Water Treatment and Corrosion Issues.

NETRA
A Maharatna Company
BoP - Water Treatment and

Corrosion Issues & Remedies
Ashwini K Sinha
AGM (NETRA)
ashwiniksinha@ntpceoc.co.in, ashwiniksinha@gmail.com
23rd May 2012
NTPC Energy Technology Research Alliance

Developing Economic and Green Energy Technologies
Presentation Outline NETRA
A Maharatna Company
1.0 Introduction
 Water Availability & Utilization
 Power Scenario with possible Water Foot Prints
2.0 Issues Related to BOP

 Summary of issues in BoP
 Schematics of Power Plant & Water Treatment Technologies
 Cost of Corrosion in Power Plants
 Quantity of Water required for different applications
 Quality of Water Required
 Commercial
3.0 Issues related to:

 Efficiency, Availability & Performance
 Reliability of Structures & Pipelines
 Optimizing COC & Recycling
 R&D and New Technologies
4.0 Role of Service Providers

Water Foot Prints NETRA
A Maharatna Company
The UN estimates that by 2050, half the World’s population will live in nations
that are short of Water. Water is needed throughout the energy sector at each
step-energy for extraction & production, refining & processing, transportation &
storage and electric power generation it self. It is estimated that water
consumption to generate electricity will more than double over the next 40 Years
Water footprint of an individual - sum of his or her direct and indirect freshwater
use. The direct water use is the water used at home, while the indirect water
use relates to the total volume of freshwater that is used to produce the goods
and services consumed.
S.No. Country/Type Water Foot Print m3/yr

1 Average Global 1385
2 USA 2842
3 China 1071
4 India 1089
5 Daily vegetarian diet 1500 lit
6 Daily Non-Vegetarian diet 3400 lit
Water Foot Prints NETRA
A Maharatna Company
Research by the Cranfield University calculated the amount of water required to

produce various common foods in the United Kingdom:
S.No Product Amount of Water

Litres
1 1 cup of tea 32.4
2 1 imperial pint of beer 160
3 1 glass of wine 120
4 1 glass of milk 200
5 1 kilogram (2.2 lb) of beef 15,000
6 1 kilogram (2.2 lb) of poultry 6,000
7 250 grams (8.8 oz) packet of M &Ms 1153
8 575 grams (20.3 oz) jar
202
of Dolmio pasta sauce
A Maharatna Company
1.0 Introduction

 Commercial


Water Availability & Utilization NETRA
A Maharatna Company
Water withdrawal Water Consumption

Water Availability & Utilization NETRA
A Maharatna Company
In India, the total utilizable water resource is assessed as 1123 BCM.
The per capita availability of water at national level has been reduced from
about 5177 cubic meters in 1951 to the estimated level of 1,820 cubic
meters in 2001 with variation in water availability in different river basins.
Given the projected increase in population by the year 2025, the per capita
availability is likely to drop to below 1,000 cubic metres, which could be
labeled as a situation of water scarcity
Water Demand (in BCM) for various Sectors
Sector Standing Committee of MoWR NCIWRD

Year 2010 2025 2050 2010 2025 2050
Irrigation 688 910 1072 557 611 807
Drinking 56 73 102 43 62 111
Industry 12 23 63 37 67 81
Energy 5 15 130 19 33 70
Others 52 72 80 54 70 111
Total 813 1093 1447 710 843 1180
A Maharatna Company
1.0 Introduction

 Commercial


Power Scenario of India NETRA
A Maharatna Company
Installed Capacity of India as on 31.03.2012 (Source CEA)
Consumptive Water foot print:

Thermal – 394804 – 723817 M3/hr @ 3 – 5.5 m3/MWh
NTPC Pan India Presence NETRA
A Maharatna Company
Geographical spread of generating facilities

Eastern, 7900 JVs, Northern, 5
4364 490
KOLDAM
KOLDAM
(800
(800 MW)
MW)
LOHARINAG
LOHARINAG PALA PALA
(600 MW)
DADRI (600 MW)
DADRI
(817
(817 MW)
MW)
FARIDABAD
FARIDABAD
Southern, 4
(430
(430 MW)
MW) TAPOVAN
TAPOVAN VISHNUGAD
VISHNUGAD
BTPS
BTPS NCTPP
NCTPP (520
(520 MW)
MW) 950 NCR,
(705
(705 MW)
MW)(2,310
(1,820 MW)
MW)
TANDA
Western, 4837
IGSTPP TANDA
IGSTPP (440
(440 MW)
MW)
(1,500
(1,500 MW)
MW) UNCHAHAR
UNCHAHAR
AURAIYA
AURAIYA (1,050
(1,050 MW)
MW) KAHALGAON
KAHALGAON BONGAIGAON
ANTA
ANTA
(652
(652 MW)
MW) NABINAGAR
NABINAGAR
(1,000 MW)
(2,340
(2,340 MW)
MW) BONGAIGAON
(750
(750 MW)
MW) 9973
(1,000 MW)
(413
(413 MW)
MW)
RIHAND
RIHAND
SINGRAULI
SINGRAULI (3,000
(2,000 (3,000 MW)
MW)BARH
BARH
(2,000 MW)
MW) FARAKKA
FARAKKA
3,300
3,300 MW
MW(2,100
(2,100 MW)
MW)
VINDHYACHAL
VINDHYACHAL
GANDHAR
GANDHAR (4,260 MW)
(4,260 MW)
(648
(648 MW)
MW)
KORBA
KORBA ROURKELA DURGAPUR
ROURKELA DURGAPUR
(120
(120 MW)
MW) (120
(120 MW)
MW)
KAWAS
KAWAS (2,600
(2,600 MW)
MW)
(645
(645 MW)
MW) MAUDA
MAUDA
(1,000
(1,000 MW)
MW) SIPAT
SIPAT
BHILAI
BHILAI
574
574 MW
MW
TALCHER
TALCHER KANIHA
(3,000
(3,000 MW)
MW)
KANIHA
No. of Capacity
2,980 MW TALCHER
2,980 MW TALCHER Thermal
(460
(460 MW)
MW)
Thermal
plants MW
RGPPL
RGPPL
(1480
(1480 MW)
MW)
RAMAGUNDAM
RAMAGUNDAM
(2,600
(2,600 MW)
MW) SIMHADRI
SIMHADRI
(2,000
(2,000 MW)
MW)
NTPC Owned
Coal 16 29195
COAL POWER STATION
ONGOING HYDRO POWER PROJECTS Gas/Liquid fuel 7 3955
VALLUR
VALLUR
(1,500 MW)
GAS POWER STATIONS
ONGOING THERMAL PROJECTS
Sub-Total 23 33150
KAYAMKULAM (1,500 MW)
KAYAMKULAM
(350
(350 MW)
MW)
Owned by JVs
Coal & Gas 7 4364
Note: Capacity includes capacity under construction; Map not to scale
Total 30 37514
10
By 2032, NTPC targets a capacity of 128 GW NETRA
A Maharatna Company with 28% capacity from non-fossil sources
2032
~128 GW
2017
~75 GW
2010
~32GW
Coal Gas Nuclear Hydro Renewables
Consumptive Water footprint (Coal)

11
2010 – 77760 m3/hr (25920 MW), 2017 – 168750 m3/hr (56250 MW), 2032 – 215040 m3/hr (71680)
A Maharatna Company
1.0 Introduction

 Commercial


Summary of Issues of BoP NETRA
A Maharatna Company
Quantity of water required & achieving required application
Effects of Quality of water on the performance of different systems
Reliability of various systems such as CHP, AHP, DM Plants, Cooling Towers,

Pipelines, RCC Structures, Firefighting systems, etc
Optimizing of COC & Water Recycling
R&D & New Technologies for water required
 Corrosion Protection and improving the performance of Structures, Pipelines

– Anticorrosive Coatings, Cathodic Protection, Water Treatment or Combination
 Cleaning of Reservoirs
 Control of Organic impurities
 Use of Municipal Treated Sewage Water as a make up water
Recycling of Waters & waste Waters – Technologies required

A Maharatna Company
1.0 Introduction

 Commercial


Typical Thermal Power Plant NETRA
A Maharatna Company
A Maharatna Company
Key to Typical diagram of a coal-fired thermal power station
1. Cooling Tower 2. Cooling Water Pump 3. Transmission Line (3 Phase)
4. Step-up Transformer (3 Phase) 5. Electrical Generator (3 Phase)
6. Low pressure Steam Turbine 7. Condensate Pump 8. Surface Condenser
9. Intermediate pressure Steam Turbine 10. Steam Control Valve
11. High pressure Steam Turbine 12. Deaerator 13. Feed Water Heater
14. Coal Conveyer 15. Coal hopper 16. Coal Pulverizer
17. Boiler Steam Drum 18. Bottom Ash 19. Superheater
20. Forced draught (draft) fan 21. Reheater 22. Combustion air intake
23. Economizer 24. Air Preheater 25. Electrostatic Precipator
26. Induced draught (draft) fan hopper 27. Flue Gas Stack
A Maharatna Company
17
Typical Scheme for Water Usage NETRA
A Maharatna Company
Typical Scheme for Clarification NETRA
A Maharatna Company
Typical Scheme for Demineralization NETRA
A Maharatna Company
Typical Scheme for CPU NETRA
A Maharatna Company
Typical Scheme for Two Stage RO NETRA
A Maharatna Company
Typical Scheme for RO Treatment NETRA
A Maharatna Company
Typical Scheme for RO and Mixed bed NETRA
A Maharatna Company
A Maharatna Company
1.0 Introduction

 Commercial


Typical Steam Water Cycle NETRA
A Maharatna Company
NETRA
A Maharatna Company
COST OF CORROSION
27
COST OF CORROSION NETRA
A Maharatna Company
28
Costs of Corrosion Problems NETRA
A Maharatna Company Affecting Fossil Steam Plants
Corrosion Problem O&M Non- Fuel Depreciation Total Corrosion
Related Corrosion Cost Cost
Corrosion Cost US $ US $
US $
All Corrosion Problems in 3,43,50,00,000 1,14,20,00,000 4,57,70,00,000
Fossil Steam Plants
Waterside/Steam side 91,60,00,000 22,84,00,000 1,14,44,00,000
Corrosion of Boiler Tubes
Turbine CF & SCC 45,80,00,000 14,27,50,000 60,07,50,000
Oxide Particle erosion of 27,48,00,000 8,56,50,000 36,04,50,000

Turbines
Heat Exchanger Corrosion 27,48,00,000 8,56,50,000 36,04,50,000
Fireside Corrosion of Water 18,32,00,000 14,27,50,000 32,59,50,000
wall tubes
Generator clip to strand Corro 18,32,00,000 2,85,50,000 21,17,50,000
Copper deposition in turbines 9,16,00,000 5,71,00,000 14,87,00,000
Fireside Corrosion of SH & 9,16,00,000 5,71,00,000 14,87,00,000

RH tubes
Costs of Corrosion Problems NETRA
A Maharatna Company Affecting Fossil Steam Plants
Corrosion Problem O&M Non- Fuel Depreciation Total Corrosion
Related Corrosion Corrosion Cost Cost
Cost US $ US $ US $
Corrosion of FGD system 4,58,00,000 8,56,50,000 13,14,50,000
Liquid Slag Corrosion of 9,16,00,000 2,85,50,000 12,01,50,000
Cyclone Boilers
Backend dew point corrosion 9,16,00,000 2,85,50,000 12,01,50,000
Generator Cooling water 9,16,00,000 2,85,50,000 12,01,50,000

clogging & plugging
FAC of steam plant piping 9,16,00,000 2,85,50,000 12,01,50,000
Corrosion of service water, 9,16,00,000 2,85,50,000 12,01,50,000
circulating water and other
water systems
All other (Corrosion of 45,80,00,000 8,56,50,000 54,36,50,000
structures, ash handling
equipment, CHP, oil pipes &
tanks, electrical equipment,
Total 3,43,50,00,000 1,14,20,00,000 4,57,70,00,000
A Maharatna Company
1.0 Introduction

 Commercial


Water Requirements for Power Generation NETRA
A Maharatna Company
Water Losses from Power Generation NETRA
A Maharatna Company
Process Flow Schematic for Wet NETRA
A Maharatna Company Recirculating Cooling Water System
34
1 GPM = 0.2271 M3/hour

Water Requirements
NETRA
A Maharatna Company
Water Requirements for a 500 MW Unit (Ref. Flow schematic)
Flow rate
S.No. Description GPM M3/Hr
1 Boiler Feedwater 7645 1736.18
2 Circulating Water 187600 42603.96
3 Evaporation & Drift 6415 1456.847
4 Make up 9537 2165.853 35
5 Blowdown water 3161 717.8631

Water Requirements for Thermal Power Plants NETRA
A Maharatna Company
Water requirement for different type of Power Plants

Typical Water Requirements of TPS NETRA
A Maharatna Company
Water Requirement & Consumption in a Coal fired Power Plant

Typical Water Requirements at Power Plant NETRA
A Maharatna Company
Water Optimization in New Plants NETRA
A Maharatna Company
S.No Description 1 X 500 MW 2 X 660 MW

M3/hr M3/hr
1 Evaporation & Drift from CT 1160 2555
2 HVAC System Losses 50 100
3 Potable Water System 70 100
4 Evaporation losses in Ash Dyke 200 570
5 Losses in Cycle make up 42 80
6 Losses in Service Water System 350 300
7 Evaporation Losses in Reservoir - 100
8 Total Consumptive Water 1872 3805
9 Water for Ash Handling 1410 1650
10 Water recovered in AWRS 1230 1190
11 Additional Make up 180 460
12 Total Water Drawl 33 Cusec 38 Cusec (Normal)
(Max) 50 Cusec (Max)
A Maharatna Company
1.0 Introduction

 Commercial


NETRA
A Maharatna Company
SOURCES OF WATER FOR
INDUSTRIAL APPLICATIONS
• RIVER
• SEA
• PONDS
• LAKES
• IRRIGATION CANALS
• BOREWELLS
• RECYCLED WATER
• RESORVOIRS
• RECYCLED EFFLUENTS
CHARACTERISTICS OF WATER & SOURCES NETRA
A Maharatna Company
OF IMPURITIES
IMPURITIES IN WATER:
• BACTERIA & VIRUSES

• MICRO – ORGANISMS
• TURBIDITY
• COLOUR
• MINERALIZATION
• METALLIC
• DISSOLVED GASES
• AMMONIA
• ORGANIC MATTER
• POLLUTANTS
APPLICATIONS OF WATER IN NETRA
A Maharatna Company POWER PLANTS (THERMAL)
• COOLING OF CONDENSATE
• AUXILIARY COOLING
• BOILER WATER
• ASH HANDLING WATER
• COAL DUST SUPPRESSION WATER
• WASHING
• DRINKING
• SANITATION
• FIRE WATER
• SERVICE WATER
• HVAC SYSTEM
DM Water Quality requirements NETRA
A Maharatna Company
Typical Deionized water requirements

Summary of Primary and Secondary Targets for Drum-type
Boilers under Steady State Operation (expressed as ug/kg
NETRA
A Maharatna Company
unless otherwise stated)
Boiler Class
Parameter 60 Bar – 100 Bar – 160 Bar – 180 Bar –

Gas Fired Coal Fired Coal Fired Coal Fired
Feed-water
Conductivity <-local decision to achieve primary target in boiler water->

(u/S/cm at 25°C)
Sodium (Na) <-local decision to achieve primary target in boiler water->

Sulphate (SO4) <-local decision to achieve primary target in boiler water->
Dissolved Oxygen-In <50 <50 <50 <50

condensate
Dissolved Oxygen-In <7 <7 <5 <5

Feed
Oil <200 <200 <200 <200

45
TOC
Hydrazine (N2H4) <— 2 x Dissolved Oxygen concentration —>

NETRA
A Maharatna Company
Ammonia (NH3) <— < 500 when copper alloys present —>
< 1000 when copper alloy absent
i.e. when SS or Titanium are present
pH (at 25oC) <— 8.8 - 9.2 (or 8.8 - 9.4 when copper —>
alloys absent)
Total Metals <20 <20 <20 <20
Spray Water 10 10 5 5
Sodium (Na) (without RH) (without RH) (without RH)
(without RH)
46
NETRA
A Maharatna Company
Boiler-water
1. Non-volatile Phosphate Treatment
Chloride (NaCl) as < 3000 < 2000 < 1000 < 500
Chloride
Silica (SiO2) < 5000 < 1500 < 300 < 200
(at pH - 9)
Sulphate (SO4) <-local decision to achieve primary target in boiler water->
Disodium/ Trisodium 2000 2000 1000 1000
Phosphate To To To To
6000 4000 2000 2000
All Volatile Akali Treatment
Chloride (NaCl) as NA < 120 < 120 NA

Chloride
Silica (SiO2) < 350 <250 < 150 < 100 47
(at pH - 9)
Sulphate (SO4) NA LD LD NA
NETRA
A Maharatna Company
Saturated Steam
Silica (Sio2) <20 <20 <20 <20

<10 (depending upon
design) with RH
Sodium (Na) < 20 < 10 <6 <5

< 3 (On AVT
48
EPRI Guidelines for Cooling Waters NETRA
A Maharatna Company
Water Quality EPRI Remarks Cu Mg/l < 0.1

Guidelin Al Mg/l <1
Paramet Units
es
er S Mg/l 5
Ca Mg/l 900 NH3 Mg/l <2 For copper based
(max) alloys present in the
CaCO3
system
Ca X SO4 (Mg/l)2 500000
pH 6.0 – 7.2 Without Scale
M Mg/l 30 – 50 Without Scale 7.8 – 8.4 Inhibitor
Alkalinity 220 - 250 Inhibitor With Scale Inhibitor
CaCO3
(Higher operating pH
With Scale
is possible with new
Inhibitor alkaline treatments)
Mg X Mg/l 35000 TDS Mg/l 70000
SiO2 CaCO3 X
TSS Mg/l < 100 For Film type Fill
Mg/l < 300 Splash type Fill
SiO2
BOD Mg/l
SO4 Mg/l
SiO2 Mg/l 150 COD Mg/l
PO4 Mg/l LSI <0
Fe (Total) Mg/l < 0.5 RSI >6
PSI >6
Mn Mg/l < 0.5
Desirable: BOD < 5 ppm, Turbidity < 2 NTU, Sulphide < 0.1 ppm (for Cu based systems), Chloride <
200 ppm for SS 304 (upto 500 ppm short duration & < 500 ppm for SS 316 (3000 ppm short duration)
A Maharatna Company
1.0 Introduction

 Commercial


Commercial Aspects of Water Use NETRA
A Maharatna Company
S.No State Water Cess Remarks

Charges
1 Kerala Re 1/m3
2 Delhi Rs. 1.5 Lac
per Cusec
3 Andhra Pradesh Rs.7.98/m3
4 Uttar Pradesh Rs. 1.16/m3
5 Gujarat Rs. 13.31/m3
Commercial Aspects of Water Use NETRA
A Maharatna Company
Cost of Chemicals used in CW Treatment NETRA
A Maharatna Company
1 ppm = 1 Kg
S.No. Chemical Rate Rs. Annual Cost of Chemical per 1000 m3/hr make up (Rs.)
(Per Kg/L) 1 ppm 2 ppm 3 ppm 4 ppm 5 ppm
1 HEDP 50% 50 438000 876000 1314000 1752000 2190000
2 PBTC 50 % 180 1576800 3153600 4730400 6307200 7884000
3 Polyacrylate 100 876000 1752000 2628000 3504000 4380000
4 Polymaleic 150 1314000 2628000 3942000 5256000 6570000
5 Zinc sulphate 25 219000 438000 657000 876000 1095000
6 BTA 450 3942000 7884000 11826000 15768000 19710000
7 HEDP 60 % 60 525600 1051200 1576800 2102400 2628000
8 ATMP 50 438000 876000 1314000 1752000 2190000
9 Carboxylate/ 150 1314000 2628000 3942000 5256000 6570000
Sulphonate
10 Carboxylate/ 200 1752000 3504000 5256000 7008000 8760000
Sulphonate/
nonionic
11 Si & Mg 400 3504000 7008000 10512000 14016000 17520000
inhibitor
12 SHMP 35 306600 613200 919800 1226400 1533000
13 Molybdate 250 2190000 4380000 6570000 8760000 10950000
14 silicate 180 1576800 3153600 4730400 6307200 7884000
A Maharatna Company
1.0 Introduction

 Commercial


Water Treatment Concerns NETRA
A Maharatna Company
Corrosion
Particle Entrapment
Deposition Growth Sites Biofouling
Optimizing COC NETRA
A Maharatna Company
Table 1
Thermal conductivity comparison of deposit-forming compounds
and bio-film
Thermal Conductivity
Substance
(W m-1K-1)
CaCO3 2.6
CaSO4 2.3
Ca3 (PO4)2 2.6
Fe2 O3 2.9
Analcite 1.3
Bio-film 0.6
A Maharatna Company
Table 2 - Effect of CaCO3 scale (of varying thickness) on overall heat transfer coefficient
Scale Thickness, Overall heat transfer coefficient, BTU per Percent loss in BTU per sq ft
Inches sq ft per deg F per deg F
0.000 92.77 0
0.012 73.68 20.58
0.024 61012 34.12
0.036 52.20 43.73
0.048 45.60 55.85
0.060 40.46 56.39
0.0625 (1/16 in.) 39.52 57.40
A Maharatna Company
Table 3 - Effect of CaSO4 scale (of varying thickness) on overall heat transfer coefficient
Overall heat transfer scale Coefficient, BTU per sq ft Percent loss in BTU per sq ft
thickness, inches per deg F per deg F
0.000 92.77 0
0.012 63.10 31.98
0.024 47.81 48.46
0.036 38.49 58.51
0.048 32.20 62.00
0.060 27.69 70.00
0.0625 (1/16 in.) 26.89 71.00
A Maharatna Company
Relative increase in power for condenser and chiller units

calculated according to fouling factors
Fouling Factor Condenser Factor Chiller Factor
0.0005 1.00 1.00

0.001 1.05 1.04
0.002 1.14 1.09
0.003 1.22 1.17
0.004 1.30 1.24
A Maharatna Company
0.01 ata increase in Condenser Back-pressure

= 10 Kcal/KWH increase in Heat Rate of Turbine
Loss due to variation in Condenser Back-pressure
Rating Annual Loss Life Time Loss

Rs. Lacs (Aprox.) Rs. Lacs
210 MW 30.25 756.25
500 MW 71.05 1776.25
Effects of Corrosion, Erosion-Corrosion, NETRA
A Maharatna Company
Cavitations on the Performance of Pumps
• According to the U.S. DOE, pumps consume about 20% of all generated
electricity
• Unlike motors, the efficiency of pumps is highly influenced by the system
they are supplying
• In a typical surface water treatment and distribution system approx. 70-
90% of energies used are for pumping
• Over an expected life span of 20 years, only 2.5 – 3% of the cost of pump
operation related to the purchase of the equipment. Further 2 – 2.5% relates
to maintenance costs. 95% is towards the cost of electricity to run the unit
•In any pumping system, over the years, the hydraulic passages of
casings & impeller vane shape gets damaged due to wear, tear &
corrosion, also the clearance in wear rings increases substantially. All
these damages lead to head and flow losses & ultimately deteriorate
hydraulic performance. Due to this deterioration of performance the
power consumption increases putting pressure on energy demand due
to inefficient operation of pump.
A Maharatna Company
A Maharatna Company
A Maharatna Company
A Maharatna Company
A Maharatna Company
A Maharatna Company
A Maharatna Company
The power required for flow of water through pipelines is as follows:

To overcome physical level difference from start of pipeline, which is at
low level to end of pipeline which is at higher level. The power required is
constant as the static head is constant.
To overcome the frictional resistance to the flow of water. This is known

as frictional head loss.
There are two types of friction losses:
Major Friction Loss – This is the friction of inside surface of pipeline to the
flow of water. For large diameter and long lines this loss consumes large
power and therefore energy.
Minor Friction Losses – Minor friction losses are:

Contraction loss
Enlargement loss
Gate valve, check valve loss
Bend loss
A Maharatna Company
Friction Head Loss:

Inside surface of pipelines in contact with water exerts friction on the flow.
This friction depends on the roughness of the inside surface coming in
contact with flow of water.
The laws governing frictional head losses are as follows:
Frictional loss generally increases with roughness of the pipe.
Frictional loss is directly proportional to the area of the wetted
surface.
Frictional loss varies inversely as some power of the pipe diameter.
Frictional loss varies as some power of the velocity.
Frictional loss varies as some power of the ratio of viscosity to density
of
the water.
Friction loss due to water flow through piping systems can be evaluated
using various flow coefficients. One such factor is the Hazen-Williams
C factor.
A Maharatna Company
Hazen Williams Equation:
Q = 0.278 CS 0.54 D 2.63

Q in m3/s, D in m, S = H/L
V = 1.318 C R h 0.63 S 0.54 (USC Units)
V = 0.849 C R h 0.63 S 0.54 (SI Units)

Where, Rh is the hydraulic radius, S is the head loss per unit length (hf/L), and C is a
roughness coefficient associated with the pipe material
Friction loss based on the Hazen-Williams formula is:
f = 0.2083 x (100/C)1.852 x (Q 1.852 /d i 4.8655).
In this formula, the following apply:
f = friction head loss in feet of water per 100 feet of pipe;
C = constant for inside pipe roughness;
Q = flow in US gallons per minute (gpm);
d i = inside diameter of pipe in inches
(1 US GPM = 0.227 m3/hr)

A Maharatna Company
• Value of C would depend upon the roughness only and for any given
roughness C would be a constant.
h f = (1.1758 V/CR 0.63 ) x L
Low value of C – means very rough surface

High value of C – means smooth surface
Material Manning (n) Hazen-Williams (C)

Plastic, copper 0.009 160
Concrete - Smooth 0.011 120
Concrete - Design 0.013 100
Corroded Cast Iron 0.020 60
Welded Steel 110
Internally coated Steel 150

A Maharatna Company
Expected life of friction factor at its original value –
Cement mortar lining 5 years
Epoxy lining around 30 years
Thickness of linings –
Cement Mortar lining 30 mm
Epoxy lining 0.50 – 0.70 mm

Scaling in Heat Exchangers NETRA
A Maharatna Company
Losses in Pipes due to Biofouling NETRA
A Maharatna Company
Pump designed for 630 m3/hr was delivering 450 m3/hr due to
Severe fouling. Corrosion products
Biofouling & MIC NETRA
A Maharatna Company
Severe Corrosion of CW System NETRA
A Maharatna Company
Control Measures NETRA
A Maharatna Company
Severe Fouling of PVC Fills NETRA
A Maharatna Company
Loss of around Rs. 1.2 Crore per 500 MW unit per year
Restoration of Heat Transfer NETRA
A Maharatna Company
Heat Rate Improvement = 183 Kcal/kwh

Annual Gain = Rs. 15 Crores
Full Load operation against 80% before cleaning
NETRA
A Maharatna Company
Other Problems of CW System
Eutrefication of reservoir RCC corrosion of Cooling tower structure
Severe foaming at CW Pump and in CW Foreway due to organic contamination

80
A Maharatna Company
1.0 Introduction

 Commercial


Condition Assessment of RCC Structures NETRA
A Maharatna Company
A Maharatna Company
A Maharatna Company
A Maharatna Company
A Maharatna Company
A Maharatna Company
A Maharatna Company
NETRA
A Maharatna Company
Condition Assessment Criteria
S.No. Concrete Potential Corrosion Electrical Corrosion

Design (mV Vs Condition Resistivity Condition
Strength Cu/CuS04) (KiloOhm
(N/mm2) cm)
1 M - 30 > - 200 Low > 20 Negligible
2 M - 30 - 350 to - Intermediat 10 to 20 Low

200 e
3 M - 30 < - 350 High 5 to 10 High
4 M - 30 < - 500 Severe <5 Very High
Condition Assessment Criteria

Condition Assessment Criteria NETRA
A Maharatna Company
Water Treatment & Corrosion Issues in NETRA
A Maharatna Company Fire Water System
Water Side related issues
Stagnancy of fire water causes depletion of oxygen & chlorine
Microbiological Influenced Corrosion leading to formation of Tubercles & Blockage
Treatment of fire water with microbiocide (chlorine/hypochlorite)
Regular Flushing of Fire water in the system (every fortnight)
Possibility of applying anticorrosive coatings or wherever possible use of HDPE/GRP

Water Treatment & Corrosion Issues in NETRA
A Maharatna Company Fire Water System
Soil Side issues
Soil causes corrosion of the underground pipelines
Soil characteristics, location, other structures, etc contribute towards corrosion
Bringing the pipelines over-ground wherever feasible
Proper anticorrosive Coatings to be applied
Application of Cathodic Protection for UG Pipelines

Structural Corrosion Issues NETRA
A Maharatna Company
Online Monitoring of CW Systems NETRA
A Maharatna Company
A Maharatna Company
1.0 Introduction

 Commercial


Some Cases of effect of Organics & Microbiology NETRA
A Maharatna Company
1. Problem of High Conductivity of DM Water, Condenser tube leakage,

Problem of control of boiler tube, tripping of SPU – reason Untreated sewage
2. Biofouling in condenser tubes, microbiologically induced corrosion (MIC)
3. Severe biofouling, scaling & MIC in condenser tubes (loss of generation)
4. Severe biofouling, scaling & MIC in condenser tubes (loss of generation),

Problem of non-availability of sufficient DM water, Fouling of PVC fills (stage II)
5. Fouling of PVC fills, Eutrefication of make up water reservoir, pH variation
6. Severe foaming in CW system, (Casuarina tree leaves)
7. Foaming in CW system, Yellow colour in water, choking of NOx filters, Severe

biofouling in raw, CW pipelines, HVAC lines, DM feed lines
8. Fouling of PVC film type fills
9. MIC in clarified water pipelines
10. Contamination of water reservoirs resulting in poor quality of make up water 96

Condenser tube Condition NETRA
A Maharatna Company
NETRA
Corrosion Control & Performance Improvement Options for
A Maharatna Company Cooling Water System
Expected Cooling water quality at different based on Raw water as make up to CW
09-10 Maximum
Cycles of Concentration
S.No Parameter Unit 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8
10.6 10.7 10.8 10.8 10.9

1 pH 7.56 9.26 9.89 10.06 10.21 10.33 10.43 10.52 10.61 8 5 1 7 2 10.97
905 987 106 115 123
2 cond µmhos/cm 1646 2469 3292 4115 4938 5761 6584 7407 8230 3 6 99 22 45 13168
103
3 Turbidity NTU 138 207 276 345 414 483 552 621 690 759 828 897 966 5 1104
107 117 127 137 147
4 CaH ppm as CaCO3 196 294 392 490 588 686 784 882 980 8 6 4 2 0 1568
5 MgH ppm as CaCO3 124 186 248 310 372 434 496 558 620 682 744 806 868 930 992
176 192 208 224 240
6 Total hardness ppm as CaCO3 320 480 640 800 960 1120 1280 1440 1600 0 0 0 0 0 2560
7 P alk. ppm as CaCO3 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
184 201 218 235 252
8 M alk. ppm as CaCO3 336 504 672 840 1008 1176 1344 1512 1680 8 6 4 2 0 2688
184 201 218 235 252
9 T. alk. ppm as CaCO3 336 504 672 840 1008 1176 1344 1512 1680 8 6 4 2 0 2688
137 150 162 175 187
10 Chloride ppm as Cl 250 375 500 625 750 875 1000 1125 1250 5 0 5 0 5 2000
11 Shulphate ppm as CaCO3 80 120 160 200 240 280 320 360 400 440 480 520 560 600 640
183 200 217 233 250
12 EMA ppm as CaCO3 334 501 668 835 1002 1169 1336 1503 1670 7 4 1 8 5 2672
101. 120. 129. 138.
13 Silica ppm as SiO2 18.5 27.75 37 46.25 55.5 64.75 74 83.25 92.5 8 111 3 5 8 148
110 120 130 140 150
14 Chloride demand ppm 200 300 400 500 600 700 800 900 1000 0 0 0 0 0 1600
15 BOD 72 108 144 180 216 252 288 324 360 396 432 468 504 540 576
105 114 123 132
16 COD 176 264 352 440 528 616 704 792 880 968 6 4 2 0 1408
17 KMnO4 No 54 81 108 135 162 189 216 243 270 297 324 351 378 405 432
PSI 5.39 4.46 3.81 3.30 2.88 2.53 2.23 1.96 1.72 1.50 1.30 1.12 0.95 0.79 0.65
- - - -
RSI 6.03 3.66 2.56 2.02 1.57 1.20 0.87 0.59 0.33 0.10 0.11 0.31 0.49 0.66 -0.81
Problems due to Organic Matter, Microbiolgy NETRA
A Maharatna Company Case 1
HIGH ORGANIC MATTER LOADING (UNTREATED SEWAGE) IN RAW WATER:
• Acute problem of obtaining required quality of DM water throughout the year
• Problem more severe in summers
• Due to high untreated sewage – proper clarification is very difficult
• Chlorine demand is very high (100 – 200 ppm)
• DM water conductivity goes as high as 0.8 us/cm (4 us/cm in DM tanks)
• pH of Boiler water drops to 7.5 – requires caustic dosing
• High Conductivity water causes deviations in Boiler & Stator water Chemistry
REMEDIAL MEASURES:
• Aeration of the make up water to remove BOD/COD
• Installation of Sewage Treatment Plant prior to clarifiers & Chlorine Dioxide
99
• Installation of Ultrafilteration system/RO water system prior to DM Plant
• Alternate source of raw water – borewell for DM plant
Analysis of Water Sample
Water Extract ( 1gm plant fruit in 500 ml)
Sample COD TOC

mg/l mg/l
Extract ( as such)
470-500 175-200
Extract after filtration through 0.45 U
270-300 100-125
In the presence of high Organic matter, clarification of water is not effective even with
Alum/Polyelectolytes(cationic or anionic)
% Reduction
Water Extract ( 1000 ppm solution of plant fruit) 120
Water Extract ( 400 ppm solution of plant fruit)
64
Water Extract ( 400 ppm solution of plant fruit)+2
ppm KMnO4 56 12.5
Water Extract ( 400 ppm solution of plant
fruit)+Aeration 48 25
100
TOC, COD & BOD Trend
Concentration in ppm
60
50 BOD
40 COD
30
20 TOC 1
10 TOC 2
0
CIRCULATING
RESERVOIR
RESERVOIR
CLARIFIED
LIVE RESERVOIR
WATER
INTAKE
DEAD
WATER
Nature of water
101
A Maharatna Company
1.0 Introduction

 Commercial


A Maharatna Company
Internal Water Conservation

Cooling Tower Cycles
5000 --
RR = 100,000 gpm
4000 -- dT = 20 F
3000 --
Makeup
2000 --
1000 --
Blowdown
0
1 2 3 4 5 6 7 8
Cycles of Concentration
COC Optimization NETRA
A Maharatna Company
S.N COC Circulating Drift Evaporati Blow Make Consumption of Cost of

o Rate m3/hr M3/hr on Down up Inhibitors l/day Inhibitors @ Rs.
M3/hr M3/hr M3/hr 33/litre
Rs/day
5 ppm 10 ppm 5 ppm 10
ppm
1 1.5 32000 160 576 1152 1888 227 453 7476 14953
2 2.0 32000 160 576 576 1312 157 315 5196 10391
3 2.5 32000 160 576 384 1120 134 269 4435 8870
4 3.0 32000 160 576 288 1024 123 246 4055 8110
5 3.5 32000 160 576 230 966 116 232 3827 7654
6 4.0 32000 160 576 192 928 111 223 3675 7350
7 4.5 32000 160 576 165 901 108 216 3566 7133
8 5.0 32000 160 576 144 880 106 211 3485 6970
Waste Water Recycling NETRA
A Maharatna Company
Evaporation+drift
40000 M3/hr
CW 700 M3/Hr
Pumps Induced
CONDENSER draft
COOLING BLOW DOWN
TOWER
AUX 240 M3/Hr (Design)
190 M3/Hr
COC = 4-5
Discharge to 9 Km
STP Effluent
MakeUp
distance
1100 M3/Hr (Design) 200 M3/day
800-900 M3/Hr C
(Actual) Drinking
water
M
Clariflocculators
B
Narmada River
Raw Water Clarified

3x900M3/hr 2 x 1100 M3/Hr Softening plant
Pumps for CW water
Intake well
One Standby
RESERVOIR
tank
unlined
3x600M3/hr Softening plant regn

waste 3 M3/day
DMP Effluent
Clarifier Gravity DM Plant
Raw Water Pumps for DM Filter 250 M3/day
Plant 275 M3/Hr
2x275 M3/hr
Water Balance
A Maharatna Company
CT BLOW DOWN
5760 M3/Day (Design)
4500 M3/Day
Softening Plant
Regeneration Waste
C Discharge
3 M3/day M
B
DMP Effluent
250 M3/day
STP Effluent
200 M3/day
Effluents discharged from Plant

A Maharatna Company
Proposed
UF+RO
Effluents system
D/G pumps
PAC+Chlorine 4*125 m3/hr
D/G tank
FeCl3+lime+Dolomite 3*55 m3/hr
275 m3/hr ACF MB

SAC WBA SBA
3*11
3*11 3*110 3*110 3*110
GSF 0
0 m3/hr m3/hr m3/hr
By m3/h
Gravity
m3/h
r
r
Reactor FW pumps
Clarifier 4*125 m3/hr
275
M3/hr FWST
2*150 m3/hr
Proposed DM Plant Scheme with UF+RO

A Maharatna Company
Cost Benefit of Recycling
Effluent 200 M3/Hr
4800 M3/day
Permeate 150 M3/Hr taken as 75%
3600 M3/day
Sl. Parameter Benefit Amount per Total Amount
No month per year
(Rs) (Rs.)
1 Pumping cost to 9 kms 0.6 KWh/M3 @ Rs 3.00/- per KWh 1,94,400.00 23,32,800.00
2 Water Charges on a/c of Rs 12.10/- per M3 for 3600 M3 13,06,800.00 1,56,81,600.00

CW water daily
3 Cess charges Rs 0.05 per M3 for 3600 M3 daily 5,400.00 64,800.00
4 Makeup water to boiler Improvement in the makeup water 25000 Approx. 3,00,000.00
quality will subsequently have less
blowdown rate in boiler.
5 Regeneration chemicals Rs 5.5/- per M3 5,94,000.00 71,28,000.00
6 life of resins Resin cost savings 5,00,000
7 Pretreatment chemicals Rs 0.25 per M3 27,000.00 3,24,000.00
Alum/lime/PAC
8 Brine treatment cost Rs 0.10 per M3 14,400.00 1,72,800.00
TOTAL 2,60,04,000.00
A Maharatna Company
Ash Water Recycling
Earlier the Ash to Water Ratio was – 1:13 to 1:15
The Ash slurry is transported to a distance 5 – 15 Km through pipes
The Ash Slurry is collected in Ash Dykes and the decanted water disposed off
Schemes have been developed to recycle the decanted Ash water with suitable
Treatment programs and only limited make up is provided to meet the requirements
A Maharatna Company
1.0 Introduction

 Commercial


Water Requirements for Power Generation NETRA
A Maharatna Company
Treatment Technologies
Table : Makeup Water Treatment Methods for Removing Impurities NETRA
A Maharatna Company
Treatment Technologies
Figure: Effects of Treatment on Raw Water NETRA
A Maharatna Company
New Technologies NETRA
A Maharatna Company
 Adoption of high density Ash Slurry disposal technology
 Emphasis on dry ash collection & disposal for ash utilization purposes
 Recycling of CW blow down by treatment with UF/RO
 Studies on adopting recycling of STP effluents from townships for process

water
 Setting up of sewage treatment plants for treating organically contaminated

water for make up DM and CW systems
 Adoption of site specific chemical treatment programs based on commercially

available chemicals with optimized COC
 Studies on dry cooling systems for extreme scarcity areas
 Studies on adopting combinations of technologies like UF/MF, RO, EDI and

Ion exchange
 Desalinated water at Coastal power plants for sweet water applications
 Application of polymeric materials (HDPE/GRP) & Organic coatings for

reducing frictional losses in pipes
Technology Drivers NETRA
A Maharatna Company
Affordability (New Plant) – NTPC Technology Vision
Water Requirement (Cusec/1000 MW)

Water Requirement (Cusec/1000 MW)
- Extreme Water Scarcity
- Business As Usual
40
35
40
35 25
25
20
7
2009 2017 2025 2032
2009 2017 2025 2032
NETRA
A Maharatna Company
Water Extraction from Flue Gas
Expected Water Recovery from flue gas of a gas station = 95 m3/hr

Pilot Heat Exchanger Installed NETRA
A Maharatna Company
Coal power station : Gas power Station:

Para- unit Flue gas Analysis
Sampling point HE Inlet HE outlet
meters parameter/fuel type unit Natural gas
ID Fan Outlet of HXe
T-gas oC 101.3 35.8
SOx mg/Nm3 560 152 T-Air oC 30.1 30.1
NOx mg/Nm3 260 215 O2 % 14.17 14.15
SPM mg/Nm3 90 52 CO2 % 3.5 3.5
CO ppm 1 1
CO2 % 11.2 11.4
NOx ppm 50 50
SO2 ppm 0 0
Flue Gas Quality variation due to moisture extraction

Pilot Heat Exchanger Installed NETRA
A Maharatna Company
Coal power station: Gas power Station:

PARAMETERS Unit Value
Parameters unit Value
pH - 4.3
pH - 2.55 K µS/cm 213
Conductivity µS/cm 2890 TDS ppm 107
Salinity % 0.1
Total ppm as Nil
Sodium ppm as Na 1
Hardness CaCO3
Potassium ppm as K 0.7
Total Hardness ppm as CaCO3 Nil
Cl ppm as Cl- Nil Ca Hardness ppm as CaCO3 Nil
M-alk ppm as Cl- Nil p-Alkalnity ppm as CaCO3 Nil
EMA - 1500 m-Alkalnity ppm as Cl- Nil
Chloride ppm as Cl- 1
Acidity - 450 Sulphate ppm as SO42- 58
Nitrate ppm as NO3- 6
Quality of Water condensed from flue gas

Water Related R&D – US DOE NETRA
A Maharatna Company
Conceptual Design of Liquid Desiccant Process NETRA
A Maharatna Company
120
A Maharatna Company
1.0 Introduction

 Commercial


Role of Service Providers NETRA
A Maharatna Company
 Development of less energy intensive technologies for water treatment
 Development of Modular treatment technologies requiring lesser space
 Improving the performance of RO systems for higher output at lower

maintenance
 Developing economic treatment technologies/combination of technologies
 Improving sewage treatment plants for better output & quality of water for
reuse
 Developing transparent techno-economic chemical treatment programs
 Creation of Institute for improving the quality of manpower & techniques
 Developing proper quality & target values for treatment programs
 Developing low temperature desalination technologies

TRANSFORMING LIVES NETRA
A Maharatna Company
12
3

Water Treatment and Corrosion Issues.

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Water Treatment and Corrosion Issues.

Hochgeladen von

Copyright:

Verfügbare Formate

NETRA

BoP - Water Treatment and

23rd May 2012

NTPC Energy Technology Research Alliance

2.0 Issues Related to BOP

3.0 Issues related to:

4.0 Role of Service Providers

S.No. Country/Type Water Foot Print m3/yr

Research by the Cranfield University calculated the amount of water required to

S.No Product Amount of Water

2.0 Issues Related to BOP

3.0 Issues related to:

4.0 Role of Service Providers

Water withdrawal Water Consumption

In India, the total utilizable water resource is assessed as 1123 BCM.

Water Demand (in BCM) for various Sectors

Sector Standing Committee of MoWR NCIWRD

2.0 Issues Related to BOP

3.0 Issues related to:

4.0 Role of Service Providers

Installed Capacity of India as on 31.03.2012 (Source CEA)

Consumptive Water foot print:

Geographical spread of generating facilities

Coal Gas Nuclear Hydro Renewables

Consumptive Water footprint (Coal)

2.0 Issues Related to BOP

3.0 Issues related to:

4.0 Role of Service Providers

Quantity of water required & achieving required application

Effects of Quality of water on the performance of different systems

Reliability of various systems such as CHP, AHP, DM Plants, Cooling Towers,

Optimizing of COC & Water Recycling

R&D & New Technologies for water required

 Corrosion Protection and improving the performance of Structures, Pipelines

 Control of Organic impurities

 Use of Municipal Treated Sewage Water as a make up water

Recycling of Waters & waste Waters – Technologies required

2.0 Issues Related to BOP

3.0 Issues related to:

4.0 Role of Service Providers

Key to Typical diagram of a coal-fired thermal power station

1. Cooling Tower 2. Cooling Water Pump 3. Transmission Line (3 Phase)

4. Step-up Transformer (3 Phase) 5. Electrical Generator (3 Phase)

6. Low pressure Steam Turbine 7. Condensate Pump 8. Surface Condenser

9. Intermediate pressure Steam Turbine 10. Steam Control Valve

14. Coal Conveyer 15. Coal hopper 16. Coal Pulverizer

17. Boiler Steam Drum 18. Bottom Ash 19. Superheater

23. Economizer 24. Air Preheater 25. Electrostatic Precipator

2.0 Issues Related to BOP

3.0 Issues related to:

4.0 Role of Service Providers

Oxide Particle erosion of 27,48,00,000 8,56,50,000 36,04,50,000

Fireside Corrosion of SH & 9,16,00,000 5,71,00,000 14,87,00,000

Generator Cooling water 9,16,00,000 2,85,50,000 12,01,50,000

2.0 Issues Related to BOP

3.0 Issues related to:

4.0 Role of Service Providers

1 GPM = 0.2271 M3/hour

Water Requirements for a 500 MW Unit (Ref. Flow schematic)

2 Circulating Water 187600 42603.96

3 Evaporation & Drift 6415 1456.847

4 Make up 9537 2165.853 35

5 Blowdown water 3161 717.8631