F. Open Cooling Water System 501x20

1

Open Recirculating Cooling Water for Power Plant

Indonesia Customer Seminar June 13 & 14 2012 Jakarta Indonesia

Overview  Pushing

the Limits

 Mechanical,

 Scale

Operational & Chemical Survey

Inhibitor Technology Overview

 PC-2040T

 Features  Performance  Comparison with other technology  Advantages & Benefit

Cooling System of Power Plant vs Other

It’s BIG !!!!

Open RCW System for Power Plant  Large  

systems

HV: 1,800 – 45,000 m3 RR: 20 – 200 x 103 m3/hr

 Surface,

well, reclaimed make up waters, sea water

 Regulated

to zero discharge

systems  1.2

– 25 cycles of concentration

 Maximizing

utilization!

water and chemical

Challenge: Pushing the Limits far can we stress our water system – increase the cycle, low etc - without too much risk?

 How

low a treatment level – heavy metal, phosphate, chlorine; etc - will perform?

 How

Tech Risks

Pushing the Limit TOC

SHE

6

Challenge: Pushing the Limits

Treatment Program Potential Risks System Survey

Monitoring & Control

Lowest TOC

Survey: Mechanical, Operational & Chemical

1. System Survey 2. MakeUp Analysis

Optimizer

Configure

Direct Connect Cross Over Cable

ISP Wireless Modem Dial Up

3D Web

Dial Up

Excel

Vantage

PSR

Import

3D Data Log

Service Report

Exciter & Stator Coolers

Hydrogen /Air Coolers

Cooling Source

Condenser

3-5% of main flow

Circulating Water Booster Pumps

Circulating Water Pumps

Lube Oil Coolers

Boiler Feed Pump Turbine Condenser

Bearing Cooling Water Coolers

Typical condenser flow: Fossil = 80 m3/hr/ MW capacity Nuclear = 123 m3/hr MW capacity CCGT= 61 o5r 164 m3/hr/MW

Typical Power Plant Circulating Water Cooling System

Survey: Cooling Tower  Tower

Type

 Cross Flow  Counter Flow  Fill

Type

 Splash bar  High efficiency  Structure:

 Wood, PVC, Cement

Fill Type, Fouling Tendency & Performance

Fill Fouling Issues •

Loss of cooling efficiency

•

High cooling water supply temperature

•

Tower capacity derating

•

Cooling tower failure

•

Expensive tower fill replacement

•

Health-related concerns due to microbial fouling

Impact of Cooling Tower Performance

Survey: Typical HX’s 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 not severe 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.

0.15-2.0 m/s Throttled

65 C skin temp

• Flow throttled to maintain minimum H2 temp. Tend to silt up in winter. • Often most severe duty in plant. • Unit must de-rate if H2 temp too high.

Lube Oil Coolers

0.15-2.0 m/s Throttled

40-65 C skin temp

• Flow throttled to maintain minimum lube oil 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

20 – 43 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.

H2 /Air Coolers (Rotor & Stator)

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 : 6 – 15 m

1. Often Key to Efficiency in Plant Operations 2. Condenser leak: boiler water contamination

15

Impact of Condenser Fouling

16

Impact of Condenser Tube Failure • Condenser Tube Failure pH 9 - 10 8,5 - 9 8 - 8.5 < 8.0

• Abnormal Boiler Cycle Chemistry

•Boiler Tube Failure

•Plant Shutdown

Hydrogen /Air and Lube Oil Coolers Hydrogen/Air Cooler • Horizontal coolers in modern combined cycle plant • Vertical coolers in traditional generator • Hydrogen for >600 MW (high heat capacity & low density) • Must derate if air or H2 is too hot Lube Oil 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

Aux/Service Cooling Heat Exchangers



Open cooling water generally on tube side



Relatively low temperatures and heat flux.



The intercooler between closed system and open system



Either shell & tube or plate type heat exchangers



Can be large if handle main HX with closed system

Survey: Metallurgy  Copper alloys - May prohibit or limit use of ammonia for condensate corrosion control - Especially for iralty 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

Survey: Make-Up Water Chemistry 

Make-up water quality  Source: river, sea water, brackish, deep well, recycle Chemical Properties-Makeup Water Calcium * Magnesium * Manganese Ammonia M-Alkalinity * Silica Aluminum Fluoride Chloride * Sulfate * O-phosphate Copper Conductivity * Zinc Iron Turbidity



Value 50 18 0,02 0 100 15 0,1 0 35 19 0,1 0 300 0 0,1 2

Variability is important !

Units ppm Ca as CaCO3 ppm Mg as CaCO3 ppm Mn ppm NH3 ppm as CaCO3 ppm SiO2 ppm Al ppm F ppm Cl ppm SO4 ppm PO4 ppm Cu uS/cm ppm Zinc as Zn ppm as Fe NTU

Potential Problems in Open Cooling Water

There are basically four interrelated problems in the operation of a cooling water system as depicted by the Cooling Water Treatment Triangle below. Each problem affects and is affected by the other problems.

Pushing the Limits: Technical Risks Silt Fouling

CaCO3 Scale

Steel Corrosion & Iron Fouling

CaSO4 Scale

Silica Scale

Microbio Fouling

Ca3PO4 Scale

Copper Corrosion

24

Nalco Advanced Technology in Cooling Water PSO Scale/ Corrosion Inhibitor Stabilized Bromine

Non PO4 Corrosion Inhibitor

Silica Inhibitor

High Stress Polymer (HSP®) High Resistant Azoles

25

What Do You Need? Super Duper Medicine?

Good Doctor Good Doctor

Good Doctor?

This is not the best time…

…to learn about a problem!

26

Is The Best Water Doctor ……

Identify Potential Issues & Technical Risks

1. System Survey 2. MakeUp Analysis

Optimizer

Configure

Direct Connect Cross Over Cable

ISP Wireless Modem Dial Up

3D Web

Dial Up

Excel

Vantage

PSR

Import

3D Data Log

Service Report

29

30

3DT Optimizer® Simulation & Program Design

Vary Temperature

HX Temperature & Velocity

Make Up Water Chemistry

Vary Cycle

System Design Optimizer

Vary pH

Vary Treatment Contaminants

System Metallurgy

31

3DT Simulation & Program Design 3DTOptimizer® Optimizer® for Diagnostic

Technical Risks

Safe Operating Window

32

Nalco Advanced Technology in Cooling Water PSO Scale/ Corrosion Inhibitor Stabilized Bromine

Non PO4 Corrosion Inhibitor

Silica Inhibitor

High Stress Polymer (HSP®) High Resistant Azoles

Total Operating Cost Simulation

Monitoring & Control: 3D TRASAR® Controller

1. System Survey 2. MakeUp Analysis

Optimizer

Configure

Direct Connect Cross Over Cable

ISP Wireless Modem Dial Up

3D Web

Dial Up

Excel

Vantage

PSR

Import

3D Data Log

Service Report

35

3D TRASAR® Stress Management for Cooling Water System



Automation control of  Corrosion inhibitor – TRASAR  Scale inhibitor- Tagged Polymer  Biocide – Bio reporter & ORP



On line measurement:    



Conductivity pH ORP Corrosion rate

Full communication capability (digital/analog/ethernet/scada/ modem)

3D TRASAR® Scale Control

Trasar & Tagged Polymer

37

Case History: 3DTRASAR® Scale Control 

Coal fired power plant in Nevada



Nalco 3D Trasar® and silica inhibitor technology allow the plant increase the cycle from 4.5 to 7.0 (+250 ppm SiO2 in 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

Date

10/26/03

10/21/03

10/16/03

10/11/03

10/6/03

10/1/03

9/26/03

9/21/03

9/16/03

9/11/03

9/6/03

9/1/03

8/27/03

8/22/03

8/17/03

8/12/03

8/7/03

8/2/03

7/28/03

7/23/03

7/18/03

7/13/03

7/8/03

7/3/03

6/28/03

6/23/03

6/18/03

6/13/03

6/8/03

6/3/03

5/29/03

5/24/03

5/19/03

5/14/03

5/9/03

5/4/03

4/29/03

4/24/03

4/19/03

4/14/03

4/9/03

4/4/03

3/30/03

3/25/03

3/20/03

mpy

3D TRASAR® Corrosion Control Corrosion Rates

3.0

XLP-170/N-23263 Manual Control

2.5

N-23263 Trasar Control/ XLP-170 Slaved

2.0

N-73292 Tagged Control/ N-73284 Trasar Control

1.5

1.0

0.5

0.0

39

Case History: 3D TRASAR® Corrosion Control 450 MW Coal Fired Plant operate as ZLD facitlity  CaSO4 and Ca3PO4 deposition Problem  Switch to Nalco 3D TRASAR® with PSO program 

3D TRASAR® Bio Control

Bio Reporter & ORP

Waste Money

41

Case History: 3D TRASAR® Bio Control 

250 MW Combined Cycle



Need to reduce bleach consumption related to the environment and copper corrosion



3D Trasar® Bio Control technology saving 75% of bleach consumption and keep the condenser performance

Nalco 3D TRASAR® + Nalco 360 Services:

1. System Survey 2. MakeUp Analysis

Optimizer

Configure

Direct Connect Cross Over Cable

ISP Wireless Modem Dial Up

3D Web

Dial Up

Excel

Vantage

PSR

Import

3D Data Log

Service Report

3D TRASAR® Reports the Data You Need the Way You Need It, When You Need It

Nalco 360 TM Nalco 360™ Service provides peace of mind that your water system is being monitored by a team of Nalco Experts, 24 hours a day, 7 days a week.

Nalco 360 TM

Nalco 360 Expert Center

3D TRASAR controller

+

Web connection

Performance reviews

Immediate alarm response

+

Nalco Sales Engineer

Automated Reporting

Nalco 3D TRASAR® + Nalco 360TM Monitoring & Controlling Your System 24/7

47

Case History: 3D TRASAR® + 360 TM



520 MW Combined Cycle Power Plant



Cooling water operate at 3-3.5 cycles



Nalco with 3D Trasar® + 360 TM that monitoring for 24/7 successfully running the system at cycle 5.

Challenge: Pushing the Limits far can we stress our water system – increase the cycle, low etc - without too much risk?

 How

low a treatment level – heavy metal, phosphate, chlorine; etc - will perform?

 How

Power Plant RCW: Pushing the Limit ! 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 !

Is The Best Water Doctor ……

Nalco Will Not Only Help You on:  Improve

Efficiency

 Enhance

 Meet

Reliability

Environment, Health & Safety Standard

But We Will Also Provide you ……..

A Peace of Mind