8

12
10

T1

TS
15

11

15

P1

AL

13
PS

14

16

22

16

23

17

19

CE

CT

NA

Steam and Water Analysis System (SWAS)

An Overview

Energy Conservation | Environment | Process Efficiency

Forbes Marshall

Forbes Marshall Arca

Forbes Marshall Codel

J N Marshall

www.forbesmarshall.com
Krohne Marshall

Spirax Marshall

Forbes Vyncke

For over six decades, Forbes Marshall has been building steam engineering and control instrumentation solutions that work for process
industry. Today we have evolved into a leader in process efficiency and energy conservation through technology tie-ups and focused
investments in manufacturing and research. Our joint ventures with the world's leading names enable us to deliver quality solutions in
14 countries. Forbes Marshall is probably the only company in the world to have extensive expertise in both steam and control
instrumentation. The dual expertise has allowed us to engineer industry specific systems that focus on energy efficiency and utilities
management for sectors as diverse as textiles, food processing, paper, power and chemicals.
Our business practices and processes have combined into a singular philosophy of being trusted partners who provide innovative
solutions. It's a philosophy we are proud to live up to.
Forbes Marshall began sixty years ago as a company offering steam engineering solutions in association with Spirax Sarco of the UK.
For decades, we have been designing, manufacturing and supplying steam engineering products and solutions to customers
worldwide. Our experience in this area is the benchmark against which all others are compared. While our oldest joint venture is with
Spirax Sarco, the world leader in steam engineering, our newest joint venture is with Vynke Energietechniek, the world leaders in
converting biomass into energy.

Today in the power plants, high pressure boilers and steam turbines are under constant attack from erosive and
corrosive lements such as Silica, Sodium, Dissolved Oxygen, Calcium, Chloride and Phosphates. Without accurate
measurement and monitoring, the plant may suffer heavy mechanical damages that can be caused due to imbalance
of turbines, reduced efficiency, deposition on turbine blades, corrosion of steam pipe work and so on.
We have designed our Steam and Water Analysis System (SWAS), to keep you in power. SWAS assures safety of your
boiler and turbines, by taking along and analyzing up to a dozen samples from all your water and steam circuits. In
today's supercritical power plants, sample conditions as high as 600 Degree C and 300 bars are quite common. Forbes
Marshall SWAS can easily take care of these samples. To protect your equipment our SWAS works in two stages:
1. Sample Conditioning
2. Sample Analysis

1. Sample Conditioning
First section of any SWAS is the Sample Conditioning section or Wet Panel

Enclosed type
Wet Panel

Open frame-free
standing Wet Rack

Here the sample is first cooled in Sample Coolers, de-pressurized in pressure regulators and then fed to various
analyzers while keeping the flow characteristic constant by means of a Back Pressure Regulating device.There are lots
of safety equipment provided in wet panels, so that the operators feel safe while working with these systems.

The schematic diagram here shows how this happens :

LINE - 1
BOILER FEED WATER
SAMPLE INLET

OTHERS

27

FM

01a

01a

BLOWDOWN HEADER
COOLING WATER OUTLET HEADER
COOLING WATER INLET HEADER

5a

5a
4
02

9
DRAIN
6

12
10

T1

TS
15

11

15

P1

AL

13
PS

14

Description

01a
01b
02
04
05a
06
08
09
10
11
12
13
14
15
16
17
22
23
27

Ht Sample Isolation Valve (globe Type)

Lt Sample Isolation Valve (needle Type)
Sample Cooler
(refer Sample Cooler Sizing)
Coolant Flow Indicator
Coolant Isolation Valve
Sample Filter
Pressure Regulator
Sample Relief Valve
Temperature Gauge
Pressure Gauge
Temperature Switch
Pressure Switch
Solenoid Valve
Regulating Valve
Rotameter
Tundish (for Grab Sampling Facility)
Back Pressure Regulator
Three Way Ball Valve
Bulkhead Union (1/2"nb S/w X 1/4" Od)

*
Ce
Ct
Phe
Pht
Doe
Dot
Hz
Si
Na

Any Of Analyser Given Below

Cond. Cell With Flow Through Chamber
Single Conductivity Transmitter
Ph Electrode
Ph Transmitter
Dissolved Oxygen Sensor
Dissolved Oxygen Transmitter
Hydrazine Analyzer
Silica Analyzer (multichannel)
Sodium Analyzer (multichannel)

16

22

16

23

17

Item No.

19

CE

WASTE DRAIN HDR

DRY PANEL
CT

NA

WASTE DRAIN HDR

DENOTES COOLING WATER LINE

DENOTES SAMPLE LINE

NOTE :
1. SAMPLE TUBING : 1/4" OD, 16 SWG, ASTM A 213, TP-316, SEAMLESS TUBE
2. BLOWDOWN HEADER (DEFAULT) : 2" NB, ASTM A106, GR.B, SCH-80, PIPE FLANGED TO 2" NB, ANSI B16.5, CLASS 300 R/F
3. COOLING WATER HEADERS (DEFAULT) : 2"NB, ASTM A106, GR.B, SCH.40, PIPE FLANGED TO 2"NB, ANSI B16.5 CLASS 150R/F
4. WASTE DRAIN HEADER (DEFAULT) : 2"NB, ASTM A106,GR.B, SCH. 40 C.S,PIPE FLANGED TO 2"NB, ANSI B16.5, CLASS 150 R/F
5. COOLING WATER PIPING : 3/4"NB, SS304 PIPING
6. SAMPLE INLET CONNECTIONS : BULKHEAD UNION FOR SR.NO.27

Some of the Important Components of Sampling Systems (Wet Rack)

Sample Cooler
Forbes Marshall Sample Coolers are coil-in-shell type
contra-flow heat exchangers. Validated by a premier
institute like IIT, we are one of the few sample cooler
manufacturers in the world who can offer
guaranteed performance. With in-house test set up
for performance testing, world-class manufacturing
and welding facilities, we offer one of the most
trusted sample coolers in the power sector. Various
options of coil materials are available such as Stainless
Steel AISI 316, Monel 400, and Inconel 625 and so on.

High Pressure Regulator

Forbes Marshall offers piston type High Pressure Regulators.
These are used in primary conditioning where sample
pressures are higher than 100 Kg/cm. As these are piston
type Pressure Regulators, there is no fear of diaphragm
rupture etc.
For lower pressure / temperature rating, Forbes Marshall
offers spring loaded diaphragm type Pressure Regulator.To
offer safety against a remote possibility of diaphragm
rupture, in-built safety valve is a regular feature.

Back Pressure Regulator

Forbes Marshall offers Back Pressure Regulator (BPR)
to avoid low flow (or fluctuating flow) conditions to
analyzers in the event of grab sample valve operation.
In the absence of such a device, the sample would
flow to grab sample line when the grab sample valve
is opened. This can create low flow alarm conditions
in samples going to analyzers.
A Pressure Regulator and Back Pressure Regulator
combination provides very stable pressure and flow
conditions, thereby ensuring reliable, efficient and
accurate analysis.

Sight Glass
Forbes Marshall offers Sample Flow Indicator (Sight
Glass) to view the sample flow inside the sample line.
A rotating wheel indicates presence of cooling water.
The sight glass is made of high grade stainless steel.

Sample Filter
Forbes Marshall also manufactures the Filter which is
required to ensure particle-free sample. Any particle
of size up to 40 microns size can be filtered out.
Forged stainless steel body and hexagonal cap help
easy cleaning of filter element.

Pressure Relief Valve

Forbes Marshall Pressure Relief Valve comes fitted
with Sample Cooler. Pressure Relief Valve is important
as it protects the Sample Cooler in case the coil fails.
This is also important for human safety as pressurized
cooler may burst due to full sample pressure under
coil failure conditions.

Hi-temp Isolation Valve

This valve is an easy to operate & can be used for most
high pressure and temperature applications. Its
unique plug/seat geometry and stuffing box design
allow these valves to operate for extended period of
time without gland leakage and passing. Valves are
designed for PN 500 (Class 2500), are offered for all
ratings upto PN 500 and Class 2500. Body seat
integral stellite is hard faced by a special Automatic
welding process. Unique non-rotating single piece
spindle plug design guarantees long seat life as
grinding between plug and seat is eliminated.

Cooling Water Isolation Valve

Cooling Water Isolation Valve is a ball valve. Its
stainless steel body makes it corrosion resistant and
light weight. Long handle makes it easy to operate.
Ball valve type design ensures full flow at open
condition.

Cation Column
The duplex type Cation Conductivity Column is a field
proven Forbes Marshall design. The Cation
conductivity measurements are considered to be
more reliable than ordinary conductivity
measurements, as this method ensures elimination of
masking effects of desired chemicals used in treating
the water. This provides a more realistic picture of
dissolved impurities in the sample. The Forbes
Marshall Cation Column is easy to operate,
regenerate and maintain.

Philosphy and importance of boiler parameters

T0C

AK

SiO2 Cond

CI2

TH

Cond

pH Na+

SiO2

Na

TOC

pH
MAKE-UP

SiO2 Na

pH

Na+

O2

Na+

O2

Cond

Cond N2H4

Cond

TOC

Na+

CONDENSER
POLISHING PLANT

O2

DE-AERATOR

Cond

FEED PUMP
COOLING
TOWER

O2

RE-HEATER
FEED PUMP

H2

SiO2

Cond N2H4

GENERATOR
HP TURBINES

O2

SUPER
HEATERS

SiO2

SiO2

PO4 pH
Na+

HP
HEATERS

ECONOMIZER

SiO2

SiO2

Cond

DRUM

Thermal Power Plant Steam and Water in-line Analytics

CONTAINMENT BUILDING
DEMNERALIZATION PLANT

Cond SiO2 Na

H2

DE-AERATOR

O2

WATER SUPPLY

AK

TH

Cond SiO2 Na

Cond

pH

SiO2 N2H4

O2

O2

pH

PO4

PRIMARY
LOOP:PWR

O2
Cond

O2

Cond

SiO2

Na+

pH

N2H4

H2

O2

pH

H2
O2

Turb

Na+
CONDENSOR

Cond

PRESSURIZER

TH

TOC

HP TURBINES

SiO2
Cond

Na+

SiO2

RE-HEATER

LP TURBINES

GENERATOR

H2

O2

Nuclear cycle measurement

H2

RECTOR CORE

COOLING
TOWER

SECONDARY
LOOP:PWR

CONDENSATE POLISHING PLANT

pH

CI

STEAM GENERATOR

Cond

Cond

H2

REACTOR COOLANT PUMP

FEED PUMP

MAKE-UP

TOC

O2
WASTE GAS DECAY TANKS

TOC Cond Na

O2

pH

CI

pH Analyzer

pH : The steam which goes to the turbines has to be ultra pure. The pH value of the feed water gives direct
indication of alkalinity or acidity of this water. The ultra pure water has pH value of 7. In a steam circuit; it is normal
practice to keep the pH value of feed water at slight alkaline levels. This helps in preventing the corrosion of pipe
work and other equipment. Typically dedicated pH Analyzers are recommended at following locations in a steam
circuit: high pressure heaters, DM make-up mater, condensate extraction pump discharge.

Features:
Dedicated pH analyzer in each line ensures
that pH is getting maintained in specified band
Two wire Aquamon Smartpro series plus
model is the simplest pH and ORP transmitter.
These analyzers are directly loop powered by
+24V DC supply from DCS and PLC
Also direct 110-230 V AC powered Aquamon
4000 transmitter is available if alarm contacts
required along with 4-20 mA output. For pH
measurement both low and high pH alarm
contacts can be used to control dosing for
chemicals. Separate PT-100 sensor input can
be used for temperature compensation for pH
measurement

Conductivity Analyzer

Conductivity : Conductivity is an important parameter for detecting any contamination of steam in the boiler
circuit. Conductivity of pure water is almost zero (1-2 Siemens). Ingress of any kind of dissolved impurity will raise
conductivity instantly. Thus conductivity is an important parameter for the detection of leakages.
Typical points in the steam circuit where conductivity should be monitored are: superheated steam, drum water,
high pressure heaters, low pressure heaters, condenser, plant effluent, D.M. plant, make-up water to D.M. plant.

Features:
Like pH Analyzers, Aquamon smart pro series is
also available for conductivity measurement. This
is loop powered through 24VDC power supply.
Both 24V DC loop powered and AC powered
options are available for this measurement
These conductivity transmitters can be used with
cells with different cell constant. PT-100
temperature sensor in conductivity cell helps to
get a compensated reading for conductivity
measurement

Silica : The presence of Silica in the steam and water circuits of a power generation plant is associated with a
number of problems both in the super heater and turbine sections.
The solubility of silica in steam increases with pressure. Hence there are chances of silica carryover. The presence of
silica in the steam can lead to deposition in superheated tubes and on the turbine blades which may lead to loss of
efficiency and turbine blade failure. For proper working of turbines, continuous monitoring of silica is highly
recommended.
Similarly, the monitoring of anion and mixed bed ion exchanges safeguards and optimizes the operation of
demineralization plant.
Thus the typical points in steam circuits where silica analysis is required are Low Level Silica Measurement in: high
pressure and low pressure turbines, steam, drum (saturated) steam, CEP discharge, make-up water, D.M. makeup
water and high level Silica measurement in drum water.

Features:
Provision to monitor silica at multiple
locations in the stream
Provision for grab sample analysis
Inbuilt data logger for analyzing graphical
trend
We offer smallest cycle time (~9 min) that
can help you to knowyour process better and
faster
Micro-piston Pumping avoids cross
contamination between
two different
channels
Automatic two-point calibration gives best
accuracy
Locally available reagents and low
consumption of the reagent ensures lowest
cost of ownership
Auto diagnostic features make our Silica
Analyzers easy for maintenance

Dissolved Oxygen : At elevated temperature dissolved oxygen causes corrosion which may cause puncturing and
failure of piping and components respectively. Dissolved oxygen also promotes electrolytic action between
dissimilar metals causing corrosion and leakage at joints and gaskets. Mechanical deaeration and chemicals
scavengers additives are used to remove the dissolved oxygen. An analytical check of process efficiency, therefore,
is essential. Dissolved oxygen monitoring is imperative in power stations using neutral or combined operating
conditions (pH 7.0-7.5 or 8.0-8.5). The typical points in steam circuit where dissolved oxygen monitoring is required
are deaerator inlet and outlet.

Features:
Measurement in ppb range
Better response time
Built-in temperature sensor for
temperature easy compensation
Sensors can be directly connected to the
transmitter through a detachable cable
for an easy maintenance

Hydrazine : Hydrazine is used as oxygen scavenger. So it also maintains feed water alkalinity to prevent acidic
corrosion. It prevents frothing in the boiler and minimizes deposits on metal surfaces. Hydrazine also helps in
maintaining a protective magnetite layer over steel surfaces. Under dosing of hydrazine leads to increased corrosion
and overdosing represents a costly waste. Therefore hydrazine monitoring is extremely important. The typical points
in a steam circuit where hydrazine monitoring is required are: re-heaters, economizer inlet and L.P. heaters.

As output from Hydrazine analyzer can be used for

precise dosing control. Hydrazine analyzer used in
Forbes Marshall's SWAS package offers:
Features:
A response time lower than 60 seconds
Measurement using 3 electrodes unlike tradition
amperiometric techniques thus eliminating
voltage is due to changes in composition of water
Reference electrode with pre-pressurized gel
electrolyte which facilitates maintenance.
Provision for grab sample analysis- A feature very
useful for PLANT CHEMIST
No moving parts such as pumps or valves that are
used to forcegases, making the analyzer the most
reliable one.

Sodium : The presence of Sodium signals contamination with potentially corrosive anions, e.g. chlorides, sulfates etc.
Under conditions of high pressure and temperature, neutral sodium salts exhibit considerable steam solubility. NaCl and
NaOH, in particular, are known to be associated with Stress Corrosion Cracking of boiler and superheater tubes. The
ubiquitous character of sodium in the environment makes it a useful indication to reveal possible Leak conditions
within the circuit, particularly in the condenser section where the measurement of sodium detects cooling-water leaks
with a much higher sensitivity than conductivity measurements. The typical points in a steam circuit where sodium
monitoring is required are. D.M. plant make up water, condensate pump discharge, condenser, drum (saturated) steam

Features:
Unmatched accuracy with 0.01 ppb detection
unit
Provision of grab Sampling , a feature very useful
for plant chemist
Wide range of measurement from 0 to
10,000ppb. Freely programmable
Use of Non Hazardous chemicals for automatic
reactivation of electrodes
Fast Response. Even in multichannel
measurement auto-adapted rinsing sequence to
reach accuracy in a minimized cycle time (10
minutes possible)
A reproducibility <1.5% of reading or <0.02
ppb, whichever is greater within 10C
An accuracy <5% of the reading or <0.1 ppb,
whichever is greater
Users can go for freely programmable FULLY
AUTOMATIC CALIBRATION SEQUENCE as an
option

Chiller

Chilled Package
Chilled water is required when the cooling
water available at site is incapable of cooling
the sample to the temperature required by the
analyzers.
If cooling water temperature exceeds 400C ,
the sample temperature would exceeds 450C ,
which is higher than the temperature required
by the analyzers. To bring down the
temperature of the sample chilled water is
required.
Chiller package is also required when a sample
is to be cooled at 250C. We manufacture these
in our factory and are the only SWAS
manufacturers havingthis capability.

Lab Sampling Module

Forbes Marshall offer Lab Sampling Module for
laboratory analysis of steam in process boilers which is
designed as per international standards. Its small and
compact size and light weight design makes it
suitable for continuous lab sample collection. It is easy
to operate and fits easily on site.
Wherever there is a Boiler, Lab Sampling Module is
required.

Photo Gallery

Photo Gallery

Forbes Marshall is the only SWAS manufacturer having expertise in Steam Engineering
& Control Instrumentation

All power majors deal with us

Alstom
Siemens
Doosan
AES Power Machines
ABB
Power Machine
BHEL
NTPC
Yokogawa
Honeywell Automation

Lanco Group
Jindal Group
Essar Group
Tata Group
Reliance Industries Ltd.
Reliance Energy Ltd.
Larsen & Toubro
Thermax
Bechtel
and many more...

Everything about steam and water analysis

Your local Forbes Marshall representative would be happy to provide you

with further information and support.

AMERICA
USA
Forbes Marshall Inc. USA
480,California Avenue,
Suite 102,P.O. Box 60670
Palo Alto CA 94306
California,USA
Tel: +1 650 327 4227/ +1 650 321 4224
Fax: +1 650 327 4127/ +1 650 321 4454
Email: forbesmarshall@ix.netcom.com

CANADA
Forbes Marshall Canada Inc.
2425 Matheson Blvd. East, 8th Floor
Mississauga, ON
L4W 5K4
Canada
Tel: +905 361 2525
Fax: +905 361 6401
Email: canada@forbesmarshall.com

COLOMBIA
Forbes Marshall Colombia
CRA 58 # 167B-19
INT: 1 Portales Del Norte, Bogota
Tel: +57 316 721 1510
Email: fsforbes@gmail.com

SOUTH ASIA
INDIA
Forbes Marshall Pvt. Ltd.
P.O. BOX # 29 Mumbai Pune Road,
Kasarwadi, Pune-411034
Tel: +91 (0) 20 39858555/
+91 (0) 20 27145595
Fax: + 91 (0) 20 27147413
Email: exp@forbesmarshall.com

BANGLADESH

INDONESIA

ETHIOPIA

Forbes Marshall Pvt. Ltd.

Rupsha Tower, C-3, 3rd Floor
7, Kemal Attaturk Avenue,
Road#17, Behind Brac Bank,
Dhaka - Bangladesh
Tel: +88 028811501/+88 01711529502
Email: bangladesh@forbesmarshall.com
rrnair@forbesmarshall.com

Forbes Marshall Pvt. Ltd.

NC 8/11, Ji Lilin Raya, Kelapa Gading,
Jakarta ( Uttara), Indonesia
Tel: +62 8 15199 17178
Email: hbhat@forbesmarshall.com

Rapture Import & Export PLC

Kolfe Keranio Sub-City, Kebele13/14,
House Nr.624, P.O. Box 28447/1000
Addis Ababa, Ethiopia
Tel: +251-911-145524
Fax: +251-115-511479
Email: Biruk.Oasis@gmail.com

SRI LANKA
Forbes Marshall Lanka Pvt. Ltd.
12/5A, 1/1, Robert Gunawardane
Mawatha Kirulapone, Colombo-06.
Sri Lanka.
Tel: +94 11 2512997/4511127/28
Fax: + 94 11 4511128
Email: fmlanka@forbesmarshall.com,
wfernando@forbesmarshall.com

NEPAL
Ekta Engineering and Marketing Pvt. Ltd.
402,4th Floor, Bagmati Chamber,
Milan Marg, Teku Road,Tripureshwor,
Kathmandu, Nepal
Mob: +977 9851022039 / 9851036530
Tel: +977 (1)4247676/4238131
Email: ekta@ecomail.com.np

MALAYSIA
Forbes Marshall Pvt. Limited
Tel: +62 8 15199 17178
Fax: +62 21 4530773
Email: hbhat@forbesmarshall.com

VIETNAM
Email: vphilip@ksc.th.com
Tel: +66 81 90 20690

KOREA
Shin Woo F.A Co., Ltd.
#510 Leaders Tower
60-15 Gasan-Dong,M Geumchun-Gu,
Seoul Korea (153-801)
Mob: ++8211 732-7695
Tel: ++822 2026-6364 (Direct)
Fax : ++822 2026-6363
Email: shinwoofa@empl.com/
forbeskorea@empal.com

SINGAPORE
Forbes Marshall Pvt. Limited
Tel: +62 8 15199 17178
Email: hbhat@forbesmarshall.com

ASIA PACIFIC
THAILAND
Forbes Marshall Pvt. Ltd.
Room No.403,4th Floor, House No.567,
Seri 6 Road Soi 51, Rama 9 Road,
Suan Luan, Bangkok 10250.Thailand.
Tel: +66 2 7203483/4 +66-81-9020690
Fax: +66 2 7203483,9435500
Email: thailand@forbesmarshall.com
vphillip@ksc.th.com

AFRICA
KENYA
Forbes Marshall Pvt. Ltd.
PO Box - 58338-00200 Nairobi,
Kenya
Tel: +254 734 763 913 /
+254 725 490 866
Email: africa@forbesmarshall.com

MIDDLE EAST
U.A.E ( Dubai)
Forbes Marshall Pvt.Ltd.
P.B.No. 9608, Sharjah Airport Free Zone,
Sharjah UAE.
Mob: :+ (971) 50 4949084
+ (971) 566 787 385
Email: : csequeira@forbesmarshall.com /
sequeira.cedric@gmail.com /
ctony@forbesmarshall.com
Technical Parts Co (LLC)
P.O.Box 5071, Dubai U.A.E
Tel: +971502458376
Landline: 04-2137888
Fax: +971-4-2823078
Email: gs@tsei.ae

IRAN
Forbes Marshall Pvt Ltd.
Unit 23. No.2, 18th Street, Golfam Building,
Naft Street, 4 Divari, End of Ashrafi Esfehani,
Pounak Tehran, Iran
Tel: +98 912 1304598
Email: m.m.rezaee@gmail.com
mmrezaee@forbesmarshall.com

EGYPT
System Technique
17 El Mahrovky Street, Off Aswan Square,
Mohandseen, Cairo,
P.O.Box 141 El-Gezirah, Egypt
Mob: +201 68802964
Ph No - +202 3036935/52/81, +202 3045637
Fax: + 202 3036897
Email: mchakraborty@forbesmarshall.com