3) Contamination of steam entering turbine beyond the steam purity

    requirements of the turbine

    - Steam could be contaminated by mechanical and vaporous

    carryover of boiler water.

    - mechanical carryover ; drum water entrainment in steam

    - Vaporous carryover ; volatilization of impurities in drum water.

    Silica presents most difficult problem due to its high solubility in

    steam at intermediate S/G pressure.

  • 8/22/2019 Training Manual for SWSS[1].pdf

    6/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 6 -

    - Steam quality requirement for typical HRSG plant during

    normal and constant operation

    Parameter Target value Units

    Cation conductivity < 0.2 /

    Sodium, Na < 10 /

    Silica, SiO2 < 20 /

    Total Iron (Fe) < 20 /

    Total Copper(Cu) < 3 /

    2.1.2 Methods to minimize the problems

    (1) Blowdown of S/G ; by continuously blowing down a portion of drum

    water (less than 1% of feedwater flow rate) the impurities

    concentrated in drum water can be removed.

    (2) Corrosion within S/G can be minimized by maintaining pH of S/G

    water at 9.0 or above, depending on the operating pressure. In

    general, sodium phosphate (Na3PO4) is injected to drum water to

    obtain desired pH level.

    2.2 Feedwater Cycle Conditioning

    Cycle conditioning is performed to minimize corrosion and subsequent

    transport of corrosion products to downstream and to the S/G.

    2.2.1 Conventional Treatment

    (1) Elevates cycle pH in reducing environment by removing oxygen

  • 8/22/2019 Training Manual for SWSS[1].pdf

    7/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 7 -

    from feedwater at condenser and deaerator or by adding reducing

    agent (Oxygen scavenger, N2H4).

    (2) Reducing environment forms protective layer of magnetite (Fe3O4)

    over steel material.

    (3) To minimize the solubility of magnetite, pH should be kept around

    9.5.

    (4) If copper is present in cycle material, the copper solubility also has

    to be minimized, which could be obtained at pH value of around 8.5.

    (5) Compromised pH value of around 9.0 is used in case copper is

    present in cycle.

    (6) Ammonia typically is used as pH control agent.

    2.2.2 Oxygenate Treatment (OT)

    (1) Mostly for all-steel cycle of once-through boiler, oxygen or other

    oxidizer is fed to the cycle to make oxidizing environment in the

    feedwater.

    (2) In the oxidizing environment, protective corrosion layer of ferric

    hydrate oxide is formed over base layer of magnetite, with the

    solubility of the former much lower than the latter, thus reducing

    corrosion.

  • 8/22/2019 Training Manual for SWSS[1].pdf

    8/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 8 -

    3 Sample Points and Analysis Selection

    Sample points and the analyses of each sample are selected based on the

    criteria that they should give data for the decision whether steam and water

    quality requirements of the cycle are met and the performances of important

    equipment in the cycle are satisfactory.

    In addition to the on-line analyses of each sample as selected, grab sampling

    facility is furnished to enable further diversified analysis at laboratory environment.

    In the following sections, each sample is discussed for the necessity of its

    selection and types of analysis for a typical HRSG Cycle as shown in Fig.3.1.

    3.1 Feedwater Pump Inlet (Sample #1, 8)

    3.1.1 Purpose of analysis

    To monitor the performance of deaerator

    To check the effectiveness of oxygen scavenging and use the data

    for dissolved oxygen control.

    To determine compliance with the steam generator feeedwater

    purity requirements.

    3.1.2 Types of on-line Analysis and measuring ranges

    Dissolved oxygen, 0~200 ppb

  • 8/22/2019 Training Manual for SWSS[1].pdf

    9/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 9 -

    Chem.

    dosing

    #1,8

    Chem.dosing

    Chem.

    dosing

    #6,1

    3

    #7,1

    4

    Chem.

    dosing

    #5,1

    2

    #2,9

    #4,1

    1

    #3,1

    0

    Note:Thesecondsa

    mplenumberinasetof

    two

    numbers

    (#7,1

    4forex.)

    isfor

    HRSG#2

    #16

    #15

    Fig. 3. 1 Simplified d iagram of typical HRSG cycle

  • 8/22/2019 Training Manual for SWSS[1].pdf

    10/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 10 -

    Cation conductivity, 0~2 /

    pH, 0~14 pH

    3.2 LP Drum Water (Sample #2, 9)

    3.2.1 Purpose of analysis

    To monitor the purity of boiler water which is critical for the

    performance and operational lifetime of boiler unit

    To use the analysis results as the basis for blowdown control

    3.2.2 Type of on-line analysis and measuring ranges

    pH, 0~14 pH

    Specific conductivity, 0~100 /

    3.3 LP Superheated Steam (Sample #3, 10)

    3.3.1 Purpose of analysis

    To determine compliance with the turbine steam purity requirements

    3.3.2 Type of on-line analysis and measuring ranges

    pH, 0~14 pH

    Cation conductivity, 0~2 /

    3.4 LP Saturated Steam (Sample #4,11)

    3.4.1 Purpose of analysis

    To determine the quantity of moisture and chemical carryover from

  • 8/22/2019 Training Manual for SWSS[1].pdf

    11/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 11 -

    the boiler

    3.4.2 Type of on-line analysis and measuring range

    Cation conductivity, 0~2 /

    3.5 HP Drum Water (Sample #5, 12)

    3.5.1 Purpose of analysis

    To monitor the purity of boiler water which is critical for the

    performance and operational lifetime of boiler unit

    To use the analysis results as the basis for blowdown control and

    Na3PO4 dosing

    3.5.2 Types of on-line analysis and measuring ranges

    pH, 0~14 pH

    Specific conductivity, 0~100 /

    3.6 HP Saturated Steam (Sample #6, 13)

    3.6.1 Purpose of analysis

    To determine the quantity of moisture and chemical carryover from

    the boiler

    3.6.2 Types of on-line analysis and measuring range

    Cation conductivity, 0~2 /

    3.7 HP Superheated Steam (Sample #7, 14)

  • 8/22/2019 Training Manual for SWSS[1].pdf

    12/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 12 -

    3.7.1 Purpose of analysis

    To check for the contamination of superheated steam due to

    attemperation water impurities.

    To determine compliance with the turbine steam purity requirements

    3.7.2 Types of on-line analysis and measuring ranges

    pH, 0~14 pH

    Cation conductivity, 0~2 /

    3.8 Condensate extraction pump discharge (Sample #15)

    3.8.1 Purpose of analysis

    To monitor for in-leakage of cooling water in condenser

    To monitor for air in-leakage in condensate extraction pump

    To check for proper functioning of air ejectors

    3.8.2 Types of on-line analysis and measuring ranges

    pH, 0~14 pH

    Cation conductivity, 0~2 /

    Dissolved oxygen, 0~200 ppb

    Sodium, 0~50 ppb

    3.9 Condensate polisher outlet (Sample #16)

    3.9.1 Purpose of analysis

    To check for proper function of condensate polisher

    To obtain base data for determining the performance of deaerator

  • 8/22/2019 Training Manual for SWSS[1].pdf

    13/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 13 -

    3.9.2 Types of on-line analysis and measuring ranges

    pH, 0~14 pH

    Cation conductivity, 0~2 /

    Specific conductivity, 0~100 /

    Dissolved oxygen, 0~500 ppb

    3.10 Aux. cooling water (Sample #17)

    3.10.1 Purpose of analysis

    To monitor for contamination of auxiliary cooling water of the plant.

    Therefore, the sample is not taken from feedwater cycle but from

    the cooling water supply line being introduced to Steam and Water

    Sampling System.

    3.10.2 Types of on-line analysis and measuring ranges

    pH, 0~14 pH

    Specific conductivity, 0~100 /

  • 8/22/2019 Training Manual for SWSS[1].pdf

    14/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 14 -

    4 Sample Obtaining and Transport

    The most important criteria in deciding methods of obtaining and transporting

    samples are whether they guarantee truly representative samples of fluids at

    their respective sampling points.

    4.1 Sample Obtaining

    4.1.1 Water sampling

    (1) Sampling nozzles

    See Fig. 4. 1 for typical nozzle for water sampling

    Sample taking from vertical pipe is preferable to avoid settling

    resulting from low velocity

    In case the water sample has to be taken from horizontal pipe,

    the nozzle should not be installed on the bottom of the pipe.

    (3) Location of sampling nozzle : on long vertical pipes to avoid

    stratification of suspended solids and ensure that all water droplets

    are carried in the flow stream.

    (4) Nozzle insertion length : For single port nozzle, assuming fully

    developed turbulent flow, the nozzle is normally inserted 0.2R of

    the pipe from pipe inner surface, since this is the location where

    actual and average velocities are equal.

  • 8/22/2019 Training Manual for SWSS[1].pdf

    16/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 16 -

    Multi-point nozzle can be used at locations where the velocity

    profile across the pipe is known.

    (5) Port size : is determined to maintain isokinetic sampling in the

    nozzle port(s) at the desired sampling rate and design flow. But

    port diameter should be larger than 1/8 inch to prevent plugging.

    (6) Structure and material of nozzle: should be designed strong

    enough to prevent failure due to vibration, thermal stress cycling

    and other possible causes.

    Nozzles normally are made of 316 stainless steel or other

    austenitic stainless steel or alloy 600.

    4.1.3 Superheated steam sampling

    (1) Since superheated steam is usually regarded as single phase fluid,

    isokinetic sampling requirement may not apply. However, the same

    nozzle described for use with saturated steam can be used.

    (2) High-pressure superheated steam can dissolve most contaminants

    which, as steam pressure and temperature are reduced at nozzle

    and sample line, can deposit on the surfaces causing biased

    analytical results.

    4.2 Sample Transport

    Sample can be affected in many ways when they are transported from

    nozzles to sample conditioning system.

    Physical phenomena such as deposition and erosion, thermodynamic

  • 8/22/2019 Training Manual for SWSS[1].pdf

    17/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 17 -

    changes such as throttling and heat loss, and chemical and physical

    changes such as reactions of oxygen scavengers, crystallization and

    sorption are major causes that change the sample constituents.

    Design of sample transport system should be focused on the ways to

    minimize these changes and keep the samples unaffected as possible

    during the transport.

    4.2.1 Sample line construction

    (1) Valves : Root valves should be installed at sample source. For high

    pressure samples, double valves may be required depending on

    safety considerations.

    Valve and bore diameter should be selected so that velocity of

    sample through the valve does not change much. Stainless steel

    316 is preferred material for wet part of the valve.

    (2) Sample line material selection; Wall thickness and material of the

    tubes should be suitable for the temperature and pressure of the

    sample source and should be of corrosion-resistant material. 316

    Stainless Steel is preferred.

    Tube inside diameter should be selected based on considerations

    of sample velocity and pressure drop as discussed in section 4.3.

    Fitting also should be selected based on their temperature and

    pressure rating and made of materials compatible with the sample.

    (3) Installation : Sample lines should be free of dead legs, particulate

    traps(such as strainers), and low velocity zones. They should be as

  • 8/22/2019 Training Manual for SWSS[1].pdf

    18/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 18 -

    short as practical.

    Adequate support to prevent fatigue failure from vibration should be

    provided but free expansion and contraction with temperature

    change should be allowed.

    Sample lines normally should not be insulated.

    (4) Fabrication : Weldings on the sample tubes on small diameter tube

    (up to 3/8 inch) should be avoided as possible.

    Tube bends are recommended instead of right angle fitting.

    Burrs that could be produced after use of hacksaws and tube

    cutters should be blown out with clean, oil free air or flushed prior

    to installation.

    4.2.2 Deposition

    Results from chemical analysis can be biased either by the loss of

    contaminants to the deposit on the tube wall or the gain of

    contaminants from the deposits.

    Mechanisms of deposition of contaminants are,

    (1) Settling of particles: particles in the sample can stick to the wall

    crossing the boundary layer by inertia, diffusion or gravity. Particles

    so deposited can be eroded later by fluid drag force becoming re-

    entrained in the fluid stream.

    Steady state deposit weights are at the minimum when liquid

    velocity is at 1.5 to 2.1 m/s. Minimum deposits is desirable because

    of their shorter period of time for equilibrium and less susceptibility

    to particulate bursts.

  • 8/22/2019 Training Manual for SWSS[1].pdf

    19/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 19 -

    All colloidal materials such as ion oxides and effluents from

    demineralizers tends to form deposits also.

    (2) Sorption of dissolved species: Deposits on tube walls are porous

    and tend to sorb dissolved species by ion exchange, absorption,

    adsorption or other mechanism.

    (3) Crystallization: Most contaminants can be dissolved in superheated

    steam. As the pressure and temperature of steam decrease, the

    solubility of many contaminants is decreased and the contaminants

    crystallize and deposit on the surfaces of dry wall tubes.

    4.2.3 Saturated steam

    (1) Typical behavior of saturated steam during transport.

    Phase changes from saturated steam to two phase liquid of

    vapor and liquid then to liquid as the sample temperature

    decreases.

    Sample velocity decrease from high speed of steam to lower

    speed of liquid. As the desirable velocity of sample in the tube is

    1.5 to 2.1m/s, which could be attained only in case of liquid

    (condensate), the length of steam portion in the transport tube

    should be short as possible.

    When the steam velocity entering sample line is high, it will

    cause pressure drop, increase the volume then further decrease

    the pressure. In case of combined cycle plants, where steam of

    pressure less than 35/ are produced, this pressure drop

    temporarily causes the steam to enter the superheat region. The

  • 8/22/2019 Training Manual for SWSS[1].pdf

    20/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 20 -

    phase changes, from saturated steam to superheat steam then

    to liquid water will result in abrupt flow speed changes, which

    gives harmful effect to obtaining representative sample.

    (2) Sample flow rate should be maintained constant as possible to

    avoid condensing length changes, regional changes of phase and

    resulting flow.

    (3) Steam sample line sizing : For deciding sample line size and length,

    calculations to determine heat loss and pressure drop for different

    flow condition is required. Table 4.1 summarizes the calculations

    for typical tube sizes at different pressure and flow condition. In the

    table, following abbreviations are used.

    Max. L : Maximum recommend length. N.R. indicates not

    recommended for any length due to excessive

    pressure drop.

    Cond. L : Length where all steam is condensed. indicates that

    the steam is not condensed within recommended length.

    SteamVmax : Maximum velocity of steam at recommended length.

    A bullet() indicates that the steam velocity is

    increasing due to expansion. Where tube size is not

    recommended for any length, required steam

    velocity is given.

    Cond. Vmin : Velocity of condensate at 500ft(154m). indicates

    that the steam is not fully condensed in the

    recommended length or within 500ft(154m).

    *

    *

  • 8/22/2019 Training Manual for SWSS[1].pdf

    21/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 21 -

    Table 4.1

    Recommended Sample Tube Sizes

  • 8/22/2019 Training Manual for SWSS[1].pdf

    22/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 22 -

    The calculations for Table 4.1 are based upon straight tubing. In

    case unusual number of bends is used in the sample transport line,

    allowance for additional pressure drop has to be made.

    4.2.4 Superheated steam

    (1) To minimize deposit and loss of contaminants on the dry wall

    portion of sample line where the temperature is higher than the

    saturation temperature of the steam, it is recommended that

    superheat be removed from steam sample as early as possible.

    Where applicable, source cooling is recommended for this purpose.

    (2) Once the sample lose all its superheat, it will behave in the same

    manner as saturated steam. Table 4.1 includes recommendations

    for superheated steam also.

    4.2.5 Liquid samples

    Liquid sample lines should be sizes for sample speed of 1.5 to 2.1 m/s.

    This velocity range will result in minimum equilibrium deposit weight

    reached in the minimum operation period of about 30 days.

  • 8/22/2019 Training Manual for SWSS[1].pdf

    23/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 23 -

    5 Sample Condit ioning

    The objective of steam and water sample conditioning system is to modify and

    control the temperature, pressure and flow rate of the samples from the sample

    sources so that they are safe for grab sampling or are compatible with the

    requirements of on-line analytical instruments.

    5.1 Pressure control

    Pressure control of a sample is performed by incorporating two control

    methods, pressure reduction and back pressure control. Final target of

    these controls is to establish a constant pressure zone so that analyzers

    being fed from this zone get constant flows independent of actions taken in

    other branch lines, while maintaining constant flow in the main sample line.

    Normally, the pressure at the constant pressure zone is controlled at

    0.5~1.5/.

    5.1.1 Pressure reducer

    (1) Pressure reducer is located down stream of primary sample cooler

    so that the liquid is sub-cooled before pressure reduction.

    (2) For samples greater than 35/, variable rod-in-tube type orifices

    are recommended for they

    provide varying pressure drop

    are cleanable in place

  • 8/22/2019 Training Manual for SWSS[1].pdf

    24/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 24 -

    Fig. 5. 1 Typical arrangement of a sample conditioning system for a high-pressure

    high-temperature sample.

  • 8/22/2019 Training Manual for SWSS[1].pdf

    25/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 25 -

    eliminate possible sample bias due to dissociation of water into

    hydrogen and oxygen that can occur across throttling valves

    when sampling at high pressures.

    (3) For Samples less than 35/, needle valve is recommended for

    pressure reduction.

    5.1.2 Back pressure regulators.

    (1) By maintaining upstream pressure at constant value (0.5~1.5/),

    back pressure regulator performs two important functions, feeding

    constant flows and pressure to analyzers and maintaining fixed

    total sample flow.

    (2) Back pressure regulator continuously discharges the flow

    difference between total main sample flow and the sum of flows to

    analyzers.

    (3) Fore pressure regulator cannot provide constant sample line flow.

    5.2 Flow control

    Flow control is attained by adjusting flow meter control valve for each

    analyzer in conjunction with pressure control of section 5. 1.

    5.2.1 Total flow rate through a sample line is basically decided considering

    optimum velocity requirement in the sample transport line

    (1.5~2.1m/sec for water).

    However, other factors such as pressure drop along the transport line,

    total transport time etc. also have to be taken into account and

  • 8/22/2019 Training Manual for SWSS[1].pdf

    26/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 26 -

    compromise has to be made when required.

    5.2.2 The total flow is obtained by adjusting the pressure reducer in flowing

    condition.

    Downstream pressure of the reducer is controlled by back pressure

    regulator at 0.5~1.5/ as described in 5. 1. 2.

    5.2.3 Once the pressure is established at constant pressure zone, flow to

    each analyzer should be set at rate required by the analyzer by

    adjusting control valve that is normally an integral part of flow meter.

    5.2.4 Flow meters

    (1) Flow meters for total flow and flow to each analyzer are

    required.

    (2) Flow meter for analyzer has manual flow adjust valve as an

    integral part of the meter.

    (3) Flow meters are normally rotameter types with visible indicator

    (4) The rotameter shall be made of materials that are corrosion

    resistant and not reactive with samples.

    5.3 Temperature control

    Temperature of all sample is reduced and controlled at 25 because most

    on-line analyzers require samples to be standard temperature to ensure

    repeatable and accurate results.

    5.3.1 Primary cooler

    Primary cooler is used to reduce the sample temperature to less than

    2.8 of cooling water inlet temperature for water sample and 5.6

  • 8/22/2019 Training Manual for SWSS[1].pdf

    27/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 27 -

    of the cooling water inlet temperature for steam sample at

    representative sample flow.

    In general, for sample temperature greater than 80, primary cooler

    can be used. But the decision should be based on the capability of

    secondary cooler and chiller unit.

    5.3.2 Secondary cooler

    Secondary cooler should be capable of 0.5 approach to the chilled

    water temperature.

    5.3.3 Material and construction

    Cooler are normally tube coils in a shell type. Cooler tube and shell

    shall be made of stainless steel, preferably SS316 for tubes. For high

    chlorides in the cooling water, however, Alloy 600 is recommended.

    5.4 Other sampling system components

    5.4.1 Blowdown valve

    (1) Blowdown valves are used to purge sample lines that are not in

    continuous service or where suspended solids deposition

    affects the sample.

    (2) The blowdown valves can be located either prior to primary

    cooler or downstream of pressure reducer or at both.

    (3) Blowdown valve prior to primary cooler may be operated on

    initial startup of the system or after long period of shutdown of

    the system to remove any foreign materials and deposits in the

  • 8/22/2019 Training Manual for SWSS[1].pdf

    28/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 28 -

    sample transport line.

    (4) Blowdown valve downstream of pressure reducer is operated

    every time before the sample line is put into operation to flush

    the cooler and reducer in addition to sample transport line.

    (5) Regulating type valve is used for blowdown valve prior to

    primary cooler and ball valve for down stream of reducer.

    5.4.2 Isolation valves.

    For sample pressure higher than 48/ double isolation valves are

    recommended.

    Regulating type or ball valve rated for sample pressure and

    temperature are used.

    5.4.3 Sample relief valve

    Each sample line should be provided with a pressure relieving device

    to protect components from over-pressurization. Spring-loaded type

    back pressure relief valve is commonly used located downstream of

    pressure reducer.

    5.4.4 Cooling water valves on sample coolers.

    Each sample cooler should have an inlet isolation valve and outlet

    throttling valve. Cooling water flow is adjusted by the outlet valve to

    give optimum cooling water flow to the cooler and make balance

    between cooling waters to different coolers from same cooling water

    source.

    5.4.5 Fitting

    It is preferable to use bends rather than fittings to change direction of

    sample tubing.

  • 8/22/2019 Training Manual for SWSS[1].pdf

    29/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 29 -

    Compression or socket weld fitting should be selected based on

    application but compression fittings are preferable.

    5.4.6 Sample filters may be installed in the line to trap particles and reduce

    plugging on downstream components. But filters can affect sample

    analytical results and are not recommended normally.

    Filters made of stainless steel 316 with mesh size of about 100 is safe

    enough if filters are to be used.

    5.5 Instrumentation and control

    5.5.1 In addition to monitoring flows by rotameters, pressures and

    temperatures of final samples are monitored either by local indicators

    or indications on control panel.

    5.5.2 To protect components and analyzer sensors from abnormal high

    temperatures due to failures on coolers, temperature switches may be

    installed on final sample line which will trigger alarms and/or divert

    sample flows to blowdown valves.

    5.5.3 Control of sample and blowdown valves.

    Control of sample valves and blowdown valves can be performed

    either local-manually, remote-manually or remote automatically.

    (1) Local manual method : Opening and closing of valves are done

    at the valve locations by hand.

    (2) Remote manual method : Pneumatic on-off valves are used

    enabling manual operation of the valve from control panel.

    (3) Automatic operation of valves: In automatic operation,

  • 8/22/2019 Training Manual for SWSS[1].pdf

    30/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 30 -

    blowndown and sample valves are operated in automatic

    sequence with the blowndown duration is preset as required.

    The automatic operation of sample lines can be performed

    individually or in groups.

    (4) Remote operation of valves can be initiated from control panel

    of the sample conditioning system or from the main control

    system (DCS) of the plant.

    (5) PLC system is commonly used to realize remote and automatic

    operation in sample conditioning system.

  • 8/22/2019 Training Manual for SWSS[1].pdf

    31/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 31 -

    6 Sample Analysis

    Sample transported to and conditioned at sample conditioning system are either

    grab sampled and analyzed at plant chemical laboratory or analyzed on-line by

    analyzers on the sampling system control panel.

    6.1 Precautions for grab sampling

    (1) Samples should be taken from continuously flowing stream, not from

    any dead leg in the sample conditioning system.

    (2) If sample has not been flowing prior to grab sampling, blowdown of the

    sample line has to be performed for enough time to flush and stabilize

    the line.

    Blowdown time to flush six times the total line volume is acceptable. But

    when the system is being started initially or when new tubes or sample

    coolers are installed, much longer period of time for flushing (preferably

    several weeks) by continuous flow is required.

    (3) The sample velocity in transport line during flushing and sample taking

    should be maintained at 1.5~2.1 m/sec.

    6.2 Precautions for on-line analysis

    (1) Proper sample conditioning, particularly constant flow and temperature

    has to be maintained.

    (2) Manufactures requirements for sensor operation, flow rate range,

    maximum pressure etc. have to be met.

  • 8/22/2019 Training Manual for SWSS[1].pdf

    32/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 32 -

    (3) Regular calibration of analyzers according to manufactures instructions

    has to be performed.

    (4) When the sensors, especially pH and Dissolved Oxygen, are out of

    service or when the sample lines have to be left dry, special cares have

    to be taken to avoid critical damages to the sensors. Instructions of

    manufacturers manual has to be followed.

    6.3 Analysis definition, methods and applications

    In this section, brief explanations on the definitions, methods and

    applications for the analyses being made in NEKA plant are given. Detailed

    information on each analysis will be presented in separate class for each

    analyzer.

    6.3.1 Specific Conductivity

    (1) A measurement of all ionic species which contributes to the electric

    conductivity of a solution.

    (2) Unit in normal use is micro Siemens per centimeter(/), which is

    the reciprocal of the resistance in ohms measured between opposite

    faces of a cubic centimeter of an aqueous solution referenced to

    25.

    (3) High-purity conductivity analyzer should adopt specialized

    algorithms to account for the dramatic change in ionization of water

    with temperature. The unique effects of ammonia, morpholine, etc.

    present in the sample also has to be compensated for.

    (4) Keeping the sample temperature at reference temperature of 25

  • 8/22/2019 Training Manual for SWSS[1].pdf

    33/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 33 -

    is very important for accurate measurement of conductivity because

    the temperature compensation algorithm cannot count for all the

    effect of varying constituents in the water and the temperature

    sensor itself could produce erroneous signal.

    (5) Specific conductivity tends to follow the concentration of pH

    adjusting agents(usually ammonia).

    (6) Electrical conductivity methods are widely used for monitoring

    makeup water, feedwater and condenser leakage for its

    comparatively little maintenance required, low cost and high

    reliability.

    6.3.2 Cation conductivity

    (1) A measurement of anionic contamination rather than total ionic

    species. Sample is passed through a hydrogen ion exchange

    resin before conductivity measurement, where ammonia, amines

    and other cationic contaminants are removed.

    (2) Removing cation ions will greatly sharpen sensitivity to

    contamination by removing the masking affects of ammonia,

    amine and convert salts to the corresponding mineral acids,

    which are a more conductive than the salts, thus further

    increasing sensitivity.

    (3) Non-ionized or weakly ionized substances (for ex. SiO2) and

    hydroxide ions are not measured by this method.

    (4) Is useful for detecting the leakage of cooling water into

    condensate.

    6.3.3 Dissolved oxygen

  • 8/22/2019 Training Manual for SWSS[1].pdf

    34/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    - 34 -

    (1) Oxygen dissolved/entrained in aqueous media.

    (2) Measured by electrochemical method. Unit is in /L (ppb).

    (3) Dissolved oxygen measurements is used to detect oxygen inleakage

    at condensate pump discharge and also to monitor deaerator

    performance and results of oxygen scavenger (N2H4) injection.

    6.3.4 pH

    (1) The negative logarithm of concentration or activity of hydrogen

    ion (-log[H+]).

    (2) Measured by electrometric instrumental probe method.

    (3) pH measurements are made on most of the samples to monitor

    whether the required pH level for minimizing corrosion of

    steam/water cycle materials are maintained. The measurements

    also provide data for the decision of pH control agent injection.

    6.3.5 Sodium

    (1) Alkali metal present in water as cation Na+.

    (2) Measured by ion-selective electrode method. Unit is in

    /L(ppb).

    (3) Sodium measurement is made on samples from condenser

    extraction pump discharge to detect condenser in-leakage and

    breakthrough from condenser polisher dimineralizer.

  • 8/22/2019 Training Manual for SWSS[1].pdf

    35/35

    TRAINING MANUAL FOR SWSS FOR HRSG UNIT

    7 References

    (1) Power Plant Engineering, by Chapman & Hall, 1966

    (2) Steam and Water Sampling, Conditioning and Analysis in the Power Cycle,

    ASME PTC 19.11-1997

    (3) Standard Guide for Equipment for Sampling Water and Steam in Closed

    Conduits, ASTM D1192-98

    (4) Standard Practices for Sampling Water from Closed Conduits, ASTM D3370-

    1999

    (5) Standard practice for Sampling Steam, ASTM D1066-97